seized power valve in head
-
- Member
- Posts: 26
- Joined: 02:53 pm Nov 08 2016
- Country: NZ
- Location: northland New Zealand
seized power valve in head
Hi All, Just Doing the top end on my 2005 H series KDX200 and all fine except one of the power exhaust power valve rods is totally seized in the casting, I have soaked over night but still can not move it in or out or spin it via the slot in the front. Any help will be gratefully received or what are my other option ie new casting needed can you drill them out then get a new rod etc. cheers
- SS109
- KDXRider.net
- Posts: 5802
- Joined: 05:11 am Aug 23 2009
- Country: USA
- Location: Tucson, AZ, USA
- Contact:
Re: seized power valve in head
Which rod? The cross rod or one of the sub-valve rods?
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
- bufftester
- Platinum Member
- Posts: 3462
- Joined: 06:03 pm Oct 31 2012
- Country: USA
- Location: University Place, WA
Re: seized power valve in head
try using some heat to soften up some of the carbon build up if possible.
-
- Gold Member
- Posts: 878
- Joined: 06:59 am Jan 27 2017
- Country: US
- Location: Florida
Re: seized power valve in head
When you say slot in the front that makes me think it's the rods that run front to back of the cylinder. Is the the right side (46102) that's stuck? If so that's the one with the oring on it that Kawasaki calls "packing" (43049). Did you happen to spray chlorinated brake cleaner in there? If so maybe the oring is swollen. Maybe it's just swollen or distorted from something else (carbon) lodging the rod in there.
If it were mine I would try the heat first like bufftester mentioned. Is every other piece of the KIPS out? I would also try to reinsert the main shaft (13107) through the right side. The smaller gear on it moves that rod front to back. If it's the left side rod that's stuck then put the main shaft plus the left gear (16085) and nut back on the left side of the main shaft. Then try grabbing the teeth of the main shaft and working the rods in and out by hand to see if you can free it up. Then I would (at my own risk of damaging the teeth) wrap a rag around the teeth and try "gently" getting the shaft to rotate with vice grips or channel locks. That's a little risky. Maybe spinning by hand only (with a leather glove where you can get some grip) and also applying heat at the same time. If it frees up you'd have to take the main shaft back out (goes without saying I guess) before the rod would fully come out. Let us know what comes of it.
If it were mine I would try the heat first like bufftester mentioned. Is every other piece of the KIPS out? I would also try to reinsert the main shaft (13107) through the right side. The smaller gear on it moves that rod front to back. If it's the left side rod that's stuck then put the main shaft plus the left gear (16085) and nut back on the left side of the main shaft. Then try grabbing the teeth of the main shaft and working the rods in and out by hand to see if you can free it up. Then I would (at my own risk of damaging the teeth) wrap a rag around the teeth and try "gently" getting the shaft to rotate with vice grips or channel locks. That's a little risky. Maybe spinning by hand only (with a leather glove where you can get some grip) and also applying heat at the same time. If it frees up you'd have to take the main shaft back out (goes without saying I guess) before the rod would fully come out. Let us know what comes of it.
-
- Member
- Posts: 26
- Joined: 02:53 pm Nov 08 2016
- Country: NZ
- Location: northland New Zealand
Re: seized power valve in head
Hi Thanks for the detailed feedback. Yes its the RH hand side horizontal rod the links the main shaft to the power valve.
Funny all the other power valve parts removed easily and looked relatively well maintained but this one is rock solid have tried heat and top much force and still will not budge. I Am prepared to sacrifice it and get a new one if only i can get it out. May have to take it in to the local mechanic to see if they know how to remove it without damaging the cylinder .
Other option has any one run their bikes with one exhaust valve in a static position as the other exhaust valve and the main one would work if i bypassed this some how???
Funny all the other power valve parts removed easily and looked relatively well maintained but this one is rock solid have tried heat and top much force and still will not budge. I Am prepared to sacrifice it and get a new one if only i can get it out. May have to take it in to the local mechanic to see if they know how to remove it without damaging the cylinder .
Other option has any one run their bikes with one exhaust valve in a static position as the other exhaust valve and the main one would work if i bypassed this some how???
- rungrandpa
- Supporting Member I
- Posts: 230
- Joined: 11:35 pm May 26 2018
- Country: U.S.A.
Re: seized power valve in head
I had to soak my cylinder in diesel for a week. That was after PB Blaster for a couple of days.
-
- Supporting Member
- Posts: 739
- Joined: 08:28 am Apr 21 2019
- Country: United States
- Location: North Cackalack
Re: seized power valve in head
Wow!rungrandpa wrote: ↑09:52 pm Apr 18 2020 I had to soak my cylinder in diesel for a week. That was after PB Blaster for a couple of days.
I like turtles
-
- Supporting Member III
- Posts: 74
- Joined: 01:45 pm Dec 25 2019
- Country: United States
- Location: roseville
Re: seized power valve in head
I like Kroil penetrating oil, works pretty good.
A guy on another forum uses this, the name cracks me up.
A guy on another forum uses this, the name cracks me up.
- Attachments
-
- s-l1600 (4).jpg (506.47 KiB) Viewed 3758 times
Mark
Roseville, Ca
'76 Bultaco 143 Frontera
'06 GL1800
'01 KDX200
'97 KDX220r
74 DT360
75 Norton
73 CB500K
63 C200
87 PW50
64 McClane Edger
Roseville, Ca
'76 Bultaco 143 Frontera
'06 GL1800
'01 KDX200
'97 KDX220r
74 DT360
75 Norton
73 CB500K
63 C200
87 PW50
64 McClane Edger
-
- Member
- Posts: 26
- Joined: 02:53 pm Nov 08 2016
- Country: NZ
- Location: northland New Zealand
Re: seized power valve in head
After this week did it free up and you could lever it out i have put my in diesel for 2 days but not that long so may leave it soaking.rungrandpa wrote: ↑09:52 pm Apr 18 2020 I had to soak my cylinder in diesel for a week. That was after PB Blaster for a couple of days.
thanks for your help
-
- Member
- Posts: 26
- Joined: 02:53 pm Nov 08 2016
- Country: NZ
- Location: northland New Zealand
-
- Member
- Posts: 26
- Joined: 02:53 pm Nov 08 2016
- Country: NZ
- Location: northland New Zealand
Re: seized power valve in head
Part at local motor bike shop now so will see if they know any more tricks to free it or even to get it out so i get a replacement part.
-
- Member
- Posts: 26
- Joined: 02:53 pm Nov 08 2016
- Country: NZ
- Location: northland New Zealand
Re: seized power valve in head
Mechanic got it out by welding a slide hammer onto the stuck power valve rod after soaking for about a week, so now just need to find a replacement part as the removed one total stuffed???
- SS109
- KDXRider.net
- Posts: 5802
- Joined: 05:11 am Aug 23 2009
- Country: USA
- Location: Tucson, AZ, USA
- Contact:
Re: seized power valve in head
Ouch.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
-
- Supporting Member
- Posts: 739
- Joined: 08:28 am Apr 21 2019
- Country: United States
- Location: North Cackalack
Re: seized power valve in head
Geez, that might’ve been overkill. Power valves don’t come cheap.
I like turtles
- rungrandpa
- Supporting Member I
- Posts: 230
- Joined: 11:35 pm May 26 2018
- Country: U.S.A.
Re: seized power valve in head
Mine came out after a week.DeKay wrote: ↑04:10 pm Apr 19 2020After this week did it free up and you could lever it out i have put my in diesel for 2 days but not that long so may leave it soaking.rungrandpa wrote: ↑09:52 pm Apr 18 2020 I had to soak my cylinder in diesel for a week. That was after PB Blaster for a couple of days.
thanks for your help