Practice English Speaking&Listening with: Rebuilding A 2 Stroke Power Valve | RM250 Rebuild 13

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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


The Description of Rebuilding A 2 Stroke Power Valve | RM250 Rebuild 13