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Discussion Starter #1
Hi friends,

My buddy just did a valve adjustment on his 2012. Ran great in the morning and most of the way back home, and then the motor lost power and siezed up. I suspect something with the rear cam chain, but we haven't been able to confirm yet.

I DID find a Gladius motor with low miles for cheap, but I'm not sure if it's a direct drop in to the Glee. If this motor is lunched, should we buy the Gladius motor and stick it in there?

Thanks in advance!
 

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It’s based on that engine, but highly doubt it will work as a drop in if at all. Don’t jump the gun, look in the top end and see what’s going on.
 

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I bet you could get it to work. There are differences, like the cams are bigger and the flywheel rotor has OPEN magnets, not encapsulated.

I'm unsure about the ECU and all the sensors though. I say go for it! :thumbup:
 

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Discussion Starter #4
Welp... Here's the front piston! There are metal shavings in the airbox. It's bad.

This will be fun to fix.
 

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Yikes...looks like a scene from "Alien"
 

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Surely all the mounting points etc. are all the same but I would be concerned about the ECU. Do you swap to a Gladius one? Would that integrate with a DL?
Finding a V-Strom motor could save you many headaches.
 

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Valve adjustment gone bad? Did it drop a valve? May be able to repair just the piston and head if the con rod isn't junk.

The crank sensors on the rotor have to be the same, and get processed the same.
 

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Discussion Starter #8
The front exhausts were at .09 and .11, well below tolerance. I can't believe the thing was still running, honestly. We weren't able to get the top end off to thoroughly examine what he may have done wrong yet. The piston is holed, though, so I'd imagine that the crank bearings could be compromised from metal shards? I'm not sure, never dealt with a repair of this magnitude before.
 

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Uhmm.... 0.09 to 0.11? Gads. If not a typo (missing a zero right of the decimal) how did he do that?
 

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Discussion Starter #10
It's not a typo. When he got the valve cover off and checked the clearances, the exhaust valves on the front were .09 mm and .11 mm. He shimmed them to the mid .2 range and buttoned it up (did the intakes too). Motor ran fine on his 60 mile ride to work, much smoother and the bike was reporting better fuel mileage as well, and then it grenaded halfway through his return trip.
 

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Ah, mm not inch. My mistake. Like others here, I'm curious exactly what may have caused the engine to pop. Intakes and exhaust set to the same spec (0.2-0.3mm for intake would be bad,) cams out of position, that sort of thing.
 

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Discussion Starter #12
I'll certainly post more pics as we tear it apart. I am curious as well. I'm about to do the valves on my Vee and this has me spooked, even though I've done it before.
 

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The Gladius engine probably can be made to work, but you almost certainly need the ECU and throttle bodies as well as the engine.

More complicated engines swaps between the road and DL variants of these bikes have been done but it's more work than you'd expect.
 

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I knew of a guy who swapped a SV1000 motor into his DL1000. I know its a different project, apples to oranges, but worked quite well. He had to use the ECU and TB's from the SV. It was quite an envolved adventure but came out great! Ran like jet stink when he was done. Was pumping out 105HP to the rear wheel once he was done. He did have a full Akro exhaust and modded the air box too. PC and a bit of dyno work too! Im sure this project "could" be done. It may not be worth the effort though. Putting in a donor DL650 motor would be a lot easier!
 

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Discussion Starter #16
Disturbed a keeper? Is that a dowel pin? I know he said that one of the dowel pins on the front exhaust cam journal was missing, but he may have lost it.
 

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The dowel pin is more correctly referred to as a piston pin - the pin that connects the conrod to the piston. Surely not what he meant.
The valve keepers lock the valves into place. Each valve has two half shells (keepers) to do the job. If one of the valve keepers was accidentally dislodged that would certainly explain what lunched the engine.
 
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The dowel pin is more correctly referred to as a piston pin - the pin that connects the conrod to the piston. Surely not what he meant.
The valve keepers lock the valves into place. Each valve has two half shells (keepers) to do the job. If one of the valve keepers was accidentally dislodged that would certainly explain what lunched the engine.
How do you make sure your keepers are OK after a valve check?
 

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Be careful to ensure that only the cam lobe compresses a spring. The tension of the spring keeps them in place.
 

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The dowel pin is more correctly referred to as a piston pin - the pin that connects the conrod to the piston. Surely not what he meant.
There are also dowel pins that ensure the alignment of parts, usually they stay in one half of the assembly, but they can fall out. It can be easy to miss the fact that one is missing, and a loose dowel is likely to mean a lunched motor.
 
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