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Well checked the valve clearance they are in spec

Looks like a ape removed the plugs on left side engine covers both threaded plugs were removed with a screwdriver to small and gouged them up. ill add new ones to my christmas list.

is it a klr deal to put silicon on with the existing rubber gaskets? ive never had to do this with several other japanese motorcycles ive had, i usually just replace the rubber valve cover gasket if it seeps. i keep runing into gasket sealer on this bike. first the oil filter had grey sealer, now the valve cover has orange peratex it looks like. what a pain to clean off trying not to get it into the engine.

I ran into what is the AIS system on this bike, ordered the EM block off and plug, took valve off and will be heading to town to get a 1/2" plug for the nipple on frame, what bothers me is i can see what looks like a nipple that goes into that airbox on the other end of the frame tube, how are you guys addressing this?

inspected the exhaust cam cap while checking valve clearance it didnt look bad to me, maybe a little wear. but nothing i havent seen on other japanese bikes ive work on the valve train on.


i was not expecting this AIS since i do not believe this is a cali bike i guess they all must have had it or the previous owner removed the vapor stuff.
 

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I personally would have re-shimmed that 1 intake valve, but I do have the full set of shims in stock.

The factory only uses clear silicone on the valve cover 'eyeballs' on the chain tunnel area. I use None on the KLR's.
But DRZ/KLX400 will leak without silicone on the 'eyeballs'. (I learned that the hard way. Do the job a second time for free.)

The AIS frame nipple may be left totally open. It breathe thru a separate air filter retained by a 4mm allen bolt at the rear end of the frame pipe by the shock mount.
The Black vent hose attached to the air box by the upper shock mount comes from the crankcase, leave it alone.

Be certain that the Evaporative emission hole or elbow just ahead of the RH front corner of the battery in the clean-side of the air box is Plugged!!

That air filter is Perfectly clean on the inside like we knew it should be, because it was well oiled thru & thru. Be certain to re-oil enough to squeeze some back out.
 

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Discussion Starter #5
i picked up some pipe nipples covers from the ato store i will install that forsure on the frame, ya i knew about the crank case hose but never touched it, i was thinking i seen a tube comming off the back of the backbone but it might have been my eyes, ill chck that front corner, but im pretty sure my bike doesnt have the evap system if thats the same as the cali system.
 

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All Gen 2 bikes have had the Air Injection System to the exhaust.

California approved bikes with the Evaporative Emissions Charcoal Can could be sold in ALL 50 States. So check for a hole or a plug ahead of the RH front corner of the battery, if it was a CA approved bike.
 

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Discussion Starter #7
All Gen 2 bikes have had the Air Injection System to the exhaust.

California approved bikes with the Evaporative Emissions Charcoal Can could be sold in ALL 50 States. So check for a hole or a plug ahead of the RH front corner of the battery, if it was a CA approved bike.


i do not see a hole in this picture would it be visable? or is it harder to spot?
 

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