I needed to get a new cylinder head for my Saito 45 and ran into the following problem that I can't solve. I have the cylinder head off the old motor along with the valve covers. The next thing is to get the old valves out and put them into the the new cylinder heads.

It looks like there is a very small "c" clip holding the valves in. What is the dis-assembly procedure for this? What tool do I need to take this little bugger apart?

Signed,

"Stumped" - Viper

For the first time or two that you pull the valves from a four stroke engine, you would be well advised to use a large "Oven" bag or similar clear plastic enclosure. That way, when parts go flying you can find them. When parts fly, even in a sterile shop, there's a small nook, cranny, or crack that any small part will find, and you will not find it. Using the bag everything is enclosed, and the small part's desire to hide from you will be frustrated. This keeps you from being frustrated.

If your engine is the really early version that actually has a separate head, put an index finger inside to hold the head of the valve, then with one thumbnail on each side of the spring cap you can press the cap down, one thumb nail will hold it after it goes down, then use tweezers or other tool that you have to pull the "C" clip off the valve stem. Reassemble in reverse order.

If yours is the one piece cylinder and head as on the later engines, I use a screwdriver with a plastic handle to hold the valve heads up. Otherwise it's the same.

Added notes: DO NOT LAP THE VALVES INTO THE SEAT. If the valve leaks after assembly, you either have some trash on the seat or a bad valve. In the late Saito engines the valve seat is a thin chrome plating, lapping the valve will damage the seat plating. If you can see a brass/bronze valve seat lapping still is not recommended, but you can get away with it.

Install new valve springs. They're cheap insurance. With age they lose strength, and sometimes break. You may find the new springs are a larger outside diameter than the originals, and they wont go into the bore in the head. If you find you have this condition send me the head, I have the tooling to open the bore. Your cost will be only postage (and insurance) two ways.

Bill.

Hello; Take the rocker shafts out, the rockers off, keeping intake and exhaust separate. At this point I usually put the engine in a big ziploc freezer bag, in case anything flies away. Then I put a socket into the bore to keep the valves from opening. Next you have to compress teh valve spring, exposing the keepers, then you have to slide the keepers off the valve stem, then release the springs. and valves. replace all parts in their original positions.
I've found that if you have the right socket, you can hold the engine in one hand with the fingers free to compress teh spring, then poke the C-clip off with a tiny screwdriver.

Hope this helps.

VERY interesting.... I will post back after I attempt this "head in a bag" thingy. [>:]

Use a really big hammer

First calm day we'll put it on my Alpha and take it up, provided I don't get my engine back first...

REMOVING THE VALVES!

Donkey DR has it right. Follow his advice.....

Do it inside a plastic bag so you do not loose the clips.

Set the head down on a vertical dowel or something that will hold the valve closed.

Push down on the valve retainer and slide the clip out.

Enjoy,

Jim

All done. Thanks for the great advice. I neglected to order the valve cover gaskets so I will need to do that soon. Otherwise, it went pretty well. A couple things I noticed:

The screws holding the rocker arms in go in from the other way on the new cylinder head. Don't know why, they just do.
The original rocker arms did not fit on the new cylinder head - they were too snug. A little grinding (just a little) and they work fine.
The O ring where the carb goes into the cylinder head looks to be just a shade different size. I will have to see what can be done to fight potential air leaks.

Engine started right up and ran real strong though.

Thanks again for the good advise.

Viper....

[&:]