Use a firm wire brush to remove any loose blobs,Īnd continue "welding" blobs around the outside of the collar.ĭon't bother welding in the cutaway notch. Some blobs of aluminium onto the surface of the collar that will take Won't be able to sustain a good arc, but all you need is to deposit You can even make enough "wire"īy cutting a thin strip of, say, eighth-inch or 3mm aluminium plate.Ī couple of inches length should be plenty.
#Kawasaki kmx 125 power valve tv
You can salvage thick aluminium wire (thin rod)įrom old TV antennas and stuff. To do this, just some scrap aluminium wire that will fit into the welding Otherwise you might like to try my method:Īn arc welder or car battery and jumper leads you can roughly build You are lucky enough to have machining facilities you could make upĪ custom collar that has no cutaway notch and is a tighter fit in the To prevent the cutaway from ever facing the rear, thus keeping the gear My idea is to reduce the clearance caused by vibration and wear, and
So severe that the powervalve no longer turns or randomly jumps into As this scenario is repeated the tooth chipping becomes Of the soft alloy gear teeth now carry all this stress, and inevitablyĬhip and fail.
Some resistance because of normal crud and carbon build-up. The KIPS mechanism suddenly activates while perhaps the powervalve offers This will happen at a moment of stress when At some point an unhappyĬutaway will sooner or later happen to be facing the back of the cylinder,Īllowing the powervalve gear teeth maximum deflection away from There to meet the bore and maintain alignment. Of the missing segment because the collar lacks a complete circumference The cutaway segment of the collar allows even more movement in the direction Not quite be enough to break the tips of the alloy teeth, but unfortunately Teeth with those of the steel shaft that drives it. Wear clearance will compromise the intended alignment of the alloy powervalve Eventually the clearance becomes quite sizeable. The powervalve bore are worn away, making the collar even freer to moveĪround. The more the collar vibrates and rotates, the more it and
#Kawasaki kmx 125 power valve free
Is free to rotate, which it will do enthusiastically as age and vibration This part has aĬutaway segment that, on the right side, locates the two collars togetherĪnd prevents them from rotating. On the right side (same part number for all three). Uses the same removable top bearing collar on the left side as the two I believe that part of the reason for this is as follows: The left valve suffers from prematurely worn and stripped Its reputation for failing earlier and more frequently than the right-side To have a design weakness which probably contributes significantly to Noticed when overhauling my top end that the left side powervalve seems Suffer from the weakness of earlier versions. 1995 and later KDX200sĪnd 220s use a different powervalve arrangement that does not seem to
Possibly some or all of the water-cooled KDX250s. The earlier air-cooled 200s ('86-'88) I'm not sure and It should be relevantįor all similar models that use the older style of KIPS powervalve. Modification is based upon my 1991 Kawasaki KDX200.
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