1992 kdx200 power valve govenor Rubber cover

[Caleb#Mx92]

Hello I am back again for the power valve govenor rubber cover leaking with exhaust system smoke. I have taken the top end off and cleaned the carbon from the power valve system and timed them correctly and replaced the rubber o ring on the govenor rod and im still having the same issue where a tiny bit of smoke is seeping out from the rubber cover piece on the govenor side of the powervalve system. I'm not sure what to do from here any suggestions on what to do next and help is much appreciated.

20250711_192942~2.jpg (1.22 MiB) Viewed 5955 times

[KDXGarage]

Hi. Did you replace the seal, Kawasaki part number 92049-1206?

[Caleb#Mx92]

I might have I don't think I did i replaced the main o ring on the powervalve rod shaft. Would that seal be the main issue on why it's smoking a little bit from the cover?

[KDXGarage]

I would think so, definitely worth a shot.

[Caleb#Mx92]

Alright I'll take a look at it and see other than that I just don't know what else it would be. I appreciate the suggestion and will try it thank you very much.

[KDXGarage]

On the parts diagram, those are the only two things keeping the oil and smoke in, I think.

[Caleb#Mx92]

Alright well I replaced one of them so I will see if the other one is the problem.

[KDXGarage]

Just grease it before installation.

[Caleb#Mx92]

I found that the new o ring is not sealing keeping the shaft covered to let exhaust go through

[Caleb#Mx92]

Hello I have found that on my bike on the govenor side of the power valve the o ring on the powervalve shaft is not keeping the slider in place and sealed and is allowing exhaust to come through i have replaced the o ring and it is brand new im not sure how to fix this issue any help or guidance is much appreciated thanks.

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Screenshot_20250816_174731_Photos.jpg (562.38 KiB) Viewed 4255 times

[SS109]

I don't see the seal in that pic. Have you replaced part number 92049-1206?

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[KDXGarage]

Try some grease to see if it helps.

[Caleb#Mx92]

Alright

[Caleb#Mx92]

I'm not sure if I did or not but would that other seal keep it in place?

[KDXGarage]

I merged your other thread about the same issue with this thread.

Why is your KIPS rod sticking out so far? Is the shaft nut attached behind the rubber boot? Generally one can not just pull it out that far and not have it snap back as it is under spring tension.

Is your KIPS pin inside the clutch cover broken?

With the butchered JIS or Philips screw shown in the first pic, it makes me wonder more.

[JimmyB]

With the guide are you installing the flanged bolt # 92009-1502 to keep the guide # 49002-1083 in place or is just free to move in and out of the cylinder as the rod moves? I don't see it installed in any of the photos but it is a bit hard to see as it is around the 4 o-clock position on the guide/cylinder.

If it is still leaking past the o ring once installed perhaps the bore where it sits is worn out, nothing wrong with cleaning everything off and putting a thin layer of sealant on the outer guide/o ring to prevent the leak.

[SpruceItUp]

Jimmy makes a very good point, there is a screw that holds in the part that holds the seal, letting the rod move in and out through the inner hole. I completely forgot to mention the seal that the rod moves through, though it is a quick and easy change. I believe SS109 already mentioned it.

I sent a photo of where that screw should be located. It prevents the whole mechanism from moving out of the case as the rod moves in and out.

I get no smoke out of my cover, though I did when I bought the bike, but changing out the seals did the trick.