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Old 05-28-2012, 07:01 PM   #28
markk53
jack of all trades...
 
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Joined: Dec 2007
Location: Delaware Ohio
Oddometer: 8,168
That's the plan. There is no need for any significant leverage factor so a screw slot is easy and a good solution. I will be doing up a few of them and send you one unless you simply want to cut the one you have down a total OAL of 95mm (per below info) and cut a slot in it with a hacksaw or small grinder wheel (Dremel) then swipe an air cap from some car somewhere... It will have to be plastic, because it will be crossthreading, valve stems aren't M8-1.25 and there is nothing out there in that thread that I found readily available. Let me know

I have the inside engine distance at 51mm plus the body/flange nut/air cap stack up at 34mm plus 10mm adjustment range equalling a total of 95mm. That is pretty much exactly the length of a 90mm hex bolt including the head thickness, which is what I will be using.

Thanks for the pictures and input so far.

In a quick afterthought, I may try dipping a bolt in some vinyl tool handle goop, let it set up then unscrew the resulting "cap" and screw it on the slotted bolt. Might work okay and is worth a try.
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Mark - klx678
95 KLX650C w/Vulcan piston bigbore, Now an 09 KLX250S, selling my 90 Zephyr 550
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