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August 9th, 2012, 01:50 PM   #1
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Help! - Valve cover stuck FS650

Ok I have taken apart my kickstart mechanism to apply some upgrades, transmission cover off, clutch of. therefore no connection between primary drive gear and the balancer drive gear. Removed the valve cover in order to inspect the auto decomp ande valve springs etc. Turned the engine and possibly the camchain aswell. Mounted the valve cover back on to the engine in order to adjust valve clearens end check the timing. The cover clicks on to place. Then i cant turn the cam around. Assemble clutch in order to move the whole package around. Cannot get the marks on the gears to line up. Something is not working in the top cylinder parts. Trying to disasemble the valve cover again but its stuck on something. Something on the camchain end. I am thinking the auto decomp got out of place or something. When trying to lift the cover the entire cam whants to come of.

What did i do wrong? And most importantly how do i fix it? Get the cover of that is... not so keen on cutting he chain with the angle grinder.
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August 10th, 2012, 12:51 AM   #2
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Re: Help! - Valve cover stuck FS650

silly boy!

what year?

Taffy
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August 10th, 2012, 11:12 AM   #3
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Re: Help! - Valve cover stuck FS650

It´s an 02. Further inspection reveals that something is probably hocked up on the intake rocker arm close to the chain side of the lid. Thinking about pulling the rocker arm out and see if that helps.. Thanks...
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August 12th, 2012, 04:31 AM   #4
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Re: Help! - Valve cover stuck FS650

Remowing the intake rocker arm did the trick. It was out of place and the axle was stuck inside one of the holes of my timing sprocket, which has holes in it and does not look like the one in the parts manual (200 276-01). But on the other hand the parts manual also covers the 01 models so that might be whats on display. So lets hope i have better luck/skill putting it back together the second time up. Thanks Taffy for your reply.
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August 12th, 2012, 07:24 PM   #5
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Re: Help! - Valve cover stuck FS650

Ok, AFTER reading the workshop manual the holes were supposed to be there. Who whould have known. A steel gear replaced the solid alu gear on late 2002 and 2003 models. This whould also mean I could mountone of your later model of autodecomps straight on without having to machine anything? Right Taffy?
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August 12th, 2012, 11:33 PM   #6
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Re: Help! - Valve cover stuck FS650

you're right - kind of. the cams had a thick shoulder on them until 2003. so you'll have to see if you have a shoulder poking through by 2mm or not.

get rid of the shoulder at an engineers and you'll be OK to fit it.

regards

Taffy
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