Inlet Valves

twistthethrottle · Sep 9, 2004

A couple of weeks ago I noticed that my inlet valves were closing up after only 200km. Sure enough a leak down test showed 20% and an air leak could be heard through the carbie.

I pulled the head off and took it down to the guys at Powerhouse to get the seats machined and inlet valves changed. The valves had pulled but the seats were fine.

The guys told me that the price on the valves had almost doubled recently going from about A$120 each to A$220. (03 model) However the 04 valves (with the new KTM type part number) measured the same but only cost A$65 each.

Picked my head up last night with a set of new (A$65 ea)inlet valves. I can't say enough good things about the guys at Powerhouse, not only do they know what they are doing but they really look after their customers.

So if you have an 03 and need new valves, order a set for the 04 model. Not sure but I would suspect the 01 and 02 may also accept these valves, well worth checking.

By the way, the 03 (and 04) have stainless steel valves.
The new valves were in a KTM box with a Husaberg sticker slapped on it.

Scully · Sep 10, 2004

twisty

Hey Twisty why are you wasting money on that Berg, when you are about to leave us????????????????
Pardon my ignorance but how is a "leak down" test done? And what kind of noise could you hear from the carby, and were there any other symtoms?

twistthethrottle · Sep 10, 2004

Hi Dale,
The 05 Huskys aren't due until late October, on past performance I don't expect them on time. I ride most weekends and didn't want to risk more damage. On top of that I don't want to sell a bike that I know is close to having a problem.

As I mentioned, the first sign was the valve clearance closing up over shorter and shorter periods. The bike still started ok.

A leak down tester basically consists of an air supply, pressure regulator, gauge and tap. The regulator is set to around 45 psi (3 Bar) and the air is supplied to the engine through the spark plug hole.
With the engine locked at just past TDC, the tap is opened to let the air flow into the cylinder. At this point you look at the pressure gauge to see how far it drops. For our bikes (non competition) a 5psi (approx 10%) drop would be ok.
Anything more indicates a potential problem.

At this stage I had 20% so I took a length of hose, put one end in my ear, the other end in the intake and exhaust ports. The air leaking through the inlet valves could easily be heard.

You can purchase a leak down tester from automotive or tool stores. If you don't buy one specifically for bikes (motion pro) you will have to make an adaptor for the spark plug thread to the air line.
There are a few web sites that show you how to make your own but be careful, most of them have the design wrong!

Scully · Sep 10, 2004

?

Thanks for that Brian, and please be careful with my plastics!!

Inlet Valves

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