Dropped Downel In Engine - Kawasaki KLR 650 Forum
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post #1 of 14 Old 12-30-2012, 12:41 AM Thread Starter
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Dropped Downel In Engine

So I was doing a valve adjustment and I dropped one of the 8 little downels into the the cam chain hole of doom. Like a total idiot I forgot to stuff a rag into the hole to keep them from falling in. I've been finishing around with a extendable magnet for about 4 hours now and I now know for sure its somewhere in the crank case. I've drained the oil and tried flushing the hole out with oil with no luck. I've also tried shaking the whole bike. I've also pull the generator cover and have been fishing in there for a bit. I've also tried around in the oil sump. What else can I do? I'm ready to start looking for a doohicky wrench to pull the stator if I can't find this damn thing
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post #2 of 14 Old 12-30-2012, 01:59 AM
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Hate to be bearer of not so fun news but you may have to bust out the wrench. I had to to when I accidentally dropped one while doing a last second check without stuffing the hole. You might try a really bright flashlight and dental mirror if you have one to see if you can locate it. Then it'll be like playing that game "operation". Best of luck with finding it.


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post #3 of 14 Old 12-30-2012, 07:19 AM
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I will bet dollars to donuts it's sitting on the chain where it meets the crank sprocket....you will need to take the rotor off and possibly the inner case to get at it.....sorry to say.....I also bet it isn't far into the cases either......and not in the sump area. There is way too much for it to get caught on before getting that far.

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post #4 of 14 Old 12-31-2012, 03:04 AM Thread Starter
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I got it out. The solution was "accidentally" dropping the bike on the left side with the clutch cover off. That knocked it out near the outer case where I got it with a magnet. At least it's out..
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post #5 of 14 Old 12-31-2012, 01:50 PM
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Originally Posted by wontian View Post
i got it out. The solution was "accidentally" dropping the bike on the left side with the clutch cover off. That knocked it out near the outer case where i got it with a magnet. At least it's out..
lucky!
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post #6 of 14 Old 12-31-2012, 04:31 PM
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The "accidentally dropping the bike" on the left side wasn't actually "thrown over in frustration" was it?

Just kidding, I'm glad you got it out! It's a sinking feeling like no other when you drop something small into the bowels of an engine knowing that you somehow have to get it out...

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post #7 of 14 Old 01-01-2013, 03:10 AM Thread Starter
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Originally Posted by 650Stew View Post
The "accidentally dropping the bike" on the left side wasn't actually "thrown over in frustration" was it?

Just kidding, I'm glad you got it out! It's a sinking feeling like no other when you drop something small into the bowels of an engine knowing that you somehow have to get it out...
Well said.

Although I've run into another problem...

Bikes cranks but doesn't start anymore. I think the timing is off
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post #8 of 14 Old 01-01-2013, 08:11 AM
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Quote:
Originally Posted by WonTian View Post
Well said.

Although I've run into another problem...

Bikes cranks but doesn't start anymore. I think the timing is off
If you're pretty sure you got it together right with all the marks aligned correctly with the cam lobes in the proper orientation, the first thing I would do before tearing into it again is to check the simple stuff, i.e. spark plug wire back on the plug, etc?




Last edited by planalp; 01-01-2013 at 08:14 AM.
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post #9 of 14 Old 01-01-2013, 11:23 AM
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Originally Posted by planalp View Post
If you're pretty sure you got it together right with all the marks aligned correctly with the cam lobes in the proper orientation, the first thing I would do before tearing into it again is to check the simple stuff, i.e. spark plug wire back on the plug, etc?

+1 on simple first

vacuum line on petcock?

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 14 Old 01-01-2013, 01:54 PM
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Every time I accidentally drop mine on its side, it is VERY difficult to start once righted. My theory is that it has something to do with fuel supply, but I know not what. Many is the time I have had to push start it after a tip over, once the battery weakens. Here's hoping that you have the same problem. Maybe if you let it sit overnight, then try cranking again the next day, it will fire up.
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