RAVE question

[slideways]

I am cleaning the exhaust valves.....well, trying to! Here's my problem: I take off the spring clip and plastic cover. Remove the next spring....and then there is a small bolt in the center that is holding the diaphragm with the cable tie around it. I seem to be having a problem getting that bolt out because the head of it is made of plastic. I tried holding the diaphragm and turning the center bolt, but if I keep going this way all I am going to do is round off the corners. Any advice in how to get that bolt out without damaging anything?

This motor has over 5,000 miles and I can't say if these were ever serviced because I've only had the sled for a year. I'm thinking this is the cause of my problem.

Have I missed something or am I looking at this wrong? Please let me know. I found a thread on cleaning these from January and it gives some excellent advice in removing the valve......I dream of getting that far some day

[AlumaDoo]

I'm not entirely sure that bolt has to come out??? When I did mine, I only had to remove 4 bolts. Two on the covers themselves, then two more inside, metric allen head screws. Then the plastic parts pulled off to expose the valve. You're right, there is a thread that I started on 1-6-08 about the exact same issue. Page 4 I think. Revrider and 1fastmxz helped me out a ton. Maybe pm them for some more info.
Thanks again revrider and 1fastmxz!!!

Rick

[1fastmxz]

Must be an older sled.
try pulling out on the diaphram a bit, my guess is the head of the zip tie is stoping you from turning. If careful you can remove the zip tie and still be able to reuse it. under the diaphram you'll have two mounting bolts. you'll need metric allen wrenches to remove.
If you need more help let me know and I'll do a step by step photo.

[slideways]

It hadn't occurred that they've changed because this is the first one I've done!

I'm working on a '96 Formula Z 583 Rotax. The cable tie is not doing anything but holding the rubber on what it is wrapped around. I can pull the diaphragm forward until it stops. I am assuming that is just opening the valve. I can't get to the allen screws with the diaphragm in the way.

Would it make sense to remove the cable tie and the rubber part of the diaphragm to see if that exposes the bolt underneath? Maybe I just didn't see it right this morning and that plastic piece is part of the diaphragm.

[1fastmxz]

I'm thinking it's part of the diaphram. it's been awhile since I've done one of the older ones I'll pull one apart tomorrow. i don't think pulling the rubber boot is going to get you anywhere.

[slideways]

Spent some time in the garage last weekend ( instead of on the trail where I should have been).

Here's how they came apart: Remove spring clip, cover and inside spring. Then remove cable tie, slide the rubber boot back off of the piece of plastic and turn the WHOLE piece of plastic (not just the little nut in front-that was my mistake) which is threaded on the exhaust valve. Remove the two mounting bolts, take off the housing, remove the O-ring and pulled the valves. Clean and reassemble. Wasn't bad once I figured out that the piece I was afraid of breaking was SUPPOSED TO TURN!

Thanks to all who contributed to this and the other threads on this subject. Couldn't have done it without you!

[AlumaDoo]

Hey, there ya have it!!! Now you can add another task to your yearly maintenance list.

[slideways]

Funny thing is that I've been finding more things to do since I built the new garage last summer!