Maintenance & Technical > KX500 Original

Main exhaust valve stuck

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Tumbleweed:
I can't seem to remove the main exhaust valve. I have a Clymer manual and it says to remove the screws and "lift it out". How easy should this be? There is a LOT of carbon but the valve flaps around.

I scraped off some of the carbon and shot some penetrating oil on it, but it's still "unliftable" Anyone got any tricks for this? I'm thinking about taking a hammer and screwdriver to it but I'm afraid I may damage it. I'm hoping there is a special method to removing it that the manual forgot to mention.

Danger4u2:
I have not had to do a top end yet on my K5 because it has such low hours.
Look this over you might find your answer.
http://www.hallbergs.net/kx500/

BDI:
You did remove the two rotary valves first right, because if you did not you can't get the flapper valve out. It should come out with no problem once the rest of the power valve has been removed. You removed the little cover and then removed the two bolts under the cover right? I have never had one stuck seems odd. If it was stuck I would not see it taking much more then some light taping to get it out.

Tumbleweed:

--- Quote from: Danger4u2 on September 30, 2007, 01:55:09 AM ---I have not had to do a top end yet on my K5 because it has such low hours.
Look this over you might find your answer.
http://www.hallbergs.net/kx500/

--- End quote ---

I checked there already doesn't seem to mention this problem, but thanks for the thought.


--- Quote from: BDI on September 30, 2007, 07:08:55 AM ---You did remove the two rotary valves first right, because if you did not you can't get the flapper valve out. It should come out with no problem once the rest of the power valve has been removed. You removed the little cover and then removed the two bolts under the cover right? I have never had one stuck seems odd. If it was stuck I would not see it taking much more then some light taping to get it out.

--- End quote ---

I removed all the parts, the two side valves, the idle gear, the main operating rod, the main valve cover and the screws inside that hold the main valve in. Because I never did this before I took a picture and highlighted the area that I THINK should be coming out. can any one verify that this whole section is suppose to lift out or am I doing it wrong?

BDI:
yes that whole thing should come out. I would try heating the valve with propane or map gas torch and see if that helps.

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