Question about 2003 kawasaki KLX 300 R

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What is the intake and exhaust adjustments on the 2003 klx 300 with feeler gauge

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Intake is .002 and exhaust is .004. When setting remember that the proper way to adjust the valves on this model is the 'go-no-go' method. For intake, .002 will go and .004 will not. For exhaust, .004 will go, .006 will not.

Posted on Nov 23, 2009


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1 Answer

How do I adjust the valves on my courage 21 engine

This might be a little late...but this is from the service manual.

With engine at TDC of compression stroke, insert
correct size flat feeler gauge (see below) between
appropriate valve stem and rocker arm. Tighten
adjustment nut with a wrench until a slight drag is felt
on feeler gauge. Hold nut in position and torque set
screw (T15 Torx drive) to 5.5 N·m (50 in. lb.). To
prevent damage to nut, torque Torx screw only.
Perform adjustment procedure on other valve.
Clearance Specifications-Valve
Intake Valve 0.127 mm (0.005 in.)
Exhaust Valve 0.178 mm (0.007 in.)

Oct 19, 2014 | Husqvarna Garden

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Adjustment clearance valve rocker tappet

Pulsar 135 original tappet clearances
EXHAUST Valve 0.10 mm
Get this valve adjustment done by the experienced mechanic with the help of Feeler Gauge

Aug 28, 2013 | 2010 Bajaj Pulsar 135 DTSi

1 Answer

Rattle nosie on tappets on engine start up,do tappets or valves need adjustment,and if so what are settings,and the best way to do the job,regards eamo.

Sometimes a dirty oil filter will cause lack of oil to the top end at startup.
As soon as the oil warms, it flows better and faster and hence the noise goes away after warm up.

If you need valves adjusted, the motor must be at TDC on compression stroke(both valves closed)
The motor must be cold do not try to adjust the valve clearance on a warm engine.

On TDC, pull the valve covers and check the clearance on the intake and exhaust valves by inserting a feeler gauge under the tappet.
INTAKE should be : .03-05mm
EXHAUST should be .05-.08 mm

Im sure you don't need a valve adjustment. but if you do: Put Engine on TDC
Loosen the locknut with a 9 or 10 mm wrench, stick the feeler gauge under the tappet, and tighten the little square tipped valve adjuster screw clockwise until you feel friction on the feeler guage.
Enough friction that the feeler gauge feels tight but you can still slide it back and forth.
Not carefully tighten the locknut. Check the feeler guage during tightening to make sure it didn't get too tight or too loose. Once you set the clearance, move to the next valve, and repeat the process using the other feeler guage.
Once both are done put the covers back on and your done,

NOTE: You may have to remove seat, gas tank, airbox, and side covers to get to the covers.

Dec 03, 2010 | 2000 Suzuki GZ 125 Marauder

2 Answers

Procedure of tappet adjustment

make sure engine is warmed up. Put cylinder one at top dead center,remove the valve cover,loosen all adjustment lock nuts,adust intake and exhaust valves on cyl #1 and intake valve on #2 and exhaust valve on #3. now rotate crankshaft 360 degrees clockwise, now adjust intake valves on cyl#3 and cyl #4 and exhaust valves on cyl #2 and cyl tighten lock nuts and install valve cover. specs are intake valves 25mm clearance and exhaust 28mm clearance, use a feeler gauge,heres a picture to show you where to check clearance.7675a52.gif

Mar 14, 2010 | 1986 Suzuki Samurai

1 Answer

Yes I need to know how to properly adjust the valves on my 87'Yamaha, 350 fourwheeler.

Same as any four stroke engine. Usually cold. remove the fuel tank and Rocker covers, small inspection bolt near top of gear case.
Simply rotate engine to TDC (With spark plug out) (Top dead centre) as indicated by aligning timing marks through inspection bolt hole.
Using feeler gauge with correct thickness selected (As per manufacturers handbook) (I do not have them)
Now insert the feeler gauge between the rocker arm and tip of the valve. If you do not know how to identify an exhaust valve to an inlet one the exhaust ones are by the exhaust pipe, inlet ones are by the intake manifold. If tappet settings are the same for both then no problem, if different (Inlets always less than the exhaust)
When adjusting loosen lock nut and gently alter gap until you can just pull feeler gauge out, recheck after tightening. Be patient as some can take along time to adjust correctly unless you have done a few.

Dec 09, 2009 | 2003 Yamaha V Star 1100 Classic

1 Answer

Valve setting for a bayou 300

Valve setting procedure for this unit is a "go-no-go". By this I mean that for the intake valves a .02 feeler gauge will go but a .04 will not go. For the exhaust valves it is .04 will go and .06 will not go.
So, that being said, the intake is .02 and the exhaust is .04.

Oct 12, 2009 | 1998 kawasaki KLX 300

1 Answer

I found the valve specs for an adjustment on my 2006 yamaha custom 1100 on line the exhaust is at .12 and intake at .07 but i am still getting a backfire and now i can hear the valves ticking what could i...

If they are ticking, they are set too loose. try tightening them until they seat snuggly against the feeler gauge, tighten the nut, then wiggle the feeler gauge out. I am assuming you know the valves need to be adjusted while the piston for that cylinder is at top dead center?

Oct 12, 2009 | 2006 Yamaha V Star Custom

1 Answer

I did a valve adjustment and now it wont start

You adjusted the valves too tight. Back off of the adjustment before you break parts. You Have to set the rocker arm clearance when the engine is cold. (Not warm, not hot)

Use a feeler gauge.
The clearance for the Intake valves is .007 to .009. (7 to 9 thousandths)
The clearance for the Exhaust valves is .009 to .011 (9 to 11 thousandths)
You want a slight drag when you pull the feeler gauge through. This technique takes a certain amount of 'Feel'.

Jul 31, 2009 | 1999 Honda Civic

4 Answers

2001 yamaha warrior valve adjustment

with the cylinder set at top dead center compression. using a feeler gauge between the tappets and the valves there should be .002-.003in clearance on the intake valves, and .006-.007in. clearance on the exhaust valves. thank you.

Mar 23, 2009 | 2003 Yamaha YZ 250

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