Stuck Shim

[93Bandit]

I'm adjusting valves on my 750 and the new shims I ordered from Z1 don't have rounded edges like the OEM shims. this makes them a little tighter fit in the bucket. After installing one of the new shims, the valve clearance is still too tight. Double checked my numbers but it's the correct shim size so I tried to remove it and it's stuck in the bucket. I suspect it's not sitting level in the bucket and isn't fully seated causing it to get stuck. I've turned the engine over probably 60 times trying to get the cam lobe to work it loose. I've tried prying it out with a screwdriver and gave it some light love-taps with a small hammer. It will not budge.

I thought about starting the bike and letting it run and get hot hoping that would free up the shim, but the bike doesn't run right now.

Anything else I should try before pulling the cams? I really don't want to go that far in if I can avoid it.

[zed1015]

I find using one (or two) of those telescopic pen magnets allows you to more easily lift a snug fitting shim square rather than prying on an angle with a screwdriver.

[allojohn]

Shims are occasionally labeled wrong, even OEM. Good luck with Zed's method to remove.

[93Bandit]

I find using one (or two) of those telescopic pen magnets allows you to more easily lift a snug fitting shim square rather than prying on an angle with a screwdriver.

I don't know man, this sucker is stuck. But I'll give it a go and see if it works. Appreciate the idea.

[Burque73]

Instead of running the engine, which you can't do anyway, maybe a heat gun or torch on that spot would help.


Curious if you used a zip tie. I've had readings not add up after changing shims even after carefully measuring thickness of unmarked (or incorrectly marked shims. Just assumed it was carbon dislodged and under the valve seat. Possibly oil under the shim. Either one would eventually rectify itself while riding, I suppose. I trusted my method and measurements and moved on. Haven't burned any valves yet. Knock wood!

[93Bandit]

Instead of running the engine, which you can't do anyway, maybe a heat gun or torch on that spot would help.


Curious if you used a zip tie. I've had readings not add up after changing shims even after carefully measuring thickness of unmarked (or incorrectly marked shims. Just assumed it was carbon dislodged and under the valve seat. Possibly oil under the shim. Either one would eventually rectify itself while riding, I suppose. I trusted my method and measurements and moved on. Haven't burned any valves yet. Knock wood!

I thought about using a torch, but I'm not too sure if it'll damage any or not? I guess it shouldn't, it's all metal in there anyway. I wouldn't get it too hot, just warm everything up.

As for method, I use my Suzuki special tool instead of zip ties. If there were a chunk of carbon holding the valve open, it would increase the cam to shim clearance instead of decrease it like it is in my situation. I've got a thinner shim, but the clearance will be way out of spec loose, probably around ~0.150mm. I don't know what I'll do about that yet, gotta get that shim out first.

[Burque73]

I thought about using a torch, but I'm not too sure if it'll damage any or not? I guess it shouldn't, it's all metal in there anyway. I wouldn't get it too hot, just warm everything up.

As for method, I use my Suzuki special tool instead of zip ties. If there were a chunk of carbon holding the valve open, it would increase the cam to shim clearance instead of decrease it like it is in my situation. I've got a thinner shim, but the clearance will be way out of spec loose, probably around ~0.150mm. I don't know what I'll do about that yet, gotta get that shim out first.

Good point.

Maybe a suction cup? Like a valve lapping thing. Of course, you'd have to remove the cam though.

You could just load your bike up onto a trailer and drive under this thing.



It'll yank it right out!

[chuck hahn]

if you can rotate the bucket you should be able to see if its seated right or not. If it is sharpen a nail real good and tap it under the shim through the buckets notch.

[storm 64]

Maybe a blast of compressed air might flutter it loose. 🤔

[93Bandit]

if you can rotate the bucket you should be able to see if its seated right or not. If it is sharpen a nail real good and tap it under the shim through the buckets notch.

I like this idea, I will add it to the list of things to try!

[93Bandit]

Maybe a blast of compressed air might flutter it loose. 🤔

Hmmmmmm... Easy enough to try.

[xkaes]

Have you been using a tappet depression tool?

tappet.jpg

[xkaes]

They are easy to get -- but somewhat more difficult to use:

tappettool.jpg

[93Bandit]

Have you been using a tappet depression tool?

[ATTACH=CONFIG]63738[/ATTACH]

Yes. As previously mentioned, I have the suzuki OEM tool that I have been using. I haven't had any issues with it like others mention on here.

[33oneill]

I had some issues w removing a shim. I used a utility knife w a new blade to break it loose thru that notch in the bucket.