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Right side cover removal
Posted: 11:26 am Aug 25 2010
by john316
I need to replace the right side cover gasket. I don't have a manual. Can I just remove the kick starter, hoses, clutch cable, and pull the side cover off, or do I have to remove the clutch cover, waterpump, and governor shaft? It looks like (from a pic I saw on the Internet) I should be able to pull the side cover without removing all that stuff.
'04 KDX 220
Posted: 12:10 pm Aug 25 2010
by Slick_Nick
You don't have to remove the governer shaft but you do need to remove the gear at the top of it that connects it to the kips system. Remember this nut is LEFT HAND THREAD!! Then remove the kickstarter and you should be good to go. Removing the water pump cover is not required but it does make reassembly easier because you can turn the water pump shaft to get the gears to mesh properly. Replace your gasket and be on your way.
Posted: 03:12 pm Aug 25 2010
by john316
Thank you for the response. I did know about the nut, a friend of mine broke his before he learned it was left handed.
Posted: 04:16 pm Aug 25 2010
by scheckaet
Posted: 09:27 pm Aug 25 2010
by Slick_Nick
Off the top of my head those 8mm bolts are tightened to 87 in lbs.
Posted: 07:23 am Aug 26 2010
by Varmint
Make sure you support the shaft when removing that LH nut or you'll end up like your friend. I think you can use a 6mm wrench to support it.