Valve Adjustments: A study on how to turn a 1hr job into a 7hr project - 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 7 Old 06-24-2019, 03:50 AM Thread Starter
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Valve Adjustments: A study on how to turn a 1hr job into a 7hr project

(Dropped a bolt into the abyss because I'm stupid and forgot to stuff paper towels in there.)

I've been on a bit of a bike maintenance spree lately, I replaced the drivechain + sprockets on mine and a friend's bike last week, and I decided that since I've been getting poor gas mileage lately, I thought I'd open up the engine and check the valves. Measured clearances, all were within spec (click here for my measurements). Since it was early in the afternoon with plenty of sunlight left, I figured that I'd record the shim sizes for future reference (I usually just buy the shims individually). Removed camshaft caps no problem, and I went to remove the cam chain cover/guide - Aaaaaaaaaaand I dropped that little bastard of a screw straight down the tunnel. Shit.

If you listen closely, you can hear me lamenting my life choices up to this point.



I tried fishing around with a magnet taped to a long wire for a few minutes, and decided to suck it up and take the cover off.



After about an hour of searching around with a flashlight (and an endoscope), I couldn't find any trace of the thing. The abyss is deeper than I thought.

So... nothing for it but to take the damned rotor off. Luckily I had a spare rotor bolt but I had really hoped to not need it til now.



And, nothing. Still can't find any trace of this stupid bolt. I was pulling my hair out at this point. I started wondering if it's possible it somehow fell through the access hole to the oil pan. (above, right)

With nothing else to do I took off the inner cover, and would you guess who was hiding behind the left balancer:




I honestly don't think I'd have been able to get that bolt out of there without taking the rotor off, but I can definitely say I'd rather just not have had it happen in the first place. Safe to say that I learned a valuable lesson today that I won't soon forget. The important thing is that the bike's running just fine now.



Also: Quick question for the experienced: Is it ok to just leave the cam chain cover removed? (Talking about part # 12053-1353 (Upper chain guide), the bit that goes over the chain between the cam sprockets) It just seems like it doesn't really need to be there.
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post #2 of 7 Old 06-24-2019, 11:57 AM
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Quote:
Originally Posted by insan3guy View Post
...Is it ok to just leave the cam chain cover removed? (Talking about part # 12053-1353 (Upper chain guide), the bit that goes over the chain between the cam sprockets) It just seems like it doesn't really need to be there.
I hate that part. It is normal to think that when a manufacturer makes a major change to a part that it is for the better and it is an important change to preserve. I wonder about changes that Kawasaki makes.

That chain guide used to be a part of the valve cover up through 1995. That guide, in the valve cover, is also used on the 250 and the Mojave.

I got so tired of messing with that part that I changed to a pre-'96 valve cover and valve cover bolts. You can still buy the guide and replace it, though you probably won't need to. I have been running it for quite a while with no issues at all (surprise, it worked for the first 10 years of 650 and in 250s up through 2005). You also need the bolts that go with the cover.

Run without it? I don't think that is a good idea, as the chain is changing direction as it comes over the cam sprocket. It needs some control so that it hits the second sprocket correctly.

Butcha don't have to put up with that damn -1353 thing.

https://www.klrforum.com/2008-klr650...tml#post634849
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Last edited by Tom Schmitz; 06-24-2019 at 11:59 AM.
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post #3 of 7 Old 06-24-2019, 05:30 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
I hate that part. It is normal to think that when a manufacturer makes a major change to a part that it is for the better and it is an important change to preserve. I wonder about changes that Kawasaki makes.

That chain guide used to be a part of the valve cover up through 1995. That guide, in the valve cover, is also used on the 250 and the Mojave.

I got so tired of messing with that part that I changed to a pre-'96 valve cover and valve cover bolts. You can still buy the guide and replace it, though you probably won't need to. I have been running it for quite a while with no issues at all (surprise, it worked for the first 10 years of 650 and in 250s up through 2005). You also need the bolts that go with the cover.

Run without it? I don't think that is a good idea, as the chain is changing direction as it comes over the cam sprocket. It needs some control so that it hits the second sprocket correctly.

Butcha don't have to put up with that damn -1353 thing.

https://www.klrforum.com/2008-klr650...tml#post634849
Hmm. That's going on the to-do list! Kawasaki never fails to confuse me with their decisions. Noise reduction on the valve cover... of a KLR650.
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post #4 of 7 Old 06-24-2019, 07:28 PM
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A decible meter doesn't care where the noise comes from. The EPA drive-by test just measures total noise.

A Dunlop D606 rear tire would probably cause an E-Bike to FAIL a drive-by sound test.

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post #5 of 7 Old 06-25-2019, 02:52 AM Thread Starter
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Originally Posted by pdwestman View Post
A decible meter doesn't care where the noise comes from. The EPA drive-by test just measures total noise.

A Dunlop D606 rear tire would probably cause an E-Bike to FAIL a drive-by sound test.
Well that does make sense. I had no idea the drive-by test was a thing
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post #6 of 7 Old 06-25-2019, 04:53 PM
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Well that does make sense. I had no idea the drive-by test was a thing
I wish the EPA would set up their drive-by test in front of any building on any towns Main street and record the 'Thundering Herds' of V-Twins with aftermarket pipes! Some in this area are just plain Out-of-Order!

I for one would like to know which V-Twin bike & pipe combo is audible from over 3 miles away in open country!

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post #7 of 7 Old 06-26-2019, 10:04 AM
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Quote:
Originally Posted by pdwestman View Post
I wish the EPA would set up their drive-by test in front of any building on any towns Main street and record the 'Thundering Herds' of V-Twins with aftermarket pipes! Some in this area are just plain Out-of-Order!

I for one would like to know which V-Twin bike & pipe combo is audible from over 3 miles away in open country!
You are forgetting:


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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