E series kdx kips shaft circlip grooves

[JZ05220r]

Hey guys I had an issue with the main shaft on my 1991 kdx 200 E in the past. What happened was the circlip came out of its groove on the main shaft and disconnected from the governor shaft. I picked up another used shaft which had much nicer teeth but I noticed the groove for the circlip is pretty worn at the end. I’m worried it’s not going to hold and wondering if you guys might have any ideas on keeping the clip in place and preventing more wear.

[Chuck78]

I would degrease it, then bake it to get any oil traces out of the metal, clean & degrease again, and use Silicon Bronze brazing rod and oxy fuel torch to build up some material on the end, and then turn it on a lathe. An electric drill held in a bench vise with the shaft chucked into it if it would fit would also perhaps suffice, and a Dremel tool with a very thin cut off wheel to shape. On second thought, I don't know if you could get that into a drill chuck as the other end is toothed also, correct?

[JZ05220r]

Good idea, the other end would definitely center in a drill. I might just leave the one that’s in the bike and throw on some new kxpowervalve.com subvalves. Thanks

[bufftester]

with small enough drill bit and some .020 safety wire you could drill the circlip and safety wire it on

[JZ05220r]

with small enough drill bit and some .020 safety wire you could drill the circlip and safety wire it on

Thanks for the idea!