Okay. I got my camshaft out today, still hoping I don't have to pull the head.
As you can see in the pictures, the rocker arm is not bent, but that left valve definitely has some damage done to the retainer and keepers. Maybe you can't tell by the pictures, but the left valve is definitely sitting higher than the right valve. Just by eyeballing it, the valve stem seems to be sitting the same height above the keepers on both valves also. So I still don't understand what is making the left valve sit higher unless it is damage in the head to the valve seat. Do any of you experts think I can fix this problem without removing the head? If so, how? As always, I'm open to any suggestions.
I've never pulled a head myself, but I really don't see this problem being resolved from the rocker side of that valve.
Illegitemi non carborundum est!
Fee-Lloyd.... it's obvious from the pictures that the top of the valve stem on the left valve has been hammered.....ham-mered.
This all goes back to the adjuster lock nut not being secured properly, allowing the adjuster screw to loosen up, go UP, creating a huge gap between the valve stem and.... eventually a unscrewed adjuster screw.
IMO, the only reason that the hammered valve stem on the left would be sitting higher than the unhampered valve stem on the right, is due to head damage at the valve seat....or.....if you are the luckiest hominid on terra firma, then the damage is isolated to only the valve itself.
Final task before removing the head:
Put THAT cylinder at Top Dead Center.
Use a valve spring compressor to compress the valve spring on both the left valve, and the right valve.... remove the valve stem keepers....do not lose them.
Remove the valve springs, then.....with your index finger and thumb, rotate the valve stem on each of those valves...spin the valve stem smoothly in both directions. Does the right valve stem feel smooth, feel like it is straight?
Now do the left valve... spin it between your index finger and thumb, rotate it both directions, does it feel smooth?
Does it feel STRAIGHT?
Now, pull UP on each valve stem, and measure the height of the valve stem....and compare the two valve stem HEIGHTS.
Tell me what you have found.
Two Million Mile Rider...All 7 Continents
Exploring the World in Comfort
Not much other than a damaged valve seat in the head... I suppose the valve could have stretched, but highly unlikely.
Compression on that cylinder, before you pulled the cam?
FM's recommendations for pulling the springs off the two valves and comparing them is sound. You could also pressurize the cylinder and see if the valves leak. If yes, well, you will be pulling the head for a valve job.
Intake or exhaust? If exhaust, maybe pull the pipe and look at the valves with a light... If intake, pull the carbs/intake boots and look in from that side.
You'll likely need to remove that stuff anyway, once you decide to pull the head.
Maybe a one in a million chance the keepers are damaged on the high valve, and allowing the spring retainer to be higher than the other one. Doesn't look very likely, though, from the pics.
If that valve seat fell out or is loose it would keep that valve stem lowered. As far as the valve seat being damage that far to let that valve sit higher in the seat it's highly unlikely.
Early versions of this engine had an issue with soft material in the valves. This created an issue of "valve tuliping". Basically the valve head would cup allowing the stem to reach further up. I thought it was resolved well before '00? I can't remember if it was intake or exhaust valves that had this issue.
But yes, either the valve has stretched or the seat has recessed into the head. I don't remember any seat issues, but I haven't done anything with Kawasaki since the late '90s. A look in the exhaust port might give you an indicator. As would using a camera in the spark plug hole.
Will keep paws crossed it is only the valve. Either way the head will need to come off.
Hold my keyboard and watch this! 🙃
one more possibility, perhaps? have you had this from new, that is, is it possible that someone else has put in a quick and dirty valve fix using a valve with a longer stem?
weirder things have happened than that.
one more possibility, perhaps? have you had this from new, that is, is it possible that someone else has put in a quick and dirty valve fix using a valve with a longer stem?
I bought this rig last April from a fellow USCA member in Florida. It's a 2005 Concours. It had about 25,000 miles on it and I've put over 4,000 on it. The P.O. said that he had put about 15,000 on it and had never done a valve adjustment. So, with about 20,000 miles and no valve adjustment I decided it was past time to take a look. Several people on the Concours Owners Group forum also mentioned earlier models have issues with valves because of soft material, but that issue was supposedly resolved in the later models like mine.
Floyd
Did you hear any valve ticking noise or any strange sound out the exhaust.
Did you hear any valve ticking noise or any strange sound out the exhaust.
I didn't notice any noises like that. I suspect the adjuster of that valve came out shortly after I bought the rig or maybe even before and I wasn't familiar with any out of the ordinary noises. I'm not suggesting that the P.O. know about this problem. I felt like he was very open and honest with me and its just one of those things that happened as a used bike purchaser.
Curious, with the adjuster getting loose and falling out there should have been some noise, loud ticking.. When this happens I have seen this bend the top of the valve ( ever so slightly )which can then wear the guide due to the sideways forces.. This then causes the valve to walk around causing undue wear on the valve seat its self. Which of course then causes the valve to recess into the head.. Hence the lack of clearance which then causes the valve its self to erode ( burn) making the problem worse.. OR I am way off base and it is just a bad valve, just cause the manufacturer identifies weak parts and supposedly fixed things doesn't mean the bad parts still didn't get into the production line.. Ask how many times I've seen that. Shite happens, either way the head is coming off to do a proper fix.. Good luck
Actually rethinking it,, With that style of rocker set up there may not have been much noise.. Some but not loud..
either way the head is coming off to do a proper fix.. Good luck
I'm in the process of taking the head off, but keep getting interrupted or running out of time. Plus it's not very comfortable here in Northern Illinois in my unheated garage and I keep finding excuses not to go our there and work on the bike.
@floyd-h Motivation for a cold day: When it is warm enough to work on it, you'd rather be riding it! 🤣
FWIW
I rebuilt a Chevy 6 cyl and a couple of v8's in an unheated garage in Nebraska, in my youth. Amazing how much fun -20F is to grab wrenches with your bare hands. Not likely to repeat that!
Local auto parts store, or Lowes, or Home Depot.....a box of nitrile gloves.....or latex gloves if nitrile gloves not available.
Keeps your hands warmer, and cleaner.
You will thank me later.
Two Million Mile Rider...All 7 Continents
Exploring the World in Comfort
