valve clearance questions (started as zxr400 questions) - Page 6

lawnmower man · #**101** 8th June 2012, 03:03 PM

Great thread altogether. Very practical advice. Chopper I was the one who called you about a month ago about the o rings for my carbs. I got them anyway and did the valve clearances like you said. They were all tight. Thanks for that. Still had problems after that but I changed petrol station and now the bike is fine. Thanks again.

eirehead · #**102** 8th June 2012, 10:26 PM

Originally Posted by lpeare

This works on xj750, xjr is only a similar bigger engine

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McGyver eat your heart out.
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**chopper** · #**103** 7th November 2012, 06:51 PM

thread cleaned up

mikewayne · #**104** 14th December 2012, 05:31 AM

Hey nice post and looks like you have touched a very major topic and i would always suggest you to take help of a good mechanic when it comes to working on your vehicle, as they have all the essential know how, and are a lot more reliable with there work.

benny13 · #**105** 13th February 2013, 09:12 PM

Question time!!

I have changed the shims on the FZR (17 out of 20) and what I have found is that 4 shims are still out of tolerence after changing 17 of them. what was installed was 180's and 178's with a tolerence less than 0.05, I then changed them to 165's and now have a tolerence between 0.05 to 0.10? I couldn't check less than 0.05, I was just guessing that It was 0.00, but now it's obvious the tolerence was less than zero. Is it safe to order 4 of the 155's or take them out and reinstall them and check again? Is this the reason when they say to check them again after replacement? It's a first for me!

cheers
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Harrington · #**106** 13th February 2013, 10:40 PM

Originally Posted by benny13

Question time!!

I have changed the shims on the FZR (17 out of 20) and what I have found is that 4 shims are still out of tolerence after changing 17 of them. what was installed was 180's and 178's with a tolerence less than 0.05, I then changed them to 165's and now have a tolerence between 0.05 to 0.10? I couldn't check less than 0.05, I was just guessing that It was 0.00, but now it's obvious the tolerence was less than zero. Is it safe to order 4 of the 155's or take them out and reinstall them and check again? Is this the reason when they say to check them again after replacement? It's a first for me!

cheers
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You don't mention what your clearance is now,I think your over complicating it a little. It's quite simple really,you had zero or possibly minus clearance so at that point it was a little guess work to get clearance back,as long as you have some clearance at this stage you just proceed as normal and work out the shim you need to bring it back in spec. You don't need to remove the current shims just yet but do turn the engine over by hand a few times and recheck so you know everything is seated nice

Unfazed · #**107** 13th February 2013, 10:47 PM

Are the problem ones the exhaust valves?
Were you able to spin the buckets when you could not get the feeler gauge in to check them first time?
Are you able to spin the buckets now on the ones you cannot get the gauges in to check?
If they spin then there is some clearance and but 155 may not give sufficient clearance.
It is possible that you may have burned out the valves from running with zero or no clearance.

Did you turn the engine over 360 degrees about 4 to 5 time to settle the shims?

Are these the clearances you are working to?
.011mm-.020mm Intake
.021mm-.030mm Exhaust

**chopper** · #**108** 13th February 2013, 10:58 PM

its a bit confusing there but from reading that it looks like there was no clearance on the 4 so you took a guess and reasembled and now when measuring theres less than 0.05 which is your smallest gauge ?. if thats the case the 155s might not get you out .

**chopper** · #**109** 13th February 2013, 11:01 PM

btw with the clearances out by that amount you need to recheck again soon as there can be carbon buildup on the valves which will stop them seating right .

**chopper** · #**110** 13th February 2013, 11:04 PM

Originally Posted by benny13

shims needed are 135, 172(170), 140, 150, 150, 175 & 160.
edit!

3 shims had been shaved by what looks to be a grinder, mother of god
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!

I haven't come across these type shims before, there a bucket shim within the bucket! 7mm in diameter and 2.2mm deep they fit into the top of the valves.

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abortions
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3 in total!

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would ya believe ive seen worse shims . ill post pics in a bit

benny13 · #**111** 14th February 2013, 12:10 AM

Originally Posted by benny13

Question time!!

I have changed the shims on the FZR (17 out of 20) and what I have found is that 4 shims are still out of tolerence after changing 17 of them. what was installed was 180's and 178's with a tolerence less than 0.05, I then changed them to 165's and now have a tolerence between 0.05 to 0.10? I couldn't check less than 0.05, I was just guessing that It was 0.00, but now it's obvious the tolerence was less than zero. Is it safe to order 4 of the 155's or take them out and reinstall them and check again? Is this the reason when they say to check them again after replacement? It's a first for me!

cheers
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Originally Posted by Harrington

You don't mention what your clearance is now,I think your over complicating it a little. It's quite simple really,you had zero or possibly minus clearance so at that point it was a little guess work to get clearance back,as long as you have some clearance at this stage you just proceed as normal and work out the shim you need to bring it back in spec. You don't need to remove the current shims just yet but do turn the engine over by hand a few times and recheck so you know everything is seated nice

ya, was thinking that alright, just hasn't happened before
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Originally Posted by Unfazed

Are the problem ones the exhaust valves?
Were you able to spin the buckets when you could not get the feeler gauge in to check them first time?
Are you able to spin the buckets now on the ones you cannot get the gauges in to check?
If they spin then there is some clearance and but 155 may not give sufficient clearance.
It is possible that you may have burned out the valves from running with zero or no clearance.

Did you turn the engine over 360 degrees about 4 to 5 time to settle the shims?

Are these the clearances you are working to?
.011mm-.020mm Intake
.021mm-.030mm Exhaust

No, all Intake
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, I have turned the engine with the battery directly on the starter, they're settled, Only took this bike on as a project last year and getting around to it now, It was in bad shape
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Originally Posted by chopper

btw with the clearances out by that amount you need to recheck again soon as there can be carbon buildup on the valves which will stop them seating right .

cheers for that, If ever it does get on the road
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the 12 intakes were reading 0.00 - 0.05, but now 8 are reading 0.15 - 0.20 and the other 4 are reading 0.05 - 0.10 after adjustment. would ya reckon I'd need to take off the head to check the valves? again I've fook all history on the bike! Probably better now since the engines out and before I start to pour money into it?

**chopper** · #**112** 14th February 2013, 12:25 AM

getcha now. just go .10 smaller on the 4 . so yea the 155 should do. they go down to 120s iirc

benny13 · #**113** 14th February 2013, 09:09 AM

Originally Posted by chopper

getcha now. just go .10 smaller on the 4 . so yea the 155 should do. they go down to 120s iirc

cool
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Unfazed · #**114** 14th February 2013, 05:37 PM

Just noticed my slip of the finger
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should have read
0.11mm - 0.20mm Intake
0.21mm- 0.30mm Exhaust

With the clearance of 0.05mm to 0.10mm the 155 should be ok

What mileage do you think is on it and was it running when you got it?
When the valves clearances are sorted, do a compression check and let that decide if you take the head off or not. The official minumium pressure is 194 psi per cylinder

benny13 · #**115** 14th February 2013, 07:03 PM

Originally Posted by Unfazed

Just noticed my slip of the finger
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should have read
0.11mm - 0.20mm Intake
0.21mm- 0.30mm Exhaust

With the clearance of 0.05mm to 0.10mm the 155 should be ok

What mileage do you think is on it and was it running when you got it?
When the valves clearances are sorted, do a compression check and let that decide if you take the head off or not. The official minumium pressure is 194 psi per cylinder

the clock says 22k kilometeres
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, but the rocker cover had been opened before, and badly reinstated, all the shims are original so I dought very much the clearances were done unless they were changed with other original shims (very doughtful tbh). I would be guessing by the clearances the way they were I'd say the mileage is approx between 25K-35K miles, but if ya saw the state of the bike(
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) it looks like a lot more
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, Overall the bike is ok, just neglected, everything on it is stripped and ready to be cleaned thoroughly and painted where needs be
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Compression is good on it, don't know the exact psi, couldn't find my tester but I'll look for it and check when the clearances are done.

Unfazed · #**116** 14th February 2013, 08:15 PM

Best of luck, keep us updated
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Unfazed · #**117** 14th February 2013, 08:21 PM

Forgot to add, I have the Yamaha service manual for an 89 model, with a colour wiring diagram, it is about 10meg in size. I can try emailing it if you want

benny13 · #**118** 14th February 2013, 09:13 PM

Originally Posted by Unfazed

Forgot to add, I have the Yamaha service manual for an 89 model, with a colour wiring diagram, it is about 10meg in size. I can try emailing it if you want

sound your grand, I've got the haynes one
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benny13 · #**119** 16th February 2013, 09:35 AM

received the 4 shims this morning, ordered them Thursday morning from the last guy I got them from on ebay and got them through parcel motel, some service, normally would be waiting a week for them
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now to fit them, but gotta do a bit of work this morning but i'll let ye know how they went later on in the day
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4 shims including postage - £10 and 3.50 euro for parcel motel, job done

edit: job done, perfect clearences and all at the latter end of the scale
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guydivinyl · #**120** 25th February 2013, 11:07 AM

hope im not off-topic - I have a 1998 CB1300 FX - jap import - and having troube getting the valve specs. Honda wont help, they just laugh.
Any ideas, sources etc?