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Discussion Starter #1 (Edited)
When I originally posted this thread 8-9 years ago the photos were hosted on Picasa. Picasa was absorbed by Google and the link lost. Since we can post pictures directly on this site now I am reposting the information. This is just a guide to help you when you are checking valve clearances. You still need a FSM (Factory Service Manual) to tear down the bike to access the valve cover as well as cam removal in case you need to change shims.
I checked my valves at 15K and 30K on my '04 XZ10R, they were within spec. In fact when I compared my clearances at 15 and 30K, the valve clearances barely changed.

If you looking for a good set of feelers gauges that measure to 4 decimal places in inches which the service manual does, I bought a set of SKF gauges. Not cheap but very good quality. I have Part Number SKF 729865 B
http://www.skf.com/group/products/maintenance-products/hydraulic-tools-for-mounting-and-dismounting/hydraulic-tool-accessories/feeler-gauges/index.html

Motion Industries carry them in the USA.
https://www.motionindustries.com/productCatalogSearch.jsp?q=SKF 729865-B Feeler Gauge


Since it easier to post the information with each picture I will use one photo-one post in sequence.

Photo #1
On the right side of engine, remove crankshaft sensor cover (small cover). Turn the crankshaft clockwise (see arrow) until TDC 1.4 mark lines up where the upper & lower crankcase halves mate (highlighted with Sharpie pen). When the marks are aligned, this means either #1 or #4 piston is at TDC of the compression stroke. Check camshaft lobe orientation or marks on camshaft timing gears to confirm which piston is at TDC of the compression stroke. Once determined check the 8 valves for this orientation.
 

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Discussion Starter #2
Photo #2
Piston #1 at TDC of compression stroke. Correct camshaft sprocket orientation. See camshaft lobe orientation (next picture) to confirm. The IN & EX marks highlighted in white on the sprockets should point at each other. Don't be confused by the markings. One sprocket is manufactured for use on both intake and exhaust cams. If the sprocket is on the intake cam (left sprocket) only pay attention to the IN mark. Like wise if the sprocket is on the exhaust camshaft (right sprocket) the EX is only mark to use.

Check valve clearance on following valves.
Cylinder #1 Intake and Exhaust valves
Cylinder #2 Exhaust valves only
Cylinder #3 Intake valves only
Cylinder #4 No valves are checked
 

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Discussion Starter #3
Photo #3
Piston #1 TDC on compression stroke. This is the orientation of the camshafts lobes for #1 cylinder to check valves clearance for:
Cylinder #1 Intake and Exhaust valves
Cylinder #2 Exhaust valves only
Cylinder #3 Intake valves only
Cylinder #4 No valves are checked
 

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Discussion Starter #4
Photo #4
Piston #4 at TDC of compression stroke. After turning the crankshaft one revolution and aligning the 1.4 mark with the upper and lower crankcase mating surface again, this is camshaft sprocket orientation to check valve clearance of the other 8 valves. Notice the IN & EX marks on the sprockets highlighted in white are now facing away form each other. Again, don't be confused by the markings. One sprocket is manufactured for use on both intake and exhaust cams. If the sprocket is on the intake cam (left sprocket) only pay attention to the IN mark. Like wise if the sprocket is on the exhaust camshaft (right sprocket) the EX is only mark to use.
Check valve clearance on following valves.
Cylinder #1 No valves are checked
Cylinder #2 Intake valves only
Cylinder #3 Exhasut valves only
Cylinder #4 All valves are checked
 

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Discussion Starter #5 (Edited)
My valve clearance chart template. Shaded valves are for #1 at TDC. Unshaded valves or for #4 at TDC.
Feel free to print it out when you do your valve adjustment.
 

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I printed off your template, that will be super handy when I'm doing my valves soon.

Thanks for the good write up!
 
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