How to Install your 1994 through 2001 Exhaust Valve
The Tools You Will Need
- Foot-Pound Torque Wrench → https://amzn.to/3FVEdr3
- Inch-Pound Torque Wrench → https://amzn.to/4j9LDpC
- Safety Glasses → https://bulltru.com
- Dremel with Sanding Disc → https://amzn.to/407t6l3
- 2-Stroke Oil → https://amzn.to/3WnyXSl
- Calipers → https://amzn.to/3BRoCXX
- Brake Cleaner → https://amzn.to/4jv9v7a
- 6mm Hex Socket
- 13/16” Box Wrench
- 8mm Socket
- 10mm Socket
- ¼” Socket Wrench
Pre-Service Notes
- I recommend opening the Service & Torque Specs in a new tab for easy reference.
- If you need parts and tools, make sure to buy them here! → https://amzn.to/4h4lDKq
- Pictures with captions are below after step.
- If you need any help don’t hesitate to ask!
Exhaust Valve Installation
- Lubricate all moving parts with two-stroke engine oil.
- If you have installed a new cylinder liner, make sure the power valves operate smoothly in the bore.
- If anything is catching, you can smooth it out with a file or small grinder.
- Be careful not to take too much material!
- Grind test, grind test, and so on.
Exhaust Valve Assembly
- The power valves are not symmetrical. Install them on the correct sides of the cylinder block.
- Install the right-side power valve first, followed by the left-side power valve.
- Use new screws to secure the power valves:
- Apply thread lock and install the power valve mounting screws.
- Yamaha does not supply a torque specification for the power valve mounting screws, so I am torquing them to 20 inch pounds so I know they are evenly tightened.
- After tightening, check the valves for unrestricted movement.
- Install the pivot shaft, collars, and link lever assembly.
- Make sure the link lever springs are positioned on the exhaust valve pins.
- Check the shaft and valves for any binding before you install the link lever screw.
- Apply thread locker and install the link lever screw.
- Install the thrust plate into the groove on the valve shaft, then secure and tighten the screw.
- Torque the link lever screw to
- 44-inch pounds on 1994 – 1995 models
- 35 inch pounds on 1996 – 2001 models
- Rotate the valve shaft manually to check for smooth operation of the shaft and power valves.
- If the valves or shaft stick in any position, there is interference in one of the components. Correct this problem before installing the cover.
- Install a new gasket, and install the cover.
- If the cover is installed upside down, the link lever will contact it, limiting the movement of the power valves.
If you have any questions, please let me in the comments, or send me a DM!
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