exhaust valve advancer lever - broken

[rofti]

It started out as a "simple" operation to fix a leaking water pump seal. I somehow managed to break the exhaust valve advancer lever while removing the engine case/cover.

I will hear tomorrow when the shops open how much of a problem it is. Kawa stopped making the KDX200H12(?) (2006) many years ago. If I cannot find some lost stock, do you know of any fixes? It seems to be a sensitive thing to try and glue together.

While I feel like a fool... I do not know where this part goes. It fell out of the engine as i opened it up. It is next to the offending broken lever and the kick start nut, for scale.

Thank you, gentlemen.

[Molly's 70]

can you tell which part off this schematic? Maybe # 13236?

https://www.kawasakipartshouse.com/oemp ... ne-cover-s

[KDXGarage]

Rocky Mountain in the USA has 10+ in stock, so maybe they still make them.

Edited by KDXGarage:

I pondered aloud, and someone didn't like it. I deleted it.

[Molly's 70]

I call it the left hand thread part.

[KDXGarage]

ha ha! Yes, that one.

[Vossman]

They are still available, the gear/arm that bolts to the top isn’t though so don’t lose that part.

[rofti]

can you tell which part off this schematic? Maybe # 13236?

https://www.kawasakipartshouse.com/oemp ... ne-cover-s

Exactly: 13236.

[rofti]

I call it the left hand thread part.

Ironically, I have not touched the left hand thread bolt.

When I opened the engine cover, I found the centrifugal "exhaust valve advancer" on the body of the bike, instead of on the casing, like I see on all the videos and photos. Perhaps I was too ham fisted. It is something else to focus on when it goes back together.

[KDXGarage]

If you didn't touch the LH thread nut on the shaft, then was it already broken when you bought the bike?

How did you get the case off without taking the nut off, in other words?

[rofti]

If you didn't touch the LH thread nut on the shaft, then was it already broken when you bought the bike?
How did you get the case off without taking the nut off, in other words?

It appears that I broke it while opening it up. It was functioning well last time I rode it.

I took the bolts off the small casing at the top of the advancer shaft and at the clutch basket/side of the engine. But I thought the gears at the top were free of each other before I pulled the casing away. I now think that was the cause of my demise. Should I undo the advancer shaft lever/LH tread before disassembly/reassembly.

Kawa sold me the part today for equal to usd 9.82.

I have watched all and read all I could get on the subject. It is depressing that I missed something. Now I have to start reassembly. My nerves...

[KDXGarage]

Shop open on a Monday AND you got out for less than US$10... WIN! :-)

Hold the flat part with a wrench or something to keep it from turning, then righty-loosy on that nut.

It sounds like you might not have a service manual. It can come in quite handy.

Again, very cool that you got it cheap and that they had it in stock.

[rofti]

Shop open on a Monday AND you got out for less than US$10... WIN! :-)

Hold the flat part with a wrench or something to keep it from turning, then righty-loosy on that nut.

It sounds like you might not have a service manual. It can come in quite handy.

Again, very cool that you got it cheap and that they had it in stock.

I have the manual... I assume (as I need someone to spell it out) that I have to undo the "comb" gear at the top of the shaft before I reinstall the side cover?

Anyway. Thank you for the input. I see that you (and the others on this forum) have been supporting the clueless for many years. It is most impressive. I hope not to break more than I can fix.

[KDXGarage]

Yes, install the side cover, THEN attach the LEFT HAND threads nut onto the LEFT HAND threads shaft.

You are not the first to break it, and will not be the last. :-)

[Vossman]

Yes, install the side cover, THEN attach the LEFT HAND threads nut onto the LEFT HAND threads shaft.

You are not the first to break it, and will not be the last. :-)

So true.

[lucy]

edit

[lucy]

I see that you (and the others on this forum) have been supporting the clueless for many years. It is most impressive.

KDXGarage has selflessly helped many folks and we are gratefully indebted to him for the knowledge he imparts!

(Now, if he could only help find me a killer deal on a 220)

[KDXGarage]

I appreciate the thought, but no need for all that.

Look on craigslist (and searchtempest.com), as well as Facebook Marketplace, OfferUp, Letgo, etc. Also, try searching for "dirt bike", not just "KDX". Also search for KDX200 and KDX220, not just KDX.

Since you are in FL, be careful about the air filter. Bikes from sandy areas worry me!

[rofti]

The local Kawasaki shop assistant advised that my mystery washer (in the third photo from the top) is part number 92022C - in the kick start assembly.

Apart from the nerves, I will start assembly.