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A few months ago I went up a steep hill on my 1991 kdx200, the bike came back down and hit the ground pretty hard on its backside. When I got back on the bike was locked up for a sec, I kicked the kickstarter a few times and it eventually went loose and the bike started, but the clutch was locked up. Opened up the bike on the clutch side and found this piece laying on the case. I wasn’t able to find where it went so I went and put it all back together and it rode and ran fine for the remainder of the season. I’m doing a water pump rebuild and putting new bearings in, so I have the motor opened up again, I’m unable to locate where it belongs even after removing the clutch and kickstarter gear. Any help is appreciated, thank you.

Ahh, the elusive and highly sought KIPS Actuator Pin! This is normally broken off during maintenance as the bolt that attaches the actuator to the shaft is left hand threaded. When it came off it likely lodged itself in the clutch basket somewhere until it came loose. Be sure to thoroughly inspect the bottom end. I would bet you saw a bunch of sparklies in your oil when you drained it.

For reference, it is part of Kawasaki p/n 13236-1260, LEVER-COMP,GOVERNOR and is attached to 13234-1101, SHAFT-COMP,GOVERNOR and can be found in the parts diagrams under Engine Covers.

Yup, KIPS pin.

bufftester wrote: 04:33 pm Nov 20 2024 Ahh, the elusive and highly sought KIPS Actuator Pin! This is normally broken off during maintenance as the bolt that attaches the actuator to the shaft is left hand threaded. When it came off it likely lodged itself in the clutch basket somewhere until it came loose. Be sure to thoroughly inspect the bottom end. I would bet you saw a bunch of sparklies in your oil when you drained it.

For reference, it is part of Kawasaki p/n 13236-1260, LEVER-COMP,GOVERNOR and is attached to 13234-1101, SHAFT-COMP,GOVERNOR and can be found in the parts diagrams under Engine Covers.
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This is awesome and a great help, thank you for your help.

concur with white91. bufftester provided awesome and useful info. Quickly, too. Also doesn't hurt to also have component concurrence from SS109.