98 crank bearing instal

[Two_stroke_brit]

Well i have a 98 kdx 220r that i am rebuilding.
needed crank seals and bearings as well as a host of other issues( beat to near death ).
have it all apart and replaced the bearings in the cases and slid the crank in one side ,
went to put the other case on and NO GO.
checked things that could be hanging it up all looks good.
finally measured the bearing and its 0.01 mm small .
now i checked both bearings i removed and they are -.005 mm at most small.
i had the crank in the freezer and the cases in the texas noon day sun ( too hot for bare hands).
before i reorder another and hope for a bigger bore.

any ideas i am reluctant to directly heat the bearing as the rubber crank seal is right there.
T I A
cheers mark.

[KDXGarage]

look up heating a slug for the inner race

[SS109]

What are you using to measure the size difference? A standard slide caliper or a bore gauge? Also, I routinely heat case halves up to 225*F in the oven with no ill effects. The seals are designed to handle temperatures much higher than that. I don't think you are getting the case half hot enough.

[KDXGarage]

freeze the half with the crank and heat a slug that touches the inner race of the bearing

For example:

[Two_stroke_brit]

Great advise there ,
thanks for all the help i will make a heat sink to warm the inner race.

cheers mark

[Two_stroke_brit]

well got the 2 halves together but i have two possibly related issues.
1= the kickstart goes around and comes to a hard stop and does not return.

2=it seems to be stuck in 1 gear and the shift star will only click up and down one position.

think i am going to have to split the cases again to see what's amiss.

any advise is welcome.

T I A Mark.

[bufftester]

1 - sounds like the return spring is either installed incorrectly, not installed, broken or has come out of the detent in the case. You only need to remove the right side cover and the clutch pack diagnose and fix that.

2 - When you pull the cover for #1 check your shift pawl/shaft installation first. Could be something binding it up. Also keep in mind that you need to turn the output shaft while shifting the gears or it won't work correctly. If there is nothing obvious there then you would need to split the cases and see whats going on. Some possible causes could be shift cam/fork misalignment, binding in the gear train, a missing washer or shim...

Good luck.

[SS109]

On the kickstart, pull the side cover and check that you got everything installed correctly.

On #2, did you rotate the output shaft after shifting to each gear? You have to do that to get it to shift more than one gear.

[Two_stroke_brit]

wow what a great wealth of knowledge this forum is.
Rotating the output shaft was the key to the gear shift issue.
also there is a top hat bush on the shift shaft that needs to fit into the claw thing to help it too ( previously on backwards).

now to take a closer look at the kickstart assembly

update ---i didn't realize you have to install the kicker shaft ,rotate it to the stop then preload the spring around to the keeper hole in the case.
all sorted now

huge thanks to all
Mark

[KDXGarage]

Heck yeah. I am glad you got it sorted out.

[SS109]

Awesome! Glad to hear you got it all sorted.