So, I'm doing the valve adjustment and then... - Kawasaki Versys Forum
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post #1 of 12 (permalink) Old 05-08-2019, 05:36 AM Thread Starter
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So, I'm doing the valve adjustment and then...

Doing a bunch of maintenance and small upgrades on my 2008 for the upcoming 20 day trip on Sunday(e). The bike has 42k km on it and all but one valve were within spec. the outside exhaust valve on the #2 was just at the narrow end of tolerance. So, I went to adjust it, ziptied the sprockets to the chain(that's what I usually do). While popping off one of the camshaft caps, one of the dowel pins went bouncing off. I saw it hit the dead center of the inside of the head and then I have no idea where it bounced next. I didn't hear it hit the floor. I spent over 4 hours looking for it and can't find it anywhere. I decided to pop the clutch cover off in case it went into the timing chain tower but couldn't find it. I'm pretty sure it didn't go there - took pics of the inside with the phone, looked, fished... nothing. I looked at the bottom end as well and in the oil - nada. I've tried poking around the valves since there are some crevices around the springs where it could have hidden but found nothing.
The intakes had shop towels in them and the spark plugs were in so I'm pretty sure it could have gone inside.

I'm not sure if I'm asking questions or just looking for shoulders to cry on.
Any input? Will try to source out the new gasket and another dowel pin.
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post #2 of 12 (permalink) Old 05-08-2019, 06:36 AM
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Ouch!

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post #3 of 12 (permalink) Old 05-08-2019, 07:35 AM
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I've never actually checked but assume the dowel pin is magnetic. Have you probed around with a magnetic extension probe?
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And most of Canada too, eh?
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post #4 of 12 (permalink) Old 05-08-2019, 01:41 PM Thread Starter
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It is magnetic. And yes, I've tried.
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post #5 of 12 (permalink) Old 05-08-2019, 03:56 PM
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Have you tried turning it upside down and shaking it?
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post #6 of 12 (permalink) Old 05-08-2019, 04:52 PM Thread Starter
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Have you tried turning it upside down and shaking it?

Of course. First thing I tried! lol
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post #7 of 12 (permalink) Old 05-08-2019, 05:37 PM
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See this thread - parts like this can end up in the oddest places, hiding in the shadows (like in the radiator shroud, as in post #13 of the linked thread):

https://www.kawasakiversys.com/forum...djustment.html

I suggest getting a camera and taking lots of pictures all over the bike, then examining the pictures carefully for clues on where to look. I like to take pics both with the flash on and again with the flash off to help with searches like this

Last edited by leftbrain99; 05-08-2019 at 06:17 PM.
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post #8 of 12 (permalink) Old 05-08-2019, 09:36 PM
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I know how small those things are but it's possible it just went somewhere other than into the engine. I've had bolts fall down and, for the life of me, can't ever see where they went. Then I look in between the rear spring/engine/chain guard/etc...and there it sits!

I'm sure you've done all this searching but, just in case you haven't!
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post #9 of 12 (permalink) Old 05-09-2019, 05:34 AM Thread Starter
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Thanks, guys. Yeah, I'm hoping(and thinking) it went somewhere weird. Little mechanical things always bounce and land in the weirdest ways!
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post #10 of 12 (permalink) Old 05-10-2019, 04:16 PM
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...Little mechanical things always bounce and land in the weirdest ways!
Ain't THAT the truth...!


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post #11 of 12 (permalink) Old 05-10-2019, 07:04 PM Thread Starter
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FOUND!!!

It WAS in one of the valve spring crevices. In fact, right next to where I saw it bounce(middle) near the intake valve on the inside of the #1 cylinder.
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post #12 of 12 (permalink) Old 05-10-2019, 07:22 PM
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Locktite the buggers in
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if I'm answering your question I assume the basic points have been addressed, such as: did you do a compression test? is it still on fire?
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