LS650 Top End Engine Rebuild Pt 1: Valve Cover Removal 

It's almost always that head cap/seal. They made 2 different models of it, and the earlier kind is known to fail. Later on in the engine rebuild I replaced it with the new style and sealed around it with matching black high temp gasket sealant. Unfortunately removing the valve cover without removing the engine from the frame is difficult or next to impossible, removing the head is impossible without pulling the engine. The head cap is a silly little problem which requires a large amount of labor.

I'm hoping to get around to editing the rest of the engine rebuild on this bike, I haven't done it yet because I'm ashamed of how poor quality the video content is and I'm very busy. Taking apart the engine at this point is somewhat simple, putting it back together is where it becomes more tricky. You will have a fair bit of labor scraping off gasket surfaces once you get it apart. I'd suggest you invest in a service manual or find a free one, this could assist in getting it apart fully and explains and shows what to do. I'm not sure when I'll have the time to edit the full engine rebuild videos so this would probably be your best bet. If you want to send me your email in a private message or on here, I can email you a PDF file of the service manual for this bike so you don't have to buy it. There are also some free copies of it you can find on the internet.

Thank you for the reply. I already do have a PDF of the service manual, but I'm a little hesitant to perform a job this big without visual help, lol

I'm having a same problem, can you send me a copy of service manual to my email? b.dominykas@gmail.com one more question, where can I find to buy that new version plug, how much it cost?

Raymond Noodels can you be more specific? Are we talking valve springs or cam chain adjuster or??

the one that opens the valve up to start it..i know im gonna burn up my starter. and your video really did help. i just got her on the road again. i cant believe the difference. its faster and smoother than when i bought it. lol. i didnt watch your video all the way threw..and ended up not getting the phillipes heads out of the mountout..so i pulled the the whole piece out..if i cant fix it m gonna take it to the shop..theyre expensive as hell though. the harley place is pretty cheap. but they are always booked up...just a parking lot full of different bikes every week.

these bikes make me feel stupid. i swapped the engine in a 600 rr in a couple hours. and my nighthawk was 3 years older than me when i bought it...had to fix it often. i love the savage though. fyi. you called it a spring loader.

Raymond Noodels from the sounds of it you removed the decompression assembly used during start up? There is a lever and spring that is Bolted into the cover. If I remember correctly from the service manual. It was pretty clear not to remove that bolt during removal of the cover. So to be quite honest, if this is what you removed I'm actually not sure how it goes back in. There are service manuals for free online you can google, it probably has a specific section detailing removal or replacement of this. If not check out forums. Without actually having a head to look at currently I won't be able to accurately explain to you how it goes back in. Worse comes to worst, shop it is!

Absolutely. Reference whatever you need. I hope to eventually put out the rest of this engine rebuild its just been hard to find the time to edit it.

Not sure to be honest. With it, it can't be more than 200-300 lbs. I was able to push it up out of the frame with a floor jack and lift it onto a block to work on.

Yeah, can't be that much weight. The weight of the bike itself with fluids is around 380 lbs. Could be lifted without special equipment, but isn't recommended lol