This weekend I got the bike 85% back together, enough I could kick it over. Many small miracles -- it started up first time (3rd kick -- I have video!!). And now it starts 1st kick every time. The engine sounds great, the few minutes I've run it. I don't have rear wheel, brakes... little stuff like that yet.
My issue is the KIPS system is not working. If you watch this video (you can jump out to 1:45) you can easily see how tell if the KIPS is working. When I do the same test, I crank the engine, even go almost wide open, and the KIPS gear just barely moves a little if at all. It barely rotates 1/2 a tooth.
I need some help figuring this out. KDXrider KIPS detectives, don't fail me now!
I cleaned all the KIPS parts, and lubed them before installing. I spent way too much time getting it all back together, but eventually everything was in, and I could rotates pieces by hand and watch it all move. I think it is all in correctly. My one clue -- when I installed the KIPS rod with the little O-ring (Part# 46102-1384) I thought it felt very tight. It was hard to get it in all the way. I tried this dry at first (to practice) and my friend said it would be easier once it was all lubed. It was a bit easier, but it still seemed harder than I expected. And after final assembly with lube, I could manipulate the entire mechanism and watch everything turn. I could see the two exhaust valve thinggys rotate. But I kept thinking... is there too much resistance. The only resistance in the entire KIPS system that I could see was the KIPS rod with the O-ring.
Any thoughts on this?
A few questions:
- 1) I assume it is OK to run the engine, this isn't going to hurt anything, just no working KIPS.
2) I also assume if I figure this out "Ron, you need to change blah-de-blah" I'm going to have to pull the engine.
3) Also, let's say in a few days I have a clue and want to try something. Won't I most likely have to pull the cylinder head? Can I re-use that gasket, or is that not worth the risk?
ps: Here is the video of first start. I took the video assuming the bike would fall on me, catch fire etc. It was for insurance purposes. When it started I almost didn't know what to do!