Every 10.000 km my Bandit needs a valve job. The hardest part of adjusting the valves is to get the valve cover off. Although the manual says to remove the whole upper body fairing, I have found that it can be much easier:
- remove the seat (0 bolts)
- remove the tank (2 bolts)
- pull the spark plug caps off and put the leads out of the way (0 bolts)
- remove the air breather on top of the valve cover (4 bolts)
- remove the oil hoses at the rear of the engine (4 bolts)
- remove the bolts in the valve cover (4 banjo bolts, 8 flatheaded bolts, 1 centrally all the way up front and 1 centrally all the way in the back)
- remove the mounting bolt holding the PAIR valve to the frame. That will give you enough freedom to move the valve cover around.
- do the magic shuffle
The magic shuffle consists of the following:
First, (after lifting it up) twist the valve cover anti-clockwise as far as you can. Then push it to the right whilst lifting it as high as you can. It will now be stuck with its leftfront top against the left fairing mounting, it's rightfront frontside will be against the fairing and the 2nd cylinder spark plug gap will push against the timing belt protector.
Now you have to wiggle a little to get the rear edge of the cover to move down a bit whilst the 2nd cylinder spark plug hole can move on top of the timing belt protector. The front will sink right in between 2 ridges in the timing belt protector.
Once you reach that position, you turn the valve cover a bit more straight. This will allow you to wiggle the second cylinder spark plug hole again on top of the ridge, but now you have advanced about 2 cm.
From here, it is a matter of wiggling a little more to clear the ridge on the timing chain protector with the second cylinder spark plug hole. You need to use a little bit of force here.
Once you have cleared it, the cover can be removed without a problem. Reverse to reinstall.
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