Cam Cap Removal - Kawasaki KLR 650 Forum
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post #1 of 7 Old 01-04-2012, 10:38 AM Thread Starter
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Cam Cap Removal

Anybody ever had any trouble getting off the left intake cam cap? I decided to walk away and try it again tomorrow morning because I was getting pissed.

All the other caps came right off, including the left exhaust cap. I tried lifting the left caps straight up with the oil tube attached, but instead the front one popped off so I just slid the oil tube out of the rear cap and removed the front one along with the oil tube.

I'm still stuck with the left intake cap on the engine and it won't budge. I threaded the cover bolt into it so I could get a better grip and pull straight up and have tried pulling it straight up while tapping it with a non-metal hammer and trying to wiggle it around, but it seems to be on there good.

Mostly just venting, but if anybody has any tricks on getting that thing off, I'd be interested in hearing them. Unfortunately, I think the only method is to keep doing what I'm doing: can't pry on it or anything. I'll give it a shot again tomorrow.




Last edited by planalp; 01-04-2012 at 11:13 AM.
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post #2 of 7 Old 01-04-2012, 11:55 AM
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Quote:
Originally Posted by planalp View Post
Anybody ever had any trouble getting off the left intake cam cap? I decided to walk away and try it again tomorrow morning because I was getting pissed.

All the other caps came right off, including the left exhaust cap. I tried lifting the left caps straight up with the oil tube attached, but instead the front one popped off so I just slid the oil tube out of the rear cap and removed the front one along with the oil tube.

I'm still stuck with the left intake cap on the engine and it won't budge. I threaded the cover bolt into it so I could get a better grip and pull straight up and have tried pulling it straight up while tapping it with a non-metal hammer and trying to wiggle it around, but it seems to be on there good.

Mostly just venting, but if anybody has any tricks on getting that thing off, I'd be interested in hearing them. Unfortunately, I think the only method is to keep doing what I'm doing: can't pry on it or anything. I'll give it a shot again tomorrow.

Have you tried wiggling the cam around? Grab both ends and herk it! No not really, rock the ends back and forth a bit.

I've had to pry up a cap before, yea I know but if that's the only way to get it off. Be carefull and pry around the bolt holes not the mating surfaces of the cam. Work one side then the other usually once it starts to lift a bit you can pull it off.

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 #3 of 7 Old 01-04-2012, 01:08 PM Thread Starter
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Originally Posted by Spec View Post
Have you tried wiggling the cam around? Grab both ends and herk it! No not really, rock the ends back and forth a bit.

I've had to pry up a cap before, yea I know but if that's the only way to get it off. Be carefull and pry around the bolt holes not the mating surfaces of the cam. Work one side then the other usually once it starts to lift a bit you can pull it off.
I tried lifting the free end (right side)of the cam up a little bit but didn't know how much force I should exert on it. I was hoping if I threaded the bolt into the top of the cap, it would give me a little more wiggle leverage. Plus, that back outside corner of the cam cap where you can get your finger under it is sharp!

If necessary to try some gentle prying, I'll follow your advice.

Does anybody know if human blood is detrimental to engine oil? I think I've got about a half-pint of it in there from a knuckle I ripped open during this process.



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post #4 of 7 Old 01-05-2012, 10:37 AM Thread Starter
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I got the cap off. It took some very gentle prying in a non-critical area. Actually, just barely pushing a screwdriver blade into the gap made it wiggle free. Thanks for the advice, Spec.



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post #5 of 7 Old 01-05-2012, 02:35 PM
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post #6 of 7 Old 01-23-2012, 07:39 PM
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Originally Posted by planalp View Post

Does anybody know if human blood is detrimental to engine oil? I think I've got about a half-pint of it in there from a knuckle I ripped open during this process.
It depends on whether your blood is synthetic or dino. The additive package might have something to do with it as well. Glad to hear you got it apart - I'm doing the 685 kit as soon as it gets above 30 here in MI.
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post #7 of 7 Old 01-23-2012, 08:24 PM Thread Starter
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It depends on whether your blood is synthetic or dino. The additive package might have something to do with it as well. Glad to hear you got it apart - I'm doing the 685 kit as soon as it gets above 30 here in MI.
Definitely "dino." No additives since I stay away from the beer while wrenching: I screw up enough stuff without throwing that variable into the mix.

I had to take those caps off 3 times due to my inability to grasp the chain/timing concept. That back left one was hard to get off every single time.



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