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That very well could be. If you follow step by step procedure in the service manual it tells you to
1st. Once you have the left hand threaded nut and lever removed, take out the screw in the side of the cylinder.
2nd. Remove the main exhaust valve cover and gasket, pull out the operating rod as far as it will go, and pull the main exhaust valve out until the groove lines up with the cylinder.
3rd. Remove the idle gear, then lift the left and right valves up until the gears are flush with cylinder surface. Remove the operating rod, followed by left and right valves.
4th. Unbolt resonator cover, remove coolant hose, cylinder, and finally the main exhaust valve.

I followed that to a T. I don't have the cylinder off yet because I'm waiting on a tool for the base stud nuts removal. I honestly don't feel the bend is significant enough to not be able to remove the collar (#92143). The diameter of the center of that part is physically smaller than the end of the rod. I'm wondering if it is pressed on and isn't meant to come off. But of course why would they sell it as a separate component if it shouldn't be removed. I also find it interesting that it says to check the o-rings on the governor rod collar for damage, but doesn't mention the oil seal that sits just inside that collar.

I'm not the most mechanically inclined person in the world but I don't see a way of getting that collar off of there without grinding down the end of the rod. Of course if I get everything put back together and the rod doesn't bind then there would be no need to remove the collar. Idk.

Oh that collar, I was confusing that with the valve guide(part that seats in the cylinder with retaining screw #49002)...

The operating collar should slide off after the retaining or e-clips are removed...you're saying the end of the rod is smashed over? That's a new one for me..So if you removed everything from the right side, surely the valve guide is stuck on the road too?

If you can post pics it really helps to diagnose the issue

Gotanubike wrote:Oh that collar, I was confusing that with the valve guide(part that seats in the cylinder with retaining screw #49002)...

The operating collar should slide off after the retaining or e-clips are removed...you're saying the end of the rod is smashed over? That's a new one for me..So if you removed everything from the right side, surely the valve guide is stuck on the road too?

If you can post pics it really helps to diagnose the issue

Yes that valve guide is on the rod. I will try to post pics if I can. But yes the end of the rod is just a bit larger then were the operating collar sits.

Alright took a couple of quick pictures this morning of the rod. In the one you can see that the edge does have a raised lip to it. It may be hard to see but I tried to get a picture showing the slight bend that I was referring to.

Looks like they are just binding from it being bent. One definite possibility is that the bike was layed down at one point and smashed the end of it off a rock....Seems unlikely but since the kips were unable to close without the inside collar e-clip, definitely increases the plausibility of that

The collar and valve guide should be ok, though that collar should be able to rotate freely and if it has a bunch of dents are marks in it now, may not be able to turn freely. I'd say your best bet would be grind enough off the rod or make a cut right at the teeth and extract the pieces that way.

I have the collar, valve guide, e-clips and the rod itself, though that valve guide is in pretty good shape, I'm surprised you were able to get that out without marking it up too bad.

Let me know what you need, also I'd check the governor assembly, well I would anyways. Remove the clutch shaft linkage, kcik starter, water pump cover, impeller and the right side cover, you'll find of these underneath hopefully in still working condition:

Gotanubike wrote:Looks like they are just binding from it being bent. One definite possibility is that the bike was layed down at one point and smashed the end of it off a rock....Seems unlikely but since the kips were unable to close without the inside collar e-clip, definitely increases the plausibility of that

The collar and valve guide should be ok, though that collar should be able to rotate freely and if it has a bunch of dents are marks in it now, may not be able to turn freely. I'd say your best bet would be grind enough off the rod or make a cut right at the teeth and extract the pieces that way.

I have the collar, valve guide, e-clips and the rod itself, though that valve guide is in pretty good shape, I'm surprised you were able to get that out without marking it up too bad.

Let me know what you need, also I'd check the governor assembly, well I would anyways. Remove the clutch shaft linkage, kcik starter, water pump cover, impeller and the right side cover, you'll find of these underneath hopefully in still working condition:

Yeah the collar seems to rotate just fine. I suppose if the bike was layed over and landed perfectly on a rock and cracked the cover and hit the rod that could happen. Sounds painful. I'd like to get the rod, guide, and collar from you if possible.That way I'll have some spares.I'm curious where you found yours at. I was able to find some 4mm e-clips from Honda that I'm getting through work. I'll shoot you an email for payment options.

Email sent. Not sure if you got it or not.

Got the cylinder pulled off today. I didn't seem to remember seeing the wave washer that is pictured in the parts fiche with the main exhaust valve. Does anyone know how that washer is installed and where exactly it should sit? I did pull out a small piece of metal, which I'm assuming was the remainder of said washer. Thanks again.

It's probably just stuck to the inner seal of the center valve bushing, that cylinder-ish piece. I don't recall that one though.

Gotanubike wrote:

Hey just curious where you found this picture? Every cylinder head blow up for the E series KDX I've found is different (i.e. those orings above the valves, no picture of the main exhaust valve, and it looks like the cylinder base is a separate component. Everything else looks the same. Just curious. And it looks like the washer I mentioned above is not pictured in the 94 model year, so I'm guessing it is actually not needed and doesn't serve any purpose since nothing else is changed according to the parts fiche.

yeah I noticed that. just did a quick image search. here's a better one...that washer is super thin. I could see how it would just disintegrate

And all the parts fiches for 92-94 do not show that washer there. I'm curious why it's even there? Seems like they figured out they didn't need it anymore.

They made a couple small changes in 92, such as the 2 piece water pump seal. If you are eliminating that washer...perhaps you would need the guide from a 92 also....don't know, just a thought.

Considering all the main exhaust valve parts are the same number between those years I'm guessing there wasn't any change between the two.

The washers are all listed as being used on all the E series bikes, but it isn't shown on all the diagrams? Weird.

here's a look at that washer. It's probably just meant to seal the bushing guide to the cylinder...likely redundant

Yeah it's kind of funny. On kawasaki's webpage parts fiche you can see what model years they've used certain part numbers on. The Center exhaust valve under the 1990 part number only fits 89-90 according to them. When you look at the part number for the 1991 year it shows that it fits 89-94 models. I may just look to see if I can find a Honda or Yamaha one at the shop to put on there. Otherwise I don't think it's worth bothering over. Seems pretty insignificant.

Just got some nice new shiny kips valves today . Just need that Governor rod, my wave washer, and I'll be ready to assemble after some cleaning.

Well I got the cylinder and head put back on today. Did a quick compression test and got the same reading as I did before disassembly so I suppose I didn't mess anything up yet. Now I just need to install the carb, exhaust, and body work. Hopefully she starts. Definitely don't want to take it apart again.

That hardware I sent out all look good to you?