Zero valve clearance on right exhaust valve -- anyone got a shim kit in Ontario? - 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 9 Old 07-21-2016, 06:56 PM Thread Starter
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Zero valve clearance on right exhaust valve -- anyone got a shim kit in Ontario?

I was hmming and hawing about checking the valve clearances on this bike (still new to me, getting it all prepped for the road) and in the end I caved and just did it. I hate dealing with these types of gaskets, I just know it'll be no fun getting back in!

Anyway, it was running fine, but I figured better safe than sorry, and lo and behold, just one valve was out of spec, and not even my 0.0015 feeler fits. That means I have no idea how much smaller of a shim I'll need, and that means I need access to a shim kit, or someone with a kit/lots of spares.

All other bikes I've had that needed shims I was able to get a Hot Cams kit for around $100, which came with more shims than any hobbyist could ever need. For this thing, there appears to only be procycle @ nearly $170 for 20 shims.

So I ask, anyone in the Toronto area with a kit or some spares (or do any dealerships around here do an exchange...I called snow city and they seemed to think I was insane for suggesting such a thing)? Or am I doomed to guess and spend?
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post #2 of 9 Old 07-21-2016, 08:15 PM
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Don't buy a kit. You'll get a bunch of stuff you don't need. Ask me how I know.

You need to remove the shim that you intend to replace and determine what size it is. You then probably need to go maybe two sizes smaller. No guessing required.

I've bought shims in Canada from Sirius Consolidated in Cambridge. Just a Sunday drive for you. Well maybe Monday becasue hopefully they are closed Sunday.

http://www.siriusconinc.com

Also the KLR valve shim is the same as that used by some BMW models. Do some searching on this forum and you should locate that info.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 9 Old 07-21-2016, 08:37 PM Thread Starter
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Yep, knew they were the same as a BMW shim, and we have a BMW dealer really close, but I suspect most dealerships are the same -- "the service dept has shims for their use, they don't sell to customers". Terrible customer service.

In any case, I guess I'll be calling around tomorrow or next week.
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post #4 of 9 Old 07-21-2016, 09:38 PM
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Quote:
Originally Posted by drumstyx View Post
------, but I suspect most dealerships are the same -- "the service dept has shims for their use, they don't sell to customers". Terrible customer service.
What 'bull-crap'! I can't believe a dealership employee would actually SAY That!

The SERVICE Department has to get their shims thru the parts DEPARTMENT. I also save and sell usable used shims, $5 each, but You have Gotta' Ask about Them! Maybe even bring Your micrometer or dial caliper, because some of them were installed with the Numbers facing UP!

I am a dealer.
In my brother and I's small dealership, I am the parts/service/janitor/errand boy. I try to keep at least 2 of every size in STOCK, and usually 3!
After all, the shims were originally designed for the 1973 Z1 (4 Cylinder) and used thru the 1983 KZ1100 series 4 cylinder bikes. And it would not be unheard of, for even a small shop to do 2 KLR650 valve tappet inspection / adjustments in ONE week. 30 years of continuous production does have a few advantages.

Mine is VIN 000423! My buddies bike is VIN 000432!
Mine Looks 30 years OLD! His Looks 3 years old.

But, more to the issue. You didn't tell us, whether it was Intake or Exhaust that was tight!
Does the bucket 'freely spin' to access the removal slot? Is it does, then assume that it has at least .0005" clearance!
So, MINUS 3 sizes (.002 per size) = .0065" of clearance. We don't want to Exceed .008" on the Intake valves. Use 4 sizes thinner if the tight valve is an Exhaust valve (.0085"). At least you will be in the upper mid-specs of either valve.

Perfect!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #5 of 9 Old 07-22-2016, 08:00 AM Thread Starter
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Yeah, customer service isn't really a 'thing' in Canada, and you don't get old school parts/service departments when you live near a big city here -- I guess they're just used to city schmucks paying through the nose for valve adjustments.

I mentioned in the title it's an exhaust valve, which does make me worry about a burnt valve a bit. Haven't checked if the bucket rotates, I'll do that this morning, as well as call around to the various dealers and shops around here.

Come to think of it, there is one old school guy in the next town over, I bet he'd trade me for a small fee if he's got em in stock.
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post #6 of 9 Old 07-22-2016, 08:50 AM
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Actually I find Customer Service in Canada to be very good. Most times if you let them know you aren't satisfied with something they will go the extra mile to make it right.

What I find annoying, but also understandable, is the lack of parts being in stock at the local level. I'm not in business but I imagine that to maintain a level of parts stock acceptable to everyone would take a significant amount of space and cash outlay. That's a lot of overhead on stuff sitting on the shelf. Most dealerships around here sell more than one manufacturers product so that doubles or even triples the overhead. Much simpler on the part of the dealer to have the parts in the manufacturers warehouse. Unfortunately for us that means a few day wait until the parts arrive. I don't think that's bad customer service though. Some times they surprise you too. I needed a water pump gasket and called the dealer to order one only to be told they had it in stock. Nearly dropped the phone.

Anyway I digress. If we knew what size of shim you needed someone close to you may be able to help you out. I may have the size you need as a spare. Only thing is it's about a week away in the mail. Now if you want to talk about customer serivce there's the mail.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #7 of 9 Old 07-22-2016, 09:00 AM Thread Starter
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Quote:
Originally Posted by klr4evr View Post
Actually I find Customer Service in Canada to be very good. Most times if you let them know you aren't satisfied with something they will go the extra mile to make it right.

What I find annoying, but also understandable, is the lack of parts being in stock at the local level. I'm not in business but I imagine that to maintain a level of parts stock acceptable to everyone would take a significant amount of space and cash outlay. That's a lot of overhead on stuff sitting on the shelf. Most dealerships around here sell more than one manufacturers product so that doubles or even triples the overhead. Much simpler on the part of the dealer to have the parts in the manufacturers warehouse. Unfortunately for us that means a few day wait until the parts arrive. I don't think that's bad customer service though. Some times they surprise you too. I needed a water pump gasket and called the dealer to order one only to be told they had it in stock. Nearly dropped the phone.

Anyway I digress. If we knew what size of shim you needed someone close to you may be able to help you out. I may have the size you need as a spare. Only thing is it's about a week away in the mail. Now if you want to talk about customer serivce there's the mail.

.
I don't mind waiting for parts when it's reasonable, but valve shims are literally day-to-day use, which is why the service dept has some. That's the difference with old school shops and modern dealers. Old school shops see you as having fun wrenching just like them, and help you out as a peer. Modern dealerships have a cold sterile environment that the plebs are allowed in, and the service dept is fort knox.

Exaggerations of course, but frustrating that it feels that way.

Anyway, I pulled a 275 out, and I *was* able to rotate the bucket with a little screwdriver. I suppose that means I had at least non-0 clearance, which means I shouldn't go for a 250, but maybe a 255 then. Just about to pop over to the shops around here to see what I can get.
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post #8 of 9 Old 07-22-2016, 12:56 PM
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Let me know how you make out. I proabably have a 255 here that you can have. Cost more than the shim to mail it.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #9 of 9 Old 07-22-2016, 02:20 PM Thread Starter
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Luckily, I found a place that exchanges shims, and I was quite surprised, as it's the local 'boutique' shop -- they deal in Ducatis and Triumphs, but service anything. So, PSA for south/central Ontario wrenchers, GP Bikes does shim exchange. I even had to go twice as 255 got me to 0.006, but I wanted to be closer to the middle, went with 250 for 0.008.

Also, I learned the hard way about the valve cover torque. The manual had them at an astounding 88inlb, but they must have stripped at 20inlb. So they're half stripped, they're in there, but next time I'll probably have to helicoil em.
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