first valve adjustment shim size data

[Jeff Saline]

Listers, Below is the data I've collected on first valve adjustment shim size changes. I'm done collecting data but would like to thank Hugh, Greg, Ken, Walt and Brian for taking the time to share their data with me. The data includes 8 KLR650s, one per year from 2000 through 2008 excluding 2005. The 2008 model info is shown using * for each valve. NOTE the 2008 owners manual I looked at indicated valve adjustment isn't required until 15,000 miles. The data from this 2008 with 995 miles on it doesn't support that interval. The range for first valve adjustment was 500 miles at the lowest to 12,300 kilometers (about 7,626 miles) for the highest. Only two valves didn't require a shim change, one intake and one exhaust. No valve required a shim change of more than 2 sizes (0.004"). Seven exhaust valves were 2 shims off compared with 5 intake valves. To use the charts... On the left side the vertical row of numbers is shim sizes that were in place when the engine was opened. The horizontal numbers are the size of the replacement shim. If a number is present it indicates how many valves required that size shim to get back to max spec. NOTE: A * is placed for each 2008 valve so you can see the difference between the 2000-2007 engines and the 2008 engine. The X is where no change would happen. A % indicates no shim change was needed for a valve. NOTE: No replacement shims were ever larger than the original shim size. %=No Change *=2008 Model Info per valve INTAKE Old Shim New Shim 275 270 265 260 255 250 275 X 1 270 X 1 265 % 6** 4 260 X 1 255 X 250 X %=No Change *=2008 Model Info per valve EXHAUST Old Shim New Shim 275 270 265 260 255 250 245 240 275 X 1** 270 X 2 265 X 2 1 260 X 255 % 3 2 250 X 1 1 245 X 240 X So using this data to help select a few shim sizes that might be handy to have available for a first valve adjustment I'd suggest folks consider 265, 260, 255 and maybe 250. But my experience is you can often swap shims from valve to valve so you don't need four new shims when doing one engine. I still think it's handy to know what shims you have in place as then you can make a more educated decision. Hope this is interesting if not helpful. 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