Shim Swap Thread - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 17 Old 12-07-2006, 12:01 PM Thread Starter
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Shim Swap Thread

I just ordered a few shims from dual star today and at $4 a pop people that work on these have to have ones around that would help the next shadetree mechanic.

I will have 2 - 260, 1 - 255 and maybe a 245 or 250 depending on how it all works out once I button it back up.

Thought it would be nice to start a swap thread for those doing checks and needing a shim or two in trade, etc. I'd be happy to do your valve check/change if you are in KC, MO as well. Act fast, I might be leaving the state in the near future.
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post #2 of 17 Old 12-08-2006, 01:32 AM
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The shim swap has been tried several times without success. The problem is the same shims are needed for the first few adjustments, so all the shims in the shim swap pool are the ones not needed. I ordered a complete set from Fred a couple years ago, (big mistake). Now I would order 2 of each size 255-250-245-240-235, this would cover almost any valve job.
The tech days are a great place to do the valve adj, almost always someone there has the set to cover all adjustments.

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post #3 of 17 Old 12-08-2006, 05:38 PM
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SHIMS

DaddyJoe, help me get this straight in my little head? What you are talking about is a total of 10 shims of the sizes you mentioned. I need to do mine over Christmas, but am balking at the cost of the "BIG" shim kit being offered.

Please advise, thanks Bill
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post #4 of 17 Old 12-08-2006, 05:54 PM
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Doing a valve adj you have several options,
1) Tear the bike down and see which shims you need, then order only the ones you need.
Downfall is the bike is down while you wait for the shims to arrive.
2) Odrer a shim kit from Fred, (Fred is too high on shims and the kit has some extreem sizes,)
3) Order a few shims (like the sizes I posted) and go from there. ( or a varitey of shims )
With these shims you should be able to do the job and not have to wait.

Most first time valve adj. will require 260-240 shims,(most of the time) the second will be 250-240 or 235. Remember you will have the 4 shims in the bike already to shuffle around.

The ideal way is to have a dealer close by that carries shims, and will do a swap with you, or a way to machine the shims down to the exact sizes.

Always record the sizes you put in so the next time you will know which ones you don't need.

Freds shims are about $5 each, and dual stars is $4 each. You can order 2 shims of 5 sizes from DS cheaper than the kit from fred.

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post #5 of 17 Old 12-08-2006, 07:30 PM
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THANKS

I will contact D.S. and order the shims. The dealer I bought my bike from here in Phoenix just gave me this blank stare when I asked about the mandatory valve adjustment on the KLR. I knew then I would definitely be doing it myself, as I was am capable.

Thanks Bill
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post #6 of 17 Old 12-10-2006, 08:01 AM Thread Starter
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I ordered my shims from DS and got them Saturday. Too bad I f'ed up ans dropped a tiny bolt into the motor. Now I need to go into this a lot further than I wanted to
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post #7 of 17 Old 12-10-2006, 09:27 AM
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Try the side cover !

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post #8 of 17 Old 12-10-2006, 10:38 AM
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Unless dual star has changed the kit they have waaaaay more shims you won't need than the kit Fred sells. Double check before you buy! I've put a few of the 270's in, but really rare, and that's the biggest shim you might ever need, IMHO. I've used a few 265's, a fair amount of 260's, and lots of 255, 250, 245, and a fair amount of 240's. Even put in a few 235's. Often the shims are shhuffled from one position to another, if they aren't all the same (or too close to the same) in your motor. People often ask what stock sizes are. I've seen from 275 down to 250. Majority seems to be 270 down to 260.

all the best,

Mike

Edit: I just looked at the dual star site - they supply 2 each of the 280, 290 300, and 310 sizes in the kit. IMHO, there is NO WAY those will be used in the KLR650. The only way would be if the head is rebuilt with shorter valves in it.
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post #9 of 17 Old 12-10-2006, 10:45 AM
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THE LAZY ROUTE

Me taking the lazy way out here, and not doing any home work/research. other than the dealer where is the best $ place to but individual shims?
Thanks Bill
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post #10 of 17 Old 12-10-2006, 10:48 AM Thread Starter
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Re: THE LAZY ROUTE

Quote:
Originally Posted by bill stanley
Me taking the lazy way out here, and not doing any home work/research. other than the dealer where is the best $ place to but individual shims?
Thanks Bill
dual star prices are very fair and the shipping is minimal. I ordered a few other small items as well.

My dealer sells them for I think it was $7/ea
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