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Re: Valve Inspection Completed
And all of the intake valves had a clearance of 0.006. Each measurement was recorded when the feeler would go in with a little effort and I could feel it grab on the way back out. The next size feeler (0.011 and o.007) could not be inserted. All measurements were within spec.
For anyone attempting to do this themselves it wans't too difficult. The biggest problem was removing enough to easilly get at the cams! I removed both front side panels the left side panel the tank, the airbox, and the bracket at the very front of the compartment that routes the throttle cables and holds some electical doohickies.... I also disconnected the throttle cables to make room to remove the front valve cover. Only one bolt was difficult to get to, the front left one on the front cylinder. I was able to loosen it from the front of the bike (through the gap between the radiator and the frame) and then remove it from the top like all the others.
I was able to get the cams in the correct position by putting the bike in top gear and rotating the rear wheel (thanks Ian). Everything buttoned up pretty easilly, except the airboox. I first connected all the hoses and then tried to get it in the right place; no go... I then pulled the hoses back off and loosened the front bracket and got her into place with only minor effort. We went for a ride and all is well.
I'm definitely glad I did it. I feel so much closer to her now....,I had 9700 on the clock. Almost all of my miles are commuting, but I've got a good mix of backroads and superslab... As far as riding style, I'm a gentle rider. I mostly shift around 5k rpm and only rarely bring it up to redline. I'm always amazed at how much I can enjoy riding without really pushing it!
With that said, last night I had a minor accident on the way home.... The results of that I'll post in another thread.,,,
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Perfecto, .006 mm intake,.008 mm exhaust.
Check the attached links,
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this table will help you. I used to own one.. beautiful bikes easy to work on too!
Valve clearance: Inlet 0.13 0.19 mm
Exhaust 0.18 0.24 mm
Valve head thickness: Inlet 0.5mm 0.25 mm
Exhaust 0.8mm 0.5mm
Valve stem bend 0.05 mm TIR
Valve stem diameter: Inlet 4.975 4.990 mm 4.96 mm
Exhaust 4.955 4.970 mm 4.94 mm
Valve guide inside diameter 5.000 5.01 2 mm 5.08 mm
Valve/valve guide clearance
(wobble method): Inlet 0.02 0.07 mm 0.18 mm
Exhaust 0.06 0.11 mm 0.21 mm
Valve seating surface:
Outside diameter: Inlet 30.8 31.0 mm
Exhaust 26.3 26.5 mm
Width 0.5 1.0 mm
Valve spring free length: Inner 35.5 mm 33.6 mm
Outer 40.5 mm 38.6 mm
Valve seat cutting angle 32 degrees, 45 degrees, 60 degrees
make the engine runs for about 30minutes before adjusting the valves, valve clearances: intake valve = 0.20mm(0.008 in) exhaust valve = 0.25mm(0.010 in) for reference only when the engine is cold, valve clearances: intake valve = 0.25mm(0.010 in) exhaust valve = 0.30mm(0.012 in) engine specs: mitsubishi 4g13 1.3L (if you have same engine)
the easiest way is to start at the first valve,first you need to know if the inlet & exhaust valves have the same clearance, starting from the left side of the engine ( standing at the front ) the first valve exhaust, the next two are inlet, the next two are exhaust, the next two are inlet & the last one is exhaust, what you do is turn the engine over by hand ( this might be easier if you remove the spark plugs ) until the valve opens & closes, after it closes turn the engine a little more & adjust the clearance on that valve, repeat this action on every valve until they have all been adjusted.......hope this helps......cheers.
Before servicing the vehicle, refer to the precautions in the beginning of this section.
Remove the valve cover.
Set the engine to Top Dead Center (TDC) of the compression stroke for the cylinder to be adjusted.
Check the valve clearance. The valve clearance specifications are as follows:
Intake valves: 0.005-0.007 inches (0.13-0.17mm)
Exhaust valves: 0.005-0.007 inches (0.13-0.17mm)
After adjustment, tighten the locknuts to 11-14 ft. lbs. (15-19 Nm).
Repeat for each valve to be adjusted.
1.8L, 2.0L and 2.5L Engines
The 1.8L, 2.0L and 2.5L engines utilize automatic hydraulic lash adjusters to maintain proper valve lash at all times. Periodic valve lash inspection and adjustment is not necessary or possible.
The adjustment is .003 - .005. You must hold the rocker arm by lifting up on the valve depressing side and pressing down on the push-rod side while making the adjustment. Any other means of adjustment and it will be incorrect.
Below is quoted from the service manual without pictures (FixYa Note TORQUE on lock screws is 61 inch pounds)
Valve Clearance Inspection NOTE ?? Valve clearance must be checked when the engine is cold (at room temperature). • Remove the rocker cover (see Cylinder Head Removal). • Place the piston at top dead center (TDC) of the compression stroke turning the crankshaft clockwise facing the flywheel. No.1 Cylinder: ?? The left projection [A] on the flywheel is faced with the right leg [B] on the #1 ignition coil [C] as shown. ?? Check the intake and exhaust valves are closed completely, if not turn the flywheel one turn (360??) clockwise and face the left projection with the right leg again. No.2 Cylinder: ?? The left projection [A] on the flywheel is faced with the right leg [B] on the #2 ignition coil [C] as shown. Follow No.1 Cylinder alignment. • Then check the valve clearance. ?? Using a thickness gauge [A], measure the valve clearance between the rocker arm [B] and the valve stem end. If the valve clearance is incorrect, adjust it. Valve Clearance (when cold) Intake, Exhaust 0.075 0.125 mm (0.003 0.005 in.)
Valve Stem to Guide Clearance · Intake
0.026-0.071 mm (0.001-0.0028 in)
0.038-0.083 mm (0.0015-0.0033 in)
With No. 1 piston (6108) on top dead center (TDC) at the end of compression stroke (Position No. 1 in the illustration), check the following valves: Position 1
No. 1 exhaust valve (6505) No. 1 intake valve (6507).
No. 3 exhaust valve No. 2 intake valve.
No. 6 exhaust valve No. 4 intake valve.
Rotate crankshaft (6303) 360 degrees to position No. 2 and check the following valves: Position 2
No. 2 exhaust valve No. 3 intake valve.
No. 4 exhaust valve No. 5 intake valve.
No. 5 exhaust valve No. 6 intake valve.