Problem with KX/KDX conversion. Swingarm/Engine Cases

ebeck

Member
Dec 13, 2006
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I got a 1999 KX 125 swing arm and a 2003 KDX bottom end. The KX swingarm shaft is slightly too thick to fit through the back of the KDX engine cases. I know some have done this swap but the case part numbers changes several times. Apparently the 2002 engine cases are machined for swingarm shafts that are a tad thinner than they were in 1999 KX swingarms. The swingarm shaft is 2mm too think. Looks like the KDX cases had the same swing arm bolt since 1989. I guess a pre 89 KDX bottom would have worked. Ehh, I prefer the newer one. I'll deal with it.

Any ideas how to proceed? Can it be done by me with specialty bits while the cases are together? I'd hate to split the cases and machine them. The bottom end is so nice and put together......
 
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