Kips Valves turn heavy

dirk · Post by **dirk** » Thu Aug 16, 2007 9:43 pm

Hi

first, sorry about my bad english.

I am Dirk from Germany and my new KR1s will not run.

After a topend inspection, i installed the cylinderhead.
Before i check the valves and clean it.
All valves will turn easy in the cylinder (without cylinderhead).

After the cylinderhead is installed and the bolts are tightened
bothe valves from the right hand cylinder moves very very heavy and the valve motor can not work

the left hand valves turn easy.

Have anyone an idea?

Thanks for your help.

regards
dirk

mgtkr1 · Post by **mgtkr1** » Thu Aug 16, 2007 10:02 pm

dirk, the top end is best assembled as follows because of sloppy tolerances etc, here goes; after fitting base gasket's assemble the barrels and head together before placing on the cases. the head should be 1/2 torqued to the barrels before placing on the cases then fully torqued in the correct sequence on on the cases. be sure the valves turn freely as this will be an indication of how the top end has been fitted. you could slacken everything off including the barrels and try and 1/2 torque the head, then fully torque the barrels and then fully torque the head. the kr1-s is very fussy on how the engine is assembled, especially the top end. next time the top-end needs to be removed it may be worth while to have the barrels skimmed(from the bottom) to exactly the same height and also check the head for flatness. i think you may get away with just slackening/redoing the top-end rather than removing completely. its a tricky job when using std 2 ring pistons but do-able. much easier with a spare set of hands. cheers matt, ps DONT TRY THE P/VALVE MOTOR WITH JAMMED KIPS VALVES AS IT CAN BURN THE MOTOR OUT AND DAMAGE THE CDI!! in fact the cdi may have already expired, are you getting a spark? the stator is also prone to failiure, if so replace with the very good value for money not to mention reliable(compared to std) zeeltronic ignition unit.

dirk · Post by **dirk** » Thu Aug 16, 2007 10:50 pm

Hi Matt,

thanks for your fast answer.

Your advice sounds like

..
Till this day i thought only Yamahaengineers are workplace drinker...
but differrent hight from barrel to barrel???????????????

Spark are fine and the engine start fine, but if was the engine warm and i turned the engine fast to higher rpm it smoke heavy from the right exhaust.
i know... right crankseal...a "new" crank is installed and i hope this was the fault.

After rebuild i do not start the engine, because the jammed valves.....
i have only two hands, so i will try to slacking the barrels and head.

Dirk

rc46 · Post by **rc46** » Thu Aug 23, 2007 3:46 pm

Valves are bent!

I have the same problem, they move in the barrels but when the head is on 1 of them is difficult to move, you can replace the valve or very very carefully straighten it! I managed to get mine straight enough to work.

You can confirm its the valves as you move the valve to another location (the other barrel) the problem will move with it...

£28 from kawasaki for new ones!

Cliff · Post by **Cliff** » Thu Aug 23, 2007 4:50 pm

How does a valve get bent?

mr_bungholeo · Post by **mr_bungholeo** » Thu Aug 23, 2007 6:19 pm

i normally snap them off at the head.....

will have some lovely steel ones soon.... $\:D/$ $\:D/$ $\:D/$

rc46 · Post by **rc46** » Thu Aug 23, 2007 6:30 pm

Cliff wrote:How does a valve get bent?

Got no idea but when they where out i could see the shaft was bent, its only soft alloy!!! i think!

dirk · Post by **dirk** » Fri Aug 24, 2007 12:03 pm

Hi,

i think the valves are cast aluminium.
that snap off before it distort.

now should i try to slackening/redoing or buy new valves and then reassemble?

thanks

Dirk

rc46 · Post by **rc46** » Fri Aug 24, 2007 12:47 pm

Move the stiff valves to another barrel and put it together again... if the problem moves with the valve its the valve if not its the barrel, They should all move freely when assembled, As i say mine where bent and i could see the shaft wasnt true, so once the head was on it distorted the base of the valve and it was stiff!

see Mr B for maybe some new ones. of kawasaki will have them!

just replace the problem ones!

the-elf · Post by **the-elf** » Fri Aug 24, 2007 3:09 pm

If the valves are not bent, the next thing to check is that the head is flat You check it with a decent straight edge.

/sucking eggs bit.
You have made sure that the holes for the valves are clean and free from carbon etc.? Are you dipping the valves into new two stroke oil before assembly?

dirk · Post by **dirk** » Mon Aug 27, 2007 5:01 pm

hi

I have clamp the valve in a drill maschine.
2 Valves are out of round... and one slack if installed

3 new Valves appointed ...
1 Valve ~22,- GBP + VAT

Head is flat.

I hopr this was (for this year

) the last defect.....

thanks for all hints

Dirk

dirk · Post by **dirk** » Mon Sep 03, 2007 6:25 pm

Hi

AHHHHHHHH

with the new Valves the problem is the same!
two Valves on the left side turn good but one have a little bit slack.
on the right side both valves clamp.
the head is flat.
if is possible that the head is skewed?

thanks for help

Dirk

the-elf · Post by **the-elf** » Mon Sep 03, 2007 7:05 pm

If its always the RHS check that the cylinders are the same height. Check that the bottom of each power valve hole in the cylinder is clean and free from dirt etc.

Make sure that the valves can turn freely without the head clamped. Make sure that you assemble it slowly and tighten each bolt in the correct order and turn each a bit at a time so that you don't torque it up until the third or fourth tightening. Check between each tightening that the valves can still turn.

dirk · Post by **dirk** » Mon Sep 03, 2007 7:36 pm

if the cylinder has different height and
i torque the head before assemble the cylinders on the crankcase are both cylinder gaskets leakproof?

Yamaha are so easy.
what i do???
Buy one very expensive KR three month ago and i can not drive this crazy thing

dirk · Post by **dirk** » Tue Sep 04, 2007 9:06 pm

hi

Both cylinder disassembled.
I dont`t find different height between both cylinders with my sliding rule.
Valve holes clean.
I have installed the head at home and no problems!
All four valves turn easy.

Everything do i wrong...

Dirk