kdx250 kips

[argclh6670]

Hey guys, im doing a topend on the kdx....my question, now that i scrapped all carbon off of valve, when fully closed the main flapper falls out of the sub valvez and just dangles down in the exhast port. This cant be right?? The subvalves show wear at groove where main valve pins engage them but nothing major. Am i missing something? Hope this is understandable.

[argclh6670]

After closer inspection. Ive come to the conclusion that the main valve pins have worn notches in the subvalves after 23 yrs of running....in turn allowing the flapper valve pins to slip out of subvalve guide grooves and dangle into exhaust port rendering it non operational! New subvalves ordered.....hope theyre here in time for HS this Sat.

[dingerjunkie]

Would you be willing to post pics of the wear and the issue so others with lest "abstract vision" could look for what you've found on their own rides...please?

[argclh6670]

Would you be willing to post pics of the wear and the issue so others with lest "abstract vision" could look for what you've found on their own rides...please?

funny, I thought they were supposed to be that way (which im sure they're not) till I started reassembling. lol....What can I say, my first encounter with these...

[argclh6670]

Update, apparently, there are NO rh subvalves to be had in the US at this time....hopefully, theyre not obsolete!

[dingerjunkie]

I picked up a complete used top-end off of ebay just for the KIPS components out of production-end fear. I will hope for otherwise, but I get a sense that these are likely unavailable going forward.

It may be possible that units from the '88-'90 KX250 are either interchangeable or can be machined to match the KDX porting, though I have not checked on their availability.

Is there anyone with a scanner or the tools that would be willing to make a CAD model of good versions so we can move forward supporting this bike with a 3-D printer or CNC access?