Flywheel Grenaded
- Molly's 70
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Re: Flywheel Grenaded
Looks Fantastic!
If you lend someone $20, and never see that person again, it was probably worth it.
- Slick_Nick
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Re: Flywheel Grenaded
Got the rivets pressed in. Didn’t use heat, didn’t really need to. Only took about 10 tons to get a good “smoosh” on the rivets.
Fit like a glove, test run was amazing. I put WAY too much effort into a frighten flywheel haha
Fit like a glove, test run was amazing. I put WAY too much effort into a frighten flywheel haha
'00 KDX 220R
- Slick_Nick
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Re: Flywheel Grenaded
Decided to also tackle my slipping Kickstarter. Diamond filed the teeth, and of course installed a new spring. Haven’t refilled the transmission yet, but on initial reassembly the ratchet action is VERY affirmative. I run a KX125 kicker (see my how-to) and it feels brand new now. Also, have a whopping 2.7 hours on the Wiseco (ProX?) basket and it’s mint.
'00 KDX 220R
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Re: Flywheel Grenaded
Man! Nice work. Those teeth are good to go.
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- Slick_Nick
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Re: Flywheel Grenaded
Thanks! I was gonna just order new gears, but they’re on back order from Kawasaki so who knows when they’d ever get some. Turned out decent for a ham fisted hack and a hand file.
'00 KDX 220R
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Re: Flywheel Grenaded
Looks great. Very clean and quality work.
- Slick_Nick
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Re: Flywheel Grenaded
Thanks everyone for the comments! As for failure analysis is concerned, I'm guessing somehow the flywheel rivets coming loose must have caused the flywheel to vibrate enough to shear the woodruff key, and then it spun the nut off. I'm lucky I caught it in time! I wonder if the increased "load" on the flywheel from my beefy lighting stator had something to do with it? Although I don't imagine it could be that much... It's a 21 year old bike after all, I guess things are bound to wear out. Hopefully my rivet trick helps someone else who may have the same issue, as the flywheel has long since been discontinued, and used ones are harder and harder to find.
I guess I need to add "flywheel rivet tightness" to the list of annual things to check for failure now!
I guess I need to add "flywheel rivet tightness" to the list of annual things to check for failure now!
'00 KDX 220R
- SS109
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Re: Flywheel Grenaded
Yes, you did but that's what KDX owners do!
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
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
- bufftester
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Re: Flywheel Grenaded
Age is likely the culprit. Your rewound stator doesn't put any physical load on the flywheel. Curious about electroplating the flywheel, did you cover the magnets somehow or just plate over them? Shouldn't really mater with the thickness that is added, just curious. Great, clean work on everything!
- Slick_Nick
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Re: Flywheel Grenaded
I covered them with high temp masking tape it stays sticky when wet. You can see in one of the pics where it lifted and tried to plate a bit.bufftester wrote: ↑03:43 pm Apr 10 2021 Age is likely the culprit. Your rewound stator doesn't put any physical load on the flywheel. Curious about electroplating the flywheel, did you cover the magnets somehow or just plate over them? Shouldn't really mater with the thickness that is added, just curious. Great, clean work on everything!
'00 KDX 220R
- bufftester
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Re: Flywheel Grenaded
Really nice work. Do you have your own plating setup at home? I've been toying with trying it, just have to find space in the shop lol
- Slick_Nick
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Re: Flywheel Grenaded
Yeah, I just use the Caswell setup. I only have about $1000 invested, but I get amazing results on a lot of my restorations. Its a nice capability to have.bufftester wrote: ↑07:54 pm Apr 10 2021 Really nice work. Do you have your own plating setup at home? I've been toying with trying it, just have to find space in the shop lol
'00 KDX 220R
- Slick_Nick
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Re: Flywheel Grenaded
Update:
The kickstarter is um.... FREAKIN AMAZING! You never realized how sh!tty and loose something was until you compare it with how it SHOULD feel!
Makes an extremely audible "click click" in the ratchet mechanism now. Sounds a lot like my KX250F. Most importantly, no slop, and no slipping!
Flywheel works great, bike fired right up. Now time to put some hours on it!
The kickstarter is um.... FREAKIN AMAZING! You never realized how sh!tty and loose something was until you compare it with how it SHOULD feel!
Makes an extremely audible "click click" in the ratchet mechanism now. Sounds a lot like my KX250F. Most importantly, no slop, and no slipping!
Flywheel works great, bike fired right up. Now time to put some hours on it!
'00 KDX 220R
- Molly's 70
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Re: Flywheel Grenaded
If you lend someone $20, and never see that person again, it was probably worth it.
- KDXGarage
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Re: Flywheel Grenaded
Thank you for the follow up report!
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To post pictures from a device: viewtopic.php?f=88&t=24128
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Re: Flywheel Grenaded
NICE WORK, really NICE WORK.
What's the story on the CS sprocket cover? Never saw one like that before.
What's the story on the CS sprocket cover? Never saw one like that before.
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Re: Flywheel Grenaded
He mentioned it somewhere in a another thread. I want to say YZ450F, WR450F??
Slick_Nick, can you show a picture of the diamond file you used to file the teeth? There are MANY KDX's that need or will need such a thing soon.
Thanks.
Slick_Nick, can you show a picture of the diamond file you used to file the teeth? There are MANY KDX's that need or will need such a thing soon.
Thanks.
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- Slick_Nick
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Re: Flywheel Grenaded
Old WR400 I think. As for the file, there's nothing really to take a picture of, it's just your standard run of the mill diamond grit needle file. Have had it for an eternity, cant remember where I inherited it from. If you're looking for one, they're not hard to find.
'00 KDX 220R
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Re: Flywheel Grenaded
Beautiful bike and workmanship!
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Re: Flywheel Grenaded
Thanks! I thought it might have been a special one.
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