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Well...I was almost home free. I was finishing up my top end rebuild on my 2000 KDX220 and I torqued the nut on the shaft (SHAFT-COMP, GOVERNOR 13234-1101) too hard. Broke the end of it right off. And this is after I read all the warnings and I WAS supporting it. And also going the right way. So now, $86 later, I have another shaft on the way. What all do I need to do to replace this part? I'm afraid I will have to split the bottom end open? I have the Cyclopedia online manual but did not see how to replace this part. Unless I just missed it. Any guidance would be greatly appreciated. Thanks in advance.

right side engine cover

How many inch-pounds did your torque wrench show??

Just take that off and I'll be able to access it?

And too much. That's how much I torqued it

Yes, and you will be able to inspect the pin at the bottom to make sure it didn't get tweaked as well. Yeah, make sure you're using an IN-LB, 74 in-lb is not a lot of force.

Did you use a torque wrench? I am thinking you cranked on it, not "torqued" it.

I'm going to be honest...I wasn't using a torque wrench and I knew I should've been while I was doing Is the engine cover easy to take off? My bike is at a different location right now so I can't take a look at it. And I'm assuming there is a gasket for the cover that should be replaced also?

Thanks guys, this is the first time I've ever been into an engine so I appreciate the help.

Yes, there is a gasket. The old one may well break when you take it off. You will need to drain the coolant beforehand also.

What all is involved with getting the cover off?

Someone help me out.

drain transmission oil
drain coolant
remove kickstarter
remove inner / outer clutch cover combo

new gasket between inner clutch cover and right crankcase half
new transmission oil
new coolant

Again, someone help me out on that

Remove water pump hose?
Remove brake lever and/or the spring?

KOOM BY YAH
KOOM BY YAH

Thanks!

Sorry to bring up a dead thread but I am just now getting around to fix it. So the crankcases do not need to be split then, correct?

Nope....Just the inner clutch cover.

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Great, thanks! I'm sure I will be back with more questions.

Look up water pump replacement, there's help in there.....and replace your water pump seals while you have it apart.

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