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Discussion Starter · #1 ·
Finished doing some top end work, and while buttoning everything up I over-torqued the valve cover bolt snapping the bolt inside the cam cap. I need a new used cam cap and bolt. Im having a hard time finding anything as most people will only sell the entire top end. Looking for someone with a parts bike who will be willing to sell what I need? Let me know. Happy Riding

Thanks, Austin
 

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2013 KLR 650/692, 2017 HD Electraglide Ultra
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The head and cam caps are matched and machined to final tolerances together, therefore the parts are not interchangeable. That’s why Kawasaki and other parts sellers only sell the complete head. Take the cap to a machine shop. They can get out the broken off bolt. Then, make damn sure you use a small torque wrench to install the valve cover bolts!
 

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Eagle Mike will sell you replacement bolts, 40mm length with a flat washer works if I remember correctly. I don't think the broken bolt can be stuck in the cam cap.
I'm pretty certain he is needing a LH valve cover bolt, which does screw into the LH camshaft bearing caps.

I recon that he is lucky that he didn't strip the threads from that cap or from more than one hole.
People see that 12mm hex head and just Can Not Resist putting the bean squeeze to them, jeeze.

If Kawasaki had used a 10mm hex head this error would probably be less frequent.
An 8mm hex head would give an even better clue as to the lack of needed torque to seal the rubber gaskets, imo.
 

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pdwestman, Thank you, I now understand the issue at hand, sorry for the erroneous interpretation of the problem. My misunderstanding was a result of the text that asked for a cam cap and bolt.
 

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KLRian: yeah, I thought the same thing when I first read it, then thought “that doesn’t make sense.” So I had to reread it more carefully.
 

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Discussion Starter · #10 ·
Update: Got it out with a fine pick and patience and now I need to find a new bolt.

question before I continue I’m at TDC and I know the timing gears SHOULD be completely level with the top but my intake gear is pointingup slightly and if I got one tooth the other way it’s down much further. Is this ok?
 

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Cam Sprocket Arrows are 'Perfect'ly normal. When the chain guide inside the valve cover presses down between the sprockets, the intake sprocket will level some.

This may be partly the reason for a twisted off LH cover bolt. The cam chain Tensioner needs to be left out of the engine UNTIL the valve cover with top guide is installed.

I usually just remove the chain tensioner CAP & Spring prior to even loosening the valve cover bolts. Rather than removing the entire tensioner & resetting. 2 less bolts to possibly miss-place or strip or forget to torque.
 

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Discussion Starter · #12 ·
That you for the advice I’ll see how it goes. I’m going to get a new torque wrench before I snap anymore bolts. I’ll go through like you said and see how it goes. Thanks, Austin .
 
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