i would deffinatly say that it is a tight valve problem....ive seen it happen on a 05 kx250f and it got so bad that the bike wouldnt start unless it was push started....you should have ajusted your valves at about 10 hrs right when the bike was done being broken in........

 

OK, you guys have convinced me that I need the valves adjusted. I will make an appt with the dealer. Not sure I want to tackle that myslef, plus I don't have the feeler guage or whatever else I may need.

 

I just looked at the shop manual and it sure seems easy enough to check these valve clearances myself. Just need to buy the feeler guage.

Any suggestions or gotchas?

thanks

 

First off buy a set of offset feeler gauges, the ends are bent at a 45 degree angle to help get them in there, 2nd only turn the engine over clockwise when you are checking them to aline the marks, if you back it up you will leave slack in the timining chain and they will be off & be loose, my best advice is take your time, Spin the engine slow and do them all twice to be sure they are set correct while you have everything apart [img]i/expressions/face-icon-small-smile.gif[/img]

 

Great! thanks. I am going to give it a shot.

 

You should turn the motor COUNTER-clockwise with your wrench on the alternator bolt, not clockwise. That is the natural rotation of the engine from the LH side of the bike where you are doing the adjustment. This is true on all current Kawi V-twin ATV motors. Remove spark plugs prior to this for easier turning. More importantly, you MUST align the letter "T" mark on the alternator rotor to the reference point on the crankcase (remove the round timing inspection cap to see the alignment marks which is just front of the oil fill cap) while slowly turning the motor by hand/wrench. Look for the marks, "TF" for the front and "TR" for the rear. But you need to align to the upper bar of the letter "T" to the reference point. I would set the clearnce to the looser side on all Kawi bikes.
Valve Clearance Specs:
Intake = 0.10 to 0.15 mm
Exhaust = 0.20 to 0.25 mm
Good Luck.

 

That did it!
The rear cylinder was WAY too tight. The front was too loose. I have 3 different feeler gauges and I was not able to get any of them in there. So I just tightened the adjustment screw 1/4 turn past the point were it contacted the valve stem.
Bike fired up immediately after this adjustment.

Thanks to all for their help on this.