exhaust valve advancer lever - broken

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rofti
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exhaust valve advancer lever - broken

Post by rofti » 02:38 pm Jun 09 2019

It started out as a "simple" operation to fix a leaking water pump seal. I somehow managed to break the exhaust valve advancer lever while removing the engine case/cover.ImageImage

I will hear tomorrow when the shops open how much of a problem it is. Kawa stopped making the KDX200H12(?) (2006) many years ago. If I cannot find some lost stock, do you know of any fixes? It seems to be a sensitive thing to try and glue together.

While I feel like a fool... I do not know where this part goes.Image It fell out of the engine as i opened it up. It is next to the offending broken lever and the kick start nut, for scale.

Thank you, gentlemen.
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Molly's 70
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Re: exhaust valve advancer lever - broken

Post by Molly's 70 » 03:14 pm Jun 09 2019

can you tell which part off this schematic? Maybe # 13236?

https://www.kawasakipartshouse.com/oemp ... ne-cover-s
If you lend someone $20, and never see that person again, it was probably worth it.

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Re: exhaust valve advancer lever - broken

Post by KDXGarage » 05:00 pm Jun 09 2019

Rocky Mountain in the USA has 10+ in stock, so maybe they still make them.

Edited by KDXGarage:

I pondered aloud, and someone didn't like it. I deleted it.
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Re: exhaust valve advancer lever - broken

Post by Molly's 70 » 06:03 pm Jun 09 2019

I call it the left hand thread part. :hmm:
If you lend someone $20, and never see that person again, it was probably worth it.

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Re: exhaust valve advancer lever - broken

Post by KDXGarage » 07:22 pm Jun 09 2019

ha ha! Yes, that one.
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Re: exhaust valve advancer lever - broken

Post by Vossman » 07:26 pm Jun 09 2019

They are still available, the gear/arm that bolts to the top isn’t though so don’t lose that part.

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Re: exhaust valve advancer lever - broken

Post by rofti » 10:45 pm Jun 09 2019

Molly's 70 wrote:
03:14 pm Jun 09 2019
can you tell which part off this schematic? Maybe # 13236?

https://www.kawasakipartshouse.com/oemp ... ne-cover-s
Exactly: 13236.

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Re: exhaust valve advancer lever - broken

Post by rofti » 11:00 pm Jun 09 2019

Molly's 70 wrote:
06:03 pm Jun 09 2019
I call it the left hand thread part. :hmm:
Ironically, I have not touched the left hand thread bolt.

When I opened the engine cover, I found the centrifugal "exhaust valve advancer" on the body of the bike, instead of on the casing, like I see on all the videos and photos. :hmm: Perhaps I was too ham fisted. It is something else to focus on when it goes back together.

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Re: exhaust valve advancer lever - broken

Post by KDXGarage » 01:14 am Jun 10 2019

If you didn't touch the LH thread nut on the shaft, then was it already broken when you bought the bike?

How did you get the case off without taking the nut off, in other words?
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Re: exhaust valve advancer lever - broken

Post by rofti » 09:32 am Jun 10 2019

KDXGarage wrote:
01:14 am Jun 10 2019
If you didn't touch the LH thread nut on the shaft, then was it already broken when you bought the bike?
How did you get the case off without taking the nut off, in other words?
It appears that I broke it while opening it up. It was functioning well last time I rode it.

I took the bolts off the small casing at the top of the advancer shaft and at the clutch basket/side of the engine. But I thought the gears at the top were free of each other before I pulled the casing away. I now think that was the cause of my demise. Should I undo the advancer shaft lever/LH tread before disassembly/reassembly.

Kawa sold me the part today for equal to usd 9.82.

I have watched all and read all I could get on the subject. It is depressing that I missed something. Now I have to start reassembly. My nerves...

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Re: exhaust valve advancer lever - broken

Post by KDXGarage » 02:58 pm Jun 10 2019

Shop open on a Monday AND you got out for less than US$10... WIN! :-)

Hold the flat part with a wrench or something to keep it from turning, then righty-loosy on that nut.

It sounds like you might not have a service manual. It can come in quite handy.

Again, very cool that you got it cheap and that they had it in stock.
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Re: exhaust valve advancer lever - broken

Post by rofti » 03:28 pm Jun 10 2019

KDXGarage wrote:
02:58 pm Jun 10 2019
Shop open on a Monday AND you got out for less than US$10... WIN! :-)

Hold the flat part with a wrench or something to keep it from turning, then righty-loosy on that nut.

It sounds like you might not have a service manual. It can come in quite handy.

Again, very cool that you got it cheap and that they had it in stock.
I have the manual... I assume (as I need someone to spell it out) that I have to undo the "comb" gear at the top of the shaft before I reinstall the side cover?

Anyway. Thank you for the input. I see that you (and the others on this forum) have been supporting the clueless for many years. It is most impressive. I hope not to break more than I can fix.

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Re: exhaust valve advancer lever - broken

Post by KDXGarage » 03:55 pm Jun 10 2019

Yes, install the side cover, THEN attach the LEFT HAND threads nut onto the LEFT HAND threads shaft.

You are not the first to break it, and will not be the last. :-)
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Re: exhaust valve advancer lever - broken

Post by Vossman » 05:19 pm Jun 10 2019

KDXGarage wrote:
03:55 pm Jun 10 2019
Yes, install the side cover, THEN attach the LEFT HAND threads nut onto the LEFT HAND threads shaft.

You are not the first to break it, and will not be the last. :-)
So true.

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Re: exhaust valve advancer lever - broken

Post by lucy » 05:53 pm Jun 10 2019

edit

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Re: exhaust valve advancer lever - broken

Post by lucy » 05:54 pm Jun 10 2019

rofti wrote:
03:28 pm Jun 10 2019
I see that you (and the others on this forum) have been supporting the clueless for many years. It is most impressive.
KDXGarage has selflessly helped many folks and we are gratefully indebted to him for the knowledge he imparts!

(Now, if he could only help find me a killer deal on a 220)

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Re: exhaust valve advancer lever - broken

Post by KDXGarage » 11:06 pm Jun 10 2019

I appreciate the thought, but no need for all that. :grin:

Look on craigslist (and searchtempest.com), as well as Facebook Marketplace, OfferUp, Letgo, etc. Also, try searching for "dirt bike", not just "KDX". Also search for KDX200 and KDX220, not just KDX.

Since you are in FL, be careful about the air filter. Bikes from sandy areas worry me! :shock:
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Re: exhaust valve advancer lever - broken

Post by rofti » 03:03 pm Jun 13 2019

The local Kawasaki shop assistant advised that my mystery washer (in the third photo from the top) is part number 92022C - in the kick start assembly.

Apart from the nerves, I will start assembly.

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