Solved the powerband issue.... almost

[KDXrider1989]

Decided to take off the exhaust and look into the cylinder to see if all the valves matched up. They did, but I noticed how the governor shaft was out of the collar that pulls open the KIPS

The shaft moves up and down easily, is that normal? This explains why the power comes on and off whenever I go over rough terrain, because the shaft slides in and out of that collar. Any way I could fix this?

[Julien D]

I made a plate that goes over the whole mess with a hole drilled for that bushing and one where the set screw goes. Seems to have fixed the problem you describe.

[KDXrider1989]

Do you have a picture of the plate you made? I might make one myself if I can't fix this problem

[Julien D]

No, but I guess I should. Someone else asked for one too. It's nothing pretty, just a piece of flat aluminum with 2 holes drilled in it.

[SS109]

Someone else asked for one too.

Yeah, I have been waiting.

[dfeckel]

Me too! ;)

However, you've described it enough that I'm pretty sure I know what it looks like already.

[KDXrider1989]

Problem fixed! Went to Ace Hardware and picked up a dowel pin that fit inside the hole and groove on the governor shaft and put the bolt back on. I think I need new handlebar grips now