Valve Adjustment - Gen 4 - Kawasaki ZX-10R.net
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post #1 of 33 Old 11-21-2016, 07:18 PM Thread Starter
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Valve Adjustment - Gen 4

I did some searching and looked at all I could find. I'm planning on doing some maintenance this winter to include checking the valve clearances. This is my first time doing this, so just seeing if anybody that's previously done it on their Gen 4 had any tips or tricks. I have the service manual in hand and don't foresee any issues. But figured I'd take any advice from those who know more than I do. Thanks.


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post #2 of 33 Old 11-21-2016, 07:35 PM
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Degree your cams

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post #3 of 33 Old 11-21-2016, 07:56 PM
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I did my first valve adjustment (on my Gen 4) a couple months ago. It was so satisfying doing it by myself!

It was straightforward for the most part. Here are a few points to consider:

- make your life easier by putting masking tape tags on all the various plug ends to match them back up after.
- you'll have to cut the rubber mat in a couple places which the manual doesn't mention as far as I recall.
- zap strap the timing chain onto the cam gears and crankshaft sprocket to preserve the timing and tilt the cams out of the way without removing them entirely. It'll be a little tight getting to the buckets for cylinder 4 but there will be enough room. I pulled my cams out the first time but still had to adjust a valve after re-installing and used the zip tie method the 2nd time around which was faster.
- make sure you have a pivoting magnet tool to extract those buckets.
- I used more 1.80 shims than any other size but I also have higher mileage (though relatively low rpm) than most bikes. I believe that most of my required shims were in the 1.75-1.85 range.
- this miniature ratchet combined with a 4mm allen bit will also make the job much faster when re/re'ing the cam cover bolts. They have a zillion threads and take FOREVER with an allen key, especially for the bolts tucked way back under the frame spar.

Naro Ratchet Driver & Bit Set | eBay

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post #4 of 33 Old 11-22-2016, 04:43 PM Thread Starter
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Awesome, thanks for the replies. I already have the ratcheting driver which has made life a lot easier doing other jobs as well. I'm looking forward to doing it since I love working on the bike and love learning new things about it.


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post #5 of 33 Old 11-22-2016, 05:40 PM
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Also have some cardboard handy. There's a piece of compressed foam sandwiched between the radiator and cylinder head. Once you remove the valve cover, the foam expands and overlaps with the mating surface of the cover. I cut a piece of cardboard and slipped it in front of the foam to push it back out of the way which gives you more room to do the service.

It's hard for me to explain but you'll see what I mean once you expose the valve cover.

2013 ABS, Bridgestone T30 Evo, Woolich, Danmoto shorty & link, Rifleman's 1/5th turn, K&N, GP shift, Gen5 shock/links/dogbone, JT (-1/+0), EK, Shorai, EBC HH, AllBallz roller steering, heated grips, shorty levers, MotoDynamic signals & relay, plasti-dipped and vinyl wrapped (all green to black), Bestem carbon, PUIG Pro sliders, solo cowl, modified OEM sprocket cover, TST fender elim. w/LEDs. 45,000km+ and going strong!
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post #6 of 33 Old 11-23-2016, 03:42 PM Thread Starter
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I get what you're saying. Thanks for all the tips.


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post #7 of 33 Old 12-12-2016, 05:13 PM Thread Starter
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I think I remember see something about this before, but is the rubber mat just for sound? Heat? Or both? And is there any issues with just removing it completely? I can't find where it was mentioned before. I know it was a while ago.


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post #8 of 33 Old 12-12-2016, 05:17 PM Thread Starter
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Never mind. I finally found my answer. I guess it's staying.


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post #9 of 33 Old 12-12-2016, 07:41 PM
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I did mine on my fiances 08 zx6r and my 07 zx6r track bike. Follow this dudes video. He is pretty spot on except one part later on when setting tdc. He said the manual is weong but its right. He forgot that one rotation of the crank does not equal 1 rotation of the cams. Other then that he is spot on.

https://youtu.be/dMSJriAucTo

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post #10 of 33 Old 12-12-2016, 07:45 PM
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Quote:
Originally Posted by Chriscm922 View Post
Never mind. I finally found my answer. I guess it's staying.


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What was the answer. I cut mine to shreads getting it out to install block off plates. I can put each piece in but its in like 7 pieces. That thing was a bitch.

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