DIY Valve Adjustment Video

[gt_turbo]

so i measured my valve clearance and 3 of the exhaust valves are out of spec. the last exhaust valve is on the bottom end of the tolerance. all the intake valves are right in the middle of the spec. so all i have to do is remove the exhaust cam gear and cam shaft to work on the exhaust shims correct? the intake side doesn't need to be touched in my case?

[quanttrom]

Originally Posted by gt_turbo

so i measured my valve clearance and 3 of the exhaust valves are out of spec. the last exhaust valve is on the bottom end of the tolerance. all the intake valves are right in the middle of the spec. so all i have to do is remove the exhaust cam gear and cam shaft to work on the exhaust shims correct? the intake side doesn't need to be touched in my case?

sounds good to me !
Make sure your timing(timing marks all align) is good when you are done and everything should be perfect !

[headshrink]

Originally Posted by quanttrom

When you are facing the engine from the timing chain side it rotates clockwise.

So basically the SM does tell us to rotate opposite (clockwise from alternator- [L] side) when adjusting for TDC.

[gt_turbo]

valve job #1 completed successfully! i am relieved my bike works again after that! what a job it was.

mental notes for next time:
1. do not drop feeler gauge into chain gap. thank goodness those things are magnetic.
2. mark chain and cam gear before taking off chain tensioner and cam covers. some how my chain/cam gear jumped a tooth after removing all that. thank goodness for the SM i had to re-time everything.

some tips for others:
1. if you have shogun sliders the right side bar needs to come off to make it easier to work.
2. if you took out your air box, re-installing the chain tensioner is super easy - just turn the tensioner in all the way and you can easily hold the screw driver and tensioner in place while you tighten the nuts.

other than those slight mishaps, everything went pretty smooth. i test rode my 250 and it feels smoother to me. major props to casey for making this video, it was very helpful alongside the SM.

[quanttrom]

Originally Posted by gt_turbo

valve job #1 completed successfully! i am relieved my bike works again after that! what a job it was.

did you sync your carbs?

[gt_turbo]

Originally Posted by quanttrom

did you sync your carbs?

not yet. i will eventually when i get around to building a manometer or vex's bottle method.

[edxmon]

Does the creator of the thread still offer his services to do valve jobs? I just bought a '08 with 10k miles and I don't want to assume the previous and 1st owner of the bike did them and be wrong (he no longer lives in the US, a sibling sold me his bike). I consider myself mechanically inclined but I'm somewhat intimidated by doing this on this machine that is completely new to me.

I will send "KC" a pm, and ask if his services are still available.

[CZroe]

Originally Posted by edxmon

Does the creator of the thread still offer his services to do valve jobs? I just bought a '08 with 10k miles and I don't want to assume the previous and 1st owner of the bike did them and be wrong (he no longer lives in the US, a sibling sold me his bike). I consider myself mechanically inclined but I'm somewhat intimidated by doing this on this machine that is completely new to me.

I will send "KC" a pm, and ask if his services are still available.

Might wanna point out the cheaper shim refill options I mentioned here as I don't think he knows about 'em. He has done more valve jobs since doing mine in the video and we were actually out of one of the sizes we needed! We ground one down but somewhere in this thread he said he wouldn't be doing that anymore.

FYI, Banning isn't terribly close to San Diego. I arranged to stay the night but that might not be an option for you. Expect to dedicate a whole day to the trip there, job, and trip back.

[edxmon]

Originally Posted by CZroe

FYI, Banning isn't terribly close to San Diego. I arranged to stay the night but that might not be an option for you. Expect to dedicate a whole day to the trip there, job, and trip back.

If he's willing to do the job, I'm willing to make the trip, assuming I don't have to relocate for my internship this summer. I already drive 100mi roundtrip to work, 100mi one way spread over two days should be ok, with a few pit stops :P

I would just like peace of mind knowing that this is being done right and by a person of trust, not to mention avoiding getting robbed by the dealer or a shady garage.

I sent him a PM, and hope to hear from him soon. Is there any member in closer vicinity to SD that does this service?

[MikeJames21]

so when i hit 7300 miles i realized that 7500 miles is when you should do this. i am now at 8500 and i'm starting to hear a rattle noise, so i've been basically trying to put it off until oct/nov sometime when i stop riding. i am in the middle of this 2nd video now, stopping it after every step/good bit of info and typing it into a wordpad document. lol. i usually watch diy videos and then just go and complete the task but this is a bit more involved, sort of so i am keeping notes and step by step instructions. i don't know when i will tackle this, maybe in 12 days when i am on a week vacation from work. wish me luck guys...

[MikeJames21]

oh yeah, thanks for the videos!!!!!!!!!!!!!!!!!

[headshrink]

Originally Posted by MikeJames21

i am now at 8500 and i'm starting to hear a rattle noise

My money is on your cam chain tensioner, which is normal. If it bothers you get a manually adjusted one. It could also be slide-slap.... also normal. I seriously doubt it is related to your valves though.

[MikeJames21]

Originally Posted by headshrink

My money is on your cam chain tensioner, which is normal. If it bothers you get a manually adjusted one. It could also be slide-slap.... also normal. I seriously doubt it is related to your valves though.

should i still try to do valve adjustment? which is needed at 7500 miles?

[headshrink]

Originally Posted by MikeJames21

should i still try to do valve adjustment? which is needed at 7500 miles?

Sure. If you're up for it.

[har0ld]

My girlfriend has an 08 250r and is in need of a valve check/adjustment. I see that the videos no longer work. I was wondering if the videos are uploaded somewhere else where I can watch them? Thanks in advance!

[CZroe]

Damn. I know Casey's YouTube channel is still running.

[cuong-nutz]

Unless someone saved them, I don't think so. There might be others out there or you could read the pictorial in the DIY.

[headshrink]

Originally Posted by CZroe

Damn. I know Casey's YouTube channel is still running.

He still around?

[alex.s]

i heard he did a wheelie off of a mountain

[headshrink]

Originally Posted by alex.s

i heard he did a wheelie off of a mountain

Joking...?

[CZroe]

Originally Posted by headshrink

He still around?

We PMed several days ago, so: yeah. He mentioned his YT channel, but now I have no link to it.

[har0ld]

Thanks for your help guys. I guess I'll just read the pictorials and take my time, but hopefully those videos can be retrieved.

[cuong-nutz]

Originally Posted by har0ld

Thanks for your help guys. I guess I'll just read the pictorials and take my time, but hopefully those videos can be retrieved.

If you get stumped on a step, just ask. A few of us are pros at doing them by now

[alex.s]

its really not hard at all. don't force anything. use proper torque specs on the cam cage bolts. don't be lazy about removing things to give yourself better access. don't use open end wrenches. (don't strip anything.) remember to set it to TDC before you take the cams out or release the CCT. remember to reset the CCT when reinstalling it or you'll mess up your cam chain. i like to lube my feeler gauge tip with some oil before measuring. sometimes it wont fit in right and it seems like its measuring larger unless its oiled up first. make sure you write down your measurements. don't be lazy and try to do it in your head, its easy to make a small mistake and then you have to take the cam cage out again.

always double check your measurements before and after you make a change to shim size. triple check all of the measurements when you think you are done and are ready to put it back together. better to catch a mistake now than have to take it all back apart again or have that thought in the back of your mind or something.

[lilyanx217]

Which gasket sealant should I use? Mine keeps leaking oil even though I applied a coat of gasket sealant around the gasket and engine

[CZroe]

Originally Posted by lilyanx217

Which gasket sealant should I use? Mine keeps leaking oil even though I applied a coat of gasket sealant around the gasket and engine

What kind of gasket maker did you use? Did you scrape off the old stuff first?

[lilyanx217]

Originally Posted by CZroe

What kind of gasket maker did you use? Did you scrape off the old stuff first?

I used the valve cover gasket, scraped off the old gasket sealant. And applied a coat of the gasket sealant on the engine and the new gasket.

This is the gasket sealant I used: http://performanceparts.com/part/Edelbrock/9300

[alex.s]

the gasket might be old and cracked. maybe its not properly aligned, its easy for it to slide just a mm out of alignment which causes those little edges to get pinched and it leaks a little oil slowly. if its got a good amount of miles maybe just order a new gasket and replace it

[CZroe]

Originally Posted by lilyanx217

I used the valve cover gasket, scraped off the old gasket sealant. And applied a coat of the gasket sealant on the engine and the new gasket.

This is the gasket sealant I used: http://performanceparts.com/part/Edelbrock/9300

Hmm. Other than Alex's hunch all I can wonder about is the temperature. Kawasaki specifically said to use a high temperature gasket maker. While that one doesn't say anything about being useful for particularly high temps, the applications do sound... applicable, and I would expect temps to be similar.

[cuong-nutz]

Could just use a tube of Moto Seal by Permatex. Not sure how different it is from their regular automotive sealers.

[DryUrEyesM8]

I think I'm overdue. Any chances someone will repost those vids?

[Graugaard]

your enigne should easly could do 15000 miles without a valve adjust... sersly... 7500 is very early O.o.

[lilyanx217]

Originally Posted by Graugaard

your enigne should easly could do 15000 miles without a valve adjust... sersly... 7500 is very early O.o.

Not really. I adjusted my valves at 7.5k and if I remember 2-3 of them were too tight. Before I adjusted it, everytime I ride on the freeway at about 80mph at 9k RPM, when I get off the freeway, I feel the side of the fairings with my knees and it's hot. I rather be safe and adjust it ever 7.5k miles. After I adjusted it, everything was fine.

[DryUrEyesM8]

Originally Posted by lilyanx217

Not really. I adjusted my valves at 7.5k and if I remember 2-3 of them were too tight. Before I adjusted it, everytime I ride on the freeway at about 80mph at 9k RPM, when I get off the freeway, I feel the side of the fairings with my knees and it's hot. I rather be safe and adjust it ever 7.5k miles. After I adjusted it, everything was fine.

Yeah I think I will adjust them. I'm already past taking the tank off since I was doing work to it already. It's also a little cold to start riding yet so no reason not to.

Blog

[Hero Danny]

Nevermind, It stinks the video is gone!!

[sjc88]

Its not too bad Danny. Just adjusted mine for the first time, not as hard as I originally thought, just time consuming. Follow Vex's DIY and ask questions if your stuck.

[Hero Danny]

Originally Posted by sjc88

Its not too bad Danny. Just adjusted mine for the first time, not as hard as I originally thought, just time consuming. Follow Vex's DIY and ask questions if your stuck.

I bought a owner's manual (ran me $25) and I printed out Vex's guides for checking the lash and adjusting them. I ordered some feeler gauges and some iridium plugs (mine as well change them since they've probably never been done) I'll plan to do it in a few weeks with my father (he used to work on valves all the time)..

[Guilty]

As the video that was posted has been removed some time ago, is there anywhere in the internet that shows this? I can only find some for 07 and earlier. Does it exist anywhere where I am not looking?

[bob706]

I have looked everywhere and cant find anything. there is a member who said he saved it and I pm'd him but no response

[peperino]

Hey guys, I hope you can help me. I couldn't measure the right cylinder.

I rotate the engine until the camshafts were aligned in the flywheel with the 2T mark and in the camshaft gears the two lines were even, like

https://goo.gl/photos/E2qgyuFsYw5N95tK6
https://goo.gl/photos/Mpv5q5zEjqsjTM2N7

With this position, I couldn't fit almost any feeler gauge, I tried 0.15 and 0.10 but they won't go in. What I'm doing wrong here?

Then, I measured left cylinder, by aligning 1T mark with the lobes pointing away from the bucket like this

https://goo.gl/photos/royJ7vcphG6ZSbjQ6


This gave me a reading, but weird one, as folows:

Intake1: 0.21mm
Intake2: 0.22mm

Exhaust1: 0.20mm
Exhaust2: 0.20mm

Are my intakes close to the upper limit and my exhausts way off the lower limit?

Help!