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How to Remove Case COver on KDX 220 97
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Posted by: Byte2009---------------------
I have removed all bolts and cooling hoses but still cannot remove this case cover (RHS).
Something seems to be locking it in place from inside.
The manual makes no reference at all to remove the tranny cover on RHS.
Help?
Posted by: julien_d---------------------
I assume you are referring to the inner clutch cover. If so, you have removed the kickstart lever, all the hoses, the clutch cable, all the bolts, and the claw gear from the top of the KIPS activating rod (Left hand thread there!). There is a small tab at the top on that cover that sticks up above the crank cases. If you put a long screwdriver or punch against that tab from the left side and give it a tap it should break the seal loose. Go around the left side of the bike and look at the top edge of the right side cover and you should see the tab I'm talking about.
Posted by: Byte2009---------------------
Thansk Julien.
followed all that and successfully completed that task.
Now, everything is back together again but bike will not start upon kick.
When kicking, I do nto feel any compression and it just does nto feel right.
THougts?
Byte
Posted by: julien_d---------------------
Sounds like the kickstart shaft isn't engaging. When you push the lever down do you feel spring tension and nothing more? There are two ratchet gears on the back of the kickstart assembly that must engage. Do you have a service manual so you can check out how the kickstart assembly should be set and installed?
Posted by: Byte2009---------------------
Thanks Julien,
Yeah - I feel no compression and only a little spring tension. I have the manual. TO access these ratchet gears on the back, do i have to remove the entire case again and clutch basket? It is not clear to me how the kickstart assembly should be be set and installed.
How could this set of ratchet gears be upset when I have only just removed the clutch basket and clutch shaft?
Byte
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