[Blade1413]

Hey Guys,
I haven't been around for a while due to finals and all. I haven't had much time at all, but now that school is out of the way I started some wrenching on the bike..

I've got most of everything apart so far and am working to get the valve cover off today.. I don't know what to hope for, because the valves are quite loud as they are. I really don't want to have to do all the work of putting new shims in but I kindof know it's inevitable because it has never had a valve adjustment done with 17,000 miles on it..

Well I'll post some pictures up soon and update you on the progress.. feel free to make any suggestions for doing the adjustment, I would appreciate it..

 

[Gas Man]

Yeah... remember, that Kaw's are notorious for loud valves... most say they are known for being clunky motors...

But I have little to input... never attempted a valve adjustment before... But Blade you said you use to do them all the time on the EX500... I'm sure that expierence will be GREAT for you working on the 9R!

 

[Gas Man]

Oh and 2 more things....

First!! Don't forget to take lots of pics.... :nopicsbs:

Second, don't forget a muffin pan to keep your screws, nuts, and bolts in order!

 

[snadamo]

if you need a picture tutorial, I have a VERY handy web page that goes through that and much more, with my 01 ZX6r (I believe that the bike in the manual is a 2000). Im sure the valve setup is the same, just probably bigger.

 

[canadaman123]

if you need a picture tutorial, I have a VERY handy web page that goes through that and much more, with my 01 ZX6r (I believe that the bike in the manual is a 2000). Im sure the valve setup is the same, just probably bigger.

what's the site?

 

[Blade1413]

Well guys.. I have to say that the process has been longer and harder than I ever expected. My old EX500 was so simple to do the adjustment, only took me a couple of hours. This bike though has taken me many many hours just to get the valves.
I have every fairing off of the bike now, including front headlights. I have the carbs off, because otherwise I could not get the valve cover out.. lol
Now I'm actually taking the measurements and going to go to the shop tomarow to get the new shims in order to bring it in spec.. I had to stop earlier and was only able to check 4 exhaust valves, with 3 off.. the worst was at .17mm where it should be between .22 and .31 or so...
Once I have everything written down and the specs taken I will go to the shop and buy the new shims..

I'm taking pictures but have to get them uploaded to the computer tonight some time.. I'll keep you guys updated..

Overall if I could go back and pay someone 300 for an adjustment and tuneup I would have.. But this is a good learning experience. The EX and this bike though use different valves.. The old EX i would only have to loosen a nut and then make any adjustments, this one I have to take out the camshaft, camchain tightner and a lot of other odds and ins just to get the new shims in..
I don't know if I will get it done by wednesday when I fly out for new york... I might work long and hard tonight just taking the measurements and taking out the camshaft and everything.. Then I will hopefully be able to put it all back together tomarow??? I do have to work tomarow night though.. hmmmm

Crunch time!! :bonk: :bonk:

 

[Gas Man]

WOW... take all that out? Man o man!! I hope you bought new gaskets for all of that!

And that amount out of adjustment isn't that bad for the miles!!!

 

[jeeps84]

WOW... take all that out? Man o man!! I hope you bought new gaskets for all of that!

And that amount out of adjustment isn't that bad for the miles!!!

It should have a reusable rubber gasket.

It is a PITA with shim under buckets.

 

[Gas Man]

Yeah I understand that...but why not just replace it versus screwing with it again if it leaks after re-essembling it!

 

[jeeps84]

Yeah I understand that...but why not just replace it versus screwing with it again if it leaks after re-essembling it!

Good point but, they will usually show any defects and only leak due to being improperly installed.

 

[Blade1413]

Adjustment Completed

I haven't been on for a week now because i'm up in NewYork, freezing my arzzz off.. I worked on the bike from 2am to 8am, being able to get on for a fifteen minute test ride before I had to leave for the airport.. :lol:

I spent about 45 minutes with the owner of a shop I always go to, just going over all the different sizes that I had and therefore what sizes I needed to bring it into adjustment.. He was great about it, the dealership wanted $11.00/shim and they would have had to be shipped.. :yikes:

Plus I didn't even have a gauge in order to compare what I had and figure out what I would need.. It ended up costing me $20 dollars as I gave the owner all my old ones in exchange for different sizes..

I'm glad I did the job myself though it was a little rushed, I've never seen anything so complicated in order to do a valve adjustment.. I'm surprised it only costs $300 to have a full tuneup and valve adjustment, I wonder if they even bother with the close ones..

Overall I believe the worst were adjusted by about .10mm from the low end of the specs, which isn't that bad but then again they were getting a little tight. Expecially the exhaust side which end up getting hotter and therefore be more likely to cause future problems...

It's probably psychological but when I rode the bike it seemed a little more responsive and a little faster.. I'm sure most if not all was in my head.. I did clean and oil the K&N which was pretty dirty, as well as spotting a problem with the airbox housing, which I fixed. (The drain line which is supposed to be plugged so no air could bypass the filter had no line on it, therefore possibly letting debri into the carbs..) New Oil and new K&N oil filter..

Next time because I know what i'm doing I could get this done in half, if not a 1/4 of the time... Though thank god next time won't be for another 15,000 miles or so.. :dthumb:

I didn't get too many pictures of the bike totally torn apart, :sorry: , I was too busy trying to get everything done before I left for NY.

Anyways I'll talk to you guys later,
Merry Christmas!

 

[Gas Man]

I'm glad that it wasn't too bad.

As far as that bypass on the airbox... I'm puzzled... I'm not quite sure what happened to the thing.... probably another North American van lines problem! :lol:

 

[jeeps84]

I'm glad that it wasn't too bad.

As far as that bypass on the airbox... I'm puzzled... I'm not quite sure what happened to the thing.... probably another North American van lines problem! :lol:

:skep: :leaving:

 

[bumblebee]

Dang GMan...bike needs valve adjustment...I guess you bought that chopper at the right time...:lol:

 

[snadamo]

what's the site?

Check it out


The navigation is a little strange, as its a home grown webstie but once you get the navigation down its cake. The "routine maintenance" page is the core of all the good stuff.

This bike goes over changing oil, synching carbs, valves, to removing bodywork and track prep stuff.

He also has other bikes on there too, but I think the ZX6r has the most info.


here is the page for valves

it goes over a lot here, but mainly its about the valves. this is how I learned how to remove my CCT...

 

[jeeps84]

Check it out


The navigation is a little strange, as its a home grown webstie but once you get the navigation down its cake. The "routine maintenance" page is the core of all the good stuff.

This bike goes over changing oil, synching carbs, valves, to removing bodywork and track prep stuff.

He also has other bikes on there too, but I think the ZX6r has the most info.


here is the page for valves

it goes over a lot here, but mainly its about the valves. this is how I learned how to remove my CCT...

Navigation isn't that bad if you have a bike he has listed. Just a lot of hyperlinks mixed in with text. It appears pretty informative and detailed as well.

 

[snadamo]

Navigation isn't that bad if you have a bike he has listed. Just a lot of hyperlinks mixed in with text. It appears pretty informative and detailed as well.

:iagree: Im just glad a guy with the same bike as me decided to share all his info and experience with the rest of the world. All my self repairs pretty much came from that site

 

[Gas Man]

Dang GMan...bike needs valve adjustment...I guess you bought that chopper at the right time...:lol:

Yeah I was going for the do it every other time of recommendation. Every mechanic I spoke to about it said that they RARELY ever need it at the 8k time frame the manufacture suggests. So I was going to the 16k time frame... and then I got rid of it.

Blade wanted to do it cause it was about the only thing that needed to be done...

That 6R link is pretty desent and I saved it..

 

[canadaman123]

Navigation isn't that bad if you have a bike he has listed.

exactly....anybody know how close this walkthrough is to a 2000 Yamaha R1? or, better yet, does anybody have something similar for an R1 specifically? my valves need to be adjusted and i really want to do it myself. thanks a lot :cheers: