Valve timing wierdness - 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 4 Old 07-01-2008, 12:29 AM Thread Starter
Join Date: Dec 2007
Location: Soldotna, Alaska
Posts: 3
Valve timing wierdness

Need help! I bought an 04, trucked it home, parked it in the yard, started it up and let it warm. When I got on I bumped the shift lever into 1st gear before I pulled the clutch in. The engine stalled, I put it in neutral and punched the starter button. It turned over 6 or 8 times but sounded a little different, maybe grinding a bit. Then it seized up. I put it in my shop and pulled my left covers off. I put a wrench on crank and when I turned it over it would not quite 2 revolutions then seize. I took off cam covers and saw that the valve timing was substantially off ie. at almost top dead center the intake valves touched the piston. The alignment arrows on the cam drive sprockets are still aligning with the horizontal case seam. The cam chain seems to be proper tension, all tensioners and guides in place, but with the sprocket alignment marks where they should be the fly wheel timing mark is probably 60 degrees too far clockwise (more towards the foot peg) rather than aligning with the case hole. Also, I found the balancer chain tensioner spring in many pieces at the bottom of the case. The doohiky adjusting bolt? was 2 or 3 turns loose. The only thing I can think of is can the cam drive sprocket on crank slip (is it keyed or pressed on)? The bike has 2900 miles, never been off road. I've been riding 40 years, owned most makes, always done my own wrenching but always ready to learn. Any ideas?
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post #2 of 4 Old 07-01-2008, 08:25 AM
4th Gear
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Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980
I am not sure if the gear is keyed or not, but obviously the bike has done what most fear will happen when a doo goes bad. I know for a fact Larryboy will know about this and I hope he will give a post with some input on this. He knows these motors inside and out.

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 4 Old 07-09-2008, 08:10 AM
2nd Gear
Join Date: Oct 2006
Location: SoCal
Posts: 103
The balancer spring and/or other parts have gone through the cam chain and sprockets. You'll need to remove the left side stuff to see what broken. It sounds like you are at least part way there if you found broken spring parts. You should probably also remove the cylinder head and see if the valves are bent. This has happened to a few people. If they are bent, I'd suggest sending it to Cary at Schnitz racing in Decatur, In. for repair.

The cam timing change is likely due to the broken parts. The sporcket slipping on the crankshaft is less likely.

all the best,

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post #4 of 4 Old 07-11-2008, 12:03 PM
3rd Gear
Join Date: Sep 2006
Location: Elk Grove, Ca
Posts: 990
Hiya, Mikey!!!!

Yep, I'd say some schrapnel took a ride up top.

Originally Posted by Swish~Married View Post
Larryboy, you're brilliant!!

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