this is not good, I think my gearbox is dead...

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skipro3
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Post by skipro3 »

I would have thought you could get a complete motor for that price. Check with Jeff Fredette and see what he sells a bottom end for. In fact, if it was a good price, chances are Fredette would have bought it first!! Ha!!
He's always buying KDX stuff off eBay.
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Post by krazyinski »

I don't think its a good price, I had Fredette build my engine that included a new or used case plus bearings porting, head work ,piston,rings, rod,crank and ,carb bore, assembled and shipped for 1300.00.
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scheckaet
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Post by scheckaet »

Thanks guys, I thought it was ab it overpriced too, just did not want to pass up on a potential good deal.
I'll have a kawi "inspector" check things out in a couple of weeks (got an extended warranty), maybe it'll pay out....not holding my breath though :roll:
thanks again y'all. More in a few weeks. Now time for a complete tear down, inspection and grease, if life gives you a lemon make some lemonade...or margarita :partyman: :mrgreen:
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TopperHarley
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Post by TopperHarley »

I have a 2003 bottom end I will let go for considerably less than Keepitroostin. :cool:
If you run into Heidi, have her look me up in her little black book and give me a call.
Im feelin a little wild today.
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scheckaet
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Post by scheckaet »

>|<>QBB<
TopperHarley wrote:I have a 2003 bottom end I will let go for considerably less than Keepitroostin. :cool:
I'll keep that in mind :mrgreen:
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TopperHarley
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Post by TopperHarley »

did we ever figure out where the mystery piece came from?
If you run into Heidi, have her look me up in her little black book and give me a call.
Im feelin a little wild today.
http://stores.shop.ebay.com/GATEWAY2-STROKE
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1998 KDX220 1/2 Brother-in-laws, soon his own
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scheckaet
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Post by scheckaet »

nope, that's why I'll have the case and everything else checked out by a kawi dealer
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TopperHarley
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Post by TopperHarley »

Did you have a magnetic drain plug? I have never heard of one losing its magnet and causing damage but there is allways a first. Just thought I would throw that out there since I just installed one. If thats the case. you can bet its coming out.

you sure the little centering button on part# 13161 is still in place? is there a pic of the shift fork assy on this thread that I did not see?
If you run into Heidi, have her look me up in her little black book and give me a call.
Im feelin a little wild today.
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2003 KDX220 mine(under construction)
1998 KDX220 1/2 Brother-in-laws, soon his own
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Post by IdahoCharley »

>|<>QBB<
TopperHarley wrote:Did you have a magnetic drain plug? I have never heard of one losing its magnet and causing damage but there is allways a first. Just thought I would throw that out there since I just installed one.
FWIW - I did have a magnet seperate from its bolt. It did not do any damage it just look like it fractured and keep itself against the ferris metal bolt. I still run magnetic drain plugs - just not the ones with the extended 1/2 magnet. (I thought maybe engine vibration got to it)
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TopperHarley
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Post by TopperHarley »

I guess the fact that its a magnet would keep it from straying from its location and doing any harm........I hope. I dont think mine iextends 1/2. just a stubby lil thing...........The saga of the mystery, stray, metal piece continues.
If you run into Heidi, have her look me up in her little black book and give me a call.
Im feelin a little wild today.
http://stores.shop.ebay.com/GATEWAY2-STROKE
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2003 KDX220 mine(under construction)
1998 KDX220 1/2 Brother-in-laws, soon his own
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Post by scheckaet »

is there a pic of the shift fork assy on this thread that I did not see?
I'll post a pic tonight.
I don't have a magnetic plug so this one is out of the equation 2
(all were good guess though)
Maybe I should have some kind a raffle about who will guess where that mystery piece came from, the winner would get my slightly used clutch housing and cracked gear and...the mystery piece :lol: :mrgreen: :lol:
Thanks for the help
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scheckaet
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Post by scheckaet »

Image

Image

Image
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TopperHarley
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Post by TopperHarley »

Wher is the rod at the bottom of the KIPS shaft?? is it behind the plate? I cant see it. Appears to be MIA. You know, the little round rod that rides between the bearing on the centrifical deal. does that make any sense to anyone? :neutral:


I beleive Inda won :roll:
If you run into Heidi, have her look me up in her little black book and give me a call.
Im feelin a little wild today.
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2005 KDX220 mine
2003 KDX220 mine(under construction)
1998 KDX220 1/2 Brother-in-laws, soon his own
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scheckaet
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Post by scheckaet »

I'm not sure I know what you're refering to so

Image

Image

Anybody has a pic of the kips rod thingy?
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scheckaet
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Post by scheckaet »

Are you talking about 13236???

Image

Cuz now I think you may be right, there's a piece missing :evil:
I can't believe I missed that! I looked at the manual then the shaft and didn't realise the whole right part of the LEVER-COMP,GOVERNOR was gone! :oops: I thought the circled portion was part of the shaft :roll: Amateur! :roll:
Size and shape would fit the profile of the mystery piece :prayer:
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Post by Indawoods »

AH HAH! I was right! :supz:
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Post by TopperHarley »

Nicely Done Inda! :supz:

when you remove or install/torque the left hand threaded KIPS shaft lever nut, allways hold the shaft with a wrench. Otherwise, you are putting all that torque on that little piece which can in turn, bend it/weaken it and perhaps cause it to fail. Not saying that you didnt do it correctly. It may have failed due to excessive carbon build up on the KIPS ports which causes excessive pressure on that dainty lil part in the case. IMO, they should of or could have made that piece a little beefier.
Last edited by TopperHarley on 10:22 pm Nov 05 2007, edited 1 time in total.
If you run into Heidi, have her look me up in her little black book and give me a call.
Im feelin a little wild today.
http://stores.shop.ebay.com/GATEWAY2-STROKE
2005 KDX220 mine
2003 KDX220 mine(under construction)
1998 KDX220 1/2 Brother-in-laws, soon his own
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scheckaet
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Post by scheckaet »

yep you da man Inda! :prayer: :prayer: :prayer:

Still can't figure out how it broke...I did install the RB head but it was months ago and it was running fine (and I did support the shaft at re-assembly). maybe it was cracked and finally gave in :hmm:
I did notice someting wrong on the previous ride, I thought I miss shifted but it was probably some of that that junk getting in the gear :doh:
I also noticed a loss of power from idle but thought it was a jetting issue since the weather was getting colder here...next time I'll know
It's funny how a $5.80 piece will cost me at least $280 and that's just for parts :evil: I still believe splitting the case is a must... so more $ :?
Oh well at least now I know what the problem is.
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TopperHarley
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Post by TopperHarley »

find out what it is going to cost for parts and labor. I beleive it may be cheaper for you to buy the 03 bottom end I have in my shop. Then you will have Extra Parts!! :mrgreen:



scheckaet said
.
(and I did support the shaft at re-assembly). maybe it was cracked and finally gave in
It is also important to support when disassembling.
If you run into Heidi, have her look me up in her little black book and give me a call.
Im feelin a little wild today.
http://stores.shop.ebay.com/GATEWAY2-STROKE
2005 KDX220 mine
2003 KDX220 mine(under construction)
1998 KDX220 1/2 Brother-in-laws, soon his own
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scheckaet
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Post by scheckaet »

It is also important to support when disassembling.
Did that too :mrgreen:
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