Valve Adjustment - 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 11 Old 07-19-2010, 11:11 PM Thread Starter
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Valve Adjustment

Does anyone have a suggestion on where to get a valve shim kit. Also, I remember seeing a step by step guide for performing this wonderful time I'm fixin' to get to spend with my '03. Thought I downloaded it. Can't find it. Anyone seen it. Help. Thanks, Chuck
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post #2 of 11 Old 07-19-2010, 11:14 PM
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This is a cool site with what looks like a great bunch of guides:

klr650.marknet.us/valves. html

Haven't done this yet so other then that I have no clue. Good luck.

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post #3 of 11 Old 07-19-2010, 11:24 PM Thread Starter
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Thanks for the Site RB. I was just reading a trip report about some Caliente guy playing chicken with trucks. Don't know him do you? Looks like you fixed the plastic pretty good.
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post #4 of 11 Old 07-19-2010, 11:52 PM
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Oh that guy geessh... He goes playing macho invincible with trucks then disappears leaving me to deal with the pain... what to do, what to doż Hehe, just passing on the awesome info from the greats around here. :-)

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post #5 of 11 Old 07-20-2010, 12:02 AM
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Quote:
Originally Posted by charles View Post
Does anyone have a suggestion on where to get a valve shim kit. Also, I remember seeing a step by step guide for performing this wonderful time I'm fixin' to get to spend with my '03. Thought I downloaded it. Can't find it. Anyone seen it. Help. Thanks, Chuck
Chuck -

If you can afford to be down for a few days, the best route is to dig into your top end and figure out which shims you need. Then think a bit, as often you can re-arrange the shims so that you need to buy fewer. Remember, as the valve train wears, you need to install thinner shims. Thus, if you have a tight exhaust with a 2.50 in it and a tight intake with a 2.60 in it, you may be able to rotate the 2.50 into the intake (that's just an example - you have to do the right math to figure out what shim you need) and only buy one shim instead of two.

Then, look at our thread on "Need Valve Shims?/Got Valve Shims?" and see if there's anything listed (I have three 2.45 shims free for the postage). If not, order up from some place like maxBMW, where you'll pay about half what you'd pay for a Kawasaki shim.

These shims are common 29mm shims and were even used in some automotive applications.

Both options will save you some serious coin over buying a shim kit. A shim kit will allow you to do it in one sitting, if that's important to you, but at a significant cost.

Tom

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Last edited by Tom Schmitz; 07-20-2010 at 12:15 AM.
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post #6 of 11 Old 07-20-2010, 07:43 AM
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That gives you an idea of what is involved in the valve adjustment.

This should help figure out what shims you need to make your adjustments.

http://klr650.carguy.org/shims.html


As Tom suggested, some of your shim replacement requirements can be filled by shuffling your existing shims. Pricing for most valve shim kits start at over a hundred bucks, and half of the shims included are too thick to use.

Ford Taurus SHO models to 1995 used the same 29mm diameter valve shims. IF you can locate a kit at a service department, they will have more thickness options for adjustment. BMW K model bikes with two valves and the early F650 used 19mm shims, as did Yamaha Seca II's.

Individual shims available here;

http://www.rockymountainatvmc.com/ve...oductDetail.do

http://www.crc2onlinecatalog.com/valve_shims.htm
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post #7 of 11 Old 07-28-2010, 08:42 PM
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Here's the shim calculator you will need

http://klr650.carguy.org/shims.html
I bought my shims from Rocky Mtn. Quick shipping and all around good customer service.
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post #8 of 11 Old 09-15-2010, 07:08 AM
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Its that being down several days waiting for shims to arrive that makes me hesitant to do this necessary procedure. That's a PITA.

Erik
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2009 KLR 650

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post #9 of 11 Old 09-15-2010, 09:51 AM
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Its that being down several days waiting for shims to arrive that makes me hesitant to do this necessary procedure. That's a PITA.

You don't have to be down. Do the check and put the bike back together.

The first few times you take the the parts off to work on the valves it seems like a big deal but it gets easier with practice!

Takes me about 10 minutes to get to the head. Pop off the side panels, seat, tank shrouds, gas tank and radiator fan. Getting the valve cover off is the worst part (for me) because you have to angle it just right to get it out.

Really it's not as bad as it seems, dive in!

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #10 of 11 Old 09-15-2010, 09:53 AM
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Its that being down several days waiting for shims to arrive that makes me hesitant to do this necessary procedure. That's a PITA.
You show NOVA as your home base. There are shims available local.

Morton's BMW on Route 1 in Fredericksburg stocks 29mm shims. Under 5 bucks a piece. I would be surprised if you really needed three shims. Usually one or two is all that I ever need to replace, if I shuffle around what is already in the bike.

Capital Cycle @ Sterling has shims in stock, around 5 bucks a piece.
800 642 5100. Short hours on Saturdays, 10-1. Open till 6PM during the week

Coleman Power Sports @ Falls Church will trade your used shims for the size you need in the service department. 703-237-3400 Service Department

Remember, you need 29mm shims. 29.5mm, 29.6mm, won't fit in the bucket. Smile and ask them three times to make sure they are 29mm.....no more, no less. Bring the shims you are replacing. Ask them to use a micrometer caliper and match what you have.

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