KDXRIDER.NET

Tedh98 wrote:Does it always run better cold and then get worse as it heats up?

Are you in North, South, East or West part of Alabama?

it's pretty much the same from startup to whenever. the power is consistantly bad, at every rpm, except one tiny sweet spot while accelerating, around 1/4 throttle. above or below that sweet spot, and it's just crap, sputter sputter cough sputter, etc

pulled the pipe to look and see if the piston was split in half or something, and saw the fueling might be off a little:


birmingham, al - kinda in the middle.



if it cured itself tomorrow, and grew an electric starter, i'd have zero desire to ride it at this point. it's just too negative an experience from all the troubleshooting that went no where. the only motivation (which is very little) now is so someone else won't have the same extremely negative experience i have. green isn't pretty anymore.

Sorry to hear you've had such a difficult time with it.

If you get to the point where you will be selling it, let me know what you'd want for it. I'm not too far from the state line in Georgia.

That's an insane amount of spooge coming from the header. I'm guessing it didn't do that prior to our teardown.


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Sullyfam wrote:That's an insane amount of spooge coming from the header. I'm guessing it didn't do that prior to our teardown.


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ya that's a lot of splooge, considering it's total runtime since rebuild is about 1 hour. new copper seal and orings doesn't seem to prevent it either. pfft whatever. if it wasn't full of gas i would have knocked it over as i walked by this morning.

OK, I think I have a solution to your problem, but before I explain, will you tell me any mods that you did to the bike before it started running like sh!t?

(I was having a similar problem with my 93 and I figured it out tonight)

6 Riders wrote:OK, I think I have a solution to your problem, but before I explain, will you tell me any mods that you did to the bike before it started running like sh!t?

(I was having a similar problem with my 93 and I figured it out tonight)

6riders, the bike was in poor shape when i first got it:

no air filter
no transmission fluid (it was sludge)
throttle hanged
chain and wheel bearings
wiring moofed

previously modified:
gnarly pipe
fmf something or other arrestor
Rev pipe (tried both, liked the fmf something or other better)
140/42 middle clip on the needle


my fixes:
new wise co piston/rings
crank bearing
seals
27watt led headlights
typical drive train stuff
keihin pj35 carburetor (to see if the old one was shot)

but, today i discovered the KIPS is not functioning.

yes, all of you that said that, i owe 2.3 beers! yes, I'll PayPal everyone that said KIPs the cash for their beer. seriously.

so now i get to pull the engine and find out why it isn't working.

i checked multiple times before the head was torqued down, and yes it did function then.

but, since then I've had the clutch cover off several times to fix a drip from that gasket. i likely damaged the dowel on the end, i hope. that's not a bad job to fix.



also, i scored a keihin pj 35mm carb on eBay for $25, and installed it today. it's much tighter internally (float/slide/etc) than mine, so i may keep it) and the bike started on the first kick. response is a little better with this one, but the noon functional kips.... well you know, needs attention.

tomorrow i need to study for finals, but this weekend I'll pull it and assess again.


much more positive now that i have something to point at, as a real problem.

thank you

Do you have a battery on your airbox?

6 Riders wrote:Do you have a battery on your airbox?

no sir, no battery, i should have mentioned, the site box lid had been removed also

I'm having the same problem with my 93. I couldn't get it to rev, top speed was 14 MPH. This started while I was riding up a street, going 45 MPH...with a bus following right behind me. Just "blah" out of no where. I took the pipe in to have it tanked & resealed a leaking (but functioning) KIPS. I put it 1/2 way back together and ran it down the street, wheelies all day, just blip the throttle and up she goes! Take it home, finish putting it back together, go ride...."blah" 12 MPH, nothing else. Go home, drain the carb, check fuel flow, take it back out....16 MPH, for 1 second and then 12 AGAIN, ARRGH! Back to the garage....remove the seat, unplug and remove the battery, back out I go......Wheelies again YES! I'm not sure if the battery or the wiring is doing this, I'll chase later, but I'm suspecting that the street kit is somehow draining spark (which wasn't the case before). A short? IDK, but w/o the battery she ran like a raped ape!

6 Riders wrote:I'm having the same problem with my 93. I couldn't get it to rev, top speed was 14 MPH. This started while I was riding up a street, going 45 MPH...with a bus following right behind me. Just "blah" out of no where. I took the pipe in to have it tanked & resealed a leaking (but functioning) KIPS. I put it 1/2 way back together and ran it down the street, wheelies all day, just blip the throttle and up she goes! Take it home, finish putting it back together, go ride...."blah" 12 MPH, nothing else. Go home, drain the carb, check fuel flow, take it back out....16 MPH, for 1 second and then 12 AGAIN, ARRGH! Back to the garage....remove the seat, unplug and remove the battery, back out I go......Wheelies again YES! I'm not sure if the battery or the wiring is doing this, I'll chase later, but I'm suspecting that the street kit is somehow draining spark (which wasn't the case before). A short? IDK, but w/o the battery she ran like a raped ape!

well, I'm tapped into the lighting circuit, so maybe I'm pulling too much current.... if that's possible?

when i find all the bone headed problems, I'll post them up for the future.

no one should ever have this much annoyance again.

also, i found out about airflow on my drz... after storing a tool bag in the air box... it killed the bikes responsiveness very quickly. nothing in the air box for me.

the nut was loose on the left (sitting on the bike) side of the kips shaft, and the gear was turning instead of actuating the left side power valve. got the timing right again, tightened the nut with blue loctite, and fired it up.

started up first kick, absolutely no change at all.

what a waste of effort.

That was not a waste of effort, your KIPS needs to be working, Eh?

Do you see KIPS operation through the LH round cover?

KarlP wrote:That was not a waste of effort, your KIPS needs to be working, Eh?

Do you see KIPS operation through the LH round cover?

exactly, yes it does need to be.


pulled the cover last night and checked everying from the kips gear onward:

gear is fine
pins at either end are intact - fine
thrust bearings - fine
pin on the shaft from the kips centrifugal to the upper shaft located between the two thrust bearings - fine
pawl on the end of this shaft - fine
kips horizontal shaft moves freely, and was rotated fully counterclockwise while installing kips pawl - fine
lower valves open/close freely/fully - fine
main valve pops up/down freely - fine

started the bike, revved it just a little,

no movement from left (sitting on bike) or right side of kips horizontal shaft.
ok, that's a problem ! i can work with that !
checked pawl, it's still engaged with both the vertical transfer shaft and the horizontal gear on the horizontal shaft
checked the movement with a crescent wrench, pawl moves freely, start to finish

started bike again and watched pawl on vertical shaft- no movement.
ok, that's a problem ! i can work with that !

so right now it looks like there is a problem with the centrifugal ? no way to really test this , is there ?

new exciter coil arrived today.

old coil: 450 on 2000 scale
new coil: 425 on 2000 scale

I'm going to install it anyway, bet it changes absolutely nothing, and wait on the ignition coil to arrive....

wasted another hour soldering on the new exciter coil, mixed fresh gas for the tenth time.

still a piece of ****. (no change)

let's see, there's a new ignition coil coming one day this week. the only thing left to replace now is the cdi. in not spending THAT much money on this piece of **** though. $#@& it, I'll wait till one pops up on eBay in a couple of years, then try it.

really, the most annoying thing about this piece of **** is whatever YOU or I think it could possibly be, had already been tried.

what a complete and utter piece of ****.

Would you ship your cdi to another member here with the same bike and let them try it?

How about this one:
http://www.ebay.com/itm/KDX-CDI-IGNITIO ... 1862722789


or this one
http://www.ebay.com/itm/2005-Kawasaki-K ... 1653236503

Put it back on ebay if it doesn't work and be out shipping.

IDRIDR wrote:Would you ship your cdi to another member here with the same bike and let them try it?

How about this one:
http://www.ebay.com/itm/KDX-CDI-IGNITIO ... 1862722789


or this one
http://www.ebay.com/itm/2005-Kawasaki-K ... 1653236503

Put it back on ebay if it doesn't work and be out shipping.

since the bike is **** anyway, i'll ship the cdi to anyone willing to test/try it in theirs.

i have no idea if my 1997 kdx 220 CDI is stock, modified, or aftermarket though, and I really don't want to screw up someone else's stator if that's possible.

the other thing about spending $100 a pop on the CDI is, if my bike kills CDI's, i really don't want to (unknowingly) screw the next guy on ebay if my bike kills the CDI. that would be a pretty bad suck for the next guy. :(

i know people here locally, but really don't want to fry anyone's bike in the process.

wasted another hour installing a new coil. zero effect.

at this point it literally has to be the cdi, since I've replaced everything else.

is the plug wire arching out? Stupid, but it happened to me.