2008 klr650, checking valves at 1000 miles, a tip and a question

[Jeff Saline]

On Mon, 08 Jun 2009 00:41:57 -0000 "harpbone" writes:

> HI... > > I'm a new member here. I have a 2008 KLR650 that's just passed 1000 > miles. Today I got the valve cover off and found that all valves > are in spec but all are at or near minimum clearance. So I'm going > to proceed with the valve adjustment. > > I've never done much maintenance on other bikes I've owned, but I > have wrenched on some 70s era VW Beetles so I've got some tools and > basic skills. I'm following the MarkNet procedure and also > referring to the 2008+ factory service manual. > > Question: The MarkNet procedure says to remove only the center 12mm > bolt and spring from the cam chain tensioner, while the factory > manual has some warning about a "non-resetting system" and its > procedure shows to remove the entire cam chain tensioning unit. The > MarkNet procedure is definitely simpler. Is the MarkNet procedure > OK for a 2008 (or newer) KLR? > > Tip: I discovered that one of those solid metal spark plug gap > tools (about the same size as a 50-cent piece) exactly fits the > slots in the plastic plugs on the left side of the engine. > > Thanks!

<><><><><><><><><><> <><><><><><><><><><> harpbone, Welcome to the list and good on you for checking your valves. I think your findings are the norm instead of the exception. I'm not familiar with the marknet instructions but I have done a few valve adjustments. You should first remove the center bolt and spring from the cam chain tensioner. Then you should remove the two bolts (one above and one below where the center bolt goes) that hold the housing to the cylinder. If you tap it gently with a soft mallet or screwdriver handle the housing should pop loose. Don't mess with the gasket surface and you should be ok for putting it back on without causing a leak. To reset the tensioner you move the small ratchet mechanism (spring loaded) so it stops engaging the teeth on the tensioner and push the tensioner back into the housing. To reinstall the housing after the valve adjustment is completed (don't rotate the engine with the tensioner out) just place the reset housing in the cylinder and tighten the bolts. Then listen carefully while you install the spring and center bolt. You should hear the tensioner adjust (clicking sounds) as you install the spring. If you don't hear the clicking try installing the spring again. If you still don't hear the clicking remove the housing and find out what's going on. Once the tensioner is reinstalled it's ok to rotate the engine (always counter-clockwise) to check the valve adjustment. Good tip on the side cover removal tool. You can also use a large flat washer if you don't have the spark plug gapping tool. 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 . ____________________________________________________________ Best Weight Loss Program - Click Here! http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTFoYakf5tYUGiv7DVEcUvOEZFJlMqfZ3Iqe6NnhEmnRwyfXrkHKgw/