Shop Manual Correction
By 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.
If you have any comments or suggestions smack the e-mail icon and send them my way or visit the JustKDX Forum.