KIPS Valve and Cylinder

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200Chaos
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KIPS Valve and Cylinder

Post by 200Chaos »

Hey guys, first post on here and hope it's in the right place. Also want to say how good the site is for friendly help!

Right that out the way, got a few questions after a long journey so far. I bought a 93 KDX 200 last year a a bargain and has been fantastic until a ride about six months ago where the clutch gave up the ghost. Figuring it was something stupid like a broken cable or a spring had come off the clutch push rod had slipped off, I took the case off to find my clutch was flopping side to side. Somehow, the clutch nut had woundd it's self off the thread to the point there was so much movement it snapped my input shaft. So began the rebuild process. Not too fussed as I figured it was a good time to give the girl a check over and have a good service I began taking the engine apart to find the worring signs of tell tale bodgery, mismatched bolts and nuts, and more instant gasket in places I didn't think possible! Anyway finally got to my gear box, so I ordered a new input shaft my model bike, that turns up after a month and it's not an input shaft that arrives and looks suspiciously wrong. To save time I ordered a whole box from eBay and guess what, wrong input shaft! After some investigating I have a 250 gear box in my 200. I was very confused but was just happy to have fixed the initial problem. Now, onto the cylinder where I need some help.
I've checked my piston size and there was a 67mm piston in there. Does this mean its been over bored or simply wear over time? Do 250 cylinders fit 200s? Could this be the reason for fitting the 250 gear box and clutch?
Not only that I also found one of my kips valve has snapped and been eaten over time where it has stayies in place and mashed by what was left. Where can I buy new kips valves?

Sorry for the long post just wanted to give the full picture and get your opinion on what has been a
b@&£!"d! So far. Cheers guys any help will be much appreciated!

Rob.
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Gotanubike
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KIPS Valve and Cylinder

Post by Gotanubike »

Somoene will need to confirm this, but I think the stock piston size is 66mm meaning it was overbored 1mm...how does the plating look?

Also, KIPS valve OEM #'s are:


Left - 12005-1121
Right - 12005-1122
Idle gear - 59051-1206

Full diagram here

http://images.cmsnl.com/img/partslists/ ... 0_7bd4.gif


they can be found online, or sometimes your local Kawasaki dealer may be able to order them for you

Also...contact me if you need a new cylinder. I have a spare also the cylinder head
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
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