a quick Bottom end question

[Charles_thib]

hi !

I'm currently rebuilding my KDX220R 2000 engine, i'm at the start of the bottom end reassembly. I'm referring to the cyclepedia manual since i don't have the oem one.

So, after putting the transmission back into the right side of the crankcase, the manual say '' insert the circlip into its groove to hold the output shaft in place''.

235604569_1420779518292114_3238225691276778306_n.jpg (592.16 KiB) Viewed 2880 times

However, this circlip is only retaining the needle bearing onto the shaft, it does not prevent the shaft to go back out the case half.
Even the online manual will say so :

cyclepedia printscreen.jpg (103.29 KiB) Viewed 2880 times

i've mounted everything perfectly, i'm setup exactly like this:

transmission kdx.png (134.77 KiB) Viewed 2880 times

SO, am i wrong or the manual is wrong ??
Thanks !
Charles

[Slick_Nick]

It just holds the gear to the shaft. Cyclepedia sucks.

[SS109]

Actually, it's the opposite. The circlip locks the shaft in to the bearing. Since the bearing is a press fit into the case, the shaft is now locked in to the case as well.

[Charles_thib]

i don't think this bearing is press fitted. it's a needle bearing without an outside casing. if it was press fit without a casing, it would not roll.
in this video, at exactly 18:53, you can see the bearing moving freely in its hole.(i know it's an 84 but it's almost exactly since except mine is a 220)

[bufftester]

That is a collar that presses into the case, and the needle bearing rides inside that collar. IIRC the circlip is big enough that it rides against the edge of the collar and keeps the whole thing from pulling out (see 14:50 in the video)

[SS109]

Sorry, yes, it's a collar the bearing rides on but it is press fit. Once you install the circlip I think it will lock it in.

[Charles_thib]

but i do have the right circlip and bearing and it does not keeps me from pulling the output shaft out the case. What is wrong ? been stuck here for a week now ...

Here's a couple pictures (tried to upload a video but it seems like the forum don't support mp4)

OEM circlip and OEM needle bearing :

236557727_661578124817031_5277531116053067590_n.jpg (230.62 KiB) Viewed 2834 times

Circlip is on :

235334111_1668110230046773_5251769662347961917_n.jpg (173.81 KiB) Viewed 2834 times

And goes through :

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234570000_252144769909468_7775759902413855479_n.jpg (132.24 KiB) Viewed 2836 times

[KDXGarage]

Sorry. The site is supported by donations.

[SS109]

Ok, now I remember. Sorry, I was incorrect.

Do you see that there is another groove on the end of the shaft? You need to mount gear that is driven by the kickstarter and fits between the kickstarter and the rear gear on the clutch basket. THIS is what locks the transmission output shaft in place. There should be a washer on each side of the gear and a circlip to retain it.

maxresdefault.jpg (144.28 KiB) Viewed 2813 times

[Molly's 70]

You have it assembled correctly. That circlip holds the bearing in place, not the whole shaft.

You can see the shaft start to move in the case as 14:55 You have to look real quick when he flips the case over ( go full screen).

[Slick_Nick]

Yeah you've got it assembled correctly, what's the issue?

[Charles_thib]

MY issue was that my shaft was still going tru, even after the circlip installed but i think it's just the way it is and i'll be closing the bottom probably tonight.

THANK YOU VERY MUCH ! to every one of you who helped me ! i really appreciate !

[Molly's 70]