KDX 200 Project thing

[dualero]

Also for you dudes that cant get a race out of the steering head...

Measure to the race top or bottom of head stock right to the base or mating surface of the race where it bottoms out... transfer the measurement outside and dimple about 2mm 1/8" above the mark... then drill with a chisel bit the ones with a smaller drill then flat tip all the way to the race. I then have a second bit the same size with the little bit ground off to finish the hole to the race because the race will destroy the good bit if you just keep pushing.

Once you have the hole just take a hard punch that is slightly smaller than the hole (1/4 - 3/8" i use 3/8) insert it and hit it with a solid blow, the race will break and you should able to remove the pieces. You can plug weld the hole or just fill it with JB after the new race is installed.

I did not get this right tune,

you mean to drill through the headstock above the bottom race or vice versa, then punch it out?

Or drilling through the headstock to hit the race directly an then break it?

Thanks

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[adventurco]

KDX 200 Project thing

I use the first method tune mentioned. Nicking the race with a dremel and prying it loose at the weak spot. Just be sure not to damage the stem. Take your time cutting. I keep a worn down cutting disc around for a smaller radius to get a more precise cut, works well.

 

[Tune-A-Fish]

I did not get this right tune,

you mean to drill through the headstock above the bottom race or vice versa, then punch it out?

Or drilling through the headstock to hit the race directly an then break it?

Thanks

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Sorry I was in the shop all day.

Just above into the race so you catch both, the drift will be half in the race and half in air so when you hit it... it snaps up or down depending on top or bottom race. I have done it several times and it works when the race has no prowd metal to bite or tap out from top or bottom of the head stock, you just don't have many options.

You could heat it but I don't like to get the head stock too hot.

 

[CaferacerMO]

I'm going to work on the races tomorrow and report back my results.
I'm currently in route with my entire bike in pieces on the way home, now I'll have access to work on it much more often and should have it done soon.

Also, remember the Harley I talked about way back when?
Traded an old jr50 pit bike and 50 bucks for it. Clean title.

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[adventurco]

Did that come with the rest of the engine?

 

[CaferacerMO]

Did that come with the rest of the engine?

Sure did, needs to be rebuilt. If I can find the time I'll try and take it on.

 

[Tune-A-Fish]

If you don't PM me and maybe we can deal

 

[CaferacerMO]

Okay I mocked up the front end and now am going to internally lower it, but where exactly does the spacer go on the chamber?
I plan to just go to Home Depot and get a pvc pipe and make a spacer. I plan to drop them 3 inches or maybe 4.

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[lostboy]

I had a dt175 and it was a blast to ride. Now I putt around on a wr250r mostly because in NJ you can't register anything without some sort of loophole.


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[CaferacerMO]

Is there something I'm missing?
I can't figure out how to release the fork rod so that I can put the spacer in to lower these forks.
I've tried to unscrew this lower screw and it simply turns.. I know I'm missing something stupid obvious..

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[Tune-A-Fish]

The dampening rod is spinning inside, you need to pull the top caps (careful spring loaded) then find a way to stop the spin. you could try an impact and see if it hit spins it off too.

 

[Nj732port]

I used a few extensions and a Allen key for my forks on the inside to hold it in place it's awkward by your self but easy enough

 

[CaferacerMO]

Hmmm. Can't seem to figure quite how to do it. Will it be easier to do if I remove the upper tubing?
Just don't wanna have to reinstall the fork seals..


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[Tune-A-Fish]

Maybe a wood wedge to hold it just enough to get the impact to bite?

 

[CaferacerMO]

Maybe a wood wedge to hold it just enough to get the impact to bite?

As in take a long wedge of wood and put it down the tuning, and then while holding it down run an impact on the other side?

 

[Nj732port]

http://www.sr500forum.com/forum/viewtopic.php?f=70&t=10474

 

[Tune-A-Fish]

Yep, some use a broom handle but you would need to break it all the way down for that

 

[dualero]

Yep, some use a broom handle but you would need to break it all the way down for that

Yes I've heard of broomsticks sharpened at one end to grip inside the rod from the upper part, while impact wrenching the bolt.

I've made one tool like the broomstick, but out of scraps of metal.

I'll show you pics

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[CaferacerMO]

Every attempt so far has failed... Cons of just cutting the springs?


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[dualero]

Re: KDX 200 Project thing

You end up with a harder rate spring, and if you don't supplement the length that you cut/remove you will have a lot of dead extension travel.

Hope you get what I mean