Kips Exhaust Valve:1999 KX250 Can't Get Out! Help

[Arrakkis666]

Hello all! I am new to this forum so thank for any and all help!

Here goes... I have taken everything off the cylinder of my 1999 KX250 except the exhaust valve itself. I have removed all the other part of the kips valve set up including all shafts, rods and guides. I am having a hard time trying to remove the MAIN EXHAUST VALVE. I am able to slide it in and out as it would when operating and I can feel the valve open and close in the port but, I just can't figure out how to remove it. Should the whole assembly just slide out and cant do to some carbon build up or am I missing something? PLEASE DO NOT POST TECHNICAL INFO on this matter if you are not a mechanic or have not worked on this particular kips system. Thanks

Check picture below VVVVVVVVVVVVVVVVVVVVVVVVVVVVV
http://i92.photobucket.com/albums/l1...g?t=1222555272

[jdager]

good question, I have a 98 that I tried for an hour to get it out on yesterday, i'm interested to hear how to do it...

[gaz]

Whats the point in asking for advice and then restrict the answes to a few owners who may not even be members. Any advice is good advice and you choose what you want to use. Since the cylinder is off the case I would scrub it up to see what is holding it in. Soak the whole thing in turpentine overnight even. I had trouble with an '05 model kx250 but eventually got it out using needle nose pliers and patience. Yes I know its a differnt sustem but it was still hard to get out. The valve should just slide out. Tis is what you get from lack of maintenance.

[Saleenguy]

I just work on them all the time, but will not help then since I do not own that year, as you asked.

[Arrakkis666]

In response to gaz. First off thanks for the info. Secondly, I disagree with your comment that any advise is good advice for the following reason. Many bikes can seem similar and or the same but info from a different year/model when applied to my bike could have me damaging/braking something. I have see this happen before that is why I am looking for advice from people familiar with this very kips system and or mechanic with first hand knowledge. I have a manual that addresses earlier year KX125s and 250s but that system is different and I do not want to damage anything trying to remove part wrongly. Thanks again for the info.

[Arrakkis666]

Do you think that it was just carbon build up that was holding it in? Here is the deal with mine. The plate that you can see in the picture will slide out but, only about 1 mm. I have tried to pry it a bit with a small screwdriver and some needle noses but I don't want to use to much pressure because, I don't know if I need to remove anything else first and I fear breaking something. The assembly it self is made up of what seems like, I think 3 separate parts. Do I need to have the valve in a certain position when removing it or does something get removed from the inside of the cylinder? These are my concerns. Thanks for your input.

[Arrakkis666]

Dude, I wasn't trying to offend anyone, I just want info that is accurate so I don't go off and break my cylinder or valve assembly. If your a mechanic and have some relevant info on this late style kips systems, I would appreciate it. Thanks

[Chazbo]

When you say you have a manual that addresses earlier years, doesn't that manual include supplemental information in the back? I mean, does the manual cover the 99 model? If it's a Clymer, then there is info in the back. Otherwise, http://s7d2.scene7.com/is/image/Motosport/KX250%5E1999%5ECYLINDER%20HEAD-CYLINDER?$oemlarge$

From the looks of it, there appears to be a pin or something that is holding the valve in place. Maybe you can get at it from the side triangular hole in the cyl.

[Chazbo]

Clean out the carbon in that area, and then you will see an allen head bolt near the bottom. That junk needs to be removed so you can see the parts. It will be more difficult to remove the exhaust valve assembly if you do not clean first.

[Saleenguy]

Running too much oil,and crap oil, causes them to gum up and get sticky.

Once you get the build up off of the bottom pull it out.

Wire wheel the thick of it off, then soak in parts cleaner and final scrub with an sos pad.

Reinstall, and use only amsoil or blue marble at 40:1 in the future, and clean it regularly.

[Arrakkis666]

Hey, how's it going? Just wanted to let you know that I worked on that dang power valve today and I was successful in getting it out! Basically here's what I did. I sprayed everything down with liquid wrench, grabbed the little actuating arm with a pair of channel lock pliers and pulled it out with some force. Then slid it back in and slammed it out again. Little by little I saw that the valve was coming out so I just keep at it. It only took about a minute and out she came. I was being a bit gentle as I didn't want to brake anything, especially not the small actuating arm that I was yanking on and I still wasn't sure if I was doing the right thing. Once I got the assemble out I did notice that the actuating arm has to be fully pulled out in order to remove the assemble from the port because when it's in it spreads the valve pieces apart making them wider then the cylinder port. Well, if you didn't get it apart yet then I hope this helps you out. If the need any further info just email me and I will do what I can to help you. Again, thanks everyone for the help.