KDXRIDER.NET

Hi All,
Looking for suggestions to repair this bracket.
It’s for the lower chain roller. Here are some pictures. Some background to this.
I added a Sidestand to this. Cannot remember the brand. It uses the roller bolt & a frame bill above it.
The whole assembly got bent out quite a bit in a crash long ago. I suppose over time, a crack developed and the part eventually broke.
Has this happened to any of you, and do you have suggestions for a fix?
Thanks.

That's a pretty good break. My guess is welding is the only fix. If you can't weld it yourself, you might have to take your bike somewhere to do so, but a good welder should be able to have that cleaned up and welded in no time.

I wouldn't trust something like JB weld to do the job, especially if you are putting the sidestand back on. Might be able to get away with it just having the chain roller on there, but if it breaks and you lose the broken piece, you'll really have a hard time getting it repaired properly.

Welding is the only option.

The aftermarket kickstand brackets that are adapted to our KDX frames and others will most certainly always cause this thin lightweight non-structural chain roller tab to crack or break in time. Mine lasted less than a year of heavy trail use.

Here's a photo of my simple welding repairs / gusseting.

I used some steel tubing that I had to extend the bolt hole, as well as some flat .120" sheet stock which I cut into a small square gusseting tab with a rounded corner where the corner weld resided for the existing gusset as well as my reinforcing weld laid down prior to installing this.
Pictured in my hand are identical pieces which I cut for my other 220.

Pardon the black spray paint job, I wanted to get the bare metal painted so it wouldn't begin flash resting on my next ride the following day, as I did not have the Kawasaki # 7F green paint on hand at the time.


I'll be making a more substantial bracket next time around for my '97 KX125 chassis / KDX220 engine'd hybrid build, welding something similar to the Trail Tech bracket directly to the frame, to avoid a more substantial (i.e. heavy) steel bolt-on bracket, shaving a slight bit of weight.

Keep in mind that adding material to this area makes it so that aftermarket frame protector pieces will no longer attach as they were designed, both the UFO Plastics and Hyde Racing plastic versions as well as the no longer available Works Connection aluminum frame guards.

A lot of people really just prefer the adhesive backed grip tape or anti-skid tape type material applied directly to the frame anyways.

In my opinion if you are to run an aftermarket kickstand, this is a mandatory mod. And in my opinion, I would rather run without a kickstand than run the heavy awkward street bike type stocker. It's ironic that the street legal Japanese market KDX 220 SR aka 1994 KDX220-B1 came with a proper frame mounted Enduro type kickstand beginning in 1994, the first of the perimeter frame h-series chassis, yet the 220R (220A) off-road model and 200H off-road model came with the pathetic stock swing arm mounted kickstand that can lead to extremely frustrating situations doing single tracking and off-road riding on steep hills when the bike slides backwards and hooks the kickstand into brush or roots. This is an absolute nightmare when it happens especially as the KDX is not as light as a KTM 200 or a KX 125 and can be difficult to slide deeply uphill when tangled in brush or roots.

Thanks for all the suggestions.
Chuck, your fix looks good. (I was hoping someone would offer some ideas & pictures)
I will do something like that.
Thanks again