hey guys so here we have an exhaust valve assembly obviously completely
disassembled for a 2002 Suzuki RM250 all this is going on to this cylinder
here which is going on to this engine got everything all cleaned up looking
sweet so I'll be walking you guys through assembly and how to set it up
and adjust it now it looks like we've got quite the mess going on here but I
promised you guys once we get going it's actually pretty straightforward so
this valve is the exact same for a 2001 and 2002 rm250, 96-00 is basically the
same and then 03-07 is a bit different design but still the same
concept so this video should be pretty helpful for 96-07 and it always helps to
have a parts that gram on hand this shows where every little piece goes I
printed this one out from Rocky Mountain before we start always a good idea to
have it and cleaned up and free of carbon check for any damage cylinder
spotless went through and recoated these pieces here the black is a seracote
micro slick helps with friction makes them last a bit longer and at the same
time I coated the covers in a cobalt seracote just to make them look good so
with that why don't we get started looks like the first thing we'll need to
assemble here is the actual valve into this plate should just slip in like so
line up the arms with the valve and then it should just slide right into the
cylinder nope we forgot our lube always a bad day when you forget the Lube
so you should just pop right in there we go we've got a couple allen head screws
that hold this plane assembly in some blue loctite on them keep them into
place now we've got to figure out where these two arms and the shaft go start
with this one looks like it goes right there locks in between these two arms
to pull those out to get it in place goes in like that and then this Swan
goes on to the actual shaft pops into those grooves then we've got the shap
that goes through the whole thing and then looking at the diagram that goes
from the clutch side to the flywheel side pop that thing on through actually
got a little spring that goes here there's a little hole it pops into you
right here there's a little hole on this shaft that the spring goes in to you
know what it's gonna be easier to get that hole in first there we go that's
much simpler pop it into here and then go ahead and slide that shaft
on through
Oh like butter man it's nice having everything all clean and fresh
I hate rebuilding stuff that's all dirty line up this hole with the shaft got a
little allen head screw that goes in there let's go ahead and test make sure
this thing's working right yep now with the valve assembled and working you can
see the function of the valve so when it opens up that increases the size of the
exhaust port increases the amount air coming out helps with power at higher
rpm and then when you close it that decreases the size create some back
pressure and helps out with auto response at low rpm so yeah these things
are very helpful on a two-stroke yeah just plain with this thing by hand feels
like that microscope made a good difference in the amount of friction
everything works really smoothly and looks a lot cleaner so got a thumbs up
in my book so far now I should mention there is a certain direction this spring
should go on so the side with the bend tighter the coils goes on this side but
once you mess with it you'll see the proper direction but just something to
be aware of there now we're gonna need to assemble this side of the cylinder or
this side of the valve we've got all these pieces here and took it all apart
to clean it up kind of shine it up we're going to start with the spring and the
inner plate these parts you can refer to the diagram see how they go together or
just look at the wear marks here how things line up so we're going to bring
the side of it over to the other end of the plate all the way around
like so now you're gonna want to keep good hold on it
this thing could be flying off into outer space you let it go get the spacer
in between here just to lock everything together ah shoot
you know I'm saying there you got to get a good strong grip on it all right we
got it back together so we're gonna set this up on the end of the shaft here now
you guys might be able to see this there's a little slot here on the end of
the shaft we're gonna line up the inner plate with that slot there we go
and then we've got this plate that goes on the outside let's pop this thing in
then we just got the retaining plate that goes on the outside and keeps
everything in place
now for some reason this plate is really sloppy on the shaft if there's a gap
between the wash and the plate I'm up to dig into this so it looks like the plate
sits lower than the actual shaft so I think what I'm gonna do here is find a
washer that fits around the shaft to try to push that plate down let's see if
this washer will do oh yeah that should work oh yeah she's nice and tight now
no more sloppy second hand parts now over on this side we're gonna install
the secondary valve I believe that's what it's called you
want to make sure you have the right valve goes on the right side of the
cylinder you can see it's marked right there and this hole is gonna need to
line up with the pin down inside of there get it all lubed up and drop her
in till that pin goes in there we go and we've got a little spacer here a little
collar that goes over the end of the shaft and a cap it off got the cover
here come to think of it you can't even see this cover when it's all together oh
well at least a little cool when you tear it apart actually I'm gonna need to
put the o-ring on there and then just drop this guy right in place ooh
now that's it for the right side the left side is basically the same also not
a bad idea that works in oil into these roller bearings here before I cap this
side I thought I'd show you guys how this exhaust valve system works it's
kind of like a two-step or two-stage system so you have the main valve right
here that works in the exhaust port here so when you move the shaft you can see
the valve inside working kind of open up the port and then when you move the
shaft all the way that opens up the side or the secondary valves you can see the
side valves don't open until you fully turn the shaft so halfway opens the main
valve and all the way opens the side valves so pretty cool system now to
verify those secondary valves are installed correctly and they're working
right just open up the shaft you can look inside the exhaust port and see
that they're opening fully now we've got a few more things to install on this
side of the cylinder and that would be the adjuster for the power valve and
believe it or not you can actually control the power of the engine or
change the power of the engine with these parts here they basically hold
tension on the exhaust valve itself and gives you control over when that valve
opens first up we've got this little collar and we'll line it up with a
spring here and then goes into this hole right here and in the end of the shaft
there's going to be another slot and you want to make sure all that lines up you
want twist it around till it lines up right there and then on goes the cap the
slot you want to line up with the spring once again
so give you guys a little demonstration of how that tensioner works so right now
we have no tension on the valve and you can notice here the valve the center
valve here it kind of binds up it doesn't want to retract all the way on
its own and that's why you need the tensioner and also that gives you the
ability to kind of change the power curve on the bike to when you're able to
control the tension on this valve here so you can see doesn't want to return
add a little tension to it will do that by turning this adjuster clockwise we're
gonna go a quarter turn see how fast that retracts now now basically how this
adjuster changes the power curve the bike is the more tension you put on the
spring the more you turn it clockwise the longer the power valve is going to
stay open so that's going to increase the pull on the low end and the hit will
be later on you when a two-stroke has that hit that'll be later on in the
power band and then when you turn when you have less tension that is going to
open the power valve sooner so it's gonna have less low end pull and then
that hit will come sooner on so if you do a lot of track riding you may want to
have less tension on the spring maybe only a quarter turn out like we have
right here and then if you do primarily trail riding maybe go like a quarter I
mean a half a turn clockwise now you can go ahead and mess around with the
tension on this thing you can go a quarter turn out a half turn out three
quarter turn out I probably won't go much more than 3/4 but you do want some
tension on the spring there so that way the power valve doesn't get sticky now
that power valve adjustment isn't gonna make a huge huge difference but
definitely something you can play with dial in to your lucky and I think would
be pretty fun too now I know you guys are curious how I got this cylinder
looking new again actually looks better than new well first off the bore was all
jacked up it had a bunch of pitting damage from detonation all scraped up
and so I sent it out to power steel USA they went through TIG weld of that
damaged I'll pop a few pictures on the screen to
show what it look like before they so tip well then let's smooth it out
replated the bore to fix all those scrapes and scratches I've got it all
ready to rip again looking good and then for the exterior look how shiny that is
I had that vapor blasted or vapor honed by my buddy Josh Traxler did an amazing
job this thing is gonna look freaking sweet up here on the engine now if you
guys are in need of any cylinder repair work or vapor blasting I will have both
power steel USA and Josh link down below go hit him up
all righty the valve is all back together I really wasn't too bad was it
all we got to do is slap the covers back on get this thing up on the engine and
we'll be up and running now it is possible to rebuild the valve and
reassemble it with the cylinder on the engine however I would recommend pulling
the cylinder off that way can go through clean everything up get it all fresh
again it's always nice to start with a clean slate so that's it for the power
valve assembly hope you guys found this helpful thank you for watching and I'll
see you in another video coming soon
you