KDXRIDER.NET

Keystone wrote:A '93 E-Series! you'll love it. I was in the same boat as you when I bought my '93. Previous owner had neglected to do much maintenance. The first thing I did was remove the cylinder to inspect the KIPS because of all the stories I've heard about them shredding. First time ever for me working on an engine of any kind. Mine were in great shape, maybe I got lucky.

Don't let anyone tell you that you can inspect the KIPS without removing the top end cylinder jug, you cannot. There are no secret tricks. Yes, you may be able to see if they are functioning without removing the top end, but you cannot inspect the important aspect of these KIPS valves, the teeth, without removing the top end. It is possible the KIPS valves are functioning with broken or worn teeth.

Buy a torque wrench and a special "motion pro" box end wrench to re-install the jug. Throw in a new weisco piston and rings while you are in there. Look into buying the new STEEL KIPS valves that have recently been developed. The original OEM KIPS are still available if you really want.

Nothing is too difficult on this bike, especially with an owners manual. Just don't make the mistake of putting it back together "guessing" it is correct. Make sure.

You will LOVE this bike.

Keystone wrote:Thanks for the heads-up on that Gotanubike. I edited my post to explain to others what you brought up, good catch!

You can see from the photo why the manual tells you to pull out the main exhaust valve 1/2" and then remove/insert the operating rod (on the '89 -91') and why this procedure in the service manual will NOT work (on the '92-'94) - would have been nice if the '92-'94 suppliments mentioned that, or did they and I missed it?.


This is Gotanubikes main exhaust valve, they were installed in the 1989, 1990, 1991 E Series KDX200: - correct?

Gotanubike wrote:

And this is my 1993 main exhaust valve, they were installed in the 1992, 1993 and 1994 E Series KDX200: - correct?









Now I know why my 1989 service manual does not explain how to properly install my 1993 main exhaust valve. Both the manual and cyclepedia do not explain that the main exhaust valve was changed in the E-series after 3 years, and neither give any explaination on how to install the updated valves in the following 3 years. I have the 1989 kawasaki service manual and also the 1993 suppliment and it does NOT explain the changes made to the main exhaust valve.

Now, I'd like to know why they were changed, there had to be a good reason and it surely wasnt for ease of installation!. Are there more KIPS failures in earlier models than later models? Could the earlier main exhaust valves have been causing stress and premature wear on the left powervalve? If so, the KIPS problem on the E-series might be solved by replacing the old original main exhaust valve with the new redesigned one.