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As described in the clymer manual for my 1986 kdx200, which is free through Google books online by the way, it refers to the small linkage bolt which is 8mm size, and says "remove". Um, ok, I've already broken 1 clutch cover trying to remove that little bugger, thank God I have a spare or id be pretty pissed. So how do I remove that small bolt without stressing 30 year old thin aluminum?

It is referred to as figure 14 in the book, it is the bolt that links the lever coming out of the right side engine cover to the actual power valve linkage on the exhaust side

I'm surprised no one has any info on this, anyone?????

I've only pulled down one P/V 200 and that particular bolt was tight to break but l didn't have the case break on me.
Was it super tight and broke the case instead of coming loose ?
How about a pic of the damage ?

That is exactly what happened. I can't figure out the pics sorry. Broke it off flush at the case. I sprayed with penetrating oil, let it sit, used vice grips to stabilize since it was broke anyway, and still wouldn't break free. I'm going to try my micro torch. I'm starting to doubt if it is standard threads.

Also, why does the manual day that on 86 models you don't have to remove that link to take the cylinder off, the only reason I got my cylinder off is because I broke off the stem flush at the cover. I really feel like the cylinder would have not cleared if I didn't break that.

What do YOU mean by standard threads??

The E series is left hand thread, but I don't know about the air cooled motors. On the E series, the little arm at the top of the actuator shaft has an arrow and the word 'loosen' stamped into it next to the nut. And the manual has several warnings that it is left hand thread.

That is what i wondered, if it could be left hand threads

On the 86 you don't have to disassemble the KIPS linkage to take the head off. You remove the two bolts holding the cover, and then remove the circlip and bushing from the valve shaft, no further disassembly required. Of course it's hard to tell which bolt you mean without a picture. On the 89 and later bikes the bolt at the top of the KIPS shaft is left hand threads and gets broken a lot by folks with no manual. Which one is it out of the following parts diagrams?

It's number 132, I actually need that little link, number 13168, to go from the engine I'm getting rid of, to put on "the good" one.

i got it now, you take of that little wheel 92027, I didn't understand bushing as what it was.

Can you post a link to ... EDITED by Jason

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