Bigfoot CAPTURED!!!
Posted: 08:56 pm Jul 10 2011
We've all heard the tales, the descriptions, the legends...but we've never definitively seen, let alone captured for study, the E series KIPS subvalve Bigfoot, also known as Juliend's mythical KIPS reinforcement plate. I am ecstatic to announce that I've captured not just one of these plates, but two, and I have photographic proof!!!!!
This all began with my basket case 1994 KDX 200 that I originally bought for parts, but decided I would resurrect for cheap and give to my buddy.
There were a couple problems on the transmission, so I had to tear down the motor and split the cases. The powervalves were absolute trash, the worst I've ever seen. Basically broken for decades and left to tumble around in their journals until they were turned into little aluminum marbles. So I got the die grinder out and removed the remnants of the subvalves that had melted onto the ports and cleaned up the journals enough to receive new sub valves. Once everything was installed and timed, I was having a lot of binding in the pushrod because the retaining screw wouldn't hold the guide square to cylinder.
Here is how it's supposed to sit.
Here is how much it moves even with the seating screw fully tightened.
The solution--Bigfoot in the flesh!!!!
I made the plate out of some aluminum I had bought to make my hybrid headstays last year. I made a rubbing of the seating surface using paper and a crayon, and then I was able to transfer the hole centers onto the aluminum with a punch. A few holes drilled on the drill press, a little coping saw action, and a little dressing up with files and sandpaper, and Bob's yer uncle!
You have to remove the c-clips that hold the collar at the end of the shaft so that you can slip the plate on, and then reassemble the shaft. I used a little gasket maker between the plate and the cylinder, and I used the paper gasket between the cover and the plate.
Now, the shaft is much more stable, and the valves don't bind anymore. While I was at it, I made another for my hybrid. I'm pretty sure it has a broken sub valve less than 30 hours after they were all new.
Anyhow, it's nice to finally have the Bigfoot conspiracy theories sasquached. I mean squashed. Enjoy! Thanks for Juliend for passing on the idea, and special thanks to my daughter Lilly, who helped immeasurably with the photography!
This all began with my basket case 1994 KDX 200 that I originally bought for parts, but decided I would resurrect for cheap and give to my buddy.
There were a couple problems on the transmission, so I had to tear down the motor and split the cases. The powervalves were absolute trash, the worst I've ever seen. Basically broken for decades and left to tumble around in their journals until they were turned into little aluminum marbles. So I got the die grinder out and removed the remnants of the subvalves that had melted onto the ports and cleaned up the journals enough to receive new sub valves. Once everything was installed and timed, I was having a lot of binding in the pushrod because the retaining screw wouldn't hold the guide square to cylinder.
Here is how it's supposed to sit.
Here is how much it moves even with the seating screw fully tightened.
The solution--Bigfoot in the flesh!!!!
I made the plate out of some aluminum I had bought to make my hybrid headstays last year. I made a rubbing of the seating surface using paper and a crayon, and then I was able to transfer the hole centers onto the aluminum with a punch. A few holes drilled on the drill press, a little coping saw action, and a little dressing up with files and sandpaper, and Bob's yer uncle!
You have to remove the c-clips that hold the collar at the end of the shaft so that you can slip the plate on, and then reassemble the shaft. I used a little gasket maker between the plate and the cylinder, and I used the paper gasket between the cover and the plate.
Now, the shaft is much more stable, and the valves don't bind anymore. While I was at it, I made another for my hybrid. I'm pretty sure it has a broken sub valve less than 30 hours after they were all new.
Anyhow, it's nice to finally have the Bigfoot conspiracy theories sasquached. I mean squashed. Enjoy! Thanks for Juliend for passing on the idea, and special thanks to my daughter Lilly, who helped immeasurably with the photography!
