KDXRIDER.NET

Looks Fantastic!

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

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.

Man! Nice work. Those teeth are good to go.

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.

Looks great. Very clean and quality work.

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!

Slick_Nick wrote: ↑08:40 pm Apr 09 2021 I put WAY too much effort into a frighten flywheel haha

Yes, you did but that's what KDX owners do!

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!

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!

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.

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

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

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.

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!

Thank you for the follow up report!

NICE WORK, really NICE WORK.

What's the story on the CS sprocket cover? Never saw one like that before.

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.

KDXGarage wrote: ↑08:10 pm Sep 30 2021 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.

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.

Beautiful bike and workmanship!

Thanks! I thought it might have been a special one.