KIPs and Govener arm

[Spudder66]

Hi All

New KDX200 H3 1997 owner I have a question, if someone can please advise in simple terms.

Have head off and need detailed info of how to strip and reassemble the power valves (proper mess of goop inside), but also about this govener rod and cog type claw below the top knut, mine moves around left to right and I am guessing it should be static (fixed) into position. so I have the clutch cover off and then will take off the inner clutch engine cover to see what is not attached in side.

But again any detailed info or piccys would help.

[Chuck78]

You very likely have a broken KIPS actuator pin on the bottom of the rod, from improper disassembly or previous mechanic improper disassembly/reassembly. It's left hand thread on the nut at the top, and must have the shaft held steady with a backup wrench on disassembly and reassembly on the wrench flats below the nut or else you weaken or shear off the $10 pin, which can get loose in your clutchcase and gearbox and destroy very expensive parts. Disassemble the clutch case to inspect, and if the $12 pin is broken off, don't stop until you've found it floating around in your gearbox or oil or clutchcase...

[Spudder66]

Thanks Chuck78, I was with much hope someone was not going to say that, but hey it is what it is, then I must strip down and dig this thing out Bugger.

[Chuck78]

The clutch case components are simple to break down, no worries there aside from requiring a new gasket from the inner clutch housing to the crankcase.
It's getting into the crankcase - splitting and replacing bearings and reassembling, that takes a bit more precision and some bearing puller tools and case splitter/crank installer + crank web support block. You won't likely need to get in that deep.

[Spudder66]

Much appreciated Chuck78 - bike is fully stripped down and engine out so may as well have a proper dig about and clean everything, new piston on way with new linkage, swing arm bearings etc and frame in bead blast. Previous owners didn't look after it I guess, but its a great Autumn (fall) and winter project.

[Spudder66]

pin.jpg (1.7 MiB) Viewed 2147 times

OMG you would not believe how lucky I have been, I stripped down clutch side of case and this small bracket and pin still in place but with slight bent pin, bought another on line. But lucky it was not all bust up and causing more damage.

[Chuck78]

Good save!!!!

[KDXGarage]

Ain't no damn way. Go to the casino right now.