GEAR CHANGE SHAFT
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
GEAR CHANGE SHAFT
91 KDX 200
Problem is gear change shaft
someone who owned it before me had end of the shaft all welded up and the teeth are all worn out, has a hole drilled through it and he ran a bolt through it, and on top of that the shaft is bent badly, and it doesn't return to center position
cant find a new shaft.
theres a guy who offered to turn a new shaft on his lathe
so my question is what sort of pullers do i need to get it out? non of my automotive pullers fit.
looking on rockey mountain ATV
Tusk Crankcase SplitterTusk Crankcase Splitter
Part #1177390001
Mfg. #17-8668
Tusk Crank Puller/Installer ToolTusk Crank Puller/Installer Tool
Part #1177380002
Mfg. #17-8667
The C-clip adaptor (part # 1329270001) is required for cranks that use a C-clip to hold the primary gear on (common on many Kawasaki models).
not sure if this stuff works on the older E series because when I select Year make and model non of these tools are on the list, so im not sure if they work
Problem is gear change shaft
someone who owned it before me had end of the shaft all welded up and the teeth are all worn out, has a hole drilled through it and he ran a bolt through it, and on top of that the shaft is bent badly, and it doesn't return to center position
cant find a new shaft.
theres a guy who offered to turn a new shaft on his lathe
so my question is what sort of pullers do i need to get it out? non of my automotive pullers fit.
looking on rockey mountain ATV
Tusk Crankcase SplitterTusk Crankcase Splitter
Part #1177390001
Mfg. #17-8668
Tusk Crank Puller/Installer ToolTusk Crank Puller/Installer Tool
Part #1177380002
Mfg. #17-8667
The C-clip adaptor (part # 1329270001) is required for cranks that use a C-clip to hold the primary gear on (common on many Kawasaki models).
not sure if this stuff works on the older E series because when I select Year make and model non of these tools are on the list, so im not sure if they work
value knowledge over money.
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
Welcome to kdxrider.net. Thanks for signing up AND participating.
Sorry that a "previous owner" was not a "Mr. GoodWrench"!
I'd hold off on a used one from eBay. Here's one that I think is worn or WORN OUT (look at the two grooves). https://www.ebay.com/itm/1993-Kawasaki- ... Swy2NfWqUX
The cases are NOT split to remove and install the gear shift shaft. The inner / outer clutch covers come off (as a pair, no need to separate them). I can't remember if the clutch has to come off or not.
This Kawasaki 13161-1170 LEVER-COMP-CHANGE SHAFT Not Available fits the following models and components:
Kawasaki Motorcycle 1992 KDX200 - KDX200-E4 Gear Change Mechanism
Kawasaki Motorcycle 1991 KDX200 - KDX200-E3 Gear Change Mechanism
Kawasaki Motorcycle 1990 KDX200 - KDX200-E2 Gear Change Mechanism
Kawasaki Motorcycle 1989 KDX200 - KDX200-E1 Gear Change Mechanism
Kawasaki Motorcycle 1994 KDX200 - KDX200-E6 Gear Change Mechanism
Kawasaki Motorcycle 1993 KDX200 - KDX200-E5 Gear Change Mechanism
Sorry that a "previous owner" was not a "Mr. GoodWrench"!
I'd hold off on a used one from eBay. Here's one that I think is worn or WORN OUT (look at the two grooves). https://www.ebay.com/itm/1993-Kawasaki- ... Swy2NfWqUX
The cases are NOT split to remove and install the gear shift shaft. The inner / outer clutch covers come off (as a pair, no need to separate them). I can't remember if the clutch has to come off or not.
This Kawasaki 13161-1170 LEVER-COMP-CHANGE SHAFT Not Available fits the following models and components:
Kawasaki Motorcycle 1992 KDX200 - KDX200-E4 Gear Change Mechanism
Kawasaki Motorcycle 1991 KDX200 - KDX200-E3 Gear Change Mechanism
Kawasaki Motorcycle 1990 KDX200 - KDX200-E2 Gear Change Mechanism
Kawasaki Motorcycle 1989 KDX200 - KDX200-E1 Gear Change Mechanism
Kawasaki Motorcycle 1994 KDX200 - KDX200-E6 Gear Change Mechanism
Kawasaki Motorcycle 1993 KDX200 - KDX200-E5 Gear Change Mechanism
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
- Molly's 70
- Platinum Member
- Posts: 569
- Joined: 04:29 pm Jun 18 2017
- Country: USA
- Location: Wichita, Kansas USA
Re: GEAR CHANGE SHAFT
IIRC the clutch basket needs to be removed. The shaft will slide out. Sounds like your going to have to cut it.
If you lend someone $20, and never see that person again, it was probably worth it.
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
Re: GEAR CHANGE SHAFT
cool, hey thank you so much KDXgarage I ordered that asap, it wasn't showing up on my search results for some reason, funny how two different computers can pull different results
what tools i need to split the case, need to clean the lower end, the teeth on the valves were all disintegrated rounded off, would like to split the case clean it out add new bearings in the lower end anyways.
( I have new kipps Steel Vavles already and new head for it im sending for replate )
are the ones i linked from rocky ATV right tools?
what tools i need to split the case, need to clean the lower end, the teeth on the valves were all disintegrated rounded off, would like to split the case clean it out add new bearings in the lower end anyways.
( I have new kipps Steel Vavles already and new head for it im sending for replate )
are the ones i linked from rocky ATV right tools?
value knowledge over money.
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
I am not sure on the tools. I know a few people on here have mentioned them in the past.
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
Re: GEAR CHANGE SHAFT
https://ibb.co/3BhKfpK
for anyone that wants to chime in, tools necessary for splitting the case on E-series motors, or any other links, names or serial numbers of the tool you use would be appreciated, thanks
for anyone that wants to chime in, tools necessary for splitting the case on E-series motors, or any other links, names or serial numbers of the tool you use would be appreciated, thanks
value knowledge over money.
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
The splitter looks good, as well as the clutch holding tool. I am not sure on the puller, if it works with an "E" model.
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
Re: GEAR CHANGE SHAFT
The front left fork is damaged worse then i thought when i pulled the boot off has large dent
i see a pair of 89 forks on ebay I can get that have no rust or dents, but the guy said he thinks the 89's are little different from the 91's and to make sure before i order
I have the outer fork tubes all powder coated up already so will the 89 inner tubes fit on 91 outer tubes?
i see a pair of 89 forks on ebay I can get that have no rust or dents, but the guy said he thinks the 89's are little different from the 91's and to make sure before i order
I have the outer fork tubes all powder coated up already so will the 89 inner tubes fit on 91 outer tubes?
value knowledge over money.
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
89 - 92 inner and outer tubes are the exact same part numbers across those years.
This Kawasaki 44013-1300 PIPE-FORK INNER Not Available fits the following models and components:
Kawasaki Motorcycle 1990 KDX200 - KDX200-E2 FRONT FORK
Kawasaki Motorcycle 1989 KDX200 - KDX200-E1 FRONT FORK
Kawasaki Motorcycle 1991 KDX200 - KDX200-E3 FRONT FORK
Kawasaki Motorcycle 1992 KDX200 - KDX200-E4 Front Fork (KDX200-E4)
This Kawasaki 44013-1300 PIPE-FORK INNER Not Available fits the following models and components:
Kawasaki Motorcycle 1990 KDX200 - KDX200-E2 FRONT FORK
Kawasaki Motorcycle 1989 KDX200 - KDX200-E1 FRONT FORK
Kawasaki Motorcycle 1991 KDX200 - KDX200-E3 FRONT FORK
Kawasaki Motorcycle 1992 KDX200 - KDX200-E4 Front Fork (KDX200-E4)
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
Basically:
the inner tubes are 1989 - 1992 KDX200
the outer tubes are 1989 - 1992 KDX200
Drive on down from Wisconsin, I'll give you a tube from my '90 ... or '91 ... or '92 ... or from my spare set.
the inner tubes are 1989 - 1992 KDX200
the outer tubes are 1989 - 1992 KDX200
Drive on down from Wisconsin, I'll give you a tube from my '90 ... or '91 ... or '92 ... or from my spare set.
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
OK, cool.
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
Re: GEAR CHANGE SHAFT
it would cost the same in gas, round trip then what id pay to order it, my truck is a gas hog
value knowledge over money.
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
Re: GEAR CHANGE SHAFT
found a whole complete lower end engine for 150, lucked out, and a swing arm with linkage, very nice condition
value knowledge over money.
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
That's pretty good! These bikes may have been plentiful, but quality spares are not cheap any more.
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
-
- Member
- Posts: 11
- Joined: 11:29 am Sep 11 2020
- Country: United States
- Location: northern WI
Re: GEAR CHANGE SHAFT
did they used to make FMF Gnarly desert pipes years ago for E-series? I know Fatty is the only current option, been keeping my eyes out on Ebays for the Desert pipe.
or maybe a muffler shop could bend a 95+ to fit?
or maybe a muffler shop could bend a 95+ to fit?
value knowledge over money.
- KDXGarage
- KDXRider.net
- Posts: 14119
- Joined: 06:45 am Nov 01 2004
- Country: United States of America
- Location: AL, USA
- Contact:
Re: GEAR CHANGE SHAFT
I don't think they ever made a Gnarly pipe for 1989 - 1994. They make two versions for 1995+ KDX. Gnarly is one gauge of steel thicker than Fatty.
I doubt it would be worth the trouble to make a 1995+ fit. The pipe runs lower at the end vs. higher style on the 1989 - 1994. This is called "low boy" pipe 30 years ago. :-)
I doubt it would be worth the trouble to make a 1995+ fit. The pipe runs lower at the end vs. higher style on the 1989 - 1994. This is called "low boy" pipe 30 years ago. :-)
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128