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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

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.

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.

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

[youtube][/youtube]

also does it sound slappy to you all.
thanks mark

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).

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.

thanks for the help guys i will make a start on the investigation when the manual arrives (Wednesday hopefully).
cheers again mark

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?

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

You have to pull the head to get to the valves but do not have to pull the jug.

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.

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

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

AH HA.
Herein lies my problem.

thanks everyone for the help.
Cheers Mark

Nice!

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.

Caught it just before it departed its home! lol Easy fix and no damage to contend with is always a good thing.

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

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

you cant beat that price