Kips help again

[Shooter88]

Ok so now I have completely rebuilt the top end of the motor new plating from millennium and piston and valves etc. I have ridden the bike twice now and it didn't seem right, so today I put my rebuilt rear shock back in and just for giggles I took the right side kips cover off. When I revved the bike the main shaft only moved out a little bit and never returned in. I also found that this was causing my lack of idle, I searched the forums here and can't find any thing about the actual governor. Is there a way to test with out tearing that side of the engine apart?

[Friedom]

You could disconnect the kips lever (the one with the reverse thread nut), then see if the kips shaft moves freely the whole stroke by hand. If it does, something is limiting the governor. If it doesn't, something is wrong with the KIPS itself.


Fun Wheel Drive

[Shooter88]

The kips valves are operating very smoothly, so I suppose I'll be tearing into it tomorrow!

[Davenay67]

Shooter,

Did you make any progress on this issue? I have a strong suspicion that I may also have issues with the KIPS governor mechanism.

I am going to remove the claw gear on top of top of the KIPS governor shaft and confirm that the KIPS valves themselves move smoothly. If this is the case then I am going to have to rip into the right hand side and further examine the KIPS governor mechanism.

[Shooter88]

Davenay,
I haven't yet torn the right hand side apart I will be tonight my kips are new and moving as smooth as butter, but the rod that connects to the are that actuates the valves just spins about a quarter of a turn. So tonight when I get it apart I will report what I find lol I'm hoping it's not too bad inside of there.

[Davenay67]

Good Luck..!! I hope your issues are small (and cheap). :)

I pulled the 'claw' gear from the top of the KIPS actuator rod to test my KIPS valves. They are stuck/broken because they still only move slightly when turning by hand. So, the head has to come off the keep the KIPS valves out for inspection and cleaning.

Given that they wouldn't move at all when the bike was running and revved hard, I am thinking that I also have to inspect for damage at the KIPS actuator mechanism behind the inner clutch case.

Not what I wanted so close to riding season. I should have been tougher and worked on this through winter in the garage....

[Shooter88]

Ok so I removed the inner clutch cover and found the little pin that sits in the actual governor bent. I am assuming this happened when the previous owner snapped a valve and never fixed it. So I very carefully bent the arm that holds the little pin back to 90 deg. Now I have to call Kawasaki dealer for torque specs on clutch spring bolts. * side note you don't need to take those off just take main clutch basket nut off with an impact. And I too should have dug into the bottom end before riding it davenay I hope yours goes well if you have any questions about parts info etc hit me up and I will help as much as I can!

[Dan The Man65]

How does the rod attached to the governor?i'm working on mine right now I can't figure out how that actually works