2004 KDX 200 Rebuild

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ericr
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Re: 2004 KDX 200 Rebuild

Post by ericr » 06:53 pm May 06 2019

Vossman wrote:
05:34 pm May 06 2019
ericr wrote:
10:26 pm May 05 2019
Vossman wrote:
08:40 pm May 05 2019
Ya, I’m gonna try but I think I may have to eat this one cause I bought it back in Jan when I was stocking up on parts and although the box is still good the sealed bags are opened and their policy says that’s a big no.
I think I will have to get the DID Narrow X-Ring. I read it measures about .725 across so that would be much better. I think that’s the chain Ericr has on his rebuilds. Maybe he can confirm it.
I bought the Primary Drive x-ring chain from Rocky Mtn. It fits fine for me but I did install a Fredette chain guide. It seems to be a good chain - after 40 hours, I've had zero stretch.
Ericr, if you can take a second and look is your clearance near the case as close as mine? Thanks.
Mine looks pretty much like your's. Pin end-to-end is 0.885". It doesn't rub. I'd say go for it. If it rubs, you'll know it.

BTW, I washed all that shipping grease off the chain. It's just going to sling off and attract dirt. But I'm one of those that doesn't lube an x-ring. I just spray it with WD-40 after washing (as in Water Displacement-40) to keep it from rusting.
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 08:21 pm May 06 2019

Thanks for the info Ericr. Ya, that white grease is a sticky mess. I’m like you, I just put a bit of chain wax on the rollers after a wipe down. I usually wipe the chain off with a kerosene soaked rag after riding. WD-40 at the end of the season before storage. Not a lot of moisture here in the mtns.

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Re: 2004 KDX 200 Rebuild

Post by KDXGarage » 08:24 pm May 06 2019

cosmoline, ALWAYS wash it off a new chain before running it

YUCK!
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 09:20 pm May 07 2019

I talked to a customer service mgr and Rocky Mtn stuck to their guns again. Said the chain and packaging wasn’t in resellable condition. We had a pleasant chat, I was honest and rational with them and they were very professional, I respect that. They recommended the PD chain you bought Ericr, I’m gonna think it over for a bit.

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Re: 2004 KDX 200 Rebuild

Post by ericr » 09:45 pm May 07 2019

Vossman wrote:
09:20 pm May 07 2019
I talked to a customer service mgr and Rocky Mtn stuck to their guns again. Said the chain and packaging wasn’t in resellable condition. We had a pleasant chat, I was honest and rational with them and they were very professional, I respect that. They recommended the PD chain you bought Ericr, I’m gonna think it over for a bit.
The difference in width between your chain and mine is only 0.040. The swingarm has almost 1/4" play, left-to-right, on its bushings to self-align the two sprockets. I'd suggest to use a screwdriver to pry to center the swingarm and then see if the chain is actually touching anything. My chain looks as close as your's in the photos, but I haven't touched at all. I think you're probably ok.
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 08:48 pm May 11 2019

I couldn’t do it Ericr. I had to try another chain. My local shop was nice enough to let me measure the chains they had and I was able to pick a good x-ring chain that I won’t have to worry about. I also realized the first chain I bought was too wide for the OEM chain guide. I’ll find a good home for it.

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Re: 2004 KDX 200 Rebuild

Post by Vossman » 08:39 pm May 13 2019

Image
A little RB Designs love in the mail today. I gotta go to Tx for a few days so it’s gonna sit for bit.

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Re: 2004 KDX 200 Rebuild

Post by KDXGarage » 09:21 pm May 13 2019

Niiice!
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 03:15 pm Jun 03 2019

Well crap. I’ve been away for a week and I come back to a puddle of oil. Looks to be several drops a day. Leak appears to be from the large clutch cover. Bolts are tight and I used a fresh gasket.
I’ll have take a few things apart to check that everything is square. I’m a tiny bit disappointed in myself honestly but I’ll get over it.

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Re: 2004 KDX 200 Rebuild

Post by KDXGarage » 06:10 pm Jun 03 2019

Hmm. What was your order of tightening the bolts?

Got an inch-pounds torque wrench?
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 07:59 pm Jun 03 2019

They were torqued per the manual spec but not in any order. I did do the cross-cross pattern though then went all the way around to double check the torque. Is there a pattern?
I’m wondering if there is something near the shift mechanism that’s a little out of place.

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Re: 2004 KDX 200 Rebuild

Post by KDXGarage » 02:01 am Jun 04 2019

I was just checking for the criss-cross.

Is it leaking from that area?

Sucks, no matter what. :?
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Re: 2004 KDX 200 Rebuild

Post by ericr » 10:23 am Jun 04 2019

Vossman wrote:
07:59 pm Jun 03 2019
They were torqued per the manual spec but not in any order. I did do the cross-cross pattern though then went all the way around to double check the torque. Is there a pattern?
I’m wondering if there is something near the shift mechanism that’s a little out of place.
There is a shoulder bushing on the end of the shifter shaft that can hold the inner clutch cover out of position. That happened to me, but the gap would have been large enough for the oil to really run out - not just drip.
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 04:43 pm Jun 04 2019

Yes, I think it is as the oil trickles out and builds up near the drain plug but the plug itself is dry. So is the gasket area by Kickstarter.
Ericr may be on to something. When I first put the cover on that bushing was out of place. I didn’t catch it till I tried tightening the bolts on the cover. I am thinking I might have bent the cover a little. I’m gonna drain the fluids tonight and see if I can figure out what’s up.

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Re: 2004 KDX 200 Rebuild

Post by ericr » 05:12 pm Jun 04 2019

Once you've removed it, put the inner clutch cover on a piece of plate glass to see if it's flat.
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Re: 2004 KDX 200 Rebuild

Post by Vossman » 08:32 pm Jun 04 2019

Image

Well that’s not cool, I bent it pretty good. I can eyeball it and see the gap, don’t need feeler gauges. I’m not even sure it can be resurfaced to a flat state without ruining the tolerances of everything else.
1. So my thoughts are first try some Yamabond and a new gasket.
2. Next would be heat and some pressure to try and bend it a bit.
3. eBay has nothing currently but I will continue to look.
Ideas appreciated and ball busting deserved of course.

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Re: 2004 KDX 200 Rebuild

Post by ericr » 11:05 pm Jun 04 2019

Heat and a rubber mallet might get some of the bend out of it. You can also try fully torquing the bolt in that spot and then torque the rest moving outward from that bolt. It's not a proper repair but it could work. Or, $176.13 at partzilla. Ouch.
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Re: 2004 KDX 200 Rebuild

Post by pumpguy » 11:40 am Jun 05 2019

You might also try filling the gap areas with something like Quick Steel epoxy or similar. Even aluminum weld if you have the skill and equipment.

After the epoxy dries, take some lipstick or Prussian Blue marking media and smear a thin coating on the plate glass. Then apply the epoxy coated case joint face to the marked up plate glass. The high spots will show up on the epoxy, which need to be removed.

Continue repeating this process until you get a uniform marking on the whole joint face, which will now be as flat as the plate glass.

Once you get close to flat, you could use a sheet of wet or dry paper laying on the plate glass and lap the face flat. For this, I would recommend using some aerosol spray light oil (WD40 or similar) to prevent the wet or dry paper from loading up.

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Re: 2004 KDX 200 Rebuild

Post by lucy » 07:58 pm Jun 05 2019

You may wanna check the other sealing surface to be sure that it is flat as well. This cover may have been bolted onto a surface that’s not flat and it warped to match the other surface.

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Re: 2004 KDX 200 Rebuild

Post by Vossman » 09:25 pm Jun 05 2019

ericr wrote:
11:05 pm Jun 04 2019
Heat and a rubber mallet might get some of the bend out of it. You can also try fully torquing the bolt in that spot and then torque the rest moving outward from that bolt. It's not a proper repair but it could work. Or, $176.13 at partzilla. Ouch.
Ericr, I saw the price last night and kind of threw up a little. Don’t forget the added $$ for the water pump parts and bearings too. I’m already in deep so I might just have to do it cause there ain’t much out there so far. I’m gonna give the heat and rubber mallet a try cause I don’t think I have many other choices. Had a few ideas from TT about doubling up the gasket but most folks said replace it.

Pumpguy, I thought about that but I have zero experience in that and I’m somewhat a gorilla when it comes to stuff like that. My fine motor skills are lacking. Can’t tie a fly or lure onto a piece of mono but I can break stuff with the best of them. :grin:

Lucy, that’s a good idea. Never crossed my mind.

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