I'm doing a 4000 mile maintenance ,and as a part of it , shims should be replaces (after checking gaps etc.)
anyway ,today went to replace the shim who needs to be replaced ,
removed the valve cover ,the right side "suzuki" cover , and the engine turns (using a lever) but wont complete 360 deg, it stops at about 300 deg , and from there can only be turned backwards...

tryed turning it forward and backwards about a half of an hour but to no avail ...

any advice?

I'm thinking of removing & dismantling the engish , and to do a complete check - to see what got (probably) entangled...

Ohad

A bit of clarification please. Did you remove the cams?

James

Dude... pull the spark plugs out and try it...
Cool.
Srinath.

a. nope , didn't remove anything yet.
b. will try removing the spark plugs right away, thanks for the idea!

Yea I knew you didn't take off the spark plugs...how...Cos the stoopid manuals dont tell you to take them off...You cant compress the air beyond 2 or 3:1 by hand...9:1 ... forget it.
Cool.
Srinath.

Eh....  I doubt you could turn the crank from the timing bolt by hand anyway.
With a "lever" (a socket and ratchet?) it should be able to turn even thru the compression stroke, unless he is a total wimp.  

If he didn't disturb the cams and hasn't screwed up the timing, then its possible that one of the cylinders may be hydralic locked with fuel.

This is kind of disturbing:
"tryed turning it forward and backwards about a half of an hour but to no avail ..."

#1 rule of working on an engine: If it won't turn smoothly, don't force it. Look for what is fouling it.

removed the spark plugs . but still no full rotation...
(yehp, ratchet+sucket="lever" ,sorry for my lack of correct english..)
didnt use brute force on it, either, don't have any plans on breaking anything within the engine for my lack of knoledge...


thank you

Is it in neutral?  
(yes I have done this before)

yehp, neutral, also tryed some shifting and turning the engine via back wheel....

no good...

Ok... so all you did is remove the valve cover and side cover and the bike ran fine before this? If thats the case.. then you shouldnt be hydro locked. I believe this motor turns backwards... so wouldnt it make sense to turn it clockwise? or is that backwards... ack.. i dont know.

If you did mess with the cams at all.. i would suspect a valve about to (or already) bend. (dont ask how i know what thats like).

No this motor turns forwards...same direction as the wheels do when riding...It shoud turn forwards and with spark plugs out hydro lock is not a issue. It may be quite tight. I always take out the plugs and in gear turn it with the rear wheel. It does turn over fairly easy in 6th gear.
Cool.
Srinath.

didnt mess with anything accept the shims , and it ran fine before trying to adjust them ...

the engine turns forward and bacwards ,but doesn't complete a turn , it stops short ,and can only be turned the other way around ,until it stps again , I have a motion range of about 300 deg ,instead of a complete 360 deg turns...

Take the valve cover off again.  Look for anything loose or jammed, like a cam lobe stuck in an empty bucket.

Maybe you put in too thick of a shim.. and its creating a tension on the cam lobe?

300 degrees is 150 degrees of the camshaft...so my new guess is that...
sometimes the bucket may lift out and not want to compress. The point where it stops when trying forward rotate the bucket that is about to be compressed. Once you do that it should not do it ever again. If it does you are in a spot of trouble. In fact the fact that it did it right now is a bit worrisome. I have had trouble putting buckets back in after lifting them out but rotating them usually works.
Cool.
Srinath.

today went on and removed the cams ,and as Rashad said , a broken (not bent) valve...

today will dissmantle engin head , and check all other valves , anyway, I'm qurious - can a broken valve be a sign of something else wrong?
= did I mess anything else ,especially inside the crank for example ,while breaking the valve?

by the way - right side exhaust valve , if relevant


Ohad
the vlave offender

Wow you must have really hossed' on it to break a valve by hand....

Its possible you could have bent a connecting rod or even the crank, but GS lower ends are pretty tough.

You may need a new piston in addition to the dropped valve.  Good thing you never got it running other wise the whole top end could have been destroyed.

I may be guilty 'only' of fitting  larger shims than necessary...
anyways , I'm optimistic , but will check the pistons ,also...


removed top engine block , valves are dirty with grit and whitish ash , pistons as well...

look like I'm on the road to a over-haul...

yyyypy