zebulon run

[ckahleer]

I bought a used 07 with only 400 miles on it. I decided to do the 500 mile valve check now. Problem is, I can't get the valve cover off. It woun't clear the cam chain guide. Fan, coil, upper engion mount, cover gasket, are removed. hoses and wires have been repositioned as not to interfere. There is a 1/4" high nub on the cover between the rear bolt holes that is hitting the frame when I lift the cover. I had my hacksaw out and was about to "Improve" my valve cover by cutting that nub off, but then thought maybe consult the group first. Craig Kahler

[klrjohn650]

I just finished adjusting my valve lash. Getting the cover off is pretty easy once you cut the wire ties allowing you to move the large wire bundles and remove the upper motor mount. The bottom bolt can be held with a 16mm box wrench. I used an impact wrench and it was a piece of cake. Check out these vids: Valve check http://www.youtube.com/watch?v=YD462lZsgMQ&feature=related Valve adj: http://www.youtube.com/watch?v=R2d-V4udwaA&feature=related Adding to the videos: 1) I taped the 8mm socket to the ratchet extension to I wouldn't drop it into the abyss if it fell off. 2) Squirted everything with motor oil prior to assy and again when rotating the engine. 3) Remove the spark plug when rotating the engine. screw in a couple threads when done to keep stuff from dropping into the cylinder 4) Use a caliper (C-type, not vernier) instead of trusting the dimensions printed on the shim. I double checked the cal on my calipers by measuring my feeler gauges. It was spot on; the shims were not. I found this out the hard way when I trusted the shim stamp, installed what I thought was the proper dimension shim, put everything together, rotated the crank a couple times, remeasured, and found the lash to be incorrect on a couple valves. Naturally, one was an intake and the other was an exhaust valve. I'm glad I ordered the shim kit. BTW, I needed a 2.25mm shim and the store was out of stock. So, I set my exhaust valves to 0.008" b/c a 2.25mm shim was not included in the kit. I don't know about the intake valves. But, I like to adjust the exhaust valves to max spec. 5) I couldn't get my torque wrench to fit on the right rear intake cam cap bolt. Torque another bolt to spec and get a feel for what it is like with a wrench that will fit so you won't under/over torque. 6) Loosen the cam tensioner bolt before removing the tensioner assy from the engine.

--- In DSN_KLR650@yahoogroups.com, "ckahleer" wrote: > > I bought a used 07 with only 400 miles on it. I decided to do the 500 > mile valve check now. Problem is, I can't get the valve cover off. It > woun't clear the cam chain guide. Fan, coil, upper engion mount, cover > gasket, are removed. hoses and wires have been repositioned as not to > interfere. There is a 1/4" high nub on the cover between the rear bolt > holes that is hitting the frame when I lift the cover. I had my hacksaw > out and was about to "Improve" my valve cover by cutting that nub off, > but then thought maybe consult the group first. > > Craig Kahler >

[Jeff Saline]

On Sat, 06 Dec 2008 23:17:32 -0000 "ckahleer" writes:

> I bought a used 07 with only 400 miles on it. I decided to do the 500 > > mile valve check now. Problem is, I can't get the valve cover off. > It > woun't clear the cam chain guide. Fan, coil, upper engion mount, > cover > gasket, are removed. hoses and wires have been repositioned as not > to > interfere. There is a 1/4" high nub on the cover between the rear > bolt > holes that is hitting the frame when I lift the cover. I had my > hacksaw > out and was about to "Improve" my valve cover by cutting that nub > off, > but then thought maybe consult the group first. > > Craig Kahler

<><><><><><><><> <><><><><><><><> Craig, I've had a tough time getting them off too. Sounds like you've done the right stuff with getting wires, tubes and metal out of the way. I find it's easier to remove the gasket sometimes which also gives a tad more clearance. Then I've got to hold my tongue just right while the stars align. Then it'll usually slide out. Sorry I don't have a magic secret for you. For reinstallation I find a very light touch of Hylomar sealant works great to stop leaks at the cover gasket and also the sealing washers under the bolts. Good luck and best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT ____________________________________________________________ Take a break - you deserve it. Click here to find a great vacation. http://thirdpartyoffers.juno.com/TGL2141/fc/PnY6rw2gGUcPl4dTwE3zHhqVaD7Hd1aUwKqyH4csmEhgtgocOlDow/

[dooden]

I remember taking fan and maybe the coil off.. Ah quick search and found "the" guide.. http://www.klr650.marknet.us/valves.html It has to be positioned just right, kinda like playing Twister... Dooden A15 Green Ape

--- In DSN_KLR650@yahoogroups.com, "ckahleer" wrote: > > I bought a used 07 with only 400 miles on it. I decided to do the 500 > mile valve check now. Problem is, I can't get the valve cover off. It > woun't clear the cam chain guide. Fan, coil, upper engion mount, cover > gasket, are removed. hoses and wires have been repositioned as not to > interfere. There is a 1/4" high nub on the cover between the rear bolt > holes that is hitting the frame when I lift the cover. I had my hacksaw > out and was about to "Improve" my valve cover by cutting that nub off, > but then thought maybe consult the group first. > > Craig Kahler >

[Tengai Mark Van Horn]

At 1:14 AM +0000 12/7/08, Dooden wrote:

>I remember taking fan and maybe the coil off..

I just cut the frame and re-weld the piece back in. It's not too big of a pain since the valves only need checking every 30,000 miles or so. Mark

[dooden]

F#$^%@%g cold weather getting to you too Mark ? Dooden A15 Green Ape --- In DSN_KLR650@yahoogroups.com, Tengai Mark Van Horn wrote:

> > At 1:14 AM +0000 12/7/08, Dooden wrote: > >I remember taking fan and maybe the coil off.. > > I just cut the frame and re-weld the piece back in. It's not too big > of a pain since the valves only need checking every 30,000 miles or > so. > > Mark >

[Rick]

Oh boy, the valve check and valve cover. The first time I did mine and my wife's, I had the same issues. Do exactly as the marknet site says and take everything off. Loosen everything is tells you to do. And even then getting the cover out is a bit of smoke and mirrors and it will slip out. Even the first time getting it back in will be fun or testing. But knowing that thousands and thousands of us had the same stress the first time is not a help but we all experienced it and now you are joining the club. And every valve check after this get easier because you know it is possible and you would have printed off the instructions and have them close by your bike. Do not modify anything on your bike as it is not necessary at all.

--- In DSN_KLR650@yahoogroups.com, "ckahleer" wrote: > > I bought a used 07 with only 400 miles on it. I decided to do the 500 > mile valve check now. Problem is, I can't get the valve cover off. It > woun't clear the cam chain guide. Fan, coil, upper engion mount, cover > gasket, are removed. hoses and wires have been repositioned as not to > interfere. There is a 1/4" high nub on the cover between the rear bolt > holes that is hitting the frame when I lift the cover. I had my hacksaw > out and was about to "Improve" my valve cover by cutting that nub off, > but then thought maybe consult the group first. > > Craig Kahler >

[Tengai Mark Van Horn]

Nah...I'm staying warm just fine. http://www.globalpackagegallery.com/main.php?g2_view=core.DownloadItem&g2_itemId=16658&g2_serialNumber=2 > Why do you ask? Mark At 4:12 PM +0000 12/7/08, Dooden wrote:

>F#$^%@%g cold weather getting to you too Mark ? > >Dooden >A15 Green Ape > > >--- In DSN_KLR650@yahoogroups.com, Tengai Mark Van Horn >wrote: >> >> At 1:14 AM +0000 12/7/08, Dooden wrote: >> >I remember taking fan and maybe the coil off.. >> >> I just cut the frame and re-weld the piece back in. It's not too big >> of a pain since the valves only need checking every 30,000 miles or >> so. >> >> Mark

[Randall Marbach]

I remember at a few Julian tech sessions ago that Eagle Mike had to cut the nub off to get the valve cover off. HTH Randy from Burbank ----- Original Message ---- From: Dooden To: DSN_KLR650@yahoogroups.com Sent: Saturday, December 6, 2008 5:14:01 PM Subject: [DSN_KLR650] Re: @#*$%! Valve Cover I remember taking fan and maybe the coil off.. Ah quick search and found "the" guide.. http://www.klr650.marknet.us/valves.html It has to be positioned just right, kinda like playing Twister... Dooden A15 Green Ape

--- In DSN_KLR650@yahoogroups.com, "ckahleer" wrote: > > I bought a used 07 with only 400 miles on it. I decided to do the 500 > mile valve check now. Problem is, I can't get the valve cover off. It > woun't clear the cam chain guide. Fan, coil, upper engion mount, cover > gasket, are removed. hoses and wires have been repositioned as not to > interfere. There is a 1/4" high nub on the cover between the rear bolt > holes that is hitting the frame when I lift the cover. I had my hacksaw > out and was about to "Improve" my valve cover by cutting that nub off, > but then thought maybe consult the group first. > > Craig Kahler > ------------------------------------ List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Member Map at: http://www.frappr.com/dsnklr650Yahoo! Groups Links

[Craig Kahler]

It turned out the valve cover is an 08 cover. The 08s have this nub that earler KLRs don't. From another reply I received, I'm not the only owner of an 07 with an 08 valve cover. In my case, that nub had to be cut off.to remove the cover. Once the nub was cut off the cover removed as per the marknet instructions. Craig Kahler

--- On Sun, 12/7/08, rick wrote: From: rick Subject: [DSN_KLR650] Re: @#*$%! Valve Cover To: DSN_KLR650@yahoogroups.com Date: Sunday, December 7, 2008, 12:31 PM Oh boy, the valve check and valve cover. The first time I did mine and my wife's, I had the same issues. Do exactly as the marknet site says and take everything off. Loosen everything is tells you to do. And even then getting the cover out is a bit of smoke and mirrors and it will slip out. Even the first time getting it back in will be fun or testing. But knowing that thousands and thousands of us had the same stress the first time is not a help but we all experienced it and now you are joining the club. And every valve check after this get easier because you know it is possible and you would have printed off the instructions and have them close by your bike. Do not modify anything on your bike as it is not necessary at all. --- In DSN_KLR650@yahoogro ups.com, "ckahleer" wrote: > > I bought a used 07 with only 400 miles on it. I decided to do the 500 > mile valve check now. Problem is, I can't get the valve cover off. It > woun't clear the cam chain guide. Fan, coil, upper engion mount, cover > gasket, are removed. hoses and wires have been repositioned as not to > interfere. There is a 1/4" high nub on the cover between the rear bolt > holes that is hitting the frame when I lift the cover. I had my hacksaw > out and was about to "Improve" my valve cover by cutting that nub off, > but then thought maybe consult the group first. > > Craig Kahler > [Non-text portions of this message have been removed]