No power valve. :)

Sorry whats a power valve?

To explain you have to understand that when the height of the exhaust port is low you have more torque and less rpm's. To increase rpm's we raise the exhaust port but suffer low end torque loss as a result.
A power valve in this plunger like thingie that sits in the exhaust port which makes the top of the port low thus more torque. Once a certain rpm is achieved, the power valve will retract thus raising the exhaust port for higher rpm's. It's to give you the best of both worlds.
Hope that helps. :)

Just seen pic.. WOW.. Not supposed to be like that!!!!!
OK, Let's make communication a lil more used friendly. I'll tell you the name of the part and you call it that.
Rear clutch: part w/weld is the post/fixed face. The other is the sliding face. Only discs are those flat/thin/fiber things that went on the rear clutch hub. :)
Front: Front outer is the fixed face and the front hub that hold the rollers is the movable drive face. Most call it a variator tho.
THe variator is stuck. I'd bet the previous installer let the notch slip off the keyway thus pinching it when tightened. Pry it off as careful as possible. Fair guess you'll be getting most all those parts new.
I prolly have everything you need here.

I really appreciate all the help. I would like a little more explanation of what to do with the power valve to fix it and once I get the variator off and get it pulled apart Id like to give you a call and see what you have. Probably most interested in maybe just buying two whole new clutch assembly's at this point. Just a whole host of problems in here LOL

Finally got the front off. Its also been tampered with before and the screws are semi stripped. I dont have time to get it apart before I go to work but I will tonight to see the condition of the rollers and see if anything can be salvaged. Definitely looking like im going to need all new. Man its bad lol.


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No powervalve. in rm250 motors and such. :)
We'll look at the variator when you get a chance to post pic. Your doing well.

So as you can see in the first picture I posted I bent that back cover piece with a pry bar removing it.

Got the screws out that hold it on, had to shock them with a chisel and ruin them but they came out one last time. Grease is rock solid and came out in formed chunks and the rollers are flat spotted and overall destroyed. Above and beyond that you will see in the pictures. It is a horrible horrible mess.

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It's just as I suspected. Prolly seen it 100 times.
Is the roller tracts in the variator gouged any?

Sorry to intrude in your thread mr jack but I been trying to find you for the longest time lol.
I got an lt80 I been working on for a couple days now I got it for 80 dollars in rough shape but I couldnt pass it up it had no airbox and plastics were rough sat for a long time. I have installed new crank bearings and oem suzuki seals and sealed cases for peace of mind and no air leaks. I also will port the reed and I have new boysen reed.
I was going to remove 2 of the rollers from the front clutch
and hold on the rear until the little one gets more comfortable riding this thing.
I got 14-26 428 sprockets and #40 chain with half links to make it tight
now the questions are the following.

what is the price for you to bore and port and mill my oem head?
I'm installing a chinese top end for now the bore was good on it and will be just to get it running to start it but I'd like a ported top end from you so I'll send you my oem cylinder and head.

Also should the clutch with the rollers be completely packed with grease or just enough to keep the rollers in place?

I removed the bottom plug of the pipe I will burn it off to clean it. I read that the stock one is a good I'm not interested in upgrading it if difference is minor.

Would running a pod vs a airbox be a problem?
. I have various machines and clean. My filter after every 2 rides

Aldo what else do you recomend doing for more power other than shoes in secondary to 175-180 and better spring?

Thank in advance jack.

Ps I know I'm working in the floor but I can spread my parts better there lol

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