Lower chain roller

Discussion specific to the various air-cooled KDX models sold in the USA
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ThatBikeGuy17
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Lower chain roller

Post by ThatBikeGuy17 »

Is there a fix to repair the stud for the lower chain roller on a 1984 KDX200? The nut/threads snapped when replacing the roller and it looks as though it’s a irreplaceable stud?
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Re: Lower chain roller

Post by KDXGarage »

Oh wow. I looked on the parts diagram, and that does look like it is the case. I think it needs to have the old one taken off and a new one welded in its place.
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ThatBikeGuy17
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Lower chain roller

Post by ThatBikeGuy17 »

It is not part of the case, it mounts "inside" the frame behind the left foot peg. I can't imagine that that would make it so it couldn't be replaced? That roller is important and I really need to repair this thing.
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Re: Lower chain roller

Post by KDXohio »

I think Jason meant "does look like the case" meaning yes it appears not to be replaceable. Should be pretty easy to cut off and weld on a new stud if you have access to that equipment if not then a welding shop or automotive shop should be able to take care of it fairly inexpensively
Good luck!
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Re: Lower chain roller

Post by KDXGarage »

It does look like it is a welded on stud. That is what I meant. As in, that is the situation, that is what is going on.

I would suggest Grade 8 bolt over grade 5.

cut it off
grind it flat
sand it down
weld on a new stud
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ThatBikeGuy17
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Lower chain roller

Post by ThatBikeGuy17 »

Ok thanks for the help! I was hoping the stud could be unscrewed or something but looks like I will try my welding skills out. I bought this bike complete in what I think is nice original condition for $225. Don’t want to fully restore just a Sunday trail putter around the yard so to speak.
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Re: Lower chain roller

Post by KDXGarage »

Thanks for the follow up. Without seeing pictures, it is hard to diagnose. On a trail bike made 34 years ago, that may have been the way it was made. If it was removable, then I am confident it would be on the parts diagram.

You may get bit by the "dirt bike tinkerer" bug like many of us and want to continue updating and improving it. :cool:
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ThatBikeGuy17
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Re: Lower chain roller

Post by ThatBikeGuy17 »

I've been into bikes for the past 17yrs lol, so I can relate to the tinkering bug...however my wallet does not appreciate it :boogie:
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Re: Lower chain roller

Post by KDXGarage »

On TT, it kind of sounds like you are going to ride it without the roller. Would that not hit the frame?
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ThatBikeGuy17
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Re: Lower chain roller

Post by ThatBikeGuy17 »

When I had it fired for the first time I rode it briefly for a couple minutes but now that I purchased rollers, it will be fixed before actually ridden.
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Re: Lower chain roller

Post by KDXGarage »

OK. That is good. I have seen frames and swingarms ground down because of the chain hitting them.
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