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Dirt Bike Discussions By Brand
Canadian Daves JustKDX
leaking oil
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[QUOTE="jdbrusch, post: 680970, member: 25926"] Ok here we go,you will have to remove the kick starter,the rear brake pedal drain the antifreeze and disconnect the kips lever attached to the top or the rod,remember this is a left hand thread,has a arrow on top of the lever on which way to loosen,make sure you also support the shaft by inserting small rod into the hole in the kips lever shaft or hold it with a good pair of pliers,failure to do so can snap of the rod in the advancer assembly and ruin your day,do this when installing the nut also.Remove the lower front coolant hose and all the case bolts.Now you may have noticed I left the clutch cable for last simply because you can now pull the clutch lever before removing the cable and the case should pop loose,saves trying to pry or jimmy it up,now remove the clutch cable.The hard part is to remove the clutch assembly,you can remove the clutch as one unit by removing the inner nut,you will have to find a way to prevent the tranny from spinning over to do this,if you have the chain still on replace the rear brake pedal and hold on the rear brake and try to remove the nut(counterclockwise).If this does not work you can fabricate up a flywheel holder with a piece of flatbar with two bolts sticking out(should look something like this I____I_____ ,hope that helped ) that can be inserted into the two outer holes on the flywheel,make sure the bolts do not stick to far into the flywheel and damage the windings.Just rest the end of the bar against the case protector on the frame.Once the clutch is off and the shift pedal is removed the shaft should slide out,as long as the end is not to badly bent.If it is badly bent,do not try to force it thru it will most likey damage the surface the shaft uses as a bearing in the case you might have to cut it off. You may have to remove the idler gear also,I can't remember off hand if there is enough clearance to get the shaft by.Reassembly is fairly simply the reverse, new case gasket and shaft seal will likely be required,just make sure you have the waterpump drive gear lined up with the primary gear.And remember to support the kips shaft when installing the nut.If you need torque specs,reply so again and I will list them for you.Good luck :thumb: James.. [/QUOTE]
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Dirt Bike Discussions By Brand
Canadian Daves JustKDX
leaking oil
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