Rocker arm removal

I'm trying to remove the valve train on the KZ200. The rocker arms are held on by a pin pressed into the head. Does anybody know the way to get them out? I don't see anywhere to pry it from the back and there's nothing to grip from the front. I just put the head in the freezer with the hopes of shrinking the pin enough to get it with my circlip pliers. Any help would be appreciated.

Thanks

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Good Fortune!

If it's a steel pin in aluminum, you want to heat the aluminum to expand it, not cool it.
Aluminum expands more than steel when heated, and shrinks more than steel when cooled.

I have used a pointed screw inserted into the pin and either pulled or pried the pin out.
Normally there's some way to drive a pin out, sometimes you have to look real close to find it though.

Are you sure there's not threads in the rocker shaft arm? Generally there are. It's usually a matter of threading a bolt into it and pulling them out. Occasionally some heat is required around the boss.

Spectre1982 wrote: I'm trying to remove the valve train on the KZ200. The rocker arms are held on by a pin pressed into the head. Does anybody know the way to get them out? I don't see anywhere to pry it from the back and there's nothing to grip from the front....

kawasaki.com's diagram shows a screwed on plate against end of rocker arm.



Consistent with the manual pages earlier posted:

Remove the screwed on plate



Needle nose (maybe cir-clip) pliers being used to pull out the shaft



Where's the pin that's pressed into the head?

Good Fortune!

I have the manual. I removed the screw plate. I'm talking about the shaft that holds the rocker arms. It's listed as Part No. 3 in the diagram. I tried removing it the way that's demonstrated in the manual, but they were both in there tight. I broke the tip off of my circlip pliers and my needle nose can't really get a bite.

crh wrote: Are you sure there's not threads in the rocker shaft arm? Generally there are. It's usually a matter of threading a bolt into it and pulling them out. Occasionally some heat is required around the boss.

Looks smooth to me. I ended up taking the head to the shop with the rockers and valves still in. I told them to leave it apart after the valve job so I can replace the seals before putting it back together. I think the pointed screw method Steell posted would be my next attempt at getting them out.

Thanks for the replies. It should be back from the machine shop today. Still waiting on rings.....

Take your new stem seals to the machine shop, let them complete the assy. They will want to vacuum check the valves after putting it together. Best let them finish it.

Will do. I'll give them a call and head down there. Thanks, Motor Head.