Houston we have a problem. 91 Kdx kips

Got questions? We got answers....
Post Reply
JZ05220r
Supporting Member II
Supporting Member II
Posts: 569
Joined: 12:36 pm Mar 28 2021
Country: United States

Houston we have a problem. 91 Kdx kips

Post by JZ05220r »

I noticed the top end power suddenly became very flat so I checked under the kips right side cover. Well when I pulled the cover off the collared piece the the kips lever shaft rides on fell right out. It appears I’m missing one of the circlips. I think this explains the top end power loss and I’m glad I found it early. Also relieved that I’m not crazy for feeling something was up. I’m gonna fish inside the rubber boot and see if I can find the clip. If not then it must’ve never been there.
Attachments
92BB88CA-BEE8-4513-AB6F-BE80A15C3BDD.jpeg
92BB88CA-BEE8-4513-AB6F-BE80A15C3BDD.jpeg (3.62 MiB) Viewed 723 times
2005 KDX220r 1991 KDX200 2022 KTM 500excf
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14062
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: Houston we have a problem. 91 Kdx kips

Post by KDXGarage »

WOW! Good catch.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
JZ05220r
Supporting Member II
Supporting Member II
Posts: 569
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: Houston we have a problem. 91 Kdx kips

Post by JZ05220r »

Found the clip in the boot. I’m gonna try reusing it as I know it was brand new. It popped in tightly. Anyone know if this is common or how it was even possible? Just hoping it won’t happen again. If it does i will try to use some type of locking agent, maybe some loctite.
2005 KDX220r 1991 KDX200 2022 KTM 500excf
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5795
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: Houston we have a problem. 91 Kdx kips

Post by SS109 »

It probably didn't snapped on fully and with a little running sprung off. Being an E clip make sure the center tang fully seats in the retaining groove and you should be fine.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
JZ05220r
Supporting Member II
Supporting Member II
Posts: 569
Joined: 12:36 pm Mar 28 2021
Country: United States

Re: Houston we have a problem. 91 Kdx kips

Post by JZ05220r »

SS109 wrote: 06:28 pm Mar 31 2023 It probably didn't snapped on fully and with a little running sprung off. Being an E clip make sure the center tang fully seats in the retaining groove and you should be fine.
Ok I will see how it goes. Thank you
2005 KDX220r 1991 KDX200 2022 KTM 500excf
Post Reply