How to Remove and Inspect 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 Removal
- Your exhaust valve has a lot of small, losable parts, so stay as organized as possible. These components are hard to get without buying an entire parts engine.
- The exhaust valve is in direct contact with the exhaust, so this will be a messy removal.
- Start by removing the exhaust valve cover, and discard the old gasket.
- Remove the screw securing the link lever to the valve shaft.
- Carefully remove the valve shaft from the cylinder and remove the Left collar and spring, Link lever, Right spring, and collar.
- Remove the screws securing the power valves, then remove both valves.
Exhaust Valve Inspection
- Inspect the valve shaft for cracks and burs.
- Inspect the holders and power valves for cracks and burs.
- Most burs can be removed with a fine-toothed file, but cracked parts need to be replaced.
- Make sure the pins are secure within the valve, but do not try to remove the pins!
- Install the power valves onto the shaft and verify that there is unrestricted movement.
- Inspect the exhaust valve operating areas in the cylinder block for excessive wear or damage.
Exhaust Valve Cleaning
- As you may have noticed, your exhaust valve has lots of small parts.
- And since these small parts are in constant contact with the exhaust, make sure to clean them as thoroughly as possible.
If you have any questions, please let me in the comments, or send me a DM!
| ← Piston Removal | Cylinder Head Inspection → |
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