Question about 2003 Gas Gas EC 400 FSE

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Cam/valve clearances Hi Ive just measured the valve clearances on my bike and they are bigger than what the manual says

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My mate says that if the gaps are bigger then its ok and that it's when they are smaller that u need to do something about them is this true? bit of xtra info: the manual says inlet 0.15mm and exhaust 0.25mm clearance. my bike measures inlet 0.20mm and exhaust 0.30mm i'm just a bit concerned 'cos if the worst happens i wo'nt be able to afford a top end rebuild.You should try and keep the clearance to 0.15 in and 0.25 ex. With the de-comp it is cridical to have the exhaust clearance correct. On the early 400/450 they had some cam problems so check the shim buckets and cams are not worn.,

Posted on Nov 10, 2008

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What are tools required/procedure for adjusting tappets?


A good feeler gauge set and a basic set of sockets, wrenches, and a screw driver set will work for most engines. I hope this helps. Rod
Now first you check the clearance and record the clearances. If they are out you need to change the valve bucket (which comes in different sizes). This involves removing the camshaft to change the buckets and then reassemble and recheck the clearances. This is a big job and dealerships will often charge $1500 plus to do this job. I am going to post some info from a thread which will explain further. Many motorcycles are similar as well.

The general procedure for checking and adjusting the clearance based on having done this on bikes is;
Before removing old belt
Measure and record each intake and exhaust valve clearance using feelers gauges. Use the crank rotation sequence and measurement order listed in the manual, else you may get erroneous readings due to cam journal clearances and the valve springs pushing the cam around in the bearings. Some are not measured on the exact base of the cam (i.e suzuki)
Compare the readings to specification
If any are out of tol, calculate the difference between the reading and spec.
Remove the camshaft with the out of tolerance readings (usually both if one is out of tol).
Record the markings on the bottom of the buckets that are out of tolerance. (I usually like to measure these with a mike to verify markings and or determine if there is any measurable wear and adjust accordingly)
Refer to the list of available bucket sizes (from svc. manual or dealer parts counter)
Add or subtract the difference you calculated above to determine your new bucket size. (bikes typically tighten up so you end up going with a thinner shim, er bucket)
Order the buckets needed (sometimes you can swap them around between locations to minimize the qty needed to order).
Install new buckets in the proper locations.
Re-install cams, new belt, new tensioners, and new Idlers.
Repeat measurement process from above.
If measurements are in spec, you are done.
If not, repeat.

Last winter I checked the valve clearance on a 2001 Focus ZX3 with the 2.0L DOHC engine. It had about 85K on it. The clearances were all pretty close to nominal. I don't know the history on the car since new so they may have been adjusted at some time in its life. IIRC the interval for that car was 75K.

As I said above, bikes typically tighten up with this type of valve train. This is due to the valves seating deeper in the valve seats due to wear. This increases the installed height of the valve, decreasing the clearance to the cam. The rate of seat wear exceeds all other wear causing them to tighten.

Tight valves are worse than loose valves. Can eventually lead to low compression, and burnt valves.

If the wear of the cam, bucket, cam journal exceed that of the valve seat, the clearance will increase.

I don't know what the general trend on these engines are as far as tightening or loosening, but if they are like a bike, they will tighten.

I can tell you that on bikes if they are operated a significant amount of time near the red line, they will require more frequent adjustment compared to one operated more conservatively. A bike that is operated conservatively may not need any adjustment at the first inspection interval (not unusual for my Yamaha FZ1, 26,000 mile interval)

Sorry about being long winded, but I thought I would do a brain dump to help people understand the process.

I hope this helps. Rod

Aug 17, 2015 | 2008 Saturn Astra XE

Tip

How to set valves


To adjust your valves you will need a few standard tools and most importantly a set of feeler gauges. You can buy these at any automotive store. The first step is removing the tank and valve cover to gain access to the valve train. You will see both the intake and exhaust cams plus the tops of the valves. This is where you will be measuring with the feeler gauge. The next thing would be to rotate the motor to top dead center. You will need to remove both inspection covers that are on the side of your ignition cover. This will give you access to the timing marks and to the bolt that allows you to turn the motor over.

Check in your manual as to what direction to turn the motor over. You do not want to turn the motor over in the wrong direction. Turn the motor over looking into the inspection (top) hole. You will notice a mark on the fly wheel. When you see this mark come around, look up at the cams. There should be two punch marks on the cam gears that line up with the gasket surface towards the outside of the head. At this point you should be at top dead center compression. Check the lobes of the cam, they should not be touching the valve buckets. If they are touching the valve buckets, this means that you are 180 degrees out of time. Rotate the motor 180 degrees and then start to measure.

After you measure the clearance between the cam lobe and the valve bucket, you will want to write that down. You will then need to check your numbers against the spec's provided in your service manual. If you are outside the specified range, you will need to remove your cams and replace the shims. There should be a chart in your manual that will help you to decide what shims you will need to bring you within the safe range. When dealing with the KXF250 or the RMZ 250, you want to make sure you use the correct shims. There are two types that will fit these bikes, but only one is the correct shim. Shims come both forged and sintered. They look the same until you put them under a magnifying glass, then the difference is very clear. The forged shims have a smooth surface, while the sintered shims have very small cavities. Using the sintered shims will prematurely wear the coating off of the valve stem. This will shorten valve life and cause the valves to go out of adjustment sooner.

Now, after replacing the shims, all that is left is to reassemble your machine. Pay closer attention to the instructions in your owners manual. Always double check your cam timing with what is recommended in the manual. Do not start your bike without turning the motor over by hand first. If you feel it is unusually hard to turn over or it will not turn over, you probably are off on your cam timing. Once again, do not try and start the bike. Go back and retime your cams.

on Nov 26, 2008 | 2006 kawasaki KX 250 F

1 Answer

Intake valve clearance keeps increasing


When this kind of problem popped up on my Honda CB 360, I discovered (about the same time Honda did) the 'floating' cam was floating right up into the head ... a bad design. I doubt this is your problem but it is worth a look-see ... how are the cam bearings? review your work ... make sure you are doing exactly what you are suppose to be doing.

Jul 19, 2013 | Motorcycles

1 Answer

Schims are rattling; can I reset them and how?


HI, FIRSTLY ARE YOU SURE IT IS THE SHIMS AND NOT THE CAM CHAIN? THE SHIMS ON YOUR BIKE CANOT BE RESET AS SUCH, HOWEVER YOU CAN REDUCE THE RATTLING BY CHANGING THE SHIMS, THE PROCEDURE IS TO MEASURE ALL THE INLET AND ALL THE EXHAUST VALVE CLEARANCES, MAKNING A NOTE OF EACH GAP BETWEEN SHIM AND CAMSHAFT LOBE WHEN IN THE CORRECT POSITION FOR EACH VALVE, AFTER YOU HAVE MEASURED THE GAP YOU THEN NEED TO REMOVE THE SHIMS FROM THE VALVES THAT ARE OUT OF SPEC, 1 AT A TIME, SOME SHIMS HAVE THE MEASURMENT STAMPED ON THEM, OTHERS YOU HAVE TO MEASURE WITH A MICROMITER OR VERNIER CALIPERS, YOU MAY THEN CHANGE THE SHIM AS REQUIRED DEPENDING ON WHETHER YOU NEED TO REDUCE THE GAP OR INCREASE THE GAP. IT MAY BE THAT A SHIM REMOVED FROM 1 VALVE WILL BE A GOOD REPLACMENT FOR ANOTHER VALVE, GET YOURSELF A HAYNS MANUAL IT SHOWS YOU THE FULL PROCEDURE INC A CHART TELING YOU WHAT SHIM TO FIT FOR ACTUAL CLEARENCE,

Jan 10, 2011 | 1994 Yamaha FZR 1000

1 Answer

I need to know the valve adjustment procedure and


Valve clearance ideal setting is 0.10mm however as ideal replacement size shims are not always available use tolerance 0.05 to 0.2mm inlet and exhaust Procedure remove tappet cover rotate motor to tdc compression (inlet valve lobe pointing to rear wheel and exaust lobe to front wheel) measure clearance if no clearance depress cam bucket hold down by wedging a screwdriver or suitable tool (allen key) between cam bucket and cam remove shim measure with micrometer an relace with a shim 0.15 thinner depress valve remove wedge and measure clearance (if any) repeat procedure 4 each cylinder if clearance to large replace shim with a thicker one till clearance is in spec

Jul 20, 2010 | 1981 Suzuki GS 750 L

1 Answer

What is the right valve clearance for a 1979 suzuki gs850 i had to replace the head and cams but the shims are not in the head how do i check the clearance and at what cam position do i check them at


You need to put the shims in and fit the camswith all the caps and bolts on.
Then measure between the cam lobes and the shims with a feeler gauge, when the cam lobes high point is away from the shim bucket.
and write down all the measured clearances.
Then remove the cams and fit the correct thickness shims to get the clearance correct.
Fit the cams again and check, this can take a couple of tries if there were tight clearances in the first instance.
either fit the cam chain up each time to do both cams or make sure the pistons are only half way up the bore and do one cam at a time, to make sure the pistons and valves dont say hello.
cant help with exact clearance but a kawasaki 750 is 3-7 thou which will be pretty close as the shims let you adjust 2 thou at a time
ie if the measured clearance was 2 thou you would need a thinner shim to adjust the clearance to 4 thou

Jul 15, 2010 | Suzuki GS 750 Motorcycles

1 Answer

What are the valve clearance specifications for the 2001 ZX-9?


Hi
Inlet valve clearance 0.15 - 0.24
Exhaust valve clearance 0.22 - 0.31
To be measured with engine cold, preferably left overnight

Ride Safe
Bike-Doc

May 13, 2010 | 2001 kawasaki ZX-9 R Ninja

1 Answer

Excessive Cam Noise


sounds like the valves are hitting the pistons. recheck cam timing and valve clearance.

May 25, 2009 | 1996 Honda RVF 400 NC35

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