Maintenance & Technical > KX500 Original

New Power Valves incorrectly machined??

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81cr450:
When I align my valves I don't use the marks. Ok yeah call me a tard, but, if you take the aluminum washer & file it to .020 from stock .040 & juggle the teeth one tooth to each side , + you don't need a fancy powervalve bolt, It also guarantees the valves will fully open. Time it right & use it

lsampson:
I played with it for an hour, and there was no possible way to time it to where the valves both fully closed and fully opened. I didn't pay attention to the marks at that point. Either way, a new OEM part should be a direct replacement for the old OEM part. I'm sending it back.

alward25:
The marks are only for install before you install the KIPS bolt.  You could have the wrong part but are you sure you are putting the KIPS together correctly?  After you install the KIPS bolt the drum marks rotate away from the front.  From Hallbergs write up:


Fit the valve operating rod and make sure is slides easily in the cylinder (remove)
Fit the left and right valves and make sure they twist easily in the cylinder (remove)
Lubricate all moving parts with two-stroke oil, no need for excess amounts.
Turn the cylinder upside down
Lubricate and assemble the centre valve. Do not permanently fix the screws for the centre valve.
Lift the left and right valves so that you can fit the lubricated valve operating rod.
Lubricate and fit the left and right valves (do not fit the valve guides at this stage) with the markings facing towards you. They should drop all the way down. There should not be any need for force.
Lift the left and right valves so that you can fit the lubricated valve operating rod. Whilst still holding (lifting) the left and right valves; slide in the valve operating rod so that the grooves are in the centre of the left and right valves. Hold it there and twist the valves so that the valve markings fit the grooves on the valve operating rod and let the valves drop into place.
Fit the 'idle gear' (the gear that operates the right valve). Make sure the markings are aligned.
Lubricate and fit all three valve guides.
Verify smooth operation of the KIPS valve by sliding the valve operating rod in and out. If it doesn't operate easily, try to find out why. Maybe you haven't cleaned enough or the centre valve is jamming up the operation?
Tighten the two screws for the centre valve and verify easy operation again.
Lubricate the oil-seal with high temperature grease (alternatively two stroke oil) before fitting it.
Do the fix for the over-closing valve 3.3.2 Over-closing valves

lsampson:
I'm absolutely certain i installed the valves correctly. My issue is syncing the right and left valve with the new RH exhaust valve. I can get them to sync, but the RH valve bottoms out before fully opening. The RH valve doesnt match the old valve, and no matter how you look at it it will not time correctly. I more or less just wanted to see if anyone else had the same issue after they ordered exhaust valves, and to make people aware that it may be a possibility if they do so.

lsampson:
I didn't want to sound snooty, so sorry if I came across that way. I appreciate the help. I'll look into it again tonight.

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