KIPS stuck in engine?

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 5, 2004

• #1

My Kaw manual doesn't seem to cover the 2000 kips arrangement and I've looked through some of the stuff on tech tips but I'm literally stck. Got the cylinder off OK no problem with the shaft, took out a couple little bolts and the allen and removed the horizontal shaft, don't see anything else to remove. The valves wouldn't budge. Some kerosene and pushing/etc has got them moving like they want to come out but no go. Are they just stuck from the carbon crud in there? The plan is to let them soak a bit over night. Anything I'm missing here?

 

K

KAY DEE EXER

~SPONSOR~

Mar 3, 2003

629

0

• Jul 5, 2004

• #2

I posted the same question like a week ago. LOL. They should just pull out but yep carbon is the probably the culprit. I used Subaru upper engine cleaner. TOP STUFF. After a liberal spray all over with that product and everything just slid straight out (covered it GOOP).

 

KelvinKDX

LIFETIME SPONSOR

Aug 25, 2000

1,622

0

• Jul 5, 2004

• #3

What model years is your manual for??

 

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 6, 2004

• Thread starter
• #4

manual year

Copyright is 87, bike is )). Obviously this KIPS part isn't there. Is there any web manual I can use or buy?

 

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 6, 2004

• Thread starter
• #5

87 ...

 

J

JasonWho

Member

Apr 10, 2002

2,109

0

• Jul 6, 2004

• #6

---

 

Last edited: Sep 16, 2004

KelvinKDX

LIFETIME SPONSOR

Aug 25, 2000

1,622

0

• Jul 6, 2004

• #7

Uh ... I think that he is working on a 2000 model KDX but has a 1987 model manual. Is that the case???

 

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 6, 2004

• Thread starter
• #8

That's it, can't type. I just spraying carb cleaner in there and it is doing much better.

 

J

JasonWho

Member

Apr 10, 2002

2,109

0

• Jul 6, 2004

• #9

---

 

Last edited: Sep 16, 2004

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 7, 2004

• Thread starter
• #10

I have the base manual so that must be a supplement right?

 

K

Krusin

Member

Jul 5, 2004

3

0

• Jul 7, 2004

• #11

Factory Service Manual

The Manual you have is not for your bike, no matter what the supplement.

The Kawasaki part number for the 2000 KDX200H Service Manual is 99924-1181-07. Have your dealer order one up or go to Kawasaki's web site and click on Vehicle Information in the header. It will then allow you to select your vehicle, by type, then by vin or year and model. You will then be able to view the factory part numbers for just about everything on the bike.

 

J

JasonWho

Member

Apr 10, 2002

2,109

0

• Jul 7, 2004

• #12

---

 

Last edited: Sep 16, 2004

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 7, 2004

• Thread starter
• #13

I want to order from Kawasaki but they are back ordered! Oh well, have a new piston kit coming, will clean up the KIPS, reed looked fine, throw it back together. Thanks

 

J

JasonWho

Member

Apr 10, 2002

2,109

0

• Jul 7, 2004

• #14

---

 

Last edited: Sep 16, 2004

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 7, 2004

• Thread starter
• #15

Too late, I ordered from Kaw, should have checked Ayers, they are pretty good.

 

J

JasonWho

Member

Apr 10, 2002

2,109

0

• Jul 7, 2004

• #16

---

 

Last edited: Sep 16, 2004

B

Bizerk

Member

Feb 28, 2004

142

0

• Jul 8, 2004

• #17

www.repairmanual.com

Kawasaki Service Manual# 99924-1181-06.

Check out the "Just KDX" website under tech info for more info on KIPS and top end rebuild:
http://justkdx.dirtrider.net/

Also check out Eric Gorr's website for all kinds of rebuild and tech articles.
<------Just click over there where it says "Eric Gorr's".

Later... ;)

 

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 18, 2004

• Thread starter
• #18

Thanks for the input.. My new manual came from Kawasaki Friday and I finished the disassembly and cleaning Saturday and got it all back together today. Runs fine with a new piston and a freed exhaust valve.

 

J

JasonWho

Member

Apr 10, 2002

2,109

0

• Jul 18, 2004

• #19

---

 

Last edited: Sep 16, 2004

J

jirvine

Member

Oct 21, 2001

94

0

• Jul 19, 2004

• Thread starter
• #20

I hadn't taken a piston off a bike in 40 years. A little booger to get the cylinder back over the piston and I had my fingers crossed that the kips was all together right. Any break in tips?

 

KelvinKDX

LIFETIME SPONSOR

Aug 25, 2000

1,622

0

• Jul 19, 2004

• #21

Look around and you'll see lot's of break in information. I always run the bike through three heat cycles. Start bike, let it run at low rpm until hot, cool, repeat. Ride.

 

KelvinKDX

LIFETIME SPONSOR

Aug 25, 2000

1,622

0

• Jul 19, 2004

• #22

It's a good thing to check your compression after the first ride or so. This way you have a starting point for a refference when you check it later. EG has told me not to check it when the rings are brand new but to let them break in for about one ride before checking compression.