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Looks like im going to be replacing the starter gear assm. on my
03 KDX. ..I've done got both gaskets, ( clutch and case ) , anything i really need to watch out for when tearing it down to replace it ?
The clutch being removed is as far as i've torn into the case...

Won't know until you take it apart....Actual gear is probably fine....Usually the spring (assuming you have a slipping kicker)

Sometimes it's a matter of simply re-placing that spring. It tends to come undone on assy. That from reading of other's woes regarding the thing. I've not re-placed it myself.

IOW...what fuzzy said.

Yep the kicker is slipping !!!

Mr. THILL, I've updated an old thread on this issue.

http://kdxrider.net/forums/viewtopic.php?t=6053

Perhaps it can be of some help. You're the guy with the KX125/KDX200 hybrids?

rdsrf, thank you !
thats the info i was looking for....

Yep im the one with the 220 Hybrid, it's the starter on it thats giving me alittle trouble....

When I called Motosport to order the parts, the gentleman I spoke to had the same problem with his KX250. He said he had gone through the same experience and not wanting to spend the money on the starter gear and ratchet, tried various ways to correct it including a new spring and attempting to shim the spring with washers.

Apparently nothing solved the problem except his eventually replacing the gears. He also said that though the gears may look fine, even some slight wear will cause them to slip.

That conversation reinforced my decision on replacing the gears and I'm glad I did as it has been trouble free ever since.

Very nice hybrid by the way...Saw the pics elsewhere. Did that pro circuit pipe go on without any mods to it? How is it on tight trails compared to a KDX? Looks like a fun project.

Re: 'He also said that though the gears may look fine, even some slight wear will cause them to slip.'

Guess that makes me a lucky KDX owner.

My bike is nine years old with thousands of hours on it. Prior to realizing the extent to which air screw adjustments (OEM carb) effected hot-starts I kicked the thing silly (kicked myself silly in the process) often enough to bend the stock kicker wonky. All that and I evidently don't have even slight wear on the gears!!

Neat!

I have a used one out of a 05. guy said it wasn't slipping at all, BUT..
i think i may go ahead and replace the small spring just in case...

On the Hybrid , the PC pipe fits right in. You do have to relocate the one mounting point thats on the right side down tube a bit lower and then weld a small piece of metal to the upper frame tube next to the tank for the upper pipe mount...The only real tweaking of any of the exhaust was the silencer where the two line up, had to heat and bend the silencer tube just abit to get it to line up.....Got another Hybrid project in the works, still rounding up some parts right now......

A btw...

On another thread KDXQuebec is asking about a c-clip he's looking for on the INside of the idler gear of this assy. Note he's got an '89.........

Is there such a clip on the 'A' or 'H' model?

I don't know why there would be...but that's what he's looking for. If one'a you guys with the assy in pieces would take a look at that thread, that would be good.

HERE!

Thanks!