How to fully remove Honda CR 125 2002 PowerValve?

[DomasMX]

Hi guys,

I am rebuilding my 02' CR 125 and now I'm trying to remove the whole powervalve assembly for a good clean up. However, I can't figure out how to take it out :bang: The shaft moves forwards and backwards about 1mm but doesn't come out. It seems that the bearing holds it in place. Manual also shows no details on how to remove it.

Any ideas?

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.lt/lh/photo/cAQRAE8NOshy-Pznk5aknw?feat=embedwebsite"><img src="http://lh5.ggpht.com/_nvBKLr0zDTE/S4WOBVaWgGI/AAAAAAAAAdE/ewdCv-ojrPc/s800/Picture%20041.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Nuo <a href="http://picasaweb.google.lt/domasenko/CR125?feat=embedwebsite">CR125</a></td></tr></table>

 

[slickpuss]

I thought you removed a circlip and the shaft pulls out and then you pull the valves out.

 

[madmike90]

take off the nut on the shaft that goes across the jug connecting both assemblies.
remove shaft
slide each power valve completely out to remove the valves.
remove the circlips that hold the valve sleeves in place, slide the valve sleeves out
done :)

 

[tommyaus]

what does taking it out do? will i benifit from taking it out on my 03 cr250? will taking it out put strain somewhere else on the motor?

 

[IndyMX]

what does taking it out do? will i benifit from taking it out on my 03 cr250? will taking it out put strain somewhere else on the motor?

You don't want to remove it and leave it out, he's just asking how to take it apart to clean it.

If you take out the powervalve, say goodbye to what little bottom end that smoker has with it.

 

[DomasMX]

The problem is that the shaft doesn't slide out. It is stuck and I can't take it out.

And yes, I WILL put it back in the jug after cleaning :nod: :)

 

[IndyMX]

The problem is that the shaft doesn't slide out. It is stuck and I can't take it out.

And yes, I WILL put it back in the jug after cleaning :nod: :)

It's stuck because of carbon buildup on the valve petals.

It can be a real PITA to get them out, but they will come out.

 

[Patman]

You need a can of Sea Foam Deep Creep.

 

[slickpuss]

Did you happen to get this out by now? I decided to do the top end on my CR125 this week and I came up with a super easy way to get the power valve apart.

1. First I took it apart exactly like you did in the picture.
2. Next I loosened up the carbon a bit with heavy duty cleaner (carb cleaner).
3. Then I soaked it for a few min in penetrant.
4. Lastly I took a stack of washers and put them on the shaft with enough room for the nut on top. Just tighten the nut and it will pull the shaft out. It will do about 1/8th inch at a time and then just add another washer and start over.

It went really easy for me and the carbon build up was bad. So bad the power valve was not really moving hardly at all. After the shaft is out, you can mess around with a small screwdriver and get the 2 piece power valve out.

Hope this helps someone out.