Exhaust valve removal & clean up

duckunter · 03-20-2008

I am trying to disassemble my exhaust valve so I can clean the carbon from it. It is a 2000 KX 250 and I would guess it has never be taken apart and cleaned. (not the original owner!) I can't get the idler gear or secondary exhaust valves out of the cylinder block. I'm sure they have a lot of carbon built up on them. Any suggestions on how to get them out without tearing up the metal on the shaft of the gears??? If I scar the metal and file it smooth again will it hurt anything? Open to suggestions.

2stroke173 · 03-21-2008

The clymers manual for my bike says "If you must use force to remove them, first wrap the shafts with a piece of shim stock (not sure what that is) or similar material. Doing so may help prevent damages to the shaft surfaces."

Maybe you can use compressed air and direct it to the exhaust port for the secondary valves (where it opens and closes port) and that will pop them loose...I just removed, cleaned, lubricated, re-installed the exhaust valves on my 93 kx125

#34 KX 250 · 03-21-2008

i agree with 2stroke173

condon66 · 03-22-2008

Shim stock is very thin metal sheet. It can be bought in varied thicknesses like .003 or .010. We use brass shim stock when needed. The idea in the Clymer manual is to wrap a piece around the bottom of the exhaust valve so that you can grab it with a pair of pliers and tug. The shim stock prevents damage to the surface and is flexible enough to wrap around the valve. Just keep working at it and be patient. They will come out.

duckunter · 03-23-2008

Thanks for the input! I let some engine degreaser soak in/on them for a few hours and I was able to pull them out. (with vice grips)

03-20-2008	#1 (permalink)
duckunter Newbie Join Date: Mar 2008 Posts: 13	Exhaust valve removal & clean up I am trying to disassemble my exhaust valve so I can clean the carbon from it. It is a 2000 KX 250 and I would guess it has never be taken apart and cleaned. (not the original owner!) I can't get the idler gear or secondary exhaust valves out of the cylinder block. I'm sure they have a lot of carbon built up on them. Any suggestions on how to get them out without tearing up the metal on the shaft of the gears??? If I scar the metal and file it smooth again will it hurt anything? Open to suggestions.

03-21-2008	#3 (permalink)
#34 KX 250 The original #34 BTK Intermediate Join Date: Mar 2008 Location: San Antonio Posts: 155	i agree with 2stroke173 __________________ C.Norberg #34 Monster Energy Kawasaki KX250

03-22-2008	#4 (permalink)
condon66 Finally Got Into First Gear BTK Beginner Join Date: Mar 2007 Posts: 65	Shim stock is very thin metal sheet. It can be bought in varied thicknesses like .003 or .010. We use brass shim stock when needed. The idea in the Clymer manual is to wrap a piece around the bottom of the exhaust valve so that you can grab it with a pair of pliers and tug. The shim stock prevents damage to the surface and is flexible enough to wrap around the valve. Just keep working at it and be patient. They will come out. __________________ 2000 KX 250 Excel hoops, Pro Circuit exhaust, Factory Connection suspension.

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03-21-2008	#2 (permalink)
2stroke173 Clutch Cadet BTK Expert Join Date: Mar 2007 Posts: 357	The clymers manual for my bike says "If you must use force to remove them, first wrap the shafts with a piece of shim stock (not sure what that is) or similar material. Doing so may help prevent damages to the shaft surfaces." Maybe you can use compressed air and direct it to the exhaust port for the secondary valves (where it opens and closes port) and that will pop them loose...I just removed, cleaned, lubricated, re-installed the exhaust valves on my 93 kx125

03-23-2008	#5 (permalink)
duckunter Newbie Join Date: Mar 2008 Posts: 13	Thanks for the input! I let some engine degreaser soak in/on them for a few hours and I was able to pull them out. (with vice grips)

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