2009 KLX 250S, 6K miles, purchased new from the dealer. Dynajet kit, FMF exhaust, snorkel removed. Valves have been adjusted 4 times between 2K and 6K miles. A couple times the valves tightened up so badly I could not start the bike. After first adjustment, went about 1500 miles before needing it again. Last time, adjusted valves to high side of tolerance and after one weekend of riding, 422 miles total- the bike would not start again. Figured it's time to investigate... so pulled the head and looked at the valves. Intake valves are severely worn with material extruded over the edge into a sharp burr. Seats look fine, no wear. Problem is with the intake valves only, the exhaust have never needed adjustment. Guides seem ok, the valves fit nicely with little or no play. My question is- can I purchase new valves, lap them to the old seats and be ok? Or should I take the head to a shop for a complete valve job.

 

I would try that first. Get some lapping compound and some prussian blue to mark the seat. See how it cleans up and if you can get the seat width into spec then you should be fine. Can you post up some images of the damage-that is very strange to have happen, especially on the intake side.

 

As everything else checks out, I think you'll be fine with new valves lapped into the seats.

 

Could be a limited run of a few soft intake valves...maybe?

 

That's what I was thinking. I didn't find any evidence of a widespread problem after searching. Used to be a problem years ago, but was confined to the KLX 300.

 

If your dealer knows the history why not write a nice note or call Kawasaki customer service and tell them of the problem. It certainly can't hurt anything. There is no reason for the OEM valves to wear out like that. Approached correctly you might get some help here. They might just be interested to see what the deal is. Maybe get valves for free or the like. Remember a nice attitude might just do the job. Defective is defective and since you bought it new you know the history and 6000 miles should be just breaking in on valves.Try working with a friendly dealership if you can, otherwise go direct to customer service.

I worked in a dealership and will tell you this kind of stuff happens. The 82 Viragos had an open ended recall on soft cams as did some Honda VF700/750s. Defective is defective and they really should help out. I gave a guy similar information in another forum when he had a jet seat fall out on his Suzuki 800 (I think that was what it was) cruiser. His dealer told him no, but clearly the carb was defective, the press fit was not there. I told him to go to another dealership. He went to ASK Suzuki in the Columbus Ohio area, near to me, and they went to bat for him, knowing there was no way that carb should have been like that. He got a new carb and no cost. Oh - the bike was 2 years old and he was the second owner too.

 

Once you lap the valves, try a leak test with some gas poured into the combustion chamber and the head upside down and see if any leaks by.

Low tech - but I see people still doing it