KDX 175 Swing Arm and Suspension Rebuild

A service reference
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mlyle11
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Joined: 02:06 pm Jun 18 2011
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Location: Central Illinois

KDX 175 Swing Arm and Suspension Rebuild

Post by mlyle11 »

Hey all KDX'ers - Happy 4th of July.
Well I have started the rebuild of the suspension on my 1980 KDX 175. I just love this old bike and will not give up on her... much to my pocket books shagrin! First step was complete disassembly, which was a breeze except for the swing arm bearings. I have never had them as seized as these ones. Of course, it looked like no one ever serviced them, so I expected tight, It took a lot of heat and a vice, but I was eventually able to drive them out. I then stripped the paint, sanded down some of the bad spots, primed and have the first coatd of "Silver Ceramic" Duplicolor engine paint. $12 bucks and some elbow grease versus $100+ for powder coating.

Now I am wainting on all my parts to come in. I wont post the details on the parts until I am sure they all fit, but here's the general list:
1) Needle Bearings for Swing Arm: 20x27x30 from some place in England - 2 each for around $30 bucks. They also look to be a standard Suzuki part for street suspension. Will post more on this when I am sure they fit
2) Sleeves 15X20X80 out of a KX250 circa 2004. I have to cut them down to 52 mm to fit the swing arms. $11 a piece
3) I am going to refurb the seal caps by cutting a small o-ring groove into them if I can and seal them with RTV. If this doesn't work, I found some Honda engine seals that may do the trick as well as some industrial seals 15X27X3 and some thicker ones if needed. It looks like I can still order these so that may be my route as well they are around $8.
4) Replacement Heim Joints and Boots from Aurora Bearing - These are sweet high wear joints with Zerts. I ordered 3 to do the Torque rod as well. It was the worst. The others wearnt all that bad for 32 years.

All the spherical bearings in the shock linkage are in good shape. Tight and smooth, as well as the sleeve bushing in the center pivot. I was surpised. These are available from Aurora bearing as well.

It took some looking to hunt down these compatible parts, but it is so worth it. People on E-Bay want $80 for a freaking NOS spherical bearing! The boots and Heims are rediculous too. Maybe if this was a show bike it would be worth it, but this is my regular rider/back up for my 2001 220R. I actually love riding the 175 - it reminds me I'm old.

Pics Link: https://plus.google.com/photos/11658141 ... 4523921553

More to come as I work through it... slow and steady!
Last edited by mlyle11 on 09:28 am Jul 05 2012, edited 4 times in total.
2001 KDX 220, 2001 Gas Gas EC 250, 1980 KDX175, 1979 KZ1300
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kawagumby
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KDX 175 Swing Arm and Suspension Rebuild

Post by kawagumby »

Nice write-up on getting the parts!
Thanks...

You might want to copy your post to the air-cooled bike section...I bet more people would access it there.
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
mlyle11
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Posts: 12
Joined: 02:06 pm Jun 18 2011
Country:
Location: Central Illinois

Re: KDX 175 Swing Arm and Suspension Rebuild

Post by mlyle11 »

Added to the air cooled section and pic's link updated: https://plus.google.com/photos/11658141 ... 4523921553
2001 KDX 220, 2001 Gas Gas EC 250, 1980 KDX175, 1979 KZ1300
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