KIPS Assembly

[Varmint]

The manual has me so confused on left and right. They say the right exhaust valve rod has has the orings on it. To me, there is only one way to put the rods in. The end with the line for sub valve alignment (third tooth in or so) has to go in first and the end with the line for the main rod gear (line near first tooth) needs to be towards the front.

Is this how the sub valves and rods should be configured?


And the o ring rod gets stuck half way in. I'm worried if I push any farther I wont be able to get it out. I don't remember it being so hard to get out.

Thanks guys!

[doctord23]

I just finished putting mine back together and I think you have the valves on the wrong sides. The rods are correct. The one with the o-rings takes a little to push it in. The other one slides right in.

[Varmint]

When I pulled the sub valves out, the one with the ring at the top was on the left. I was sure to note that. I thought that was an obvious clue to remember. I'll have to review my pictures.

[Varmint]

It's clear in this pic that the ringed sub valve is on the right side of the bike (or left when you are working on the KIPs) hence my confusion.

I also noted how it all worked. When I turn the main shaft all the way clockwise (towards the front of the bike) the sub valves were both close. Is this correct?

I'm not sure what I'm doing wrong here.

[Mr. Wibbens]

I just finished putting mine back together and I think you have the valves on the wrong sides. The rods are correct. The one with the o-rings takes a little to push it in. The other one slides right in.

You must be looking at it wrong

[Varmint]

I just finished putting mine back together and I think you have the valves on the wrong sides. The rods are correct. The one with the o-rings takes a little to push it in. The other one slides right in.

You must be looking at it wrong

So it looks right to you wibbs?

[doctord23]

I just finished putting mine back together and I think you have the valves on the wrong sides. The rods are correct. The one with the o-rings takes a little to push it in. The other one slides right in.

You must be looking at it wrong

The manual clearly states and I quote "The left sub-valve has a groove and the right exhaust valve rod has an o-ring for identification." Are you saying that the manual is wrong? I hope not because that is what I followed.

Think about where you need the o-rings. It would be on the same side that has the shaft seal because the rod is outside of the seal.

The right side is the pipe side of the bike. Your right as you sit on the bike.

Maybe the valves were put in incorrectly before the OP got it.
The manual also says to grease the o-rings on the rod. That helps it slide in easier.

[Mr. Wibbens]

I donut have an H manual, so you are on your own there

Look at the fiche http://fiche.ronayers.com/Index.cfm/Mod ... embedlinks

Tell me where you see it

[Mr. Wibbens]

I know there's something in the H manual that was incorrect

Dunno if it was pertaining to the valves though??

[doctord23]

I donut have an H manual, so you are on your own there

Look at the fiche http://fiche.ronayers.com/Index.cfm/Mod ... embedlinks

Tell me where you see it

The fiche shows the groove on the right. Either the fiche or the manual is wrong. I'm hoping it's the fiche because I put mine in per the manual but haven't started it yet. I'll let you know how it runs when I get a chance to ride it.

[Mr. Wibbens]

Here ya go http://justkdx.dirtrider.net/correction.html

[Julien D]

Here ya go http://justkdx.dirtrider.net/correction.html

yeah, you beat me to it.

[Julien D]

Here ya go http://justkdx.dirtrider.net/correction.html

yeah, you beat me to it.

If you've got the subvalves backwards and you look up through the exhaust at 'em, you'll plainly see that something isn't right. It just doesn't line up how it should.

[Mr. Wibbens]

Somebody aint gonna like that

[doctord23]

Here ya go http://justkdx.dirtrider.net/correction.html

Thanks for the info. So much for following directions.
Looks like the head is coming back off.
I'm glad I found this thread before I ran it.

[Varmint]

Phew! I played with this puzzle for a hour and I knew something was wrong. To me it can only go together one way.

Thanks for clearing this up guys.

Back to how much pressure for right rod... Does it take a lot mor force to get the oring past whatever is holding it up?

[doctord23]

Somebody aint gonna like that

Done!

Unfortunately the jug and head have to come off of the bike to remove the sub-valves. At least everything was already clean.

I should send Kawasaki a bill for their screwing up the manual.

[KarlP]

Quote:

Does it need a little extra umph to get it in there?



It does.

Do a search on here on that rod o-ring, its actually called packing and doesn't come with the typical gasket kit, as I recall.

After the KIPS is all fully assembled it should move silky smooth. I had some issues in the bore that right hand rod goes in and thought it would work itself out. It didn't and I ended up riding for a year with a sticky KIPS. I ended up fixing it by running a drill bit wrapped with emory cloth in that bore.