PowerValve Flap removal technique

[MattR]

Originally Posted by GMP

Next week I'll start my teardown and top end job. I'll take photos. I may not have time to put together a formal tech presentation, but photos are no problem.

That would be great if you could take some pics.

The step-by-step instructions that Uwe Hale did is adequate, but with your pics to supplement it would be complete. It shouldn't take too much work afterwards to link these photos with the previous instructions.

[HydroDog]

Originally Posted by GMP

After the rods are removed, the main flap is rotated and turned sideways and can be removed through the exhaust spigot. It will come out easy in the right position, do not force it.

Can you be a little more specific on the flapper removal?
I got everything else removed but I can't get that flapper out of the port. Do I have to push it back on top of the piston to turn it sideways?

[MattR]

Originally Posted by MattR

The step-by-step instructions that Uwe Hale did is adequate, but with your pics to supplement it would be complete. It shouldn't take too much work afterwards to link these photos with the previous instructions.

Here is the revised PV Disassembly article.
http://www.gasgasrider.org/pv_disassembly_mattr.pdf

[GMP]

You can remove the main flap without removing the spigot, as the spigot is the widest point in the exhaust tract. Just get it in the right position and it slips right out. If there is a lot of carbon or a rough spot in the casting this could make it harder but it should still come out.

[HydroDog]

Thanks Glenn for the reply but I'm still having no luck. My exhaust port is real clean and I reached in thru the side valve holes to scrap the sides of the flapper off but still no go. I even turned the flapper upside down and it's not coming out. Maybe I'm just one of the lucky one to have the port casted a little small. It's about .060" smaller than the spigot.

[Brian VT]

I'm lol 'cuz I've been there. Don't kick the dog ! He doesn't know how either. lol
I wish I could remember which way it needs to face to come out but it does so easily when you turn it right. I can't remember because I instantly ran to the fridge for a celebratory beer. You're gonna just shake your head when you have it out and in your hand.

[PEB]

If I remember right, after the pins are pulled drop the valve down a bit and turn it length wise should come right out. It definately can come out the front and does so lenth wise.

Paul B

[HydroDog]

Originally Posted by Brian VT

I'm lol 'cuz I've been there. Don't kick the dog ! He doesn't know how either. lol

Man do I feel bad. After beating the dog to a bloody pulp and throwing the cat across the garage, PEB comes up with the winning answer.
Drop the piston down below the port, push the flapper up on top of it and turn it sideways and it falls right out.

[GMP]

Sorry, I assumed you had the cylinder off, much eaiser that way.

I delayed my top end rebuild as mine is still fine and I have had no time to ride and break in new parts before a race in wet sand this weekend(not a good idea on a fresh top end). I have all the parts so likely next month and I'll shoot some photos. I also bought a neat little tool for installing piston pin clips I'm anxious to try out.

[PEB]

It seems like i have taken the flapper out with the piston up, but who knows. Glad you got it out. Glen, Those d#$% little clips give me fits. Sometimes they jump right into the little groove other times ( like a couple weeks ago) it takes me numerous trys to get the thing in. I like to hold the rings in place with the jug while puuting the clip in. Tell us how the tool works and maybe post a pic of it.

Paul B

Paul B