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  • powervalve issue KTM 300

    Long story short version:
    I have a 300 top end here on the bench... the power valve seems stuck down. I suspect too much sealant has been used upon reassembly of the powervalve cover and this has caused it to bind up. Is there anything else I should check?
    Can i simply remove cover clean up sealant and replace or do i need to strip the entire PV assembly and go again?

    One other thing... From memory the power valve should be in the up position when installing the cover, I wasn't the one who installed the cover... could this be another reason for it to bind?

    Cheers for any help DBW legends
    2011 300

  • #2
    Undo the power valve flap bolt on front of engine. Push down flap hold
    It and re tighten then it will
    Move bud.


    Sent from my iPhone using Tapatalk
    "When you face that knarly lookin hill, stare at it study it & conquer it"



    Home Loans & Bike Finance for DBW users PM JB for details
    (29yrs in the game)

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    • #3
      Thanks JJB,
      you're meaning the 4 bolts around the exhaust port?
      2011 300

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      • #4
        Yes


        Sent from my iPhone using Tapatalk
        "When you face that knarly lookin hill, stare at it study it & conquer it"



        Home Loans & Bike Finance for DBW users PM JB for details
        (29yrs in the game)

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        • #5
          Okay so problem solved. It wasn't what I thought.... I pulled the exhaust flange still no go. So complete disassembly and discovered one of the side port valves had gummed up and become stuck.
          The long story is this motor has sat for a couple of years and a couple of people have looked at it before me. Glad I caught this issue before it's back in the frame filled with coolant and fresh gaskets
          2011 300

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          • #6
            Good job bud. The
            Issue i mention is usually the culprit having done it myself twice but im a slow learner. Lol.


            Sent from my iPhone using Tapatalk
            "When you face that knarly lookin hill, stare at it study it & conquer it"



            Home Loans & Bike Finance for DBW users PM JB for details
            (29yrs in the game)

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            • #7
              L
              l lĺĺl lĺ l m

              Sent from my SM-G950F using dirtbikeworld mobile app

              Michael :grinning-

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              • #8
                Appreciate the help mate, hopefully my post can help someone in the future.
                2011 300

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                • #9
                  Originally posted by fnlow View Post
                  Long story short version:
                  I have a 300 top end here on the bench... the power valve seems stuck down. I suspect too much sealant has been used upon reassembly of the powervalve cover ............
                  Cheers for any help DBW legends
                  Glad you got it sorted FnLow. As you found that this was not the key issue. But just posting for those playing along at home or in future....

                  Most brands have a sealant whether for Oil pans etc. That is Anaerobic. Meaning it wont set till all oxygen is dispelled.
                  So great for this situation if cover is warped and a large qty is needed to be initially applied.
                  Excess squashed in side the cover wont cure without oxygen first being dispelled.

                  Same for 4stroke head covers etc.

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                  • #10
                    If you've had both the subvalves out, be aware they are side specific.
                    Make sure the subvalve passages are fully open with the main flapper fully up

                    Edit - and loctite the RHS bracket CS screws.You don't want them in the gearbox
                    Last edited by Rebuild; 2 weeks ago.
                    Steve
                    Ariel MCC
                    Covering SA in singletrack since 1928
                    09 KTM300EXC-E
                    89 KTM125EXC

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                    • #11
                      I've held-off posting here... 'cause... quite frankly... I've got no ffing idea.
                      Yet: I've used Loctite gasket-goo in places: That worked for me @ then.

                      https://www.henkel-adhesives.com/au/...ctite_518.html
                      Not endorsing a product; ages ago; I barely remember.

                      Edit: I do remember it worked for me; way back when.
                      Careful prep & general nous; to reward you in spades.

                      Edit: Silicone is shit imo.. Is good.. Not for that-there.
                      Better Permatex.. I was a Mechanic in a/my past-life.
                      The More I Learn... The Less I Know.
                      That Which Doesn't Change... Stays The Same.
                      Those That Don't Fall... Just Aren't Trying Hard Enough.
                      Genius or Idiot... Sadly it's Defined by the Mediocre Masses... With their Hindsight.
                      Dicklaimer... The Text above is to be Evaluated by a Responsible Person... Prior to Any Action Being Taken.

                      *George Carlin*What We Do*No Bravery*Tell the Truth*911*Genetic Armageddon*Carbon Tax*Interplanetary Climate Change*Fracking*Shock Doctrine*Extinction Protocol*

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                      • #12
                        I tend to put a blob of Permatex Black/Blue on a few particularly popular bolt heads on my bike as added security. So far never failed me where just loctite blue/red have. Not pretty but that's how it is. Easy to scratch the blob off when I need to remove.

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                        • #13
                          Yeah axel... I'm not about pretty (nor pretty)... I'm all-about practical:
                          I'll often put a blob of epoxy-putty on-a bolt-head: To-be chipped-off.

                          It-thus means-implies: No-need to-stress a suspected weak-thread:
                          Easy to see if it's moved: Since-it must-then crack the-exterior blob.
                          The More I Learn... The Less I Know.
                          That Which Doesn't Change... Stays The Same.
                          Those That Don't Fall... Just Aren't Trying Hard Enough.
                          Genius or Idiot... Sadly it's Defined by the Mediocre Masses... With their Hindsight.
                          Dicklaimer... The Text above is to be Evaluated by a Responsible Person... Prior to Any Action Being Taken.

                          *George Carlin*What We Do*No Bravery*Tell the Truth*911*Genetic Armageddon*Carbon Tax*Interplanetary Climate Change*Fracking*Shock Doctrine*Extinction Protocol*

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                          • #14
                            Same same, nice one

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