Valve Clearances (check and adjust)

[werner1]

Every 16.000 miles or 2 years.
After a few crashes and different speedometers (now a BMW-one ;D) I do'nt have anny idea how many miles ago i checked these.

So , here we start.

First we remove sadle and fueltank. Airbox and oil-cooler.
And me, I also loosen the carburator to have more room to remove the valve cover.
Then remover the "second _air_induction_system" tubes from the cylinders and the spark-plugs.
With an "alley" -key of 5mm, remove the 12 coverbolts of the valve cover.
The cover probable remains stuck . Don't try to lever it out with a screwdriver , while this will certainly damage the gasket.
Instead, tap gently around the sides with a rubber hammer.


In the middle runs the cam chain. The cover has to be lifted over.


This is the camshaft lobe (intake)of cylinder 1.
After 100.000km it stil has no sign of wear or pitting.The round shine metal plate underneath the camlobe is the shim.
Clearance is measured between shim and lobe


Valve cover, inside

[werner1]

At the left hand side of the mmotorcycle, you kan turn the engine with a 14mm spanner (always anti-clockwise)
we start be turning the engine until the lobe of intakevalve cylinder1 face away of the shim.
Here is also the mark on the timing plate


Good vieuw on the shim in it's "bucket"


To measure the clearance we use a feeler gauge .
Clearance of the intake valves are between 0,11mm and 0,15mm.
0,15mm does not fit, but 0,10mm does.



In this way you check every valve by turning the engine until the next
camlobe faces away of it's shim
The exhoust valves have a clearance between 0,16mm and 0,20mm
I make a drawing of the 8 valves (shematique) and write down the measured clearances.
Cylinder 3 and 4 exhaust valves are not within the tolerance and need adjustment
There's a special tool (p/n 90890-04125) to push domn the valve
for changing the shims.
This tool kosts about 20£. But there's another method.
Instead of pushing the valve down, you can also "lift" the camshaft ;D
No special tools required

[werner1]

First we turn the engine to the top dead centre of cylinder 1.
This when the cylinder is at its hichest point and the exhoustvalve is just closed
and the intake valve is about to open.
Or...
The timer plate is at the "T"-mark and the camshaft lobes are facing
away from each other.
And at the camshaft right-hand there's a punch mark



Next, remove the tensioner




Remove the valve cover bolt holders (in the middle of
the camshaft next to the sprocket.
Look how they are marked.
whatch out for the dowels, so they don't fall down in the engine.
It's strongly adviced to cover the hole inwitch the camchain runs with a rug.


Remove the front guide . Just lift it out


Know you can loosen the camshaft holders.
slacken them a little at a time in a criss-cross patern.
One of the camschaft lobes is pusching down a valve, and the camshaft
is therefore under preassure.
slackening them in this way prevents bending or breaking the camshaft.
De camshaft holders need to be put back in the same place afterworths,
so a make little drawing on the workbench where they belong.


Now you can lift the camshaft enough to remove the shim
Cylinder 4 Bucket, exhoust valve


shim 272 (2,72 mm)


Always check for wear


My drawning
With this methode it is possible to interchange the shims
I need to interchange these 2 shims


Tighten down the canshaft holder bolts in the same criss-cross pattern to avoid bending or breaking the camshaft.
Tighten with 10nm

After replacing the tensioner, turn the engine a few times and than
start rechecking the clearance.
It took me 4 hours to finish this job.
That includes taking the pictures ;D

[teejayexc]

Very informative article Werner 1.

Encouraging me to have a go

Trev

[HRHpenfold]

I thought you used a tool to push the valve spring down so you can hook out the shim, without removing any of the caps ;D

[teejayexc]

fazerian said:

I thought you used a tool to push the valve spring down so you can hook out the shim, without removing any of the caps ;D

Stop being picky Penfold, werner does say there is a special tool for the job, just giving another option for al us tight wads

Trev

[Fiasco]

I used to have one of them special tools !

I am sure I will get it back one day from the person I lent it to that no longer has a Divvy hence no excuse

Dave ;D

[m40man]

Do you have one for a Fazer Dave?