Help me figure out what this part it...please!

[JasonRan]

Ok, this has TOTALLY got me stumped. I was riding my 2000 KDX 200 yesterday and here's what happened.

I had been riding for about 25 minutes and the bike was running great. I tried to go around a big puddle but ended up falling to my right into the puddle which laid the bike down completely on it's side. No water got into the bike at all. I killed the motor as soon as I went down. I pick the bike up, put it in neutral, and crank it. It cranks perfect. I pull in the clutch and it is real loose. I put it in gear and it immediately stalled. The clutch lever has no tension on it, but the cable is working fine. We pulled the clutch over off, took out the basket and found a metal bolt looking part wedged between the clutch discs. I have attached the links for the pictures. We looked ALL over the clutch area and there are no signs of anything broken and no other pieces of parts. The bike rode out of the woods (probably 2 miles) perfect...no problem (except for no clutch).

My question is...what the heck is this part and where did it come from?!?! It looks like it is probably part of a bigger peice and this is just the pivot point or something. It's not a bolt, so it has to have something else that holds it in. If anyone can help me figure this out, you will be a hero and the smartest person alive. I hate to tear the whole bike down to look for a broken part, but I may have to. Thanks a million!!!

http://i33.photobucket.com/albums/d63/JasonRan/Picture046.jpg

http://i33.photobucket.com/albums/d63/JasonRan/Picture043.jpg

http://i33.photobucket.com/albums/d63/JasonRan/Picture041.jpg

 

[motogps]

Alabama mud puddles are crawling with those things, lucky you didn't have any in your cylinder--but seriously it looks like part of the push rod, check out the parts microfiche if you don't have a manual.

 

[kelseybrent]

Go to your favorite parts looker up place. I used www.buykawasaki.com, but I can't get a clean url link to paste here.
Look under Engine Covers and look for ref. # 13236, LEVER-COMP,GOVERNOR
Is that it?

It looks like the same basic shape with the mounting bracket broken off. I can't really picture where it is mounted though, or if it's internal to the right side cover.

Good luck.

 

[KX250Dad]

My best guess is the part (while pretty beat up in the photo's) may be a #13114 pusher-clutch. Obviously, your plates/fibers didn't separate when you pulled in the clutch so I suspect either the pusher clutch lost position and fell, which I don't inderstand myself, or it was worn whereas it left the slot in the arm. Regardless it seems to me your lucky if this is the case as no other clutch components were killed. Check the vertical clutch arm closely, this may be one of those this influences that things. Gooc luck, you can find this part within any of the on-line parts fiche(s).

 

[JasonRan]

kelseybrent-

I think we may be onto something. I looked through the parts diagrams again right after posting this and found that part. I really think that is it. I have NO idea what it is or where it goes, but I think that is it. I am going to the dealer at lunch today to see if they can order it for me and maybe tell me what it is. If anyone knows what it is, that would be great. Thanks!

 

[strider80]

It goes in the center of the clutch, it just slips in if I remember right. I have no idea how it could have come out though .

 

[strider80]

It is the center part.

I hijacked this picture, it is from a different year, but you get the idea. I still don't know how it can come out though.

 

[JasonRan]

Thanks for all the replies. It is actually part of the power valve assembly. It is part 13236. I talked to a mechanic at lunch and he told me all about it. The part was $13 and I plan to do a piston while I am in there. Thanks again for all the help!!!

 

[strider80]

Really? Is the piece I pointed to still in your clutch? I will quietly sulk away now......

 

[JasonRan]

strider- yep, that piece is there and has no problem. With that other piece wedged in the clutch plates, that piece would not go down all the way that it should. I really got lucky that nothing else got damaged! Don't feel bad though...that would have been my first guess too!

 

[Green Hornet]

Go to your favorite parts looker up place. I used www.buykawasaki.com, but I can't get a clean url link to paste here.
Look under Engine Covers and look for ref. # 13236, LEVER-COMP,GOVERNOR
Is that it?

It looks like the same basic shape with the mounting bracket broken off. I can't really picture where it is mounted though, or if it's internal to the right side cover.

Good luck.

Yes that is it..$7 part.. Buy the Right Engince Gasket, Clutch Gasket, Hell the Top end Kit also...You will have to check the KIPS to find out how it happened...

 

[JasonRan]

It actually cost $13 at my local dealer, but they are criminals. :)

I plan to do the top end while I am in there. I am going with the Wiseco piston kit and will get the gasket kit also. I think the reason that it broke is probably because my engine is all gunked up from running rich for so long. I'm going to clean it all up, reassemble, and jet properly. :ride:

 

[Green Hornet]

Remember, when you tighten or loosen the ADVANCER SHAFT in the future, to use a WRENCH(located under the bottie)to keep the SHAFT form ROTATING. Someone else may not have done that & that WILL BREAK that portion of the KIPS. But the KIPS GEARS may be SEIZED UP ALSO. But you know that already;)