Kdx200e 1991 Gear box and crank case reassembly help!

ChrisKDXE · Post by **ChrisKDXE** » 08:53 pm May 06 2016

So I got this beauty of a kdx in pieces and was told it would only need a top end rebuild and re assembly.
Turns out it was over due a bottom end rebuild and had blown main bearings.
So I have stripped it down, popped the crank case and replaced seals and bearings. Now while putting it all back together I have hit a bump.- The gears jam and wont turn when the casing is put together, the casing is squashing the gears.
I have put it all in how it came out, and have looked over this: http://www.partzilla.com/parts/search/K ... parts.html

I have tried putting the gears in different sides of the casing, and tried dry fitting it without the gear forks, but nothing is working.
Anyone else had this issue?
Here are some clips of what I am talking about:

Tedh98 · Post by **Tedh98** » 10:28 pm May 06 2016

How did you split the cases? And what did you use to put them together?

Tedh98 · Post by **Tedh98** » 10:36 pm May 06 2016

I was going to say that your piston is in backwards, but you have the crank installed backwards.

ChrisKDXE · Post by **ChrisKDXE** » 11:48 pm May 06 2016

Put the crank back in the right way and still no go

Tedh98 · Post by **Tedh98** » 06:46 am May 07 2016

What about my other questions - What are you using to split the cases and put the cases back together?

I cant really tell from the videos but it looks like there is a gap front to back between the cases when you are spinning the tranny and then clamping the rear of the motor with your hand. If I am seeing that correctly, what is keeping you from bring the cases all the way together?

Tedh98 · Post by **Tedh98** » 06:58 am May 07 2016

ChrisKDXE wrote:Put the crank back in the right way and still no go

Good. That wouldnt cause your binding problem, but it would create a few problems down the road.

eprovenzano · Post by **eprovenzano** » 08:07 am May 07 2016

When installing the tranny I've found it best to install the tranny with the gears in neutral I'm guessing your tranny is not in neutral which is what would act like it's bound.

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Post by **Julien D** » 11:19 am May 07 2016

Please don't post the same question in multiple sections. I have deleted your duplicate post.

Thanks, and good luck with your project!

ChrisKDXE · Post by **ChrisKDXE** » 03:08 pm May 07 2016

eprovenzano wrote:When installing the tranny I've found it best to install the tranny with the gears in neutral I'm guessing your tranny is not in neutral which is what would act like it's bound.

Its not being in gear that is the problem unfortunately.

The casing does go together, but seizes the gears.
I will try dry fitting the casing but only putting one gear shaft in at a time to see which is binding

Tedh98 · Post by **Tedh98** » 04:28 pm May 07 2016

Ok I get it - I will quit asking. But hopefully that hammer isnt being used in any part of the work you are doing.

ChrisKDXE · Post by **ChrisKDXE** » 05:25 pm May 07 2016

Having another crack now, hammer is for keeping the neighbours away ;)
Cheers for the help

ChrisKDXE · Post by **ChrisKDXE** » 06:20 pm May 07 2016

This is what I've got, yes all bearings are seated correctly

6 Riders · Post by **6 Riders** » 08:59 am May 08 2016

I had this problem on a CR85.......After 6 months of messing with it, we finally sent it to a shop. Turned out a shift fork was bent. This particular bike went through a full seize, but we still don't know what caused the shift fork to bend. Also couldn't tell by eyeballing it.

eprovenzano · Post by **eprovenzano** » 09:08 am May 08 2016

Wow I'm stumped. It's as though there's one washer / spacer too many. I know you said all the beating are seated, but I'd recheck that. Go through the gears to ensure all is where it belongs. My only other thought is somethings bent. Something seems to be out of alignment. I just can't tell what it is.

Sorry I can't be more helpful.

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Tedh98 · Post by **Tedh98** » 11:23 am May 08 2016

6 Riders wrote:I had this problem on a CR85.......After 6 months of messing with it, we finally sent it to a shop. Turned out a shift fork was bent. This particular bike went through a full seize, but we still don't know what caused the shift fork to bend. Also couldn't tell by eyeballing it.

Luckily I have never had to deal with a bent shift fork. What causes them to bend? Forcing into a gear or just normal use/wear and tear?

6 Riders · Post by **6 Riders** » 11:31 am May 08 2016

Tedh98 wrote: Luckily I have never had to deal with a bent shift fork. What causes them to bend? Forcing into a gear or just normal use/wear and tear?

I believe, in this case, it happened when the bike seized. My son was riding it and the bottom end locked up (we found this was caused by the lack of needles in the rod bearing) he simply skidded to a halt. My Brother in Law did try to break it free (thinking it was a top end seize) and could have done it at that time. We completely rebuild the motor and when we tightened the case halves together, the bike wouldn't shift, it did shift BEFORE we tightened the cases down. We went through that motor five or six times before sending it to the shop. They are the ones that found the bent shift fork. The bend is so slight that you can not see it, you have to measure to find it.

eprovenzano · Post by **eprovenzano** » 01:51 pm May 11 2016

Just wondering if you found the issue? Curious minds want to know.

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kx200 · Post by **kx200** » 05:04 pm May 13 2016

Your video show that you don't have the shift drum and forks in at all. You absolutely must have the shift forks in so the gears will not mesh all at once.

Tedh98 · Post by **Tedh98** » 08:14 pm May 13 2016

kx200 wrote:Your video show that you don't have the shift drum and forks in at all. You absolutely must have the shift forks in so the gears will not mesh all at once.

Good point. I had assumed everything was installed in the one video where he was squeezing the back of the cases together.

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