Setting valves-----abyss of doom - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 30 Old 06-12-2014, 11:25 AM Thread Starter
1st Gear
 
PaulieeT's Avatar
 
Join Date: Feb 2014
Location: Wisconsin
Posts: 61
Setting valves-----abyss of doom

Was taking the tapet cover off to do the valves. One of the rubber/metal spacers for the cover went missing as I took the cover off. Didn't see or hear it drop, and looked everywhere on the bike. What's needed to get into the abyss of doom. I tried running a magnet down there and turned up nothing. The engine doesn't turn over counter clockwise now, so it must be jammed up down there.

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light
PaulieeT is offline  
Sponsored Links
Advertisement
 
post #2 of 30 Old 06-13-2014, 05:27 AM
2nd Gear
 
Join Date: Apr 2012
Location: Cairns, Australia.
Posts: 191
I've just checked and reshimmed the valves on a friends '05, noticed that one of those rubber washer things stayed with the bolt while one stayed with the cover-you might be lucky !
Unless you pull the cam chain up (you have tied it so it can't fall down haven't you?) it will "pool" around the crankshaft sprocket and kind of jam things up down there when you try to turn the engine over. Definitely not a good idea to force things.
If you have dropped something down there, the very least you're going to have to do is to take off the left outer cover and go fishing-again you may get lucky.

hope this helps

iddy
iddy is offline  
post #3 of 30 Old 06-13-2014, 08:07 AM
2nd Gear
 
fradsham's Avatar
 
Join Date: Jun 2012
Location: Paradise, NL, Canada
Posts: 378
Always my biggest fear as well, when I take of the top cover for any work. Loosing something down in that dark hole with a pool of black oil at the bottom... Ouch. Hope you have luck in finding it.
fradsham is offline  
 
post #4 of 30 Old 06-13-2014, 08:24 AM
Moderator
 
klr4evr's Avatar
 
Join Date: Mar 2007
Location: Fort Sask , Alberta, Canada
Posts: 3,479
Garage
Send a message via Skype™ to klr4evr
Are you absolutely sure that it isn't somewhere else? I've had similar happen only to find a screw or washer rolled up against a wall. Hate to see you go to a lot of work for nothing.

However, as you say, you can't turn it over so as mentioned the left side cover has to come off. You may have to go further than that and get the rotor off too. Good time to do the Doo if you had any intention of that.

Sorry to hear about your dilemma. It's frustrating. Keep us posted with a picture or too of what you find.

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. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

This information makes it much easier for other members to answer/comment on your posts.
klr4evr is offline  
post #5 of 30 Old 06-13-2014, 08:06 PM Thread Starter
1st Gear
 
PaulieeT's Avatar
 
Join Date: Feb 2014
Location: Wisconsin
Posts: 61
Quote:
Originally Posted by iddy View Post
I've just checked and reshimmed the valves on a friends '05, noticed that one of those rubber washer things stayed with the bolt while one stayed with the cover-you might be lucky !
Unless you pull the cam chain up (you have tied it so it can't fall down haven't you?) it will "pool" around the crankshaft sprocket and kind of jam things up down there when you try to turn the engine over. Definitely not a good idea to force things.
If you have dropped something down there, the very least you're going to have to do is to take off the left outer cover and go fishing-again you may get lucky.

hope this helps

iddy
Yea I knew about typing up the cam chain, just had no idea those rubber washers were in the cover. I took off the left side cover and didn't find anything. I ordered the tool to take off the stator and then I'm hoping to find it. Terrible timing because I'm had been planning an 11 day, 4-5,000 mile ride starting on Monday. What's even better is that I paid for 2 day air shipping from bike bandit for the tool on Friday afternoon. As we speak they have yet to process my order.

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light
PaulieeT is offline  
post #6 of 30 Old 06-13-2014, 08:08 PM Thread Starter
1st Gear
 
PaulieeT's Avatar
 
Join Date: Feb 2014
Location: Wisconsin
Posts: 61
On a side note, I was suprised to see that kawi recomends doing the valves at 7,000 miles. I've read that a lot of people say to check them at 600-1,000 miles. My bike has 1,000 miles on it and one exhaust valve was at the tight tolerance and another intake valve was not too far behind it. Bad luck that I had, but I'm glad I did the maintence.

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light
PaulieeT is offline  
post #7 of 30 Old 06-14-2014, 06:43 AM
OverDrive
 
Join Date: Jan 2011
Location: NW MO
Posts: 5,337
Quote:
Originally Posted by PaulieeT View Post
On a side note, I was suprised to see that kawi recomends doing the valves at 7,000 miles. I've read that a lot of people say to check them at 600-1,000 miles. My bike has 1,000 miles on it and one exhaust valve was at the tight tolerance and another intake valve was not too far behind it. Bad luck that I had, but I'm glad I did the maintence.
My Gen2 manual calls for the first valve clearance check at 15,000 miles and apparently every 15,000 miles after that if I'm interpreting it correctly since it runs out at 22,500 miles.

I checked mine at 5K and pretty much found what you did, especially 1 exhaust valve that was outside the tolerance. I can't imagine what they'd be like if I'd waited until 15K. That's coming up and I'll check them again around the 15K mark at the end of this season. I set them all really loose.



planalp is offline  
post #8 of 30 Old 06-17-2014, 12:08 PM Thread Starter
1st Gear
 
PaulieeT's Avatar
 
Join Date: Feb 2014
Location: Wisconsin
Posts: 61
Update: My order from bike bandit shipped yesterday and I'll have the tool for the stator by tomorrow before the end of the day. Hope I can locate that washer then and get the bike back on the road.

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light
PaulieeT is offline  
post #9 of 30 Old 07-08-2014, 10:26 PM Thread Starter
1st Gear
 
PaulieeT's Avatar
 
Join Date: Feb 2014
Location: Wisconsin
Posts: 61
Well, I recieved my puller from bikebandit a few weeks ago. They sent the wrong size puller, even after I asked on their website in the tech section under that puller if it would work. They sent me a 20mm puller. Due to it being a close out item, they would only give me in store credit and wouldn't do anything about my $30 I spent for expedited shipping costs. So I ended up ordering from Happy Trails the correct puller and after 12 days they finally processed my order and I recieved the puller today. I know a lot of guys run Happy Trails crash bars and skid plates, but I wasn't impressed with their extremely slow processing time.

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light
PaulieeT is offline  
post #10 of 30 Old 07-08-2014, 10:34 PM Thread Starter
1st Gear
 
PaulieeT's Avatar
 
Join Date: Feb 2014
Location: Wisconsin
Posts: 61
I got the washer out and tried to rotate the motor to get it back to TDC and it doesn't turn over all the way still. I noticed that there is a big gap between the cams and the valve shims. It also sounds like a thud from inside the cylinder like the connecting rod is banging into the cyclinder wall or something. Anyone have any ideas about what is going on/happened? I'm pulling my hair out with all these delays with crappy customer service with two different companies and my bike being laid up for 6 weeks already.


Attachment 4874

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light

Last edited by PaulieeT; 06-03-2015 at 07:38 AM.
PaulieeT is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Setting the sag... shil 2008+ KLR650 Wrenching & Mod Questions 4 10-10-2013 08:57 AM
Shock Absorber Setting armedmissouri 2008+ KLR650 Wrenching & Mod Questions 1 01-30-2012 12:26 AM
Valves Valves Valves Question tractorking 1987 to 2007 Wrenching & Mods 9 06-28-2011 03:14 PM
Subframe bolt torque setting too old for dirt 2008+ KLR650 Wrenching & Mod Questions 6 12-12-2010 08:51 AM
Rear Suspension setting? jlmoore KLR & Other Motorcycle Related Discussion 13 07-28-2010 01:54 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome