KDXRIDER.NET

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:

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

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

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

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?

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.

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.


Sent from my iPhone using Tapatalk

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

Thanks, and good luck with your project!

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

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

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

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

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.

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.


Sent from my iPhone using Tapatalk

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?

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.

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


Sent from my iPhone using Tapatalk

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.

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.