Stuck Shim

[93Bandit]

I was able to get the bike to start and run today, so I ran it up to op temp. I'll see if that freed up the shim. If not, I'll start down the list of suggestions from all you guys. Thanks for the help!

[chuck hahn]

I have the genuine factory bucket tool now. Had the motion pro one but after a while the edges start wearing off at which point it continually slipped off the bucket. OEM tool is made of hardened steel while moton pro tool is no where near the metal quality of the real deal.

[93Bandit]

I have the genuine factory bucket tool now. Had the motion pro one but after a while the edges start wearing off at which point it continually slipped off the bucket. OEM tool is made of hardened steel while moton pro tool is no where near the metal quality of the real deal.

Huh... After reading this I checked which tool I have. I have the motion pro tool. I bought it years ago and thought it was the OEM Suzuki tool, but apparently it isn't. Where did you get your genuine one? My motion pro tool still has sharp edges but I'm sure it'll wear out eventually.

[chuck hahn]

Came with the factory shim kit i bought. has the factory tweezers for shim removal too.

[93Bandit]

Came with the factory shim kit i bought. has the factory tweezers for shim removal too.

Ah, are you the one who bought the shim kit that was posted here a year or so ago? Lucky man.

[chuck hahn]

that was me....

[93Bandit]

you lucky dog you.

[93Bandit]

Finally got the stuck shim out. It's a 2.65 and was too tight despite my calculations. So I put in a 2.55 and it's too loose, 0.125mm. I don't have another 2.60 shim to use. 0.125mm is quite a bit out of spec but I read somewhere on here that these motors can tolerate up to 0.150mm on exhaust valves. Can anyone confirm?

[sacruickshank]

Finally got the stuck shim out. It's a 2.65 and was too tight despite my calculations. So I put in a 2.55 and it's too loose, 0.125mm. I don't have another 2.60 shim to use. 0.125mm is quite a bit out of spec but I read somewhere on here that these motors can tolerate up to 0.150mm on exhaust valves. Can anyone confirm?

In another recent thread, Nessism stated that .11mm was fine and that similar Kawi engines allow .15mm on exhaust. That being said, I have all mine under .08mm

[93Bandit]

In another recent thread, Nessism stated that .11mm was fine and that similar Kawi engines allow .15mm on exhaust. That being said, I have all mine under .08mm

Ah, that sounds about right. All other valves are under 0.08mm, but this one is on the loose end. If I had the right shim handy I would swap it but I don't and I don't want to pay the shipping for one shim. I think I'll run it and see what happens. Loose is better than tight...

[93Bandit]

I realized I never shared how I got the stuck shim out. I tried all the suggestions but nothing would get that shim out. So I lined up the cam timing marks, removed the intake cam and chain idler assembly, then removed the bucket. I put the bucket in my freezer for a while, then heated the bucket with a torch and tapped on the lip of the shim. Still wouldn't budge. Tried that several times with no success. Starting getting frustrated so against better judgement I used a small sharp flat head screwdriver and smacked it harder than I probably should under the shim and it finally popped out. Carefully inspected the bucket and shim for damage but both were fine.