Assembly time

[Pizzaboy]

Time to assemble shaft lever and weight. Not quite sure what Im doing. How does this look?

[Chuck78]

That looks correct. Be certain to never tighten or loosen the left hand thread nut on the other end of that shaft without holding it very firmly in place with a backup wrench, and also while observing that it is a Left Hand Thread fastener....

If not handled properly as described, those pins will weaken and snap off and get loose in the gearbox or clutchcase area and destroy expensive gears and possibly leave you stranded....

[Chuck78]

Did you ever remove the shaft that the KIPS pin bolts onto? I can't recall from the photos, but it looks like the KIPS pin is at a minimum insertion point. If you remove the tiny screw/pin that keep that shaft locked into it's bore (but free to rotate). On reassembly, just make sure the retaining pin/screw is put back correctly so that the pin locks the shaft in place from being removed. It's depth position is fixed. You're probably good on this, but I just wanted to double check.
The KDX200E '91-94 has a notably longer shaft as well as mounting for the pin assembly, whereas the 200H/220R KIPS pin is significantly shorter and barely engages to the center point of the KIPS centrifugal governor assembly slot.


On a side note, another member had discovered that the entire clutchcase housing for the 200H carries a different part number than the same years of KDX220R, and it's entirely because the deck heights of the cylinders are very slightly different for differing port timing configurations, and as such, the top forked paw or pawl that the left handed nut holds in place have slightly different height requirements due to this, and the pin/screw location is slightly different because of this.