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Service Manual

Posted: 09:48 pm Mar 25 2013
by icepick
Hello, I just bought a 1993 KDX200, and there is black splooge coming from the KIPs valve, the black rubber tube that comes down on the right side of the engine, I want to do some preventative, (hopefully) maintenance before I take it for the first good ride, and I can't find a service manual, that I can get my hands on, I could use a pdf version but when I search for one all I get is some BS to download a PDF reader.
thanks

Re: Service Manual

Posted: 10:12 pm Mar 25 2013
by turtle
You can get an online version right here at this site. or you can buy the book from various sources, either a factory or a Clymer. But regardless you're going to have to pay for it, I think. I have looked for downloadable versions but have always come up empty with every bike I've had.

Re: Service Manual

Posted: 10:16 pm Mar 25 2013
by icepick
Yea, I saw that link while looking around after my post, I had a bad experience from a site to download a manual after paying for a "Manual" live and learn.
thanks

Service Manual

Posted: 10:59 pm Mar 25 2013
by turtle
by the way, welcome to the site and congratulations on your new bike!

Re: Service Manual

Posted: 12:16 am Mar 26 2013
by KDXGarage
Congrats on the bike. Be sure to shop for the second version of the manual, with the USD fork information.

www.ronayers.com has very good prices if you can't find a used one on eBay.

Re: Service Manual

Posted: 03:04 pm Mar 26 2013
by sarrant
If the powervalve assembly is spooged up bad enough to be leaking down and out of the boot on the actuator arm, it's probably a reasonable assumption that the subvalves are also spooged enough to be immobile and stripped/broken. Kinda a well-known pattern failure on E-bikes.

You probably want to pop the head to take a look.

Re: Service Manual

Posted: 08:52 pm Mar 26 2013
by icepick
Ok, so with out a manual, I need to take the cyl. head off to check the kips valve?

Re: Service Manual

Posted: 09:00 pm Mar 26 2013
by icepick
has anyone used this site to download a manual?

"EDITED by Jason"

Re: Service Manual

Posted: 09:44 pm Mar 26 2013
by KDXGarage
Nah. I just did it the legal way and paid for a legal one.

Re: Service Manual

Posted: 07:47 pm Mar 27 2013
by sarrant
icepick wrote:Ok, so with out a manual, I need to take the cyl. head off to check the kips valve?
Well technically, you could remove the exhaust pipe, look through the port with a flashlight, and manually operate the valves to see if they are opening (both sides and center).

But I have a really strong suspicion the subvalves are shot. And even if they aren't -- you're gonna need to pop the head to clean them, if they are as spoogy as you say.

Re: Service Manual

Posted: 09:19 pm Mar 27 2013
by icepick
well crap! it runs good but I'm not taking any chances, looks like it might be tricky work, I guess if I can tear a TT225 down and rebuild it I can do this, I think I'll get the manual from Cyclepedia, I like pictures!

Service Manual

Posted: 09:46 pm Mar 27 2013
by SS109
Cyclepedia is a good choice. I'm sure you will be happy with it. :supz:

Re: Service Manual

Posted: 12:34 am Apr 12 2013
by icepick
got the Cyclepedia subscription, amazing!
Thanks to all.