Hello,

I've been doing valve edjustments on my '04 gs500f and everything went fine, until....
1. After taking off camshafts to and replacing shims underneath I realized that I don't have instructions on how to align camshafts back. '02+ model has a slightly different marks on the crankshaft. I've put everything back together as seemed appropriate (just aligning the marks on the crankshaft), but it ran poorly after putting everything together.
2. When following instructions from this forum on how to properly align shafts I've dropped the washer that sits on the left part of the intake camshaft in to the crankcase. And yes, it fell all the way through.

Now, I need to take out that washer. I assume that I would need to drain the oil  and then open the crankcase. Check if the washer is easily accessible and remove it.

Can you tell me what else do I need remove in order to find that washer?
Do I have to replace the gasket on the crankcase?
Is it easier to take off left or right crankcase cover?
Would there be more to it than just opening the crankcase ? What if the washer is not "easily accessible"?

(Can I just turn the bike upside down and shake it vigorously so the wahser will fall out?)


Thanks,
--Sasha

The pan can be removed and the washer should be in it if it fell all the way down.
Cool.
Buddha.

>The pan can be removed and the washer should be in it if it fell all the way down.
>Cool.

Thanks.

Is there a gasket the needs to be replaced there?

My next questions is where can I get the camshaft alignment info?
The pickup is located on the right side, and not on the left side as most instructions say.
They also mention that I should align "RT" mark, but on the actual plate it has the notch, and (clockwise), after the nothc, it says "R . T || ".

Which part of the text or notch should I align?

Thanks,
--Sasha

Hi there,
I guess you also now know that you DON'T have to remove the cams to replace shims, right?
You can use a shim installation tool that presses the shim bucket down so you can remove and replace the shims.
But you know that now, right?

And also, whenever I do a valve adjust, I ALWAYS tuck clean shop rags into the engine cavities around the valve shim pockets so nothing can drop down there.
Sorry you had this experience.
I hope you get it resolved quickly.

Yours,
Todd

> you DON'T have to remove the cams to replace shims,
> tuck clean shop rags into the engine cavities around the valve shim pockets so nothing can drop down there.

After searching this forum - yes, I do know these things now.

> Sorry you had this experience.

I consider it fun and learning and I don't regret because I really enjoy working on the bike.
Bike is not my primay transportation, so it ok for it not ot run for a while.

Thanks,
--Sasha

Yea oil pan gasket ... prolly $10 at dealer. be careful when you take it off, make sure you get all bolts off and dont pry the edge too much. Also clean oil screen when you're in there.
Cool.
Buddha.

(short summary of the problem: dropped a washer inside the crankcase)

So I removed the oil pan, and there is nothing in it. I also have looked on the metal mesh filter that sucks in the oil, and there is nothing on top of it either.

From looking at the diagram ( http://cgi.stanford.edu/~sanjayd/gs500/Main/CrankCase ) , washer fell inside the hole that takes in the chain. So it should be located somewhere inside the crankcase.

I've turned the crankshaft, and it turns freely. Can I just leave the washer inside ?

Is taking apart the crankcase the only way to get it out? I guess I have to take the engine from the frame and remove the cylinder head, correct?


Thanks,
--Sasha

If you leave the washer in the crankcase, not knowing exactly where it is, you may find it someday when you're @ 8,000 rpm's.  Actually, your engine will find it and try to gobble it up.  I  would get one of the extension magnets and drop it down the hole the washer fell into.  You may just get lucky and pull it out!  I'd be afraid to leave it in, but then again, I'm paranoid like that!

I'm not sure what to disassemble in order to remove the washer (I am sure someone will chime in with this info), but I agree with lewismug that you don't want to find the washer at 8000 rpm.

I know it's a hassle to deal with right now, but it might cause much more expensive/dangerous problems later if you ignore it. 

I like the idea about the magnet (assuming it's a steel washer)... I hope it works out!   

You can try one of those magnets that has the long flexible handle.Go down through the head where the cam chain runs and then go around inside the case after removing the oil pan.Are you sure it didn't come out when you pulled the oil pan?It could be in the oil that was drained out.Another thing to try is lifting the rear of the bike(on a hill) and bouncing it.the try it the other way.The washer can't go forward to far,but back in can go a ways IIRC.