Head replating

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Jan 18, 2003
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#1
Ok here is the short version of my problem. While removong the cylinder head from my 2002 KDX 200 I ran into this problem. I believe it is the governer not quite sure. It is located on the right side of the bikeand attaches to near the exhaust valve. While tring to remove the cylinder there was a gear in the way, I attempted to rotate the gear to clear the cylinder when i heard a click. I was one of those bad clicks that cause alot of aditional work :ohmy: My question, is there a part in the engine that could be damaged by tring to rotate the governer shaft. If this seems vague please feel free to ask questions as i am without a doubt not a mechanic


Thanks in advance for any help.

Chuck
 

Woodbyrd

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#3
phyerftr,

Yes you could have caused a problem! Goto the KDX Tech tips at http://justkdx.dirtrider.net/, read the two articles under the Engine heading - KIPS power valve & Top End Pictoral. Next make sure you get an owners manual, comes in very handy. After you read this you will have a better understanding of how these items go together.

Just remember that shaft has a left handed thread on the top!!

Now to what you could have done, nothing but that is not my luck. You could have broken the shaft that leads down to the right engine case. Or you could have broken the bracket at the bottom of the shaft. The last two are easy to fix but you will have to take the right engine case off. I would not run the engine until you have done some reading and figured out what has happen.
 

canyncarvr

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#4
So...you attempted to remove the cylinder without detaching the KIPS from the actuator shaft?

Ooops. :(

There is no 'rotation' of gear to clear the cylinder if the segmented gear is removed. They aren't even close at that time.

No, it's not a governor.

It's fairly common to damage the KIPS actuator rod just by removing the LHT nut while not supporting the shaft.

If you tried to force the segment gear past it's normal operating position, you at least broke the pin that's holding it in place!!

If that much force was applied (and the pin isn't broken) you should replace the activating shaft (the one that goes down into the engine), anyway.

BTW...KIPS= 'Kawasaki Induction Power System' ;)
 
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Sep 29, 2003
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#6
cc said--- :laugh:
BTW...KIPS= 'Kawasaki Induction Power System'
"--------------------ok, so what's BTW mean?? ROTFLMAO :laugh:
 

wibby

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#9
BTW...Out in the real world..... Have you ever mistakenly spoken "LOL" when someone said something funny?

I have! :eek:
 
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#10
Wibby said---"..... Have you ever mistakenly spoken "LOL" when someone said something funny?" --------------------------------------------------------------------------------can't say that I have----though I might have commented along the lines of--"coffee on the keyboard". DOH!!!
 
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#11
Thanks everyone. I have ordered a service manuel and the head is off for replating. Hopefully be back riding soon
 
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#14
BTW, IMO, I thought KIPS was for "Kawasaki Integrated Powervalve System" BTW ! FYI, LOL !!!