Noob notes: the 6 hour valve check

[Egaeus]

I just take the tank off with the fuel in it.  Why drain it?  Sure, it's heavier, but 35 lbs. isn't that bad.

[DGBone]

My point and what I did exactly Egaeus. Next time, however, I will not top off the tank before doing a job that involves removing the tank    doh!
(I have a habit of thoroughly topping off the gas tank before putting the bike away, to minimize rust buildup in the tank).
But I agree with ya. Draining the gas? C'mon, lifting the GS gas tank, even when full, is no big deal.
I was just trying to be constructive here.
Cheers,

[Egaeus]

Yeah, removing a topped-off tank can be messy unless you have a tank cradle.

[DGBone]

Yeah, removing a topped-off tank can be messy unless you have a tank cradle.

Agree. Still, probably no messier than draining/pouring the gas, don't ya think?

[Admiral Crunch]

My first valve adjustment took two weeks.   

First, I fabricated a hand tool out of aluminum to push down the buckets.
Then I made another one out of steel like I should have done the first time.   
All the shims were out of spec, and I had no idea what size any of the existing shims were, so I popped them out one by one to see what they were.
For the ones that were too tight, I had no idea what size I would need, so I guessed and ordered some a little thinner than what I had, and I also ordered a super-thin "test shim" so I could measure properly.  Of course, I guessed wrong, so I had to order more shims.  Another week goes by, and I get my second batch of shims, and I can FINALLY put the bike back together.

Note to anyone who hasn't done their first valve adjustment yet:  have a thin test shim BEFORE you start to take the bike apart.   

[indywar360]

>>New clutch lever (unable to remove old one due to stripped nut/bolt from impact, considering buying dremel tool)


the last five hours have been a painful ordeal that would rival any POW or survival story.

I started by sawing the clutch lever bolt head first one way, then another way, making an X in it. Then I pried off the 4 quadrants with a wrench. Continued sawing and started banging on it using an interchangeable screwdriver (cheap kind with removable rod) as a chisel, and a crescent wrench as a hammer. Later progressed to using my ratchet wrench as a hammer, and went to the hardware store and got a "punch".

Continued banging on it, often using a section of 2x4 as a hammer. (I thought I had a rockworking hammer at home, but when I got home I realized I threw it out.)

By this time the mount for the clutch lever itself is notched, sawed in places, and the bare metal is showing through.

Now I start chiseling the bolt head's edges so it goes flush with the hole. Apparently the metal is blending in with the lever mount now and it's all a mass of shiny jagged pockmarked metal all mashed together. Still banging on the top. Still won't budge.

Keep in mind every 3rd or 4th strike goes on my left index finger.

I am getting really pissed and tired and after a break for Taco Del Mar and another trip to the store (now closed) I give up. I am just going to ride the mother f%$ker with the head cut off the clutch lever bolt. f%$k you.

Going to order a new mother f%$king clutch lever mount and f%$k the old one. God damn mother f%$king son of a Buddha Loves You.

I guess what I should have done was buy a drill (?) or a dremel tool, although I can't see either of those tools sparing the virginity of the clutch mount. f%$k it.

Oh, and my socket extension is no longer functional since I used it as an extension for the punch and banged the tip out of square. Likewise the aforementioned interchangeable screwdriver has its rod driven into its own handle and coming out the back. So, total cost: ratchet extension, screwdriver, punch, clutch mount = way too much mother f%$king money for this goddamn piece of shaZam! bolt.

All thanks to some deaf lady who spun out her Jeep in front of me on the fwy.

Was found 0% at fault by my own insurance company, btw. Other co. has yet to pay or even call me.

[Foreverunstopable]

Keep in mind every 3rd or 4th strike goes on my left index finger.

I am getting really pissed and tired and after a break for Taco Del Mar and another trip to the store (now closed) I give up. I am just going to ride the mother f%$ker with the head cut off the clutch lever bolt. f%$k you.

Going to order a new mother f%$king clutch lever mount and f%$k the old one. God damn mother f%$king son of a Buddha Loves You.

I guess what I should have done was buy a drill (?) or a dremel tool, although I can't see either of those tools sparing the virginity of the clutch mount. f%$k it.

Oh, and my socket extension is no longer functional since I used it as an extension for the punch and banged the tip out of square. Likewise the aforementioned interchangeable screwdriver has its rod driven into its own handle and coming out the back. So, total cost: ratchet extension, screwdriver, punch, clutch mount = way too much mother f%$king money for this goddamn piece of shaZam! bolt.

Its a right of passage in the long experience curve of becoming your own mechanic. Everyone who has ever picked up a tool has had this happen at least once. Usually at the worst time in the worst place under the worst conditions compounded be rage, pain and a general attitude that your either going to fix the part or die trying. Murphy's Law. When this situation happens its best to walk away before blood shed, cool off and return with a better angle on the situation. Good to hear you have enough guts to do the valve check/carb clean, saved some $ and learned something in the process.  Next time it will go much smoother! If you plan on doing more work on the GS it would be best to get one of the manuals available, PLUG, like the one we have listed on the main page.

http://www.amazon.com/exec/obidos/ASIN/0892878339/ref=nosim/gstwincom