2007 valve check HELP! PLEASE! - 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 22 Old 03-04-2010, 03:23 PM Thread Starter
 
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Exclamation 2007 valve check HELP! PLEASE!

stoked to find this forum!! So, I am knee deep in checking my valves (bike has 7000 mi on it) get to taking the head off and find that there is a little nub between the rear bolts!! what the heck is that?! I can't get it off, I've taken the radiator off upper engine mounts, fan, and tied up all the rest of the cables there just isn't enough clearance with that little nubby thing in the way!

Has anyone done this on their '07 and seen what I'm talking about. None of the writeups I have found, marknet and the vid on youtube mention it.

HELP PLEASE!! Any great ideas I don't want to have to pay hundreds of dollars for someone to do it for me.

Thanks all,
RAD
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post #2 of 22 Old 03-04-2010, 05:13 PM
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RAD -

I'm not sure exqactly what your reference is, as you say "back bolts" and "head" when I think you mean valve cover and perhaps "front bolts".

Is what you are talking about the nub that is barely visible under the spark plug wire below?



I thought those were only on the '08s, but...

Any way, I'm a pretty fair mechanic and I tried until I was blue in the face to get the valve cover off and it would simply not clear the cam chain sheet metal cover, no matter what I did. It must happen on one in a million bikes where the engine winds up sitting one millimeter higher in the frame than it is supposed to.

All I could do was take my dremel tool and cut it off. Then the cover came of very easily.

Tom

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post #3 of 22 Old 03-04-2010, 07:06 PM
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Valve cover removal

Rad,
you can indeed remove the valve cover without modifying anything. That said, if I hadn't been told, I would have ground the little nub off as well. As I recall, there wouldn't be any major consequence.

Make sure that you slide the valve cover gasket off first- it adds the little bit of clearance that you will need. It will be very close, but at just the right angle, it does come off.

Tomatocity can explain this better than I can as he has much more experience than I do and is more patient than I am.

Dave

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post #4 of 22 Old 03-04-2010, 07:26 PM Thread Starter
 
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sweetness thanks for the pic, I don't have my camera with me.

so it looks like you are on the right, when sitting on the bike, side of it...correct?

my little nubby thing is between the two bolts (intake side) yours looks like it is exhaust...am I crazy? I have been trying this for a few hours today!

i almost did shave it off, it looks like it doesn't go through the valve cover all the way.

KLRZIN: did take off the gasket and that clearance just isn't enough on the right side, non cam chain side the cover hits the cam lobe.

Thanks friends for the replies, I may shave it off if I don't hear better, or call a mechanic if I have to (really want to get it on my own tho)
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post #5 of 22 Old 03-04-2010, 08:05 PM
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I wouldn't doubt Tom at all (Put the wrench DOWN, Tom!) ...there are undoubtedly manufacturing discrepancies with such a...ahem...well put together machine as the KLR. But I will say that when I did my valves (with tomatocity, Mark, and Zin) that was the hardest part, but we stuck at it and eventually it worked. OK, the math was hard for me, too. I drank the beer pretty good though (thanks again, Dave). Not enough homebrew in my life.




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post #6 of 22 Old 03-04-2010, 08:14 PM
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Yes, my nubbin was between my exhaust...

OK, LJ, go.

Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #7 of 22 Old 03-05-2010, 12:11 AM
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The first 'nub' we encountered was August of 2006 at the Redding Tech Daze (great function). EagleMike, TOBJ, Larryboy, MotoPhoto, and other knowledgeable KLRistas. They could not get the valve cover off the 2007 KLR650. They ended up using a dremel to remove the valve cover. After it was off they ground it smooth and painted the valve cover. If you did not know, you wouldn't.

So if you...
...remove the gasket.
...lift the valve cover at an angle.
...use a light loose wiggle hand so the valve cover does not bind.
...stop and start.
...then you need to trim some of the nub off to remove the valve cover.
...after the valve cover is removed you can do what you need to do to make you happy.

Hope this helps.

TIP: after you change the valve shims and have everything, except the valve cover, rotate the engine at least two times, by hand, and recheck the clearances.

Tim

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2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #8 of 22 Old 03-05-2010, 10:08 AM
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Quote:
Originally Posted by Tom Schmitz View Post
Yes, my nubbin was between my exhaust...

OK, LJ, go.

Tom
Hmmm, this could be interpreted so many ways.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

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-------------------
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post #9 of 22 Old 03-05-2010, 10:14 AM
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I should add that the nub on the Gen2 valve cover (on the front, exhaust end of the cover) is used to secure a clamp for the air injection clamp, which is why I thought only the new bikes would have a problem. A bit of a problem if you don't intend to remove the air injection stuff.
The nub sticks up about 10mm.
Does the earlier nub have a purpose, or is it just there?

Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #10 of 22 Old 03-05-2010, 01:14 PM
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The 07 nub was just there. nothing attached or to be attached.

Looks like they had the new cover before the air Inject clamp was used..

That cover was not coming off unless it was cut first...

- Joe

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