givi bags for sale

[Bill Holton]

Ok guys I need help. I just finished rebuilding the top end on my A3. Had the valves reworked at a bike shop for $90.00, New seals and seating. I was careful to make sure the arrows were pointed forward on the Cams when I installed the timing chain. I checked the valve clearances and they were within spec. Put it all back together. Added coolant, new plug (set gap) I started the first time today, with help from a can of starting fluid. It runs if I keep on the throttle back and forth, very rough. Something strange is going on. I seem to be getting exhaust out of my Air intake. And its backfiring. Seems like it is white smoke from the tail pipe. What's wrong, or could be wrong. Thanks Bill Holton Pearland, Texas KLR650 - A3 [Non-text portions of this message have been removed]

[BCSavWill@cs.com]

Hi, Er, not to state the obviouse or seem to hard Was the crank at tdc when you aligned the marks, try checking again to see. Did you set the timing with the front of the cam chain tight? Did you check the timing after you replaced the cam chain tensioner? White smoke in the exhaust can indicate a head gasket coolant leak. But the sound of backfiring thriugh the intake I might put money on cam timimg. Brian KLR A14 KLX C1 TE 410E Honolulu, HI [Non-text portions of this message have been removed]

[Bill Holton]

Yes, I did have it set to TDC. (It felt like my air intake was the exhaust, definitely not good!) I am not sure about having the cam chain tensioner in at the time or have it tight at the front when I checked for clearance. I hope to have time tomorrow to take the cover back off and recheck the timing and clearance. One of the exhaust valves had a clearance on the low side. I figure if they are too tight, the valve might stay open and leak exhaust through to the carb? thanks for the advice. This whole thing has been a first for me. Ill let the group know the outcome... - Bill Holton - A3

----- Original Message ----- From: To: Cc: DSN_klr650@yahoogroups.com> Sent: Tuesday, November 13, 2001 7:13 PM Subject: Re: [DSN_klr650] rebuilt A3 problems > Hi, > > Er, not to state the obviouse or seem to hard > > Was the crank at tdc when you aligned the marks, try checking again to see. > Did you set the timing with the front of the cam chain tight? > Did you check the timing after you replaced the cam chain tensioner? > > White smoke in the exhaust can indicate a head gasket coolant leak. > > But the sound of backfiring thriugh the intake I might put money on cam > timimg. > > Brian > KLR A14 > KLX C1 > TE 410E > Honolulu, HI > > > [Non-text portions of this message have been removed] > > > Checkout Dual Sport News at > http://www.dualsportnews.com > Be part of the Adventure! > > Visit the KLR650 archives at > http://www.listquest.com/lq/search.html?ln=klr650 > > Post message: DSN_klr650@yahoogroups.com > Subscribe: DSN_klr650-subscribe@yahoogroups.com > Unsubscribe: DSN_klr650-unsubscribe@yahoogroups.com > List owner: DSN_klr650-owner@yahoogroups.com > > Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/ > >

[Bogdan Swider]

> I am not sure about having the cam chain tensioner in at the time or have > i > tight at the front when I checked for clearance. >

Let me think. If you removed the cam chain without disabling the tensioner it could move out all the way. When you tried to re-installed the chain it thus would be too short/tight if it was a fairly new not stretched chain. That would show up how ? Seems it wouldn't go on or go on tight and then stretch prematurely. Still shouldn't effect the timing. Have I got this right? It's been a long day. Did you turn the engine over manually before starting it ? Did all line up ok ? Did it turn easily and smoothly ? Anyway you should take the entire tensioner mechanism out and reset it. Only a 15 minute job. Wonder if the shop that did the valves messed up. Do let us know. Bogdan

[Jim Hyman]

Bill, The arrows on each cam sprocket must point toward the front of the engine and line up with the gasket surface on the top of the cylinder head when the crankshaft is at top dead center (TDC). See page 3.8 in the BASE service manual for a diagram that shows the correct alignment. You didn't say what valve clearances you used for the intake & exhaust valves. After everything was installed, did you rotate the crankshaft 2 or 4 full revolutions & then double check the valve clearances? If one of the intake valves is not fully closed, you will have blow back through the open valve, back through the carb & airbox. Did you perform a compression check? White smoke coming out of the exhaust indicates that coolant is leaking into the combustion chamber & being burned. A leaking head gasket or a crack in the cylinder head are the most likely causes. I assume that you properly torqued all 11 of the cylinder nuts & bolts in the proper sequence. Was there any other engine work done during your rebuild? Did the shop grind the valves? Did they cut new valve seats? Were the reconditioned valves tested for leakage after the shop work was done? Was any carb work done? When you remove the valve cover again, the first thing you should do is to check the cam chain slack, then the cam/crankshaft timing & finally the valve clearances. Bogdan is clearly NOT PUI/PWI, once you've checked these things, I would remove the cam chain tensioner, reset the tensioner, and re-install it. Check again for proper cam chain slack. Any changes? I agree with Brian, my money is on improper cam timing & a coolant leak. A leak-down test can determine if any valves are leaking. You can use a Mity-Vac (hooked up to the spark plug hole) to help determine if there is a leak to the coolant chambers or the head gasket. If the cams are mistimed, you might have nicked one or more valves. Professor A9 Federal Way, WA. [USA] ++++++++++++++++++ Bill wrote: Ok guys I need help. I just finished rebuilding the top end on my A3. Had the valves reworked at a bike shop for $90.00, New seals and seating. I was careful to make sure the arrows were pointed forward on the Cams when I installed the timing chain. I checked the valve clearances and they were within spec. Put it all back together. Added coolant, new plug (set gap) I started the first time today, with help from a can of starting fluid. It runs if I keep on the throttle back and forth, very rough. Something strange is going on. I seem to be getting exhaust out of my Air intake. And its backfiring. Seems like it is white smoke from the tail pipe. What's wrong, or could be wrong. =================== Brian replied: Was the crank at tdc when you aligned the marks, try checking again to see. Did you set the timing with the front of the cam chain tight? Did you check the timing after you replaced the cam chain tensioner? White smoke in the exhaust can indicate a head gasket coolant leak. But the sound of backfiring thriugh the intake I might put money on cam timimg.

[Ted Palmer]

Walter Lesnowich wrote: [...]

> It sounds like you have the ignition 180 degrees out.

d=:-O

> There are two TDC's.

As far as cams are concerned, yes, but the TDCs are 360 crank deg apart.

> You must be at TDC, both cam gear marks aligned > with the head facing foward AND ignition. > At TDC, both cam gear marks aligned with the head > facing backward, NO ignition.

The ignition trigger is on the flywheel, not a cam, so anytime the crank is in the right spot there is ignition. "Waste spark" is one name for that system. Firing the plug at TDC on the exhaust/intake stroke overlap doesn't hurt anything, not in this engine at least. All this assumes that the ignition pickup in the alternator cover has not migrated somehow. Mister_T Melbourne Australia

[bobk8844@yahoo.com]

FOR SALE Black Givi hard bags with Happy Trails mounting rack. Cost over $500. Sell $300 plus $35 shipping. Located in Tucson, AZ Bob Kerry 100 N. Bella Vista Dr. Tucson, AZ 85745 520-792-1370