I'm just gonna leave this here

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
lizardfungus200
Supporting Member II
Supporting Member II
Posts: 78
Joined: 03:52 pm Feb 06 2019
Country: United States

I'm just gonna leave this here

Post by lizardfungus200 »

Hate it or not, I saved myself some money
Built to shred
lizardfungus200
Supporting Member II
Supporting Member II
Posts: 78
Joined: 03:52 pm Feb 06 2019
Country: United States

Re: I'm just gonna leave this here

Post by lizardfungus200 »

Whoops forgot picture
Attachments
2019-08-16 20.06.21.jpg
2019-08-16 20.06.21.jpg (1.14 MiB) Viewed 6366 times
Built to shred
kdxsully
Supporting Member
Posts: 739
Joined: 08:28 am Apr 21 2019
Country: United States
Location: North Cackalack

Re: I'm just gonna leave this here

Post by kdxsully »

Let’s play don’t ruin the bearing
I like turtles
lizardfungus200
Supporting Member II
Supporting Member II
Posts: 78
Joined: 03:52 pm Feb 06 2019
Country: United States

Re: I'm just gonna leave this here

Post by lizardfungus200 »

Can't say I'd recommend this to anyone, but it can be done. I'll be making sure the new seal is in as straight as possible and using permatex formabond 3
Attachments
2019-08-16 21.52.55.jpg
2019-08-16 21.52.55.jpg (1.18 MiB) Viewed 6362 times
2019-08-16 21.51.40.jpg
2019-08-16 21.51.40.jpg (1.66 MiB) Viewed 6362 times
2019-08-16 21.50.20.jpg
2019-08-16 21.50.20.jpg (1.56 MiB) Viewed 6362 times
Built to shred
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: I'm just gonna leave this here

Post by KDXGarage »

Please tell the next potential owner what you did before he buys it.

I hope the glob of silicone does not break off and float around in the engine.

Good luck with it.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: I'm just gonna leave this here

Post by Slick_Nick »

Isn’t it faster to just split the cases?

The crankcase sees combustion pressure. There is a LOT of force pushing on the backside of that seal, hence the casting to hold it in. It won’t take long for that seal to be pushed out.

There was a machinist on here who did it successfully back in the day, but he had the cases split, and machined removable tabs that could be bolted on to hold the seal in once installed. Without those, I’m afraid you’re pissing straight into the wind here.
'00 KDX 220R
User avatar
Kdxfan4130
Supporting Member II
Supporting Member II
Posts: 116
Joined: 09:24 pm May 30 2019
Country: Usa

Re: I'm just gonna leave this he

Post by Kdxfan4130 »

Makes one wonder if the new seal will hold during a pressure check/leak down test. 7 lbs for 7 minutes.

Especially when it’s warmed up far away from the truck.
Restore rather than replace
lucy
Supporting Member III
Supporting Member III
Posts: 198
Joined: 09:58 am Jan 05 2016
Country:
Location: Orlando, Florida

Re: I'm just gonna leave this here

Post by lucy »

Many new bikes have crank seals that can be installed from the outside.
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: I'm just gonna leave this here

Post by SS109 »

Interested to see how this plays out. :pop:
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
John_S
Gold Member
Gold Member
Posts: 875
Joined: 06:59 am Jan 27 2017
Country: US
Location: Florida

Re: I'm just gonna leave this here

Post by John_S »

I have a Honda 250r that both crank seals install from the outside and don't use retainers to hold them in. The seals aren't going to blow out of there. I would do a leak down test right away (6psi) before you start putting the engine covers back on to check your work.
image.png
image.png (1.48 MiB) Viewed 6330 times
Vossman
Supporting Member II
Supporting Member II
Posts: 262
Joined: 06:23 pm Jul 24 2017
Country: USA

Re: I'm just gonna leave this here

Post by Vossman »

Agree with Lucy. If they had to be pressed in they should hold. Please let us know how it holds up.
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: I'm just gonna leave this here

Post by SS109 »

The only thing that actually concerns me is squaring up the seals. Without that solid edge to seat them against you are almost guessing a bit.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
Vossman
Supporting Member II
Supporting Member II
Posts: 262
Joined: 06:23 pm Jul 24 2017
Country: USA

Re: I'm just gonna leave this here

Post by Vossman »

Great point.
lizardfungus200
Supporting Member II
Supporting Member II
Posts: 78
Joined: 03:52 pm Feb 06 2019
Country: United States

Re: I'm just gonna leave this here

Post by lizardfungus200 »

I measured the retaining lip against the old seal, and it's pretty consistent all the way around. Yes I plan on a pressure test. Most bikes I've worked on had seals on the outside, it shouldn't be a problem once it's in there straight because it is quite a secure way to hold it all tge way around the seal. but I am thinking of ways to hold it in better, maybe some jb weld anchored on the outside for good measure. I think that'll do. Crankcase pressures barely exceed 5psi, but do experience a lot of heat and vibration. Anyway I can't say much about what could be, I'll just have to see. Btw, my bike is in pieces, I'm putting in all new seals everywhere, porting it, painting it, styling it like a 1993, rewinding the aux stator, and making it a dual sport. If you have swingarm decals for a 93, please let me know.
Built to shred
User avatar
bufftester
Platinum Member
Platinum Member
Posts: 3455
Joined: 06:03 pm Oct 31 2012
Country: USA
Location: University Place, WA

Re: I'm just gonna leave this here

Post by bufftester »

Trying to understand why, if you already have the bike in pieces, you wouldn't just split the cases. Gives you a chance to check the crank and bearings as well as the tranny, and not really sure where you saved money at since you really don't need any special tools to split the cases. Don't think you're in danger of blowing out a seal, but I would clean up the edges real well so you don't damage the seal skirt installing it.
User avatar
JoKDX220r
Gold Member
Gold Member
Posts: 201
Joined: 04:04 pm Oct 03 2008
Country:

Re: I'm just gonna leave this here

Post by JoKDX220r »

For those who remember, tedh98 already made this kind of conversion in 2015-2016,
https://haroldbawlzangya.com/2015/12/03 ... the-cases/

https://haroldbawlzangya.com/2016/02/01 ... model-392/
User avatar
Kdxfan4130
Supporting Member II
Supporting Member II
Posts: 116
Joined: 09:24 pm May 30 2019
Country: Usa

Re: I'm just gonna leave this here

Post by Kdxfan4130 »

That kdx main seal is a different design than that Honda 85 atc250r main seal. I would have split the cases, then did that mod if I was going too. The costs associated with a top end seizure would have that seal retainer being used for sure.

How often do you need to replace the main seal to necessitate this mod?
Restore rather than replace
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: I'm just gonna leave this here

Post by KDXGarage »

...while keeping the old main bearings.

lizard, no need to worry about us hating it / you saving money. You are the one who bought it and will be riding it. I think there are just a few of us that would have split the cases and done it "the right way".

Good luck on the engine as well as the sticker hunt.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
lizardfungus200
Supporting Member II
Supporting Member II
Posts: 78
Joined: 03:52 pm Feb 06 2019
Country: United States

Re: I'm just gonna leave this here

Post by lizardfungus200 »

Update on my build, in case anyone is interested. Ill slowly be putting up pictures so anyone can see the build. I regret what I did to the case, and instead wish I would have invested in a case splitting tools, because I have other projects that require them. Anyhow its not a big deal, crank seal is in, and I have no worries whatsoever about it.

Got the kips valves back together and timed, and the motor is now Almost complete.

Up next is the Frame, sanded ready to paint, swingarm, brakes, refurbishing the plastics, rewinding the stator and wiring for road legal use

I never thought I would, but I may consider selling the whole thing because I sustained an injury to my wrist, which now developed a nasty arthritis. I might not be able to ride a motorcycle at all, or i may just ride through the pain. I don’t know yet, but ill be seeing some great doctors. Who knows!
Attachments
71915B2D-E99B-42F5-8032-0F7307BD0D50.jpeg
71915B2D-E99B-42F5-8032-0F7307BD0D50.jpeg (101.88 KiB) Viewed 5775 times
62193A32-1CCC-42D2-A711-E2B215A10E45.jpeg
62193A32-1CCC-42D2-A711-E2B215A10E45.jpeg (91.23 KiB) Viewed 5775 times
834402FD-AB24-41DF-98C3-40DB792E2209.jpeg
834402FD-AB24-41DF-98C3-40DB792E2209.jpeg (172.28 KiB) Viewed 5775 times
5EABBE30-0F32-438F-8C4F-DF4F41D07CCF.jpeg
5EABBE30-0F32-438F-8C4F-DF4F41D07CCF.jpeg (87.89 KiB) Viewed 5775 times
Built to shred
kdxsully
Supporting Member
Posts: 739
Joined: 08:28 am Apr 21 2019
Country: United States
Location: North Cackalack

Re: I'm just gonna leave this here

Post by kdxsully »

Is that JB weld?
I like turtles
Post Reply