Doing the valves, dropped a bolt into the motor - 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 10 Old 12-10-2006, 08:08 AM Thread Starter
 
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Doing the valves, dropped a bolt into the motor

How far do I need to tear this down to get it out. a magnet did not get it and I can not see it.

It is the little 8mm maybe 3/8" long that holds the "girddle" over top the timing chain. I was thinking I should have put a rag in there and 2 nano seconds later my fat fingers fumbled it into the drink. :m0146

I even took the head off thinking I could see the bolt and get it out and that was not the case. I am about to agree with my neighbor and tip it upside down and shake it :h0005
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post #2 of 10 Old 12-10-2006, 09:25 AM
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You should be able to get it by removing the left side cover. Make sure you check to see that it isn't wedged into the chain, DO NOT TURN THE FLYWHEEL until you know it isn't in the chain or gears. Worst case is the bolt finds its way into the oil sump via the little passegebehind the doo.
A long magnet (MIGHT) fish it out without removing the side cover.

(I had to remove the side cover) :???:

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post #3 of 10 Old 12-10-2006, 09:49 AM
 
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Ouch! Good luck.
I don't remove the timing chain shield when doing the valves so I've missed the fun you're having now. But side cover removal seems to be the next step...
Are you sure it fell into the abyss? I've dropped many small parts and thought they fell inside the engine I was working on... only to find them on the floor of the garage..
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post #4 of 10 Old 12-10-2006, 09:52 AM Thread Starter
 
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Quote:
Originally Posted by DSjunky
Ouch! Good luck.
I don't remove the timing chain shield when doing the valves so I've missed the fun you're having now. But side cover removal seems to be the next step...
Are you sure it fell into the abyss? I've dropped many small parts and thought they fell inside the engine I was working on... only to find them on the floor of the garage..
Trust me I looked and cleaned up the tools, floor and did not find it. If I do find it on the floor when I get home tomorrow I will have a GREAT laugh and get this POS back together to ride it. I have not riden in a few weeks I bet. Weather is tolerable right now
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post #5 of 10 Old 12-10-2006, 12:09 PM
 
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NOOOOOOOOOOOOOOOOOOOOOooooooooo! (you know, the slo-motion kind from the movies) :shock:

That's the kind of thing that sends the kids screamin', the wive's cryin', and the men tearin' their hair out and breakin' stuff. Sorry it had to be you, dude... :cry:

here's hoping you find it!
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post #6 of 10 Old 12-11-2006, 07:40 AM Thread Starter
 
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I will get the rear wheel on it tonight so I can drop it off the lift and get the skid plate off to remove the side cover and HOPE I can get this phugger out and get ti all buttoned up tonight so I can ride someday.

Thanks
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post #7 of 10 Old 12-12-2006, 05:23 AM
 
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The problem was you thought about putting a rag in there. If you weren't thinking it, the bolt would not have been dropped :smile: .

I'm in the middle of a valve adjustment myself, and I did not use the rag. I got one in there now while I'm awaiting the shims from Fred, hopefully to avert my son from dropping an action figure down there.

One time a dropped a screw (not KLR), I heard it hit the ground and could not find it for the life of me. It turned up a couple of hours later in the laces of my shoe.
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post #8 of 10 Old 12-12-2006, 06:50 AM Thread Starter
 
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Got it out through the side cover. Took all of a couple hours and it was all buttoned up. I need oil and a filter to fire it and see if all is well. Also need to call KLR650.com as they sent me a 106 link chain with 2 master links and a 45 tooth rear sprocket over a 43 and with the wheel all the way forward I can get it to connect, but there is not much slack and I know by the time I set it on the ground (on a jack now) it will be far too tight :m01
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post #9 of 10 Old 12-12-2006, 11:41 AM Thread Starter
 
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Quote:
Originally Posted by Bones
Got it out through the side cover. Took all of a couple hours and it was all buttoned up. I need oil and a filter to fire it and see if all is well. Also need to call KLR650.com as they sent me a 106 link chain with 2 master links and a 45 tooth rear sprocket over a 43 and with the wheel all the way forward I can get it to connect, but there is not much slack and I know by the time I set it on the ground (on a jack now) it will be far too tight :m01
Well I gotta hand it to KLR650! They are a real nice company to deal with it. They are sending me a 43 tooth in exchange for my 45 to make the 106 chain work out. They were unaware that the 106 would not work with the 45 tooth, so they will make note of that.

Kelly even offered me up a master cylinder gaurd for MY troubles. I was the dipsh!t that ordered the 45 tooth and they did not know it would not fit. I declined the guard

#1 it is not right for them to give parts away
#2 I already have one
#3 I want to see them stay in business.
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post #10 of 10 Old 12-12-2006, 02:06 PM
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I'm in hopes that my chain will strech a little so I can try my 45 tooth sprocket. I tried the 14 tooth front but it wasn't good for on road riding. I'm hoping the 45 tooth rear will be somewhere between the 14 and 15 front. That would be sweet. :razz:

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