valve clearance procedure - Kawasaki
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post #1 of 5 Old 04-10-2006, 08:36 PM Thread Starter
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valve clearance procedure

Hi all,

I will attempt the valve clearance adjustment within the next week or so. I need little help clearing up the procedure on page 2-31 of the manual. I don't quite understand it.

- Position the crankshaft at 1, 4 piston TDC.
TDC Mark [A] for #1, 4 Pistons
Timing Mark [B] (crankcase halves mating surface)

- Using a thickness gauge[A], measure the valve clearance between the cam and the valve lifter.

- When positioning #1 piston TDC at the end of the compression stroke:
Inlet valve Cleance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders measuring valve [A]

- When positioning #4 piston TDC at the end of the compression stroke:
Inlet Valve Clearance of #2 and #4 Cylinders
Exhaust Valve Clearance of #3 and #4 Cylinders measuring valve [A]

Here's what I understand.

1. set piston #1 to TDC by aligning mark A to mark B on crankcase. what does it mean by #1, 4 pistons?

2. measure the clearance using the apropriate gauge.

I'm lost for the next two steps. I think I'm good on shim selection and calculation.
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post #2 of 5 Old 04-10-2006, 09:00 PM
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?? i let Ivan figure that shit out!

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post #3 of 5 Old 04-10-2006, 11:40 PM
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Pistons are numbered 1,2,3,4 from left to right. Pistons 1 and 4 are at top dead center at the same time, so the mark on the crankcase corresopnds to TDC for both. (when 2 and 3 are at the bottom of their stroke.)

However when #1 is at the top of the compression stroke, the cam lobes are in a position (pointing up and away from the valve lifters) different from #4, which is closing the exhaust valves and about to begin the intake stroke (cam lobes are facing down, either ending or just beginning contact with the valve lifters)

Measure clearance at the cam lobes facing away from lifters.

When you're done taking the first four measurements, turn the crank 360 degrees to #4 TDC (it will now be in compression) and measure the other four listed clearances.

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post #4 of 5 Old 04-11-2006, 02:26 AM
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It is easier for me just to forget about all that #1 #4 TDC chit. Turn the engine until the valve you want to check has the cam lobes pointing directly away from the valve. The reason they give you that procedure is so that you can check the valves with the minimum number of turns, important for a mechanic workin' on flat rate but not important at all for the guy workin' under a shade tree.

If you end up needing to remove the cams, do yourself a favor and spend a little extra time to map the shim size on each valve so that the next time you will know what shim size you need without pulling the cams.
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post #5 of 5 Old 04-11-2006, 08:36 AM Thread Starter
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so the marking is not all that important? just sort of eye ball the cam lobe pointing away from the valve lifters? thank you very much.

from another valve thread, it makes sense if the cam has to removed, might as well replace all the shims. i haven't check the price or local store for part. what do they go for?
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