Tight drive shaft fit on bearing? Attempting to re-assemble

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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cstuckless
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Tight drive shaft fit on bearing? Attempting to re-assemble

Post by cstuckless »

I'm about to put my cases back together after a split. Just doing a dry run before I put the gasket material on, and it seems like the drive shaft is going to have a hard time clearing the bearing on the flywheel side of the case. Is that normal? Should I heat up that bearing to make it easier or just tap the case over it?

I recall it was slightly hard to work off, but nothing out of the ordinary... the inner portion of the bearing is not scored or anything, so I'm a bit baffled how it seems to be such a tight fit getting it started back on. Once the sealant goes back on I want to be able to work pretty swiftly, so I want to get a handle on this before I start.

I double checked the bearing part numbers, as I wasn't sure that the original owner might have substituted the wrong bearing. It's marked as a 6205, as per the parts diagram (part 601A): http://www.ronayers.com/oemparts/a/kaw/ ... /crankcase

Here's pics of the bearing, shaft, and the two coming together:

Image
Image
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Colin
cstuckless
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Re: Tight drive shaft fit on bearing? Attempting to re-assem

Post by cstuckless »

So I heated up the bearing a bit, tapped the case past the driveshaft with a rubber mallet, and using the Tusk crank tool got everything sealed up no problem. I tried sanding down the edges on the driveshaft a bit but I don't think that made any difference - the steel was too tough for my sandpaper to make any diff.

Colin
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Re: Tight drive shaft fit on bearing? Attempting to re-assem

Post by cstuckless »

Now that I've got everything buttoned back up after my first ever case split, I have to install it back in the bike tonight and give it a kick. I feel like it's a 50/50 chance it either runs like a dream or blows up. Anyone else get that feeling after a split?? Should I drink beer before, during, or after??

Colin
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Gotanubike
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Tight drive shaft fit on bearing? Attempting to re-assemble

Post by Gotanubike »

lol...film it and post results on youtube or vimeo
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
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Tioli
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Tight drive shaft fit on bearing? Attempting to re-assemble

Post by Tioli »

Iv put a few motors togeather over the years and I think every one has some level of anxiety.
2001 KX125 with a 1997 KDX Tioli Hp motor

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Trials.com.au / Forum / All about...me! / My long time friend the prancing horse / page 9
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Re: Tight drive shaft fit on bearing? Attempting to re-assem

Post by cstuckless »

Problem with the kickstart not engaging/returning properly. Have to take the clutch case back off and check it out. Always one more step it seems :)
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Tight drive shaft fit on bearing? Attempting to re-assemble

Post by Tedh98 »

Tioli wrote:Iv put a few motors togeather over the years and I think every one has some level of anxiety.

The piston circlips are the ones that bother me most. I probably check each side 10 times to make sure they are fully seated. I would have a hard time letting it go that I didn't have it in all the way and it ruined the top (and possibly bottom) end.
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Re: Tight drive shaft fit on bearing? Attempting to re-assem

Post by cstuckless »

Thanks Ted... I wasn't worrying about that before, but now I am. :wink:
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Re: Tight drive shaft fit on bearing? Attempting to re-assem

Post by cstuckless »

Kickstart fixed, bike's running great! Going for a run this weekend to see how she rides. Colin
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