KDXRIDER.NET

2004 KDX200
I have read so many KIPS articles.....I'm just jetting more confused. So here are some pics of my situation:

2nd pic....Why are these dots not lining up???

1st pic .....This is the inside which should be the "Low RPM Position" exhaust opening is smaller and subvalve flat spot is parallel with front of engine which I think is letting exhaust into resonator.
Does this look right?

If I make the dots line up then the subvalves are in the "High RPM Position" parallel with the side of engine and exhaust valves open up wider.

What is going on?? The paw moves to the right when KIPS is actuated right????

Looks like the kips gears are improperly timed. I would take the head off and checked the marks below each inspection cap.

there are timing marks on the subvalves and their corresponding actuators that have to be correctly indexed, based on pic 2 that is not the case. You may be able to do it with the engine in the bike, but it's easier with it out.

The kips paw should line up with a marked line on the shaft if I remember correctly not dot to dot

DonnyV wrote: ↑12:57 am May 02 2023 The kips paw should line up with a marked line on the shaft if I remember correctly not dot to dot

ditto...
The pawl lines up with a white line on the small gear, not the dot on the large gear. Unless your white line is gone like mine was - so I lined up everything else inside, and put the pawl on with everything lined up since it can only go on one way. It runs fine on the the first few heat cycles after new top end, I hope to hit the trails this weekend to see how the upper rpm's are!

Service manual walks you through proper alignment of the exhaust valves, the sub valve actuator, actuator rod and the pawl. If you've never had the head apart, and it's running fine, then go ride. If it's very flat on top with no rev out then you'll want to inspect the valaves and their alignment. looking at the pics above I'd say you're in the ride category.

i am having the same issue. trying to put the "paw" on and it hits the cover. does it need to index clockwise against the spring pressure?

With the kips valves closed in the cylinder and the engine off (obviously), the paw should line up in the correct position by the locating pin.

As for indexing the subvalves they can be reset or retimed with just the head removed, there are two teeth on the subvalves with a slight relief that center over the pull rod groove.

The glitch in the manual topic here on KDX.net should be reviewed also as the manual labels the left subvalve as the right.