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Discussion Starter #1
Hi all,

I am adjusting the valve clearance for my 2001 Ninja 500R. The problem is that the valve stem and the adjusting screw on the rocker arm are not properly aligned.
This makes one side of the gap thicker than the opposite side. See the attached picture with the two green arrows.

How should I go about measuring the gap? Should I measure at the thinner end and adjust the screw to bring this end to within spec?

As long as the cam lobes point up (for a given cylinder), and the rocker arms are at the highest position, does it even matter to look at the "C" and "T" marks on the rotor?
I am thinking no, but want to make sure.

When I put the cylinder head cover back, do I need to apply any grease or anything else to the gasket? I don't want any oil to leak.

I noticed the yellow color on the copper oil pipes, and also some purplish spots elsewhere in the cylinder head assembly. Should I be concerned?

Also, any pro tips for easily removing the cylinder head cover without loosening the throttle/choke cables? Removing the cover completely makes it much easier to
remove the copper oil pipes, adjust the clearances, and properly re-torque the locknuts. I ended up taking the radiator out just to create enough room to push back
the cover so I can get to the intake valves, and to get to the exhaust, it's still a bit of work.

Since the bike is already somewhat taken apart, are there any other maintenance that's worth doing or checking? Anything with carburetor, cables, or anything else?

Thanks!
 

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cover the whole gap with the feeler gage, IE: measure the tightest point. the cover should fit tightly with out any grease or cement provided it is not damaged.
Yes as long at the cam lobes are pointing up ,your fine, the cams are round but for the ramps.

FOG
 

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Discussion Starter #3
Thank you, fog. So, the fact that the stem tip face is not parallel to the adjusting screw face, is not important?
 

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Thank you, fog. So, the fact that the stem tip face is not parallel to the adjusting screw face, is not important?
Well it indicates either a bent rocker arm or a mfg defect. your question was were to adjust it. Seems unusual but not a major problem.

FOG
 

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The end of the valve stem is flat; the end of the adjusting screw is curved. When the cam moves the rocker down to open the valves, the curved end of the adjusting screw will "roll" over the flat end of the valve stem. Just slide the feeler in there to measure the clearance at the tightest point. Perfectly normal; not likely you have a problem.

The yellow color on the oil feed tubes is where the tube is brazed to the end fittings.

If the gasket passes the "thumbnail test" (i.e. still soft rather than rock hard), there's no problem reusing it. Just clean both the gasket and the sealing surface and use a small dab of RTV sealant at the corners of the half moons. Be careful tightening the hold down bolts; they have a shoulder which bottoms out. Many a novice has broken a bolt by going overboard when tightening.
 

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You should apply the RTV sealant along the entire dip of the half moons.

 
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