1:11 YZ250F 2019-2023 Full Motor Rebuild (Part 2) Crank true & assembling the valves in the head — Transcript

Full transcript

1. 0:01welcome back to the shop this is part
2. 0:03two of the yz250f 2022 full motor
3. 0:06rebuild in part one um I showed you how
4. 0:10this motor dropped the valve and just
5. 0:11completely trashed the cylinder head the
6. 0:14cylinder and bent the rod all the parts
7. 0:17are in I believe they are I'm going to
8. 0:18have to go through all them make sure we
9. 0:19have all of them if you didn't catch
10. 0:21part one there'll be a link in the
11. 0:22description where you can catch that but
12. 0:24yeah all right I got to run through all
13. 0:26these parts so let's do that we have
14. 0:29about
15. 0:31$3,315 worth of
16. 0:34parts and if you remember in part one I
17. 0:37mentioned that he was going to consider
18. 0:38going with the gytr race kit uh that
19. 0:42comes with a modified cylinder head cam
20. 0:44shaft um the ECU CDI whatever you want
21. 0:48to call it all that but he decided to
22. 0:50opt out of that because they're shooting
23. 0:52for the stock class they're working to
24. 0:54get to go to theetta and they're going
25. 0:56to be racing the stock class so we have
26. 0:59to keep the bikes stock for the most
27. 1:00part so so far here we got uni filter he
28. 1:03decided to go ahead and put some
29. 1:06GTR uh radiator supports on it we got a
30. 1:08lot of parts to dig through here uh he's
31. 1:11going with aluminum throttle
32. 1:13tube get rid of the plastic one oh we
33. 1:16have a ton of Parts we're going to dig
34. 1:17through all this stuff uh some new new
35. 1:20brake pads while we're at it but yeah
36. 1:23$3,315 worth of Parts it's crazy but you
37. 1:27know it's how it goes sometimes
38. 1:31and uh we will be doing some
39. 1:32Blueprinting we're going to check the
40. 1:33crankshaft make sure it's true um just
41. 1:37so just some general Blueprinting what
42. 1:39that is is just trying to get the motor
43. 1:41as perfect and accurate as we can
44. 1:43without actually breaking any of the
45. 1:45rules as far as modifications are
46. 1:48concerned we can't really do any
47. 1:50modifications because it's a stock class
48. 1:52and if he gets protested and they rip
49. 1:54the bike open well you don't want to
50. 1:55fail that test so keeping it stock but
51. 1:59we will will be doing some Blueprinting
52. 2:01try to do what we can to so the bike
53. 2:04runs as efficiently and as powerful as
54. 2:06it can within while staying relatively
55. 2:10stock all right what I'm going to do is
56. 2:12verify that all the parts there's no
57. 2:14parts missing I'm going to run to the
58. 2:15order right there make sure we have
59. 2:17everything I'm going to put that in fast
60. 2:19speed so you know you don't have to sit
61. 2:21here and you can watch it but it'll be
62. 2:23fast let's do
63. 2:28it
64. 2:48okay it appears we have everything
65. 2:51besides the other stuff I showed you
66. 2:53earlier on you got two spark plugs one
67. 2:56spare some valve seals or the guide
68. 2:59seals
69. 3:00um all four new valves one two three
70. 3:04there's a fourth one here somewhere here
71. 3:05it is all four new
72. 3:09valves brand new crankshaft and we're
73. 3:11going to true that we got brand new
74. 3:14valve strings here's I guess I should
75. 3:16explain this remember in the first video
76. 3:19when I was trying to figure out what
77. 3:20happened what went wrong um well I think
78. 3:24we I think we kind of nailed it narrowed
79. 3:26it down we got brand new headbolts and
80. 3:29because we don't okay first off we
81. 3:33thought this bike only had 56 or 52
82. 3:35hours on it at least the whole bike
83. 3:37right we bought it from a race team I'm
84. 3:39not going to mention which race team so
85. 3:41you know but uh we bought it from a race
86. 3:43team it was supposed to be their
87. 3:44practice bike we were assuming it was a
88. 3:46stock bike I don't know if he was told
89. 3:48if it was a stock bike and never opened
90. 3:49up or not but when I first saw it when I
91. 3:52was told it only had 22 hours on it at
92. 3:54that time um I was I was under the
93. 3:57impression it was a stock bike myself
94. 3:59and never been torn apart but after
95. 4:00further observation I noticed that that
96. 4:02piston is not a stock piston the Piston
97. 4:04that we pulled out of it in video number
98. 4:06one that's a uh like a pro X piston or
99. 4:09whatever okay we got a brand new
100. 4:10cylinder for it and uh so what that tell
101. 4:13told me is someone has been in that
102. 4:15motor now here's the thing it was a race
103. 4:17team's bike maybe a practice bike and
104. 4:20someone's already been in the motor but
105. 4:22I don't think the motor had ever been
106. 4:24out of the bike I checked all the bolts
107. 4:26that hold the motor down I don't see any
108. 4:28witness marks that anyone's ever removed
109. 4:30that motor out of the bike but someone
110. 4:32has definitely done a top end on it so
111. 4:35with that kind of it makes me suspicious
112. 4:38as far as like you know usually race
113. 4:40teams will put modified Parts on a bike
114. 4:42so did that bike originally have a
115. 4:45modified head on it cam shafts and
116. 4:47piston and then when they went to sell
117. 4:48it they had to convert it back to stock
118. 4:51um they might have just when you have
119. 4:53multiple bikes and you're a race team
120. 4:55you you have all these parts on the
121. 4:56shelf and they all get mixed up we don't
122. 4:58know that cylinder had how many hours it
123. 5:01had on it okay you got a brand new K
124. 5:03piston kit here we don't know how many
125. 5:05hours it had on it we have our
126. 5:08gaskets cylinder gasket head gasket for
127. 5:12some reason they sent this two of these
128. 5:16gaskets whatever it's better to have
129. 5:18extra parts than missing parts
130. 5:20right um so here's what I'm speculating
131. 5:23I'm speculating that they pulled their
132. 5:25race head
133. 5:26off and just thre any piston in there
134. 5:30and uh and just any head off the shelf
135. 5:33and with unverified hours we don't know
136. 5:36how many hours on that head which means
137. 5:38we don't know how many hours we're on
138. 5:40the valves now valves should be replaced
139. 5:43at 200 hours no matter on a race bike or
140. 5:45a track bike I understand the guys that
141. 5:48are play riding in the woods or whatever
142. 5:49it's totally different story I get I get
143. 5:51in the comments often times I've gotten
144. 5:53600 hours out of my bike well yeah you
145. 5:55know you're just riding to your trail
146. 5:56riding to the woods track bikes are
147. 5:58different they're doing jumps you don't
148. 5:59take them chances when you're when
149. 6:01you're going wide open throttle in
150. 6:02fourth gear at a big triple and uh plus
151. 6:05the extra abuse that a bite gets it's
152. 6:07punched out of every corner it's just
153. 6:09pinned out of every corner lap after lap
154. 6:11after lap um so valves should be
155. 6:15replaced at 200 hours with your
156. 6:17crankshaft at 200 hours no matter how
157. 6:19good it checks out for safety reasons I
158. 6:21have seen valves where the head can just
159. 6:25fall off after a certain amount of hours
160. 6:27they it it can it just happens they get
161. 6:28tired they get fatigued too many heat
162. 6:31Cycles I'm thinking I'm starting to
163. 6:33think that's what happened on this one
164. 6:35because uh because we couldn't find any
165. 6:37other reason why that valve would have
166. 6:39would have made contact with the Piston
167. 6:41the way it did I believe it just started
168. 6:42to fall off made a little bit of contact
169. 6:44with the piston and that just did it in
170. 6:47I've seen it man you know and that's all
171. 6:49I can say um got new grand new brand new
172. 6:52crank Bears here now that being said I
173. 6:55do have to correct an error from video
174. 6:57number one in that
175. 7:01because I was able to rotate the motor
176. 7:02by hand before I pulled it apart I
177. 7:05should at least verify the cam timing to
178. 7:07make sure that we didn't have a timing
179. 7:09chain tension or fail and it jumped
180. 7:11timing and that's why the valves hit the
181. 7:13Piston however I will say if you
182. 7:15remember part one you can see that only
183. 7:18one intake valve originally made contact
184. 7:20not both that indicates to me that it
185. 7:23didn't jump timing because anytime it
186. 7:24jumps timing both valves intake valves
187. 7:26mve together and both would have made
188. 7:28contact with the Piston so it didn't
189. 7:30jump timing however for good practice
190. 7:32and for you guys out there that are
191. 7:34watching this video to learn or whatever
192. 7:36um if you if you can rotate your motor
193. 7:39by hand still verify the cam time before
194. 7:41you rip it apart because anytime the
195. 7:43motor blows it's real important to find
196. 7:45out what caused it to happen so you can
197. 7:48avoid from going through that again so
198. 7:51so it doesn't happen again we got a
199. 7:52brand new cylinder head we're going to
200. 7:53have to put that together we're going to
201. 7:55be doing that in this video there might
202. 7:57be a part three to this build because
203. 7:58this is going to going to be a lot of
204. 7:59work so we're going to start with the
205. 8:01cylinder head crank twing first then
206. 8:04cylinder head and I think part three is
207. 8:06where we're going to put the motor
208. 8:07together and put it back in the bike and
209. 8:08get it
210. 8:09running all right um and if you remember
211. 8:13in part one I mentioned about the cam
212. 8:15shaft when anytime it anytime a uh
213. 8:17valves make contact with the with the
214. 8:20Piston it can sometimes shift the cam
215. 8:22shafts the gear that's pressed on there
216. 8:24it can shift it and just knock your cams
217. 8:26out of whack so I mentioned the him we
218. 8:29should at least get a new intake cam
219. 8:31shaft for that reason he doesn't want to
220. 8:33take any chances they don't want to miss
221. 8:34out on this season they don't want
222. 8:36another failure so he told me just get
223. 8:38both cam shafts I'm like okay you got it
224. 8:41let's get both cam shafts and
225. 8:43he's he's trying to have this thing
226. 8:45built to a level that it just hangs in
227. 8:48there and we no we don't want to leave
228. 8:50any stone on
229. 8:51turned so because of that we did get a
230. 8:54brand new chain cam chain tensioner
231. 8:57again it was my error I should have
232. 8:59checked the C uh the cam time before I
233. 9:02pull it apart to make sure this thing
234. 9:03didn't fail cuz sometimes these can fail
235. 9:06and but on the bench they'll bench test
236. 9:07just fine you put it back in the bike
237. 9:11and it jumps timing again on the bench
238. 9:13you can squeeze it you can pull this out
239. 9:14you can put it anywhere and touch and
240. 9:16it's holding up but for some reason on
241. 9:18the bike with the vibration and stuff
242. 9:19they can actually give up I've seen it
243. 9:21it's rare but it does happen um for you
244. 9:23guys are wondering where you get them
245. 9:24little keyways that help you hold the
246. 9:26cam timeing in they usually come on a
247. 9:28brand new timing chain tenser right
248. 9:30there watch this it's going to extend
249. 9:31down on here there it is there's your
250. 9:33little tool for that let me stick that
251. 9:36back in the bag don't want to lose that
252. 9:37actually I'll just put it right up here
253. 9:39add it to my collection those things are
254. 9:40really cool to have when you ever get
255. 9:41them hold on to them little tools them
256. 9:43are
257. 9:44nice all
258. 9:46right so we have a brand new oil filter
259. 9:48I know I'm doing a lot of talking here
260. 9:49but I have a lot I have a lot to tell
261. 9:51you guys brand new timing chain and the
262. 9:55uh timing chain tensioner
263. 9:57gasket woo well that's all the engine
264. 10:00parts as you know we also have the brand
265. 10:02new grips for o Yamaha grips some brake
266. 10:04pads uh air filter and radiat supports
267. 10:07but that's it for the OEM parts and I
268. 10:10know I'm leaving something now as I
269. 10:11remember things I had to tell you guys
270. 10:13through through the video I'll just spit
271. 10:15it out let's go ahead and get that crank
272. 10:17on the truing stand and let's check it's
273. 10:19true oh that's right because again we
274. 10:22don't know this top 's already been
275. 10:24apart so I H I've got new cylinder head
276. 10:26bolts um My Philosophy is these should
277. 10:30be replaced every other top end that you
278. 10:32do on a bike they stretch out right um
279. 10:35in the Motocross World some people say
280. 10:37every third top end you replace them um
281. 10:40I just do it every other ju uh in my
282. 10:42experience when I go to torque it down I
283. 10:44can tell when they've been um stretched
284. 10:46out too far they're torque yield bolts
285. 10:49and I can I can feel it on the torque
286. 10:51wrench and how it it's hard to explain
287. 10:54but um I found if you try to run them
288. 10:56three times it's just a little bit too
289. 10:58much so I do it every other time it's
290. 10:59perfect but we don't know if this has
291. 11:00had a top end already done three times
292. 11:02we don't know this is not a virgin bike
293. 11:05we thought it was a virgin but it's not
294. 11:07so we're going to go ahead and um
295. 11:10replace the the cylinder head bolts
296. 11:13while we're in
297. 11:15there and the same applies for the valve
298. 11:17springs at 200 hours remember I said at
299. 11:19200 hours you should replace your
300. 11:20crankshaft on a track bike no matter how
301. 11:23well it checks out um just to be safe
302. 11:26rods break out of nowhere just like
303. 11:28valves can break out of nowhere the rod
304. 11:29can snap after 2 and hours just from
305. 11:31fatigue heat Cycles abuse and again it's
306. 11:34just a safety thing I understand some
307. 11:36people say they've gotten 500 hours out
308. 11:38of the crank sh right we're talking
309. 11:39about track bikes here and we're doing
310. 11:41this for safety I understand it might
311. 11:43make it 200 hours but by changing it I
312. 11:46mean 400 hours but by changing it 200
313. 11:48hours you just you're going to keep your
314. 11:49Rider safer so that's why we also got
315. 11:52new valve springs we got new valves new
316. 11:54valve springs for this brand new
317. 11:55cylinder head because valve springs can
318. 11:57break too they're a million miles an
319. 12:00hour just they break after a while and
320. 12:03then yeah so we got new bow
321. 12:06rings okay got my little trusty Tru and
322. 12:08stand here you know sometimes people
323. 12:11make something for you it's custom made
324. 12:12or whatever Joe made this for me these
325. 12:15things are so cool man I love it when
326. 12:17when I have stuff like this I keep it
327. 12:18for years you know just become kind of
328. 12:22personal it's really cool that's all I'm
329. 12:24saying all right spec
330. 12:27say right here from from the manual now
331. 12:30you see how they have it connected
332. 12:32they're checking the true you see it's
333. 12:34all the way on the very end of doal
334. 12:35indicator on a tring
335. 12:37stand uh run out should be no more than
336. 12:410.3 mm
337. 12:4403 all right so that's how I have it set
338. 12:46up here let's do this I'm going to zero
339. 12:49it out anytime I see a negative I'll
340. 12:51zero it out
341. 12:53again I had to get created and put a
342. 12:55little washer perfect size right here in
343. 12:57this on this bearing race all the way up
344. 12:59in there because it was actually there's
345. 13:01a part of the crank that was catching
346. 13:03the the uh truin stand as I turned it
347. 13:05there so that's what that's there for
348. 13:07but it
349. 13:08works okay there's a negative anytime
350. 13:10you see a negative I'll zero it out so
351. 13:12we can get the highest
352. 13:16number okay so far we're at
353. 13:21one when it's right I should be able to
354. 13:24get all way back down to
355. 13:27zero
356. 13:33there it is let's go ahead do another
357. 13:34rotation just let's get two rotations in
358. 13:37let's see there's
359. 13:39one this crank's looking great by the
360. 13:43way cuz that's they're saying a maximum
361. 13:46of
362. 13:4803 so anything tighter than that there
363. 13:51we are back to zero this is a 01 that's
364. 13:54great I'm not going to try to get it any
365. 13:56better than that because most time you
366. 13:58can't that's why they have a 03 a lot of
367. 14:01times from the factory you're going to
368. 14:03find them at if you buy a brand new
369. 14:04crank 03 02 if you get a 01 that's
370. 14:08actually kind of exception except
371. 14:10exceptional crank if you get zeros all
372. 14:13across well you got yourself a a
373. 14:15unicorn now I'm not going to check the
374. 14:17other side as you saw in the manual they
375. 14:19didn't show the checking the other side
376. 14:20you don't have to if one side is out of
377. 14:22true in any way you're going to see it
378. 14:25on one side or I'm saying if either side
379. 14:26is out you're going to see it just on
380. 14:28this side alone and the reason I'm not
381. 14:29going to check both sides is because you
382. 14:31really can on this crank there this this
383. 14:34right here is not a smooth M machine
384. 14:36surface and these are definitely not
385. 14:38smooth there's really nowhere to put
386. 14:39your doal indicator like this is a
387. 14:40smooth machine surface and that's why
388. 14:42the manual showed you setting it right
389. 14:44here this crank's good it's really good
390. 14:47we're going to use it just the way it
391. 14:50is now if it was off true just a little
392. 14:53bit I would have tempted to put it back
393. 14:55in true if it's off a lot I'm going to
394. 14:58mail it back get another one but this
395. 15:00one's good if you're curious on how to
396. 15:01True a crank I'll put a link down in the
397. 15:03description on chewing cranks where I
398. 15:05cheed my own crank and give you a walk
399. 15:08through there let's continue on all
400. 15:10righty brand new crankshaft and what
401. 15:12we're really checking when we check the
402. 15:14true morning thing else is to make sure
403. 15:15it wasn't dropped during you know um
404. 15:18they wrap it pretty good in the Box as
405. 15:20you saw when I was opening all the boxes
406. 15:22for everything but you know sometimes a
407. 15:24crank is dropped at at you know Rocky
408. 15:26Mountain Motorsport the mail man
409. 15:29whatever it hits them just
410. 15:31right you'll see in my uh truing video
411. 15:33in the in the description where I
412. 15:35dropped my crank and knocked it off true
413. 15:37and actually had to put it back in the
414. 15:39true it happens you know so that's what
415. 15:42we're checking some Brands don't even
416. 15:44wrap them that good in the Box yamha
417. 15:46actually comes wrapped pretty well I've
418. 15:48seen some Brands where it's just sitting
419. 15:49in the Box you buy the crank and it's
420. 15:51just sitting in a dang box with nothing
421. 15:52around
422. 15:54it that's really all we're checking
423. 15:57brand new cylinder here look how shiny
424. 15:59that thing is
425. 16:00wo all right we got to assemble this
426. 16:04thing it's going to be fun fun no
427. 16:07actually before I assemble this I still
428. 16:10have to take the parts that are reusable
429. 16:12out of the original cylinder head so
430. 16:14let's go get that dang it my airline's
431. 16:17leaking right there that drives me
432. 16:19nuts I'll replace that later anyway
433. 16:22let's go ahead and start taking this
434. 16:24stuff
435. 16:27off
436. 16:31hm let me try to get that a little bit
437. 16:33better
438. 16:37here there we
439. 16:45go all
440. 16:46right we have that off there man this
441. 16:49thing
442. 16:50stinks huh smells a little
443. 16:54funky okay
444. 16:57whatever
445. 17:01these put them back over here so when I
446. 17:04go to put the motor back
447. 17:09together okay let me set that aside so I
448. 17:12don't bump
449. 17:14it I have to get these studs out and
450. 17:17these studs out I'll save that for the
451. 17:19last thing I do man look at that I'll
452. 17:21save that for the last thing I
453. 17:24do okay I guess I'll start with the
454. 17:27intake do one at a time I don't want to
455. 17:29get anything mixed
456. 17:33up I'll keep the stock shim valves I'll
457. 17:36I'll start with them when it's time to
458. 17:38shim the new valves because um that'll
459. 17:41get us pretty close and then from there
460. 17:43we'll just make Minor Adjustments got to
461. 17:45get these out cuz I need some of the
462. 17:47parts from in there okay break out my
463. 17:50valve spring Pooler for my valve spring
464. 17:52puller it's just a Big C clamp with a
465. 17:54socket cut out they do sell valve spring
466. 17:57pullers in they're reasonably priced and
467. 17:59um you can go ahead buy one of them I
468. 18:01made this years ago and it's just been
469. 18:04doing me good so i' just kind of stuck
470. 18:07with
471. 18:10it let's see I'm trying to figure out
472. 18:12how I can arrange this to get it on
473. 18:14video let me get all this set
474. 18:16up okay for my homemade valve spring
475. 18:19puller I got the
476. 18:22little swivel off the end there so the
477. 18:24ball will sit right in the little
478. 18:26concave part of the head here
479. 18:29again I put this together years ago um I
480. 18:32didn't have a valve spring puller and
481. 18:34someone needed me to change some valves
482. 18:36and it works so well I just kind of
483. 18:39stuck with it so yeah I'll put this in
484. 18:41here on top of the
485. 18:44uh the spring retainer and I'm just
486. 18:47going to compress
487. 18:54it there we go it'll pop when you first
488. 18:57get it compressed you're going to need a
489. 18:58magnet for all this stuff the smaller
490. 19:01magnets like that one right there work
491. 19:03best for this I grab the
492. 19:06keepers there's
493. 19:11one that's all we're doing get on camera
494. 19:14here so all I'm doing I'm pulling off
495. 19:16these little Keepers there's two for
496. 19:17each
497. 19:22valve now I can loosen up the uh spring
498. 19:25compressor all the way the valves spring
499. 19:29compressor there we go we have the
500. 19:32retainer thing do hickey deal the valve
501. 19:35spring one observation which I'll
502. 19:36mention a few times in the video the
503. 19:38pain inside of the spring is always the
504. 19:40upside it's always the side that goes up
505. 19:42because the coils get tighter down at
506. 19:44the bottom and they're more spread out
507. 19:46up top so it's less weight as it's uh
508. 19:48pushing the valve up and down less
509. 19:50likely to
510. 19:52float so that's why they do that okay
511. 19:54that's for that intake now it has a um
512. 19:59let me push the valve on out actually
513. 20:01there we go got the
514. 20:04valve all right it has a uh a valve what
515. 20:08do you call it valve guide seal in there
516. 20:10I need to pull that out let me grab
517. 20:12something yank that out of there here we
518. 20:15go I'm just going to going to destroy it
519. 20:16pulling it out that's all right we have
520. 20:18new
521. 20:19ones here it is your valve guide seal
522. 20:23that goes in the
523. 20:25trash okay now where's my magnet here it
524. 20:29is we got the spring seat I guess you
525. 20:32can call it it's probably not the right
526. 20:33name for
527. 20:35it got the oil kind of holds it there
528. 20:37you just there we go comes right on out
529. 20:40of
530. 20:41there all right and that's it for that
531. 20:44one everything's out of there this is
532. 20:46the broken valve how am I going to do
533. 20:48that I'm just going to think I'm have to
534. 20:50get a
535. 20:51little uh heavy-handed here for a second
536. 20:54let grab myself my
537. 20:57hammer
538. 21:02head's trash
539. 21:06[Music]
540. 21:10anyway well that sucker is in
541. 21:16there
542. 21:21wow titanium likes to
543. 21:26spark huh
544. 21:29hm well well
545. 21:32well
546. 21:34huh there there is more more than one
547. 21:37way to skin a cat if I all I need to get
548. 21:40them Keepers off there because I want to
549. 21:43what I need is I don't need the spring
550. 21:45we have a new spring I need this part
551. 21:47off the bottom I probably should have
552. 21:48just bought one honestly I wouldn't have
553. 21:50to sit here and try to pull this off my
554. 21:53bad
555. 21:55well let me see if I can just uh
556. 21:57compress press it and pull them Keepers
557. 22:00out oh I don't well I guess I do need
558. 22:03it all
559. 22:05right let's see see what we can get done
560. 22:26here all
561. 22:32right come on there's one got one out
562. 22:36all right I think the other ones are a
563. 22:38little bit tighter we'll see how we see
564. 22:40what we can do
565. 22:42here let me try like
566. 22:46this loosen it back up we got one
567. 22:56out
568. 23:05if I could just get that other one out
569. 23:06whe will be
570. 23:13good yes got it all
571. 23:21right well actually I need two parts
572. 23:23from here I need the uh the top and the
573. 23:26bottom piece so yeah
574. 23:29cuz them aren't really wear
575. 23:31items so we can reuse
576. 23:34them got this that goes on top of the
577. 23:37spring ding
578. 23:42ding the old B
579. 23:45spring I'm going have to get the
580. 23:48uh valve seal out of there come on there
581. 23:52it
582. 23:53is I'm sorry the valve guide
583. 23:56seal
584. 24:01and let me
585. 24:02pull this out there we
586. 24:05go okay that's the intake stuff now
587. 24:09let's go ahead and get the exhaust stuff
588. 24:11out it's going to be pretty much the
589. 24:13same thing as with the intake
590. 24:16valves got the valve shim right up in
591. 24:19there want to keep that again I'm going
592. 24:21to start with all o i mean the original
593. 24:23shims y that'll get us really close
594. 24:35I have one valve shim that's being
595. 24:37stubborn there when that happens like
596. 24:38that all you have to do is take a little
597. 24:43punch put it right on the side right
598. 24:45here and just give it a tap don't not on
599. 24:47the valve shim itself but on the uh on
600. 24:50the uh this thing right here there it
601. 24:56is
602. 25:02got two of them to remove here okay I'm
603. 25:04going to do this the same way I did the
604. 25:05intake valves I'm going to do it in fast
605. 25:07motion to save time so here we
606. 25:26go
607. 25:48okay this old head is pretty much
608. 25:50stripped down for the most part I still
609. 25:51have to move this uh plug over to the
610. 25:54other cylinder and remove the studs but
611. 25:56I'm going to do that after I get get the
612. 25:57vals in I don't feel like doing that
613. 26:00right
614. 26:01now I'd rather stay up on the valve
615. 26:05job all right I got to move these cam
616. 26:25caps there we go
617. 26:33anytime you buy a brand new cylinder
618. 26:34head it will come with Cam caps um they
619. 26:38won't sell you just the cam caps if you
620. 26:40ever damage these they you know the old
621. 26:43practice was every set of Cam caps was
622. 26:45drilled out to that cylinder head was
623. 26:47cut out to it but I can tell you the uh
624. 26:49Machining nowadays is so accurate that
625. 26:53if you did damage a cam cap and you had
626. 26:55to get one from someone maybe use on E
627. 26:57day whatever nine times out of 10 you're
628. 27:00going to be fine they're they're the
629. 27:02Machining is so accurate
630. 27:04nowadays okay time to uh start putting
631. 27:08this thing together so let me get some
632. 27:10new parts
633. 27:12out first I'm to figure out what valve
634. 27:15guide seals go where two are for the
635. 27:17intake two are for the exhaust the
636. 27:19intake will have a on this motor some
637. 27:22some Motors are the same but on this
638. 27:24motor the intake I believe we'll look at
639. 27:27intake valves and see or actually I can
640. 27:29just look in here and see so there's the
641. 27:31intake you can see the hole is bigger
642. 27:33than the exhaust where the valve goes in
643. 27:36so the intake has uh the
644. 27:39uh the valve stem is
645. 27:47bigger has a larger
646. 27:50diameter
647. 27:53so lay these flat here and see which
648. 27:56ones are which these two are the exhaust
649. 27:59they're smaller um I think I'm going to
650. 28:01start with the intake let's start with
651. 28:03the intake so I'll set these
652. 28:05aside and these are the two intake ones
653. 28:08I'll leave these right
654. 28:10here
655. 28:12okay so we're going to start with the
656. 28:16intake I'll take these two things are
657. 28:19way I just cleaned them in some
658. 28:21gasoline drop them in their respected
659. 28:25seats I use a magnet and get it up in
660. 28:34there there we
661. 28:36go of course you want the uh that end
662. 28:40right there facing upward
663. 28:48obviously all right I have them in place
664. 28:53now we need to drop the valve guide
665. 28:55seals on there I'm going to take the old
666. 28:58intake valve
667. 29:00that's you know we're not going to be
668. 29:02using it but I'll what I'll do is I'll
669. 29:03slide
670. 29:06that into the valve
671. 29:08guide that one that one tried to jump
672. 29:12out actually no I don't think I yeah
673. 29:15there we go going to say it's not going
674. 29:17on cuz that's going to by having that in
675. 29:19there it's going to help me slide the
676. 29:22new valve seal valve guide
677. 29:24seal on there
678. 29:28went and found a a socket that fits on
679. 29:30there like
680. 29:36that so I'll just set the valve seal on
681. 29:40the valve here now obviously the
682. 29:43valve uh stem's going to hit inside the
683. 29:46socket so as I push it down I'll let the
684. 29:49I'll let the valve just drop
685. 29:52down there we go all that does is keep
686. 29:54it align for
687. 29:56us so it goes on nice and easy let's do
688. 29:59the next
689. 30:02one them suckers keep trying to roll out
690. 30:05of
691. 30:07there there we go once you get the um
692. 30:11once you get the valve guide seals in
693. 30:13there that little
694. 30:16spring
695. 30:17seat stays in place all right take this
696. 30:22like said on once the valve um tip hits
697. 30:25the socket I'll just let the valve drop
698. 30:27there it
699. 30:28is all
700. 30:30right they're in
701. 30:35place okie
702. 30:37dokie now it's time to set the new
703. 30:40intake valves in
704. 30:42place cut the new intake valves out
705. 30:45about to take my gloves off here in a
706. 30:47minute CU this part of the job you have
707. 30:50to be really really clean and when I'm
708. 30:53barehanded um I can feel if any grit got
709. 30:55on my fingers and dress that before it
710. 30:58becomes an issue with gloves on it's
711. 31:01kind of hard to feel that so here they
712. 31:06go
713. 31:11okay the valve seats this is a new
714. 31:14cylinder so we're good we're okay but if
715. 31:17you got a used one you want to clean the
716. 31:19valve seats before you drop in new
717. 31:21valves I I suggest very fine steel wool
718. 31:25here's the stuff right here you want the
719. 31:27steel wool you want 00000000 super fine
720. 31:31that's what you want to
721. 31:33use and you'll just do it by hand just
722. 31:35just go wipe all around the valve seat
723. 31:38here on the cylinder head and just clean
724. 31:41off the carbon that's all you're looking
725. 31:42to do do not use sandpaper do not use
726. 31:44anything abrasive like that you just
727. 31:47want to use steel
728. 31:48wool we're expecting metal I know it's
729. 31:51titanium but basically metal to seal on
730. 31:53metal there can't be any scratches there
731. 31:55can't be nothing like that so very F
732. 31:57Steel W only now if you're reusing your
733. 31:59vals and they still are in good shape
734. 32:02and they have carbon and stuff on it and
735. 32:03you want them to get them the seal quick
736. 32:07tip put them on a drill and you can spin
737. 32:10them take your fine steel wool and as
738. 32:13it's spinning you can you can clean up
739. 32:14your valve that's how you do it don't
740. 32:16use sandpaper don't try to scrape it off
741. 32:18don't none of that stuff just very fine
742. 32:21steel wool but anyway what I'm going to
743. 32:24do here is before I drop each valve in
744. 32:28I'm going to wipe it with my finger
745. 32:31here
746. 32:33sorry uh yeah let's do that wipe it with
747. 32:36my finger make sure it's real clean
748. 32:38knock out both sides while I'm
749. 32:41here I'm just trying to get anything
750. 32:44that I can feel off of there that's it
751. 32:46you know any dust that might have fallen
752. 32:47on it and then for the valve seat right
753. 32:50here or the where the valve makes
754. 32:52contact with the seat I want to wipe
755. 32:55that clean too
756. 32:58now because if if if this was a used
757. 33:00cylinder head and we're just doing a top
758. 33:02end putting a new valves it's not that
759. 33:04critical but because them valve guides
760. 33:07are brand new and the valves brand new I
761. 33:09will put a dab of assembly Lube on the
762. 33:12shaft of the
763. 33:13valve and just wipe it
764. 33:17in I'll do that to the other one too cuz
765. 33:21it's going to take a little bit for the
766. 33:22oil to slowly get to them through the uh
767. 33:25valve guide seals you know that that's
768. 33:28where they get their oil from but it'll
769. 33:30take time on this will start up so I got
770. 33:33the oil on that now I'm going to make
771. 33:35sure these are clean
772. 33:37again I'm going to double check this cuz
773. 33:41even just one grid of sand it's going to
774. 33:43make it where when we go to adjust our
775. 33:46valves we'll uh we won't get a proper
776. 33:48reading because it'll keep the valve
777. 33:50lifted up just a hair but what I like to
778. 33:54do before I adjust the valves and make
779. 33:55sure that there's no sand or anything
780. 33:57blocking it is we'll just check it with
781. 33:59some water pour it in this port and make
782. 34:01sure it seals
783. 34:07good
784. 34:16okay there we go let's go ahead and lock
785. 34:19these
786. 34:21in I Tred to keep the valves both of
787. 34:24them fully seated once they're in there
788. 34:26don't let them kind of pop their head up
789. 34:28a little bit because again you don't
790. 34:29want any any dust in the shop or
791. 34:32anything to land on the surface surface
792. 34:35and jack up your your
793. 34:39work okay so we're doing the intake
794. 34:41valves so uh got to find the intake
795. 34:44Springs instead of searching up the part
796. 34:46numbers I just I know the intake Springs
797. 34:48are
798. 34:49fatter so I'm just going to pull them
799. 34:51all out of the bag and use the the
800. 34:54fatter
801. 34:55Springs
802. 34:58they're bigger valve so they use bigger
803. 35:00fatter springs on the
804. 35:05intake all right dro the trash
805. 35:08everywhere okay them are my two exhaust
806. 35:10so I'll set these over here these are
807. 35:12the two intakes now just like I
808. 35:14mentioned earlier the painted side
809. 35:16that's the side that goes upward you'll
810. 35:17notice that the that the coils are
811. 35:20tighter down here at the bottom where
812. 35:21it's not pained and up here they are
813. 35:24wider painted side goes up top just just
814. 35:28remember
815. 35:32that
816. 35:37okay going to get some grease
817. 35:44here okay I'm going to take these parts
818. 35:46right here take some grease let me get a
819. 35:49Q-tip and just don't want to get this
820. 35:51grease all over my
821. 35:55hand
822. 35:59that's just going to help hold it on top
823. 36:01of the valve spring for
824. 36:09me there we
825. 36:15go all right time to compress them
826. 36:18and Slide the keepers on let me get the
827. 36:21ones for the intake over here there they
828. 36:25are
829. 36:27okay let's do
830. 36:28it for this part you're going to want a
831. 36:31long screwdriver that preferably has
832. 36:33some magnetic properties see how it can
833. 36:35pick that up but if not it's okay cuz we
834. 36:38will still be relying on Grease to hold
835. 36:40that keeper on and in
836. 36:43place just like
837. 36:47that you can put grease on there and
838. 36:50it'll hold it on just
839. 36:51fine pick a rag here to get all that
840. 36:54dirty grease on all right here we go let
841. 36:57me let me try to get you up in here a
842. 36:58little bit better with the camera if
843. 37:00possible cuz this is going to be the
844. 37:02tougher part for most you
845. 37:07guys just going to go ahead and start
846. 37:09with the bottom
847. 37:11one I'm going to compress the valve
848. 37:14spring with the valve spring
849. 37:25compressor
850. 37:27I like to bottom it out
851. 37:30completely but
852. 37:33gently it just keeps things more stable
853. 37:36that
854. 37:38way oops it came off the seat a little
855. 37:43bit the uh the socket kind of fell off
856. 37:46to the side let me straighten that
857. 37:55up
858. 38:10and it did it again all right here we
859. 38:25go
860. 38:27actually let me remove this valve spring
861. 38:29out of there for right now it's getting
862. 38:30all up in my face okay this is where you
863. 38:33put the keepers back on now let me get
864. 38:35on the camera here you'll notice and get
865. 38:38something to point
866. 38:39with you'll notice it on the inside of
867. 38:42the keeper has a ridge right up here up
868. 38:45top that part goes up top and it goes
869. 38:47into the
870. 38:50groove that's on the valve right
871. 38:55there
872. 39:11put a little more grease on it if you
873. 39:13put some grease on this side I kind of
874. 39:14made a mistake forgot to put grease on
875. 39:16that
876. 39:17side there we go that will hold it on
877. 39:21the valve once we get it on the
878. 39:24valve all right let's try this again
879. 39:26again I was sitting there putting it on
880. 39:28the valve and wonder why it wasn't
881. 39:30sticking it's cuz I forgot to put Greeks
882. 39:32on
883. 39:45it that thing's being a
884. 39:47bear I'll get it
885. 39:55though
886. 40:03try to use this pick get it better in
887. 40:09place okay I got that one on there I'm
888. 40:12going to try to get you in the C with
889. 40:13the camera here you can
890. 40:16see get the light up in
891. 40:19there if you can see I have it on
892. 40:24um I have it on on the bottom side of
893. 40:27the valve there you see it there so now
894. 40:29we have room CU what I did with that
895. 40:30pick was after I stuck it on the top
896. 40:32side the part that's facing up uh what I
897. 40:35did with the pick is I rotated around to
898. 40:37the other side so that I can put the
899. 40:39next one
900. 40:40on on the top side where I have better
901. 40:43access to
902. 40:45it all right let's do the next
903. 40:53one again I got to put grease on the
904. 40:57inside here first and then you use the
905. 41:00grease to hold it on the
906. 41:23Flathead okay I think I have it let's
907. 41:25see we get some better glasses too I'm
908. 41:28getting
909. 41:30older I used to never have to wear
910. 41:36glasses about two years
911. 41:39ago that all started to
912. 41:42change okay I think I have it correct
913. 41:46okay both keepers are in place on the
914. 41:49valve let me show since it's so hard to
915. 41:52get the camera in there I'll show you
916. 41:53what I
917. 41:55mean
918. 41:59they're both on the valve like that
919. 42:01they're being stuck on there with grease
920. 42:03but that's that's how they are on the
921. 42:04valve right so now that I have both them
922. 42:06on the valve okay let's go ahead and
923. 42:09remove the valve spring
924. 42:12compressor and I'm going to try to
925. 42:14center it out the best I can oh I see
926. 42:16one's trying to jump out of his seat
927. 42:18here let me pop that one back
928. 42:21in you want to keep the valve spring
929. 42:25retainer centered as best as you can so
930. 42:28it doesn't knock one of the valve
931. 42:30Keepers
932. 42:31off all right let me show you what we
933. 42:34have
934. 42:36here you can see both these keepers are
935. 42:40in their seat it's looking good this
936. 42:42one's good I'm going to go ahead do the
937. 42:45other one now I'll do that one off
938. 42:47camera the same way just like I did this
939. 42:49one and then we'll test our
940. 42:52work okay the two intake valves are in
941. 42:56so let's go ahead and test the work what
942. 42:57I'm going to do is pour some water into
943. 42:59the intake ports here and uh let's just
944. 43:05see if they hold the
945. 43:13water make sure I got both valves
946. 43:19covered oh tilt it but yeah look you
947. 43:22don't see any water dripping out of the
948. 43:24bottom of the or anywhere on these
949. 43:26valves so uh these valves are good
950. 43:28they've sealed well and now what I'll do
951. 43:31is I'll dump this water out spray some
952. 43:33WD40 in there and blow that out just so
953. 43:35you know for obvious
954. 43:37reasons all right I dump the water out
955. 43:39going to spray some w40 in
956. 43:42here wish it around a little
957. 43:45bit and dump that out and blow that out
958. 43:49and now what I'll do is take a valve
959. 43:51bucket cam bucket whatever and put it in
960. 43:54each one just make sure slides in Easy
961. 43:57goes in and out
962. 44:01easy there you go there you go that's
963. 44:04just making sure that I didn't scratch
964. 44:06any of the walls that this slides up and
965. 44:08down in while I was doing that job or
966. 44:11that there wasn't any it's a factory
967. 44:13defect or whatever the case
968. 44:16is all right let's start working on the
969. 44:19exhaust we have to get the um the valve
970. 44:22uh guide seals in so I'll take these
971. 44:25little spring seats right here to go in
972. 44:26the bottom um let me see I actually do
973. 44:31it this way it almost makes it easier
974. 44:32I'll take one of the old exhaust valves
975. 44:34put it in the
976. 44:36hole there you go sure does make that
977. 44:39easy while well I did that I might as
978. 44:40well go ahead put the valve uh guide
979. 44:43seal on too same thing is with the
980. 44:45intake valve just use a
981. 44:51socket actually let me get it on there
982. 44:53first a little bit deeper in the hole
983. 44:58there we
984. 45:02go there it
985. 45:04is now let me do the other
986. 45:13side great I
987. 45:19missed there we go get the new valve
988. 45:21seal valve guide
989. 45:24seal
990. 45:26keep pronouncing that
991. 45:34wrong all
992. 45:41right and again this is where the gloves
993. 45:43come off I'm going to kind of walk you
994. 45:45through one of these exhaust valves and
995. 45:47then I'll do the other one off camera
996. 45:49it's the same thing as the intake
997. 45:51honestly but I figured I'll do it
998. 45:53twice uh for for the guy at home home
999. 45:56that is trying to do this on his
1000. 46:01own go ahead and cut these things out of
1001. 46:04the bag like I said there's going to be
1002. 46:05a part three to this video or this
1003. 46:09build um there may even be a part four
1004. 46:13just depends on how fast I move along
1005. 46:15with it does take more time to do these
1006. 46:17builds when I'm making a video same
1007. 46:19thing I'm wiping it clean with my finger
1008. 46:21oh almost forgot I S me L where did I
1009. 46:24put that stuff here we go going to
1010. 46:27sprinkle some of that on
1011. 46:31the right here and just just wet it up a
1012. 46:34little like I said on the first startup
1013. 46:37it's not going to have any oil and these
1014. 46:38things are
1015. 46:40new and the valve guides are new too so
1016. 46:44it's going to be a little bit of extra
1017. 46:46friction until them Parts break into
1018. 46:48each other okay wipe my hands clean
1019. 46:52again make sure all the dust is off of
1020. 46:55here I like to use a clean finger
1021. 46:57instead of a rag cuz Rags you know they
1022. 46:59can leave debris behind on their
1023. 47:03own okay same thing I'm going
1024. 47:07to cuz you saw the intake valve sealed
1025. 47:10perfectly fine if you put it together
1026. 47:12clean like
1027. 47:14this they'll seal right off the
1028. 47:17top if it didn't seal um
1029. 47:21sometimes I've had luck with pushing the
1030. 47:23valve open by you know putting the tool
1031. 47:25on it pushing it the Springs aren't that
1032. 47:27tough cracking it open just a little bit
1033. 47:29and blowing air in there to to uh shoot
1034. 47:32off whatever debris is there and then I
1035. 47:34check again if that doesn't work then I
1036. 47:36take the valve back out and see what's
1037. 47:39going on and um if
1038. 47:45your if if your valve guide or your
1039. 47:47valve seats damaged that's a whole
1040. 47:49another topic you might have have to lap
1041. 47:51a valve and that's a whole another topic
1042. 47:53and I have other videos where I explain
1043. 47:54how to do that but I'm already
1044. 47:56explaining enough in this video I don't
1045. 47:58want to bombard you guys with too much
1046. 47:59info info so uh I'll leave that out of
1047. 48:02this one
1048. 48:06okay let's get ready to put in the first
1049. 48:10one a brand new valve spring again the
1050. 48:13painted side goes
1051. 48:15upward but if you are curious of how to
1052. 48:17lap a valve um just shoot me a message
1053. 48:20or whatever if you really need it need
1054. 48:22that information I do have other videos
1055. 48:24out there where I had um showed how to
1056. 48:27do that and I can you know provide the
1057. 48:30link for that
1058. 48:32um and all honesty you should never have
1059. 48:35to lap a valve in these dirt bikes they
1060. 48:37the the valve seats are so well machined
1061. 48:42and the toleran tolerances are so
1062. 48:46good it should never you should you
1063. 48:48really shouldn't have to but sometimes
1064. 48:50you know you might have a slight scratch
1065. 48:52on your on yours and you don't want to
1066. 48:54buy a new cylinder head
1067. 48:56and um sometimes it's acceptable but as
1068. 48:58long as you as long as your valve seats
1069. 49:01are in good shape and they don't have
1070. 49:02any damage just clean them it's all you
1071. 49:04have to do this is not the car world you
1072. 49:07know where you know you always have to
1073. 49:09lap them you know uh I will be doing a
1074. 49:11video here shortly on even things like
1075. 49:14uh checking ring in gap on your pistons
1076. 49:16and when you have to file them down
1077. 49:18should you file them down things like
1078. 49:20that because there's a lot of people
1079. 49:21still doing that kind of stuff on these
1080. 49:23bikes and in most cases it's not not
1081. 49:25necessary I'll explain that in that
1082. 49:27video um all right we have to compress
1083. 49:30this one
1084. 49:31in think I'm going to use my smaller
1085. 49:35cutout socket here put some gloves
1086. 49:39on okay let's get the keepers in on this
1087. 49:42exhaust
1088. 49:54valve
1089. 49:56again it's the same thing as with the
1090. 49:57intake valve I'm going to do my best to
1091. 50:00hold it centered as I can press
1092. 50:15it
1093. 50:18okay get my Flathead with the grease
1094. 50:24here
1095. 50:34there we
1096. 50:40go this one actually um I'm probably
1097. 50:44going to be able to show you a little
1098. 50:45bit better it looks like I'm I'm going
1099. 50:46to be able to get the camera in there
1100. 50:48just a little bit
1101. 50:52better let me get them in first
1102. 51:04voila all right going grab one of these
1103. 51:07bent exhaust valves here let me show so
1104. 51:10same thing it has that little
1105. 51:12Ridge right
1106. 51:15there goes on like that
1107. 51:21and see how that
1108. 51:24is
1109. 51:26I'm putting them on there like that and
1110. 51:27the grease is what holds them
1111. 51:32on now let me get you down here and show
1112. 51:37you you can see
1113. 51:41uh grease strings everywhere you can see
1114. 51:45they are on top of the valve one's on
1115. 51:47this side the other one's on the other
1116. 51:48side so let me go ahead and and uh
1117. 51:52loosen up the spring
1118. 51:54compressor
1119. 52:11voila that one's in there let me blow it
1120. 52:14out the
1121. 52:17[Music]
1122. 52:20grease give you a better view of it here
1123. 52:23you can see it's right up in there
1124. 52:24perfectly good so all right I'm going to
1125. 52:26knock out the other one off camera then
1126. 52:27we're going to check the work all right
1127. 52:29both valves are in I'm going to fill it
1128. 52:30up
1129. 52:32water and let's just sit here and watch
1130. 52:35it for a
1131. 52:42minute it's looking good I don't see any
1132. 52:45water leaking out or anything so uh yeah
1133. 52:48I think we're going to be good we'll
1134. 52:50build adjust them oh let me dump that
1135. 52:52water
1136. 52:53out and again I will spread bra this
1137. 52:55port with w40 and go blow it
1138. 52:59out don't need to leave any water up in
1139. 53:02there let me go blow it
1140. 53:05out oh and one last thing before I
1141. 53:08consider that part of the job done take
1142. 53:11a cam bucket here yep you went it nice
1143. 53:15and
1144. 53:23smoothly there we go all right we're
1145. 53:26good now I'll take this thing set it
1146. 53:29aside for now and break out this old
1147. 53:33junker let's get these studs off of
1148. 53:41there went ahead and put the wrench on
1149. 53:43it ahead of time take one nut put it on
1150. 53:46upside
1151. 53:52down the idea here is I'm hoping to lock
1152. 53:54them in in together really
1153. 54:05good and that should be able I should be
1154. 54:08able
1155. 54:09to there it
1156. 54:21is first one's out of
1157. 54:24there
1158. 54:29and I'll put it in this cylinder head
1159. 54:32let me put this one on the
1160. 54:33top I'll put the other one on the
1161. 54:37bottom that way I have the space to
1162. 54:50work there it is all
1163. 54:54right so that's pretty much how you do
1164. 54:56the
1165. 54:59studs get this one off
1166. 55:04there come on out there we
1167. 55:11go I'm going to do that to the other
1168. 55:15three I'll do that off camera to save
1169. 55:17time but I'm just going to do it the
1170. 55:18same way I did this
1171. 55:21one I have to do that one there and the
1172. 55:25these two down here I'll knock that off
1173. 55:27camera uh to save time but that's how
1174. 55:29you do
1175. 55:31it but it's 508 p.m. check out this
1176. 55:35beauty 2022 KTM 450
1177. 55:39SXF fifth gear went out I'll be doing a
1178. 55:42video on that full um I guess you can
1179. 55:45say transmission repair we'll be putting
1180. 55:47a new piston in it while we're in there
1181. 55:49um stay tuned for that that'll be after
1182. 55:51I'm done doing all the stuff in the
1183. 55:54yz250f this is one beautiful bike but
1184. 55:57yeah that's pretty much a wrap for this
1185. 55:59video stay tuned for part three that'll
1186. 56:02be coming up tomorrow evening um where I
1187. 56:05go ahead and assemble the bottom end
1188. 56:08well first I have to pull the bottom end
1189. 56:09out of here and uh put a new crankshaft
1190. 56:13in it all that reassemble it and put it
1191. 56:15back in the bike and then we got to get
1192. 56:17the cylinder head on it and everything
1193. 56:19else like that and get her fired up for
1194. 56:21the first
1195. 56:22time I appreciate all you guys out there
1196. 56:26and catch you in the next video