500 mile check - 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 13 Old 05-22-2008, 07:17 PM Thread Starter
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500 mile check

I am gettin pretty close to the 500 mile service for my 07. What is the dealership supposed to do for this service besides change the oil? I think they want 210 bucks plus parts. What are the pros and cons of haveing them do this service? Are they supposed to check the valves or is that necessary at this point? Is it worth it to get them to do it? Will this void my warrenty if I don't have them do the service?

thanks for the help

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm
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post #2 of 13 Old 05-22-2008, 07:58 PM
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Forget the dealer and do your own services and save a fortune. As long as you keep reciepts and proof of work done, your warranty cannot be voided. The dealer will do nothing but change the oil and filter, check all fastners and check cables and brakes. For extra $$$ they'll do the valves, it is not included in the 500 mile service or any other mileage check up. My valves were a little tight at 1500, and at 6000, I actually had to order four new shims to get them back to the loose side of the specs. Just change your oil and filter. Put loctite on any fastener you can get to and get off and you will be set to go. Use the blue loctite, not the red.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 13 Old 05-24-2008, 04:38 PM Thread Starter
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Ok let me ask ya this. I asked them today about the service and what was needed. They told me that the valves are on the list to do for the 07 and earlier models. On the 08's it's not done. I assumed (yeah I know) that the valve adjustment was included in the price of the first service. You mean the valve adjustment is an additional cost? I should have but forgot to ask again I "assumed" it would be included.

There is some noise from the valves but I am to understand they are happiest when a little noisey right? I don't think the noise is excessive by any means. Are there any other supplies I would need to do the valve check except the shims if necessary? Also do the shops normaly carry the shims for retail customers and not just in the shop?

Thanks again for the help

Gary

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm
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post #4 of 13 Old 05-24-2008, 08:06 PM
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Not sure about different dealers, but mine charges over and above normal 500 mile service cost to check and adjust valves.

Yes Slappy valves are Happy valves. When you do check them and need to adjust them, set them at the farthest end of the spec. ie: with the most clearance between shim and cam lobe.

There is not anything you will need as far as supplies to just check the valves. The valve cover gasket is rubber type and unless you do something very weird removing the cover it can be used several times. Some guys go buy a tube of silicone for extra insurance, but I have done five bikes so far and never used anything on them and have not had one leaker yet. Yes anything can happen, but the key to it all it taking your time and patience and everything works out great. My dealer didn't even know what size shim the bike needed and had no way of knowing unless I brought one in for them to measure. That kinda told me to do my own thing and I ordered my shims thru www.arrowheadmotorsports.com. Fred is awesome at getting things in the mail ASAP...and he has a complete list of all the different sized shims you might need.

Also, I have this lil program that I downloaded called shimcalc. It is a calculator that you install all your current specs, type in what gap you are wanting and it will tell you specifically what size shims to order. No guessing, no fuss.

Just do a google for SHIMCALC Or KLR SHIMCALC. If you download it, you have to have a key to type in to get it to function for all four valves, just let me know when you d/l it and I will send my key to you. It doesn't cost anything to get the key, just a bit of aggrivation is all.

Hope this helps some.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #5 of 13 Old 05-24-2008, 08:55 PM Thread Starter
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Sounds good to me. Yeah takein my bike to a dealer is a bit scary to me anyway. I'll check out the site you suggested tonight in a minute.

Yeah I went in to get a couple of filters and talked to the guy about the service. They had to check to see if the 07 needed it or not. Anyway he said it would be 5 weeks till he could get it in anyway. I told him no thanks I'll do it. Can you imagine 5 weeks!!!! Kinda hard for me to believe.

Hey what are the chances the valves are still in spec? I am breakin it in with a mod motorman system. I keep it under 4k but use a lot of engine brakeing and run it strong through the gears. Not over hard but harder than I normaly ride. I changed the oil and filter at 25, 50, 100 and 300 miles with another at 500 then at 1500 from then on. Only have about 80 miles left to the 500. No way am I waitin 5 weeks for the service anyway.

Is there a link to a step by step how to adjust the valves? I've never done bucket and shim valves before. I've only done the screw and lock nut type. I am told once the bucket type seat they stay pretty close for a long time.

thanks again

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm
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post #6 of 13 Old 05-24-2008, 09:05 PM
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With only 500 miles and you say the valves make some noise, I wouldn't even worry with it. My 07 was a little tight at 2000 miles but still in spec. During this past winter with nothing else to do, my buddy and I do all our preventative maintenance and with 6000 miles on my odometer my valves were at the tight end of the spectrum.. Four new shims a week later and it was good to go. My buddies 05 had the same mileage and on valve was so tight we couldn't get a guage under it at all. ended up ordering a couple smaller shims than the others we needed just to make sure we would have the right one. Worked out great and was amazed at the power difference in his bike after the valve adjustment.

Here is the link for the valves:
http://www.klr650.marknet.us/Valves.pdf

And this is the main page for all the mods and maintenance you should need:
http://www.klr650.marknet.us/pdfdownloads.html

I printed all of those out and made my own binder. Comes in very handy while in the garage with no computer around.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #7 of 13 Old 05-24-2008, 09:22 PM Thread Starter
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Hey thanks again

Is the KLR shim calc this one? http://www.ironjungle.com/

I have to send them an email to get the code to unlock the download so right now I am waiting.

I really appreciate your help here. So you really didn't do any valve checks until about 6K? I probably won't go that far but when I do the doo I since the bike will be down I'll probably do it then

Hey another thing did you see the valve adjustment video this guy has? Just wonderin if you think it's worth it or if I'm concerned about nothing.
http://www.angelfire.com/mo/motormar...heckVideo.html

Just checked out the links you sent. Really great stuff..........thanks Everything in one place is a good thing

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm

Last edited by thumbs; 05-24-2008 at 10:03 PM.
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post #8 of 13 Old 05-24-2008, 10:23 PM
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Yes that is the correct link for the shimcalc is correct.

I checked my valves initially at about the 2000 mile mark.

I had seen that last link you showed at some point in time.. Good pics to go by too.

Here is my code to unlock the shimcalc, it should work just fine.
LOCKCODE: 1963

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #9 of 13 Old 05-24-2008, 10:59 PM Thread Starter
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Thanks again. He send the unlock back and I have it downloaded. Should make things easier.

Did you have to make any adjustments at 2k?

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm
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post #10 of 13 Old 05-24-2008, 11:02 PM
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No, the clearance was on the tight side, but still in spec. At 6000 miles the clearances were maxed "too tight" and required new shims...

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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