How to shim 82 Xj650?

I have 2 new valve cover gaskets. (One extra to measure and reinstall the cover while I await my replacement pads) - A valve shim tool and a basic understanding of how to shim the valves. Youtube videos. But when i put the valve covers back on, what order do I tighten the bolts back on and what are the supposed to be torqued too? I don't want to crack anything.

 

Torque is 7.2 ft/lbs. tightening sequence is on page 107 of the Haynes manual. I'll try to post a picture of the sequence tomorrow. I get my shims from the local Kawasaki dealer, 29 mm shims are used by the 2014 KLR 650 and are usually in stock at the parts department. I take it apart in the morning, do my measurements, go to the shop and get the required shims and complete the job the same day. Good luck. These are great motors, with regular maintenance they run for a really long time. I have over 50,ooo miles on my Seca and it is still going strong. Shims are the only thing I don't order from Chacal. You can't beat his service and the parts are top quality.

Gary

 

Make sure to get NEW valve cover donuts. If you don't it will probably leak. Also, check at the half-moons and see if there are any sharp edges or burrs...dress the burrs if they are there--they'll cut the new gasket and it'll start leaking shortly otherwise.

Now, once the new bolts/donuts are on, run them down til they all just stop. they have a shoulder that prevents them from drawing down to far. Once they are all lightly bottomed out, just go around and snug them a little bit. You'll probably see the new valve cover gasket "plump" a teeny bit all the way around.

You don't need a "torque sequence" for this, but basically work it in an "X" pattern and you'll be fine.

A light smear of elmers glue in the cover groove will also help hold the gasket in place. let it get a bit tacky first, then install the cover. The glue will also push into any tiny irregularities on the top of the gasket and seal those, too.

Dave F

 

Those 29 mm shims will fit in an 1982 xj650 lol? Thats cool. How much are they at the dealership? I don't want to wait on ebay. Haha

 

Thanks man!

 

If you get your measurements, let me know what sizes you need. I run a shim pool and if I have used ones in those sizes, it's a swap except for mailing costs . The pool works this way---- a deposit for each shim is required, once deposit is sent I send out your shims .... You do your swap and send the used ones back. Then your deposit is returned. If I don't have used ones, I do have some new ones that are purchased but I give a discount for each used shim sent to me for the pool.

Start a conversation with me....

Btw, my sister is in Dallas ( well, just outside of Dallas)

Dave

 

Alright ill see about getting those measurements next Saturday and see what we can work up. Thanks Dave.

 

And Dallas is where its at man! Haha

 

Naaaaa....ya can't ride snowmobiles down there------well, NORMALLY you can't, this past week might have been an exception..... Lol

 

Do I need to use any RTV on gasket? And which kind

 

You can if you wish.....but you don't need to, as long as you make sure the aluminum is very clean, degreased, and dry.

THAT being said, I personally DO use an rtv..........I like the permatex Black. I put the thinnest layer down that I can possibly make, and I try to keep it spaghetti-thin....right in the center of the aluminum. I haven't had any leaks.

The reason for NOT using it--you're gonna be taking it off again in 5,000mi, so you want it to lift off and be re-usable.

The reason FOR using it--so you don't end up with a leak

The reason I use such a thin layer- so hopefully I won't have any leaks, AND i'll be able to lift it w/o too much trouble. So far, so good---- But then, I haven't had leaks on ones that just got the new donuts, either......

YMMV

 

I'll send you those measurements today. I got them last night, I did notice that the cam chain was slightly rubbing the valve cover though. Ha. The new valve cover gask i was sent is the wrong size. So I had to put the old one back on. Leaking about the same amount it was before lol

 

I need 2x 255 for exhaust and 2x 255 for intake and a 240... The rest can be moved around. I think. Can you take out a shim and not damage the lobe. So you can exchange between valves? If not I need 2x 255, 2x 260 for exhaust and 2x 255 and 245, 240 for intake.

 

I would not remove a shim and then spin the crank. Consider that the face of the shim is nearly perfectly smooth and coated in oil to prevent abrasion (as much as it can be prevented). Remove the shim and now the lobe of the cam is contacting the valve stem directly, which brings the sharp edges of the stem into contact with the smooth surface of the cam. This causes wear, rapidly, as in one revolution could cause enough damage to shorten the life of the cam lobe.

 

i know a guy who has plastic shim blanks that solve that problem. they say he has everything for XJ's and he ships real quick