How to remove your exhaust valves from your 88 KX500

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How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Tue Nov 24, 2015 6:15 am

First, look at the diagram..
1988 kx500 cylinder.png
1988 kx500 cylinder.png (104.72 KiB) Viewed 2007 times
If you haven't already, remove the right governor cover 14024-1611

Then remove CIRCLIP-TYPE-E,4MM 482J4000

Next remove COLLAR,GOVERNOR ROD 92027-1834

Then remove the other CIRCLIP-TYPE-E,4MM 482J4000.
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Re: How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Tue Nov 24, 2015 6:22 am

1988 kx500 cylinder 2.jpg
1988 kx500 cylinder 2.jpg (82.81 KiB) Viewed 2005 times
Now remove PLUG,12X10 92066-1222

Then remove GASKET,12.5X18X1,DRAIN PLUG 92065-073 or 11009C

The ROD-GOVERNOR 49046-1057 will not come out yet because it is still meshing with the exhaust valves 12005-1080.
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Re: How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Tue Nov 24, 2015 6:24 am

Move the ROD-GOVERNOR 49046-1057 so that is is roughly centered.
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Re: How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Tue Nov 24, 2015 6:30 am

1988 kx500 cylinder 3.jpg
1988 kx500 cylinder 3.jpg (47.54 KiB) Viewed 2005 times
Grab on to the bottom of the exhaust valve and pull the valves down about 1/4"
If you have aluminum valves BE CAREFUL AS THEY WILL BREAK EASILY
If they don't pull down easy, STOP, squirt the valve heavily with a good penetrating oil.
Be sure to squirt both valves not from the bottom but into the exhaust port as shown below
1988 kx500 cylinder 4.jpg
1988 kx500 cylinder 4.jpg (37.24 KiB) Viewed 2005 times
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Re: How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Tue Nov 24, 2015 6:49 am

Sometimes they come out easy and some times they don't. Be patient :shock:
Use lot's of oil and try to move the valves with the governor shaft but don't force them.
I like to stick my finger up the exhaust port and push down on the valves.
Often times they will move a little at a time.
Remember, we only want to pull the valves down a 1/4"
Once you have both valves moved 1/4" down, pull the governor rod out in this direction
1988 kx500 cylinder 5.jpg
1988 kx500 cylinder 5.jpg (118.19 KiB) Viewed 2005 times
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Re: How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Tue Nov 24, 2015 6:52 am

Once the governor shaft is out, then you can pull the exhaust valves the rest of the way out..
Remember, take your time, use as much penetrating oil as required, soak them in oil for a day or two if required, and DON'T FORCE ANYTHING!!!
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Re: How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Mon May 01, 2017 2:13 am

This was a impromptu example of how to remove your kx500 exhaust valves when they are stuck :o
kx500 valves.png
kx500 valves.png (259.82 KiB) Viewed 892 times
https://youtu.be/xek9MELRXPA
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Re: How to remove your exhaust valves from your 88 KX500

Post by Sandblaster » Tue May 02, 2017 3:38 am

Here is an additional tip from Steve Parris.

Warm the cylinder up in the oven or with a heat gun until hot to the touch, put autimatic transmission fluid on the valves keep it warmed up for about 15min and the carbon and oil should loosen up and let go.
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