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So I wrote a really long post explaining everything I've been through to this point with my Bike, But unfortunately as I went to take a picture of the damage I erased the whole post. So I will keep it simple. I've been working on this bike for over 7 months. I expected many problems along the way as this was my 1st time working on a bike. I guess the frustration of it all finally came to a head yesterday when I went to Fill the bike with transmission fluid and there was a noticeable leak. I had already tightened everything down to spec (78 in/lbs.). This is when i shoulve walked away. Instead, out of pure frustration I attempted to tighten the bolts to close the gap....as you already guessed....CRACK! There goes my inner clutch case. I know that this is a very hard item to find. Can anybody point me in the right direction. I feel like a little kid wanting to get this bike running. Its a true passion i've idenrified and have learned a lot along the way. Unfortunatly it has cost a lot as well. Thanks in advance for any help. Can i get it repaired?? Ive attached some pics. Thanks again.

Place a wanted ad here in the classifieds, scour Ebay, or you could have it repaired if you know a competent welder who has experience with welding cast aluminum. I've never repaired the inner but have had the outer clutch cover welded on two different KDX's and held up great.

There is one on ebay for 20 and 14 for shipping.

I believe i saw that one, but i thought t was for an E Series. Ill do some deeper digging. Thank guys

If that cracked simply from tightening the bolts, then something isn't right inside. Those bolts will strip out LONG before ever doing damage like that. Something is probably binding up inside the cover. Suggest a thorough inspection upon tear down.

Thanks Slick Nck. Im beginning to think either the clutch release lever was not in proper position, or i didnt properly install mechanical seal, oil seal, etc.

I cracked one due to a defective torque wrench. Had it set correctly, started going around the bolts, and CRACK! My heart sunk when I heard it. Took me a few to track one down but got it. Saved the old one as I know it can be repaired if necessary. Just be real careful when tightening and NEVER go more than the spec torque rating to try to stop a leak.

kaidoooo1987 wrote: 02:11 pm Nov 13 2022 Thanks Slick Nck. Im beginning to think either the clutch release lever was not in proper position, or i didnt properly install mechanical seal, oil seal, etc.

You should always install them separate (the inner and outer covers). Where that is cracked I would be looking at the shift pawl mechanism. Your mechanical seal is in the front, and the clutch release is on the outer cover.

Thanks Bufftester. I did have an issue with the shift return spring upon reassembly. It actually came off. I read that the shift return spring is not symmetrical and must be installed correctly. While I'm almost positive I installed it properly, the rod that holds the spring seemed to have been loose as i was able to slide it a cm+ in both directions. In fact I was worried it was going to slip off.

After monitoring EBAY for the 95-06 inner clutch cover, I was able to locate it from a seemingly nice 03 model for. 250 (20 tax + 14 shipping). Its on its way, so well see how it looks and hopefully, properly place everything according to spec...To be continued.

$250 ???

kaidoooo1987 wrote: 06:51 pm Nov 24 2022 After monitoring EBAY for the 95-06 inner clutch cover, I was able to locate it from a seemingly nice 03 model for. 250 (20 tax + 14 shipping). Its on its way, so well see how it looks and hopefully, properly place everything according to spec...To be continued.

Holy crap!!! Could probably buy a factory new one for less than that!

Ouch! I just looked it up.

Even if you think to know what the reason ist why it cracked you should check if the gear fork is installed correctly. Sometimes its not in the right position even if it looks like that - it needs to sit verymuch inside the engine. Otherwise you cant close the cluthcover exactly, just that close that u might think u can close it by tightening the screws…

Looked around, but every site said it was unavailable (discontinued). I will check that the Gear fork is in the correct position. It did come off At one time And have noticed Some slight movement

Also check the kickstart spindle assembly to make sure it is fully seated. I had this problem with mine during reassembly. The cover should sit flat all the way around before any bolts are even installed. If not, pull the cover back off and check things over .

Hey everyone, thanks for all the feedback. So I got my side cover in from an '03 and looks to be in great condition. There is small areas of what appears to be some kind of mineral deposit from the coolant (almost has a rusty look). It also came with an impeller/shaft. I was so excited to finally get her running again, when i realized that my actuator rod has what appears to be some kind of small bend or warp that is not allowing it to seat properly in the case. It takes a lot of manuevuering around to get it through the case, and once it is set in position, the lever becomes VERY hard to rotate. I can tell this will not cut it. Im in a dilemma of possibly purchasing another discontinued part or can i somehow get it measured and straightened?? Any suggestions?? The actuator rod is black...Is this some kind of composite metal??

The rod for the KIPS?

Yes. Part #13234A.

Heys guys...OK, after heavy rainfall in California for what seems like over a month, im back to the KDX. As mentioned before, im relatively new at working on bikes. So, i got the inner clutch cover/new advancer shaft, but i noticed my shift pawl keeps slipping off the shift mechanism. I also noticed that the shift mechanism actually shifts out of the turret, becoming disengaged. Is this normal?? I figured it would be worthwhile to remove and replace the stock friction and steel plated, but after buying the tusk clutch tool, i noticed the output end of the clutch is still spinning. Is this because the bike is not in gear?? I know a good impact is ideal, but my little 12 volt isnt powerful enough. Any help will be very much appreciated. I also uploaded a few pics so you can see. Thanks again!