KX 250 Power Valve Assembly Questions.

[KStacoma]

I have a 1994 kx 250 and am having a terrible time getting the powervalve assemblies to cooperate and work together right. I've installed the operating rod and secondary valves correctly and lined up the short teeth w/the marks on the rod so I am sure they are in correctly. The main powrevalve is also installed correctly and will move through it's range of motion just fine as will the others, but I can't get the secondary valves to ever end up opening to exactly where they should be, i.e. flush w/the ports. I think my problem is the "main valve rod". My manual says slide it in al the way until it stops in the cylinder bore, but mine will just go in all the way until I can't push any more. Also, it says that it is correctly timed if the rod is flush w/the cylinder, but I still can't get it right. I'm horribly confused, if you can make sense of this i would be in awe, please help me if you can,
Jamie

 

[AST]

dont know if this helps or not but on my 2000 kx250 I tried lining the short teeth with the marks(this was a colored dot) and they would not fully open at that setting. I learned to set it all in the cylinder loose and experimented with where the small gears had to be lined up to fully open.The proper setting was 1 tooth past the colored dot on the small gears.(thats 1 tooth towards the center of the cylinder) Like I said,dont know if that helps or not but it could be your problem?