I am leaving to Idaho next week and need to fix my air leak. When I put pressure in the motor, air starts leaking out the exhaust valve into the crank case. It leaks past the small oring. It will seal after a little time(applying the air pressure) but then after I ride it slides over or something then starts leaking again. There is enough room on the exhaust valve shaft to put two orings on it(between the bearing and the retainer) would that help? I know it would keep it from sliding around. Yes the oring is brand new from Suzuki. Please help if youve seen this problem. Thank Jason
P.S. Im talking about a lt500r 2 stroke Quadracer.

 

Two questions:

1)How many psi are you pressurizing your engine to (it takes very little and too much will cause damage).

2)Do you know that the exhaust valve has two o-rings. I just replaced mine and, if I remember correctly, there is one around the shaft itself and another oround the outter ring. The Suzuki manual does a poor job of showing the individual parts of the exhaust valve and describing how to service it.

Just so you know, an air leak from the exhaust valve will not cause any damage to the engine the way other air leaks can. You can safely run the engine that way but you may experience some transmission oil blowing out of the vent tube. If you want to ignore the exhaust valve leak and check for others, simply plug the case vent tube (behind and below the cylinder). Then you will be pressurizing the entire motor,including the trans area, but you can check for any damaging leaks. Go to Duncan Racing's website for an explanation of proper two-stroke pressure testing.

 

Yes I was only useing low pressure. I fixed it this weekend. I installed two orings on the small shaft. Now it seals. Weird deal, thats why I was wondering if it had happen to somone else. It was not leaking around the larger retainer.