Thought I Was On The Home Stretch?

So I went to put the case back on the KX85 tonight. Its the left side case that I had removed to inspect the crank area for piston debris after the rings went south.

Everything seemed to be in order and the case went on about halfway and then I met resistance. I convinced it on with my rubber mallet going in a little more than gentle sequence around the case. I got it down to about .5mm of being together and then inserted the bolts in hopes of drawing it together the final .5mm ---------- No Dice.

Once the case was drawn together, neither the crank nor the counterchaft would spin freely, something got cocked up.

So now I am at that moment of having to take it apart again which is going to fun and figuring out why it didn't go on properly.

My question now is have I shagged any of the bearings by it not going on completely straight?
When the case came off the last time, the crank bearing stayed in the case. If I heat the case, the bearing will probably come out of the case this time you think? Then it will be stuck to the crank where I guess I can heat it some to remove it there.

This is all pretty frustrating. My son is supposed to race this bike on Saturday night to open the series. I had thought for sure that we could have this bike done by then......now I am not!

I have never had much luck with 2-strokes it seems. I have built 6 streetbikes over the last 3 years and never ran into these types of issues. I feel like a total newb when I get to working on 2-strokes. LOL
I thought they were supposed to be easier?

Cheers
Bernie

I think I may know where I screwed it up?

There was a small o-ring that came off the countershaft assembly when I removed the case.

I think I may have inadvertantly placed that o-ring on the inside between the bearing and the gear?
I couldn't remember exactly where the o-ring went and from looking at the Kawi parts fiche, I think I got confused and placed it wrong.

Now that I am looking at the fiche again, is it possible that the little o-ring goes on the outside of the bearing, sandwiched between the bearing and the spacer?

If that is the case, thats where I messed up.

Cheers
Bernie.

BTW - Indy, I appreciate all of your help. If you ever have a turbocharged motorcycle that needs any info, I'm your man!
I own 4 of 'em!

Hey Indy,

No, I don't have the service manual, just the owners manual. Thats been one of the hiccups in getting this done.
Trying to find out the proper info.

I think the o-ring is what caused the problem as it is not letting the cases mate up flush. Having a bitch of a time now getting the case split again.

I'll keep my chin up here in hopes of having this thing ready for Saturday but I am sure I will be back for more info before it is done.

Cheers
Bernie

No, I did not heat anything when reassembling the case.

Just to be clear, I only removed the left side case. The right side is still in place.
When I got the left side off, the bearing stayed with the case. It came off of the crank.

To reinstall it again, the only option I have for heat / cold, is to place the entire motor in my beer fridge (if it will fit) and then try to gently heat the inner race of the crank bearing (I say gently because the crank seal is still in place as well). I don't want to risk destroying the crank seal. It cannot be replaced without removing the crank bearing from the case.

The other option is to get the bearing out of the case and install it to the crank prior to putting the case on.

I am thinking that option 1 might be the best way to go but you'll have to tell me?

Thanx For Helping!
Bernie

Thanx Heaps Indy....
Thats a great help!

BTW Guys,

Since the crank bearing stays in the case on this motor, is it ok to put a little heat from a heatgun or my propane torch to the inner race of the bearing to open it a little for putting it back on the crank? I am worried about the crank seal on the other side but I want to use less violence on the case when I put it back on again.

Wife says that I cannot put the engine in the freezer...lol

Cheers
Bernie

Whew!

Got it back together.
I hope it is all well? The countershaft sprocket rotates freely. The crank turns smoothly but I am not certain how easily it is supposed to spin by just my hand spinning the flywheel?
Sounds like it is probably not unlike what you had going on Indy so hope that it all settles in once I get it all back together.

Yea, the wife....lol
Actually the problem was that we had nowhere else to put the frozen goods that were in there and she wasn't thrilled about having meats sitting on the counter for a couple of hours.
We don't have a stand alone freezer, just the one above the fridge.

Anyway, I have you guys to thank especially Indy who has more than tolerated my barrage of questions.

Hopefully, it will be smooth sailing from here on in?

Cheers
Bernie