Pulling my hair out

[Kevin2502000]

I decided to replace the stock piston this winter in my 01 220r. It ran perfect beforehand. Tore it down, cleaned the kips valves, lots of carbon. Now it has no power. Has power in low band but falls on its face after that. Does not Rev out at all. Tore it down again assuming I didn't assemble the kips correctly. Followed the directions to a T and triple checked it. It does turn the left gear when reved up so it's activating it. It used to do 3rd gear wheelies on its own. Now it just barely pops up in 1st and loses power. I put in new reeds even though the old ones looked good. I didn't do anything else other than a new Wiseco piston and the reeds. What am I missing?? Also fresh gas,new plug, no change. Carb was still clean. Thanks in advance.

[KDXGarage]

Hi. Did you take any measurements? any pictures to show us?

"Followed the directions to a T"

Which directions from whom?

[Kevin2502000]

From this post. http://kdxrider.net/forums/viewtopic.ph ... ips#p87845 and also have the manual. I literally checked it 5x before installing the cylinder thinking it had to be wrong. It seems like there is a potato stuck in the exhaust. Best description on how it runs.

[KDXGarage]

HA HA!! (potato) sorry, could not help but laugh

Check it from airbox to spark arrestor. It has to be something.

[doakley]

I had this problem once with an old Honda 125 2s. Turned out I had doubled up on the head gaskets. Had very low compression. Not saying you did that, but asking if you’ve checked compression?

[Kevin2502000]

Thanks for the reply, I haven't checked compression with a gauge, (because I don't have a decent one I trust), but my foot says it's has just as much if not more compression as before.

[Slick_Nick]

Maybe the valves themselves are fine, but they aren't opening. Did you break the pin on the KIPS governor? Or maybe it slipped out?

[Kevin2502000]

When it is running, I have the L side cover off and can see the gear turn when it is revved up. I did have that clutch side cover off though and did find the very first time I ran it, the pin for the shaft had fallen out. This let the lever lift up and disengage. I believe I have fixed that and since the gear moves when revved, that should indicate as such?

[ScruffyDroid]

Check the ring gap.

[ericr]

What year manual do you have? The first couple years have an error that reverses the installation of the left and right valves. It results in just what you describe.

[Kevin2502000]

I did check ring gap on the new rings before install, good.
It's a cyclepedia service manual 1997-2005 kdx220a. I put the valve with the groove on the right side as u sit on it. I pulled the carb today, clean. Took off muffler, ran the same. Checked air box, clean, new filter with no time on it. New plug again,no change. I remember I had an 85 rm250 that acted like this, ended up being the stator. I just am finding it hard to believe it would go bad during a tear down. Another thought, I just bought this bike last fall and my first kawasaki. What are the chances the valve was carboned up and not working, give it more of a punch? Maybe it's supposed to be doggy like this? Doubtful but a thought. Open to any other ideas. I'm still thinking it's the kips.

[Molly's 70]

If it were me, I'd back track though everything I did.

[Kevin2502000]

Is it possible to hook up the shaft coming up out of the clutch wrong on the right side? Like 180 off? I don't think so because of the locating pin-up I am a noob.

[ScruffyDroid]

Did you reassemble the KIPS using this procedure? Step by step instructions here
https://haroldbawlzangya.com/2014/04/02 ... -kdx-kips/

[Kevin2502000]

That link doesn't work for me

[Kevin2502000]

I think I will disconnect the kips actuator lever and ride it again and see if it runs any worse. If it is the same, the kips definitely isn't working correctly.

[bufftester]

Sounds as though you don't have the subvalves installed correctly, it's very easy to get them lined up incorrectly. The fact that it runs fine down low and won't rev out indicates KIPS issue. It could also be a timing issue is you removed the stator, but I didn't see anywhere that you touched that

[Kevin2502000]

Thanks for the reply, I agree with your thinking. I can't get the link above to work, is that a good resource?

[Kevin2502000]

Can someone explain how to post pics?

[SS109]

Can someone explain how to post pics?