Shop Manual CorrectionBy Canadian Dave
Shop Manual:1995 to 2001 KDX200/220
Chapter:4 - Engine Top End
Page:4-12 - Installation of KIPS Valves
A mistake in the KIPS valve sub-port installation procedure has been made in the 1995 to 2000 KDX200/220 shop manual. This mistake has since been corrected but a number of misprinted manuals were sold. The instructions used to identify the right and left sub-valves have been reversed. If you installed the sub-valves according to the manual then your engine may not be performing properly. The following correction needs to be made to the KIPS valve timing procedure:
Do not mix up the sub-valves and the exhaust valve rods on the right and left.
The RIGHT sub-valve has a groove (A) and the right exhaust valve rode has an o-ring (B) for identification.
(the manual incorrectly indicates the left valve has a groove)
If you have an older version of the manual and you followed the identification procedure exactly your sub-port valves are likely reversed. Luckily you can check without disassembling the top end. If you remove the exhaust pipe/expansion chamber and look into the exhaust port you can see the sub-port valves. The valves should be completely closed. If they are partly open then they're reversed and the head will need to be removed and the valves reversed.
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