KDXRIDER.NET

So, after a big weekend with 12 hours riding, my 94 KDX200 wouldn't change down below 2nd. Was running fine and shifting fine from 2nd to 6th.

After checking shifting mechanism was working fine, we split cases to find the piece of metal in the picture jammed in the gearbox. The gearbox now (with cases split) seems to be shifting fine.

My question is, does anyone have any idea where in the engine this piece of metal came from? There is no obvious spot anywhere that I can see... The piece of metal looks as if it has been riveted into somewhere.

my money would be on the kips actuator shaft doohickey

take of the inner clutch cover and you should see what is left of it sitting on the bottom of the actuator shaft




part number 13236-1190

I have had a long hard think over several minutes & to me the piece of metal looks like a foreign coin of some sort probably of western origin & its possible it could be used as some kind of bartering currency from around the 21st century ?
How it found its way into the motor of your kdx is a mystery...perhaps you may have been `short changed` ?
As for its value in the current market I would suggest it may be worth in excess of around £1.25p in new English money however due to the recent economic market fluctuations it is quite possible to go up as well as down.

Has the penny dropped?

Bet ya if you break down that motor a little more your find a bag of cannabis & a tube of fruit pastilles, that bike was no doubt destined for Holland before you made the purchase, my advice.... ebay it & keep schtum, but then wat do I know?

@DIYMIRAGE, bingo! That's it! Thank you! Just waiting on a call back with a price for a replacement.

Such an annoying thing to happen. Bike has had about 50 hours since full restoration (frame painted, all bearings, top and bottom end rebuild etc)

yeah, I thought I had seen it before




not sure what one of these runs on your neck of the woods but RMATV has them for $7.85 and offers free shipping on orders over $100 so you just need to pick yourself out another $92.15 in parts, shouldn't be too hard

Yeah mine had broken the same as yours, I also found the little half-circle piece that was holding it in, but in the clutch side. Didn't notice the bit broken off when I first pulled out the kips system.

Would that have meant the kips valve wouldn't have been working? Or what function does that piece actually have? (don't have the pieces of the bike with me atm to have a look).

Also, $20 but a 2 week order from Japan to get it here. I'll see how much postage is from some US sites as it might be quicker.

it basically means your KIPS valves never got opened
you get the down low grunt of the closed kips system but not the op top hit of the open system

the bike will run notable better once this is fixed

KIPS.
Read newb thread in sig for how to put the kips properly.

Yes, I had this happen to me also. I think they can break if your powervalves get carboned up and can't move freely or when you put the top end back on people forget to support the shaft with a wrench when tightening the gear down.

I've ordered new bits. I'll tear down the rest of the kips system and check it out while I've got everything apart. I've got a couple of spare top ends that came with the bike so hopefully I don't need any bits for this. I didn't notice power loss after the gearbox jammed (I lost neutral and 1st gear), so I'm assuming the KIPS valve hasn't been working since I got the bike. Will be interesting to see how much power it has now (I always thought it was missing something up the top end).

Also ordered new gaskets, oil seals, D.I.D X-ring chain and JT sprockets, spare levers, and a bunch of spark plugs from Partzilla.com

Common failure when folks work without a manual. The threads on the actuator nut are left handed, and the shaft has to be supported with a wrench or you break this little bit off. A lot of folks get confused by the KIPS valve setup, just remember main valve closed, sub valves closed.