Stuck valve cover

I could not remove the valve cover on my 1978 KZ1000A2 1015cc stock engine, without first removing the timing chain idler pully. The manual did not say it was needed to be removed in order to remove the valve cover.

1. Could there be somthing out of wack with the engine mounts?

2. Could the frame be bent?

3. Could this be normal?

4. Could it be the wrong valve cover?

they can be a pain some times but you should be able to take it out without removing tensioner,that would make it a major pain to reinstall.:whistle: goodluck,happy wrenching!

There was know way to get it out without removing idler tensioner.

I had the same problem on my 77 KZ1000, after trying for an hour and researching this forum, I finally determined that I had to remove the tensioner. I was afraid to move the crank without having the tensioner in place, so I replaced it prior to checking my valves.

I was then able to get the valve cover back on with the tensioner in place, but I scratched the very top of it on one of the coil mounting screws. This leads me to believe that maybe loosening the coils, may help next time in removing the cover.

Caution:
If you do remove the tensioner be careful not to drop any plastic or metal spacers down into the block like I did! They are a PITA to fish out. Luckily with a magnet and a hook made out of an old bicycle spoke we were able to retrieve the parts. :whistle:

fortunately my valves are all within spec, so I don't have to pull that cover again for a while...

I can get mine off with little or no problem. Did you go out the right side?

donthekawguy wrote:

I can get mine off with little or no problem. Did you go out the right side?

And with a tilt towards the carbs?
My 77 is pretty snug,but it DOES come.
I really don't think You had to remove the idler.
Were there any wires(section of the harness) in the way,cause that can be enough right there,to cause a problem.:whistle:

:laugh: I went left, I went right, I went forward, I went back, I tilted up, I tilted down... perhaps in the 29 years of this bikes life something has shifted that makes this job more difficult. I was able to sqweeze it back on with the idler in place, but when I did that I put a big scratch in the top from one of the coil mounting screws... ...hmm it matched another one that was already in the top...

:laugh: Today I was needed to remove my valve cover again... After a LOT of trying I quit and gave it a rest. After talking to my buddy, I realized that my KZ1000 has VM29 smoothbore carbs - not the original carbs! I think this was my clearance issue. I removed the carbs, and the valve cover came off with ease.

I don't want to have to remove the carbs everytime I need to get into the valves, but at least I figured out what the problem is. I hope this sheds some light on this for others.

JoeK wrote:

:laugh: Today I was needed to remove my valve cover again... After a LOT of trying I quit and gave it a rest. After talking to my buddy, I realized that my KZ1000 has VM29 smoothbore carbs - not the original carbs! I think this was my clearance issue. I removed the carbs, and the valve cover came off with ease.

I don't want to have to remove the carbs everytime I need to get into the valves, but at least I figured out what the problem is. I hope this sheds some light on this for others.

i dont think there is any noticable differance between 26 and 29mm carbs,ive got tops and bottems on one set of 29 smooth bores that came off stock 26s.

Well, I don't really know... I'm kinda green at this KZ thing, just learning as I go along. Thanks for your response.

I had the same problem trying to remove my valve cover. Instead of removing the idler :blink:, I went to KZRider and found this thread.

I already had the carbs off for maintenance, so by following the advice to tilt back and exit from the right, I was able to remove it with relative ease.

KZRider saves the day...again!

Thanks guys.

Well I'm running 29 smoothies too,and I can still take the valve cover off without having to remove anything else.
It's not "PIE" easy,but it DOES come off.
What I noticed,was a section of the harness under the tank,that was getting in My way,and making it more difficult to remove.I zap-strapped that wiring up tight to keep it out of the way,during the whole procedure.

Oh,and...I remove Mine from the left side(shifter side of the bike).
That's pretty strange that You Guys are/were having those problems though.:huh: