Illustrated Valve Clearance Adjustment - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 99 (permalink) Old 10-18-2006, 2:17 AM Thread Starter
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Illustrated Valve Clearance Adjustment

Here you go...

Illustrated Valve Clearance Adjustment for the 2006 Kawasaki EX-500/500R (1.76 mb)

Adobe PDF format, ready to print and enjoy
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post #2 of 99 (permalink) Old 10-18-2006, 6:56 AM
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Re: Illustrated Valve Clearance Adjustment

Thank you!

2006 ZX10R - nuff said<br />2006 ZX6R - The last 636 :-(&nbsp; SOLD<br />2006 500R - Will be around for a long time :-)&nbsp; SOLD<br /><br />
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post #3 of 99 (permalink) Old 10-18-2006, 10:57 AM
 
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Re: Illustrated Valve Clearance Adjustment

this seriously just made my day. thanks!
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post #4 of 99 (permalink) Old 11-3-2006, 3:24 PM
 
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Re: Illustrated Valve Clearance Adjustment

That's a really good write up. It makes me wonder why all bikes don't have adjusting screws.

My new bike has a shim under bucket set up. I'm not exactly sure what the advanage of this would be. But I think I need to get new shims and stick them in there somehow.

Anyone know more about this?
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post #5 of 99 (permalink) Old 11-3-2006, 3:32 PM
 
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Re: Illustrated Valve Clearance Adjustment

yea man i do actually, my brother and i just installed some new "Hot Cams" in his Suzuki DRZ400SM, and his of course has shims under buckets. They are a pain in the ass, because in order to get to them you have to take the cam out, and all that allows for that, then take the bucket out with like a magnet and underneath there u will see a small disc, i.e. the shim, and in order to get the proper clearences you have to decrease the size or increase the size of the shim from which you can choose them from a SHIM KIT, which came with my brother's Hot Cams set.

And you have to keep doing this until the clearences are right, so measure everything before hand as far as clearences, and then add or subtract thickness accordingly.
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post #6 of 99 (permalink) Old 11-3-2006, 7:35 PM
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Re: Illustrated Valve Clearance Adjustment

The reason your Ex has Adjuster screws is the designers used rocker arms. Since this method is not a reliable as Shim under buckets the adjustment must be made more frequently. Why they did that is anybody's guess. Usually it's because of a single cam to do both intake and exhaust. Since the EX has two cams it's a bit of a puzzle.
I can only assume that it was a cost thing,(shim under Buckets are more costly to manufacture) or a space thing (SUB are taller and make the engine taller).

But The Shim under bucket system is far superior from a point of view of performance ( it's the lightest ) and reliability ( no adjustments to go off). There is a shim over bucket system too, where the shim sits atop the bucket in a recess. These can be changed with out removing the cams, by just depressing the spring and fishing out the shim. Downside here is the shims can come out if you float the valves (overrev).

Yer pays yer money and yer takes yer choice
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post #7 of 99 (permalink) Old 11-13-2006, 2:09 PM
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Re: Illustrated Valve Clearance Adjustment

Thanks for reposting. I was hoping that this write-up wouldn't be gone because it was so well done. I was thinking I probably should do this because I've put 10,000 miles without any adjustment. Is there really any way of knowing when it is time to readjust the valves? My bike runs great but was wondering how you know when you need to do this?
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post #8 of 99 (permalink) Old 11-13-2006, 7:21 PM
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Re: Illustrated Valve Clearance Adjustment

You check them.

FOG

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post #9 of 99 (permalink) Old 12-11-2006, 4:27 PM
 
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Re: Illustrated Valve Clearance Adjustment

I want to buy an EX250 as my next bike. Is the procedure the same on the little twin?
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post #10 of 99 (permalink) Old 12-15-2006, 10:54 AM
 
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Re: Illustrated Valve Clearance Adjustment

Something very important was left out of the writeup. The crankcase breather (not the thermostat, like the writer believes) - which I believe is called something like an air valve in the manual - has two tiny and short tubes that go in between the head cover and the head. Be sure that these stay in the head or they may fall out of the head cover down into the engine!

I was doing my valve clearances yesterday and this tiny piece fell down into the timing chain gallery. Luckily I noticed it and plucked it out. If I had not noticed it, it would have trashed the timing chain / gears.
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post #11 of 99 (permalink) Old 4-5-2007, 1:41 PM
 
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Re: Illustrated Valve Clearance Adjustment

What a great help - Tony Reyes - A BIG thank you.[/color]
Just purchase an '06 (Lime) with only 540 miles. Doing first service.
I also have an '04 r1150r and doing valves is a breeze on that.
Back to Tony's info. Spent 1 hour last night..(just signed on yesterday) and am as far as #11.
Did note that on #6 no mention of the 2 forward tubes under tank near Rt T/Tree. This was obvious though.
The info on this site is just amazing.
Friend has an '04 ex250 and info on Ninja 250 forum great too.
Will be doing all service on that as well.
Thanks to you all.

Alan, Cypress, CA
'06 ex500 600 mls - my new commuter bike. Just love it,
'04 BMW r1150r 33,000 mls
'04 M-G 750 Breva 18,000 mls.
'
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post #12 of 99 (permalink) Old 4-18-2007, 2:42 PM
 
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Re: Illustrated Valve Clearance Adjustment

When doing this service are there any gaskets that I need to worry about replacing?
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post #13 of 99 (permalink) Old 4-18-2007, 5:02 PM
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Re: Illustrated Valve Clearance Adjustment

no

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post #14 of 99 (permalink) Old 4-28-2007, 11:59 PM
 
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Re: Illustrated Valve Clearance Adjustment

Hi, this is Tony Reyes. Thanks to Wikipedia I found this site. I was quite upset when ex500 riders died and didn't realize another ex500 site had sprung up. I'm glad to see my valve clearance guide survived. Thanks to whoever put it together! This is my first post here, but I hope to become more active and maybe produce a few more maintenance guides. My 7500 mile maintenance is coming up next weekend.
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post #15 of 99 (permalink) Old 5-18-2007, 9:38 AM
 
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Re: Illustrated Valve Clearance Adjustment

I just adjusted my valves last night following this guide to the letter, except where you rotate the crank to the "F" position. To get the cam and lobes to the position described, I couldn't use "F". Is that OK? I made sure the dot on the cam was in the same place as the guide showed, with the lobes facing upward. I'll start it tonight when I get home so if I did it wrong please somebody warn me now.
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post #16 of 99 (permalink) Old 5-18-2007, 10:04 AM
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Re: Illustrated Valve Clearance Adjustment

your fine.

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post #17 of 99 (permalink) Old 5-18-2007, 8:12 PM
 
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Re: Illustrated Valve Clearance Adjustment

Thanks FOG.

Those valves were as tight as a.... well you finish the thought, let's just say they were way out of spec. Runs pretty good now and actually idles where it's supposed to instead of almost dying.
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post #18 of 99 (permalink) Old 6-20-2007, 12:30 PM
 
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Re: Illustrated Valve Clearance Adjustment

I performed my second valve clearance check this past weekend and made a video how to this time to supplement the write up. This time I made sure to correctly refer to the air valve as an air valve and not a thermostat!

The first part can be seen at http://www.livevideo.com/video/lessd...stment-on.aspx

The second part is at http://www.livevideo.com/video/lessd...stment-on.aspx
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post #19 of 99 (permalink) Old 6-30-2007, 5:53 PM
 
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Re: Illustrated Valve Clearance Adjustment

I followed the guide, and it helped me soo very much, Good news too, the valves were all in spec, so no work needed to be done. its good to have peace of mind though.. Thanks for the guide!
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post #20 of 99 (permalink) Old 7-22-2007, 10:58 PM
 
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Re: Illustrated Valve Clearance Adjustment

i did my first valve adjustment today, the write up is excellent. had to make one phone call to dad during the process, for a little more explanation, but all in all it went good without any difficuties, except for the strong gust of wind half way through process blowing my print of the write up away. blew it out from under my drill, across the road up over the neighbors house and into the woods, that was alittle nerve racking. had to adjust the exhaust side, they were all .002 out of adjustment. intake side was still golden. i'm sure this was the first time the valve cover was off, and i was at 14,175, so it was a good way to spend a sunday afternoon. anyone considering doing it themselves or taking it in to a shop, i can eaasily say it is rather easy, so do it yourself.

Bastard Child
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post #21 of 99 (permalink) Old 8-12-2007, 5:06 AM
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Re: Illustrated Valve Clearance Adjustment

holy crap, this writeup was awesome. i didnt bring my bike for its first tune up and this was long overdue. i did the valve adjustments and took out the play from the throttle and now it runs awesome. all the exhaust valves were off spec, i wonder how much mileage i will get now. this did take me 5 hours longer than anyone else but at least its done. thanks again
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post #22 of 99 (permalink) Old 8-21-2007, 9:44 AM
 
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Re: Illustrated Valve Clearance Adjustment

Thank you VERY much for the guide, it was quite helpful!

I have a few corrections or modifications I would like to propose, however...mainly because common sense didn't prevail for me when the instructions didn't work perfectly. First, I ran into problems on page 12 where the guide instructs the reader to turn the crank to the "F" position. On my 2001, this did not line up the cams properly. I even turned the crank 180 degrees with the same results. After adjusting the 1st cylinder, I observed the cams and waited until they were both pointing up. At this point, the crank was not at the "F" mark, but the intake cam gear had the correct mark on it.

Additionally, page 8 instructs the reader to "Remove the two cooling hoses at the thermostat and tuck the thermostat behind the right side carb." The two hoses and cylindrical device in the image are not coolant hoses and thermostat. The "thermostat" is actually the air switch valve mentioned in the maintenance section of the operator's manual. The thermostat is attached to the radiator cap assembly and immobile.

Besides those two minor issues the guide is quite helpful and very straightforward. Thank you for taking the time to write and publish it for public use!
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post #23 of 99 (permalink) Old 12-2-2007, 8:43 PM
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Re: Illustrated Valve Clearance Adjustment

Hmm I should do this. It's been about 8k since it was last done . Is the procedure the same for pre-94's?
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post #24 of 99 (permalink) Old 12-23-2007, 12:40 PM
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Re: Illustrated Valve Clearance Adjustment

The guide is great. I did my valve adjust in a little more than 4 hours.

4 hours?!?!? That was with fending off my 2 boys, explaining the purpose of valves to my visiting brother, and eating dinner. It could have been less time, but I played with removing the valve cover longer than necessary. I finally gave up, and pulled the 4 mounting bolts out of my radiator/fan assembly. After moving the radiator and fan out a few inches, I had no trouble getting the valve cover out of the frame.

My EX500 is a 2007 model, and the routing for one of the coolant hoses and the location of the radiator fill cap are different than the guide. This may have contributed to my need to deviate from the walkthrough. In addition, the mark on the cam gear was correct for cylinder #2, but the "F" wouldn't line up. Oh yeah, thanks MaximX for mentioning the small tubes that connect the head and valve cover. Mine were stuck in the valve cover, and fell into the gallery as I removed it. Yeah for magnets!

All in all, since both of my intake valves on cylinder #2 were out of spec, this was a worthwhile endeavor.
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post #25 of 99 (permalink) Old 12-23-2007, 3:49 PM
 
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Re: Illustrated Valve Clearance Adjustment

you may have been mistaking the T for top dead center for the F mark i did that took me a good five mins to break out the droplight and my fathers glasses
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