2000 kdx with some issues

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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two-stroke-brit
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2000 kdx with some issues

Post by two-stroke-brit »

well i got this tired old kdx .and i am going through the usual maintenance ( ignored my PO).
And waiting on a manual.
but i pulled the round inspection cap from the Kips and when i rev it nothing rotates.?
i think i saw a vid someone posted showing some rotation of the gear while revving ( have searched in vain for the thread) .
i am thinking the gears on the kips valves are damaged.
is it a barrel off job or can they be replaced via the head removal.?

although it sounds quite piston slappy so probably should take the barrel off and check/replace the piston.
i had a camera down through the plug hole and there are no obvious damage to the cylinder.

cheers mark
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Davenay67
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2000 kdx with some issues

Post by Davenay67 »

When my KDX had the same issue of KIPS not operating, the KIPS valves were perfectly OK and it was a broken actuator pin behind the right hand engine case cover. A $6 part, but a bit of labor involved.

And the reason for the broken actuator pin was a bolt had backed out of a stripped thread holding the KIPS main valve, jamming the KIPS mechanism shut, in turn busting the actuator pin.
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Re: 2000 kdx with some issues

Post by bufftester »

Another reason that pin breaks is because the nut securing the rod is left hand thread, and most guys without a manual try and crank it off like a normal right hand thread. Easier job to do barrel off, which you may want to do anyway it sounds like. IIRC it can be done with the cylinder on the bike, but a PITA. I have always just pulled the cylinder since I do it annually and check the piston/rings/etc at the same time.
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two-stroke-brit
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2000 kdx with some issues

Post by two-stroke-brit »

here is a link to a vid of the non complying kips.

[youtube][/youtube]

also does it sound slappy to you all.
thanks mark
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Re: 2000 kdx with some issues

Post by bufftester »

Sounds like every other KDX out there :-) I would check the actuator under the RH cover first since it doesn't appear to be moving. Keep in mind that it doesn't actuate until around 6000 rpm, and when it does it should rotate about 1/4 turn. That means draining the oil and pulling the inner clutch cover, but an easy enough job on these bikes (don't forget to get a new gasket).
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Re: 2000 kdx with some issues

Post by Julien D »

If you remove the pawl gear and you can twist that actuator rod by hand without resistance from the governor spring, that pin is broken.
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Re: 2000 kdx with some issues

Post by two-stroke-brit »

thanks for the help guys i will make a start on the investigation when the manual arrives (Wednesday hopefully).
cheers again mark
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Re: 2000 kdx with some issues

Post by JL4049 »

That sounds fine, it looks like the valve just about moves on a couple of the last revs. It has to be fair singing before the valves move. Does it rotate freely by hand?
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two-stroke-brit
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2000 kdx with some issues

Post by two-stroke-brit »

Hi All, i have the manual now (its nice to have )
i am just a little confused
can i remove,clean,check and reinstall the kips system without removing the barrel.

also i removed the Pawl gear and the actuator shaft rotates freely and i think the pin is intact as it hits a stop but there is no spring action for it to return?

although in Julian's post above it sounds like its broke so the clutch cove etc is coming of too.

Thanks for the help ,i do appreciate it.
cheers Mark
She might not be pretty but always a fun ride !
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Re: 2000 kdx with some issues

Post by KDXohio »

You have to pull the head to get to the valves but do not have to pull the jug.
1990 KDX200 FMF Fatty, Answer VFC silencer, VForce 3 Cage, Wiseco Piston, KX125-J series KYB USD fork conversion, Race tech goldvalves, J series front brake assembly, air-box snorkel removed, Acerbis Headlight, KX450F Front fender, Pro Taper RM bend bars, ASV front Brake lever, MSR Clutch perch and lever, RB Head mod, 36mm PWK carb, Trail Tech Kickstand.
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two-stroke-brit
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2000 kdx with some issues

Post by two-stroke-brit »

Thanks Ohio,
i am used to Haynes manuals where they take everything apart but this manual breaks it all down to separate assembly's.
i am sorry to keep asking but can you leave the clutch in place and remove the inner crankcase over it to accses the suspect pin/spring Kipps assembly.
or does the clutch have to come off too.
thanks again Mark.
She might not be pretty but always a fun ride !
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Re: 2000 kdx with some issues

Post by KDXohio »

You can leave the clutch in place on the 89-94 not sure on the H series I would imagine you should be able too
1990 KDX200 FMF Fatty, Answer VFC silencer, VForce 3 Cage, Wiseco Piston, KX125-J series KYB USD fork conversion, Race tech goldvalves, J series front brake assembly, air-box snorkel removed, Acerbis Headlight, KX450F Front fender, Pro Taper RM bend bars, ASV front Brake lever, MSR Clutch perch and lever, RB Head mod, 36mm PWK carb, Trail Tech Kickstand.
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two-stroke-brit
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2000 kdx with some issues

Post by two-stroke-brit »

Excellent.!.
i have taken the head off and happy to report the bore/piston looks great .
getting busy with the inner clutch cove now.
thanks again Mark
She might not be pretty but always a fun ride !
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two-stroke-brit
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2000 kdx with some issues

Post by two-stroke-brit »

AH HA.
Herein lies my problem.
Image
thanks everyone for the help.
Cheers Mark
She might not be pretty but always a fun ride !
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Re: 2000 kdx with some issues

Post by KDXohio »

Nice! :partyman:
1990 KDX200 FMF Fatty, Answer VFC silencer, VForce 3 Cage, Wiseco Piston, KX125-J series KYB USD fork conversion, Race tech goldvalves, J series front brake assembly, air-box snorkel removed, Acerbis Headlight, KX450F Front fender, Pro Taper RM bend bars, ASV front Brake lever, MSR Clutch perch and lever, RB Head mod, 36mm PWK carb, Trail Tech Kickstand.
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2000 kdx with some issues

Post by Davenay67 »

Well, that certainly explains the marginal KIPS operation Vs none at all. Good catch, as you don't want that broken pin bouncing around in the tranny and clutch. There is a series of 5 YouTube videos of a member on here tearing down a KDX because his tranny wouldn't shift due to a broken KIPS actuator pin breaking and jamming in the works.
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Re: 2000 kdx with some issues

Post by bufftester »

Caught it just before it departed its home! lol Easy fix and no damage to contend with is always a good thing.
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Re: 2000 kdx with some issues

Post by two-stroke-brit »

yep lucky i guess ,
waiting on the new parts ordered.
took the head of and the Kips assembly all moves as it should.
cant wait to get it back together and give it a ride in the woods.
need boots/helmet etc first though.
cheers mark
She might not be pretty but always a fun ride !
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Re: 2000 kdx with some issues

Post by david »

Check this seller for your size. I bought this Fulmer helmet a few months ago on for under $50. Its pretty light and suits my trail riding just fine.
http://www.ebay.com/itm/Fulmer-AF-AF-RX ... Cy&vxp=mtr
'81 KDX 175
'90 KDX 200
'07 Vulcan 2000 Classic LT (totaled 4/25/15)
'82 Honda GL500 (sold)
'96 ZXi 1100 JetSki
'98 STX 1100 JetSki
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two-stroke-brit
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Re: 2000 kdx with some issues

Post by two-stroke-brit »

you cant beat that price :supz:
She might not be pretty but always a fun ride !
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