Lost a washer, O.M.G.!

[tim.kyfl]

This evening I was installing the carburetor assy. The manifold bolts were left in place after removal for easy finding and storage. I needed to remove them again in order to push the assembly through and install. As I removed the right rear bolt , I heard the washer go plink, plink. I am 99.0% sure it fell into the cylinder head opening. It also appears the valve is open. Cannot see the washer. Am I going to have to remove the cylinder head an get to the piston to retrieve it? Any chance to cross fingers and continue?

[DenverWinger]

See if you can find one of those little probes like a telescoping antenna rod with a magnet on then end.

First try the probe in the intake port, the washer may not have gone past the valve. If you don't find it there......

Then tip the bike over onto the opposite side of where the washer is so that the piston with the washer is upward. The washer should fall against the piston. Turn the crank so the piston is mid-stroke. Laying the bike on its side won't hurt anything, especially with the carbs off.

You should be able to fish out the washer with the magnet tipped probe thru the sparkplug hole, pretty sure the washer is smaller than the hole. You can confirm that easy enough with a washer you haven't lost. Turning the crank slightly to move the piston up or down may aid in you getting that washer with the magnet.

Gonna be fun, the magnet will want to stick to the cylinder walls, but it should grab the washer too.

[tim.kyfl]

WOW. That sounds near impossible, but, is a probable. I would think if the washer is magnetic and the head is magnetic, it would not slide around. I'm in the weeds aren't I?

[DenverWinger]

No, the washer isn't magnetic, so it won't stick anywhere, it'll slide just fine. And since the washer is steel, a magnet will grab it... And the head and piston are aluminum, not steel.

[tim.kyfl]

You seem determined on this course of action and it's the best i've got. It appears no one else wants to touch this one. The laying on the side is the worst. This things heavy. Will search for a magnetic doo-dad. Know what i need.
Thank you.

[Charlie1Horse]

There's no problem about laying it down. Go to youtube.com and search 'pick up goldwing' you'll see little girls pick them up. It's really not hard at all. I am 68 and pick mine up every now and then. Not bad, even for us 'old guys'. It's just embarrassing, that's the worst part.
Russell

Those who say it cannot be done should try not to interrupt those who are doing it.

[tim.kyfl]

I am a 68 y.o. After it dumped me 3 times while dying in a tight turn while feathering the clutch, I have picked it up. Its that I would rather not. It's heavy. Reason for the carb and general internal cleaning. Hoping a "snake" type magnetic retrieval device can be worked around without having to do that.

[Charlie1Horse]

Well, it's just my thought that if I had dropped a small washer down the intake, I would rather lay it over than pull intake manifolds and heads off to retrieve the washer, just my thought cause I'm kind of lazy. I don't want to do more work than is necessary. You could get a little dowel magnet and glue a short piece of it in the end of a small diameter vacuum hose. Then take the spark plugs out on the affected side, turn the engine over slowly,BY HAND, to push the washer out to the spark plug hole and possibly fish it out with the magnet. It would be worth a try. I would get a small 'bore scope' camera and look all around the top of the engine and find that possibly it didn't fall in the intake. Just my thoughts.
Russell

Those who say it cannot be done should try not to interrupt those who are doing it.

[DenverWinger]

If you can find a flexible "snake" retriever with a magnetic tip you might have success finding that washer without tipping the bike.

The point of tipping the bike it to get the washer away from the head, the angle of the sparkplug hole kinda prevents you from reaching anything right next to the head.

With the bike laying over you can be pretty sure anything in the cylinder will be at the bottom of the cylinder bore right against the piston, a lot easier to find "blind".

Have a riding buddy come by and help you lay it over.

[tim.kyfl]

I found a snake on Amazon. Walmart,Lowes and the auto stores do not stock them locally. Not much available locally, though they are building a Harbor Freight. Can't wait that long.
Thanks guys

[tim.kyfl]

So, my magnetic snake arrived today. Dropped it into the cylinder and within 2 minutes snagged it.
OH NO. THE WASHER IS BIGGER THAN THE OPENING!
Everyone chillax. Since the valve was open and I knew where the washer lay, I probed through it, and, retrieved it on the third try.
WHEW! I had been a little sour since I dropped it in.
Thanks again guys

[DenverWinger]

Glad to hear of a good outcome!

[Wing--Man]

Lay some rags over the entire area and anything dropped will be easily caught and seen.
I have old bath towels and they cover quite an area. Also double as finger wipes.
When it comes to open orifices to the engines or trans depths, they get double covered or plugged.

[Aussie81Interstate]

Nice to hear of the great result.

It only cost some time and a magnet - so definitely a winner solution.

[tim.kyfl]

Thanks WingMan, I had te orifices stuffed while working on carbs and air box. I had put the bolts back in the head after twisting the intakes. I had removed the rags while trying to install the intakes. Should have removed the bolts before shoving the cab assembly in.

[stephenricci]

Tim, glad things worked out. I had the same problem when I did the Doo-hickey on my KLR. I though that I would post a couple of picks of my savior. As far as I know, you can only pick these up at True Value. They bend as if they are made of solder but of course they are not. Saved my butt. I thought others may want to pick one up and have on the shelve just in case. I think it was around $6.

[tim.kyfl]

Amazon was V8 Tools 3826 26" Mity Magnet. Chosen for diameter of the magnet to fit through plug opening. I looked online at Wally and Lowes, which sold them, but listed as out of stock. What does that say about us shade tree mechanics.

[stephenricci]

Tim, at least it says that we are working on our own bikes/cars/trucks. We also always learn from our mistakes. I checked out the tool that you referenced and for anyone needing that tool there are plenty to be had on eBay (about $12). Here is a pic for anyone that need to see what you are talking about.

[baltes]

How is it that you "turn the motor over by hand" ?

[WingAdmin]

How is it that you "turn the motor over by hand" ?

On the back of the engine, you'll find the cylindrical stator cover. On the back of that, you'll find a cover about 1.5 inches in diameter that you can unscrew, much like the fill cover on your final drive. Once it is unscrewed, you'll see a bolt exposed that you can put a socket wrench on, and use to turn the engine over by hand (recommend that you remove the spark plugs first).

[baltes]

Thank You I will give that a try.

[Wing--Man]

Thank You I will give that a try.

What goes in, will come out.
Blow some compressed air in the spark plug hole in different angles.
But DO put a rag over the intake port and catch that metal critter.
You sure want to know that it is out.

[pidjones]

Thank You I will give that a try.

What goes in, will come out.
Blow some compressed air in the spark plug hole in different angles.
But DO put a rag over the intake port and catch that metal critter.
You sure want to know that it is out.

I've read that auto mechanics use compressed air through the plug hole to get the plug terminal out if it falls in.