Check your valves folks

[z400clone]

Many have been asking how to check the valves. I made a guide today to help with this task. I have already taken the plastics off here.

First, take the rubber cap off of the fuel valve. Take a flat blade screwdriver and turn the valve clockwise until it stops which will be closed. Then move the clamp back so you can get the fuel hose to come off. There will be quite a bit of fuel to run out here so I get something to catch the fuel.
http://i32.photobucket.com/albums/d41/friedad1/Picture020.jpg


Take this return line off.
http://i32.photobucket.com/albums/d41/friedad1/Picture021.jpg


Take the low fuel sensor connection off.
http://i32.photobucket.com/albums/d41/friedad1/Picture025.jpg


Unhook this FI connection. To do so, you have to squeeze the grey plastic tabs to let the hose come undone. Kinda tricky the first time. Just be gentle with them so you don't break them.
http://i32.photobucket.com/albums/d41/friedad1/Picture022.jpg



Take off the two bolts holding the tank down and slide the tank out some. Then get to this other FI connection line and take it off.
http://i32.photobucket.com/albums/d41/friedad1/Picture027.jpg


Remove the tank. The fuel valve assembly will come with it and that's what you want. Leave it all connected. You will see this after you remove the tank. Take this black heat cover off and it will expose the cam cover.
http://i32.photobucket.com/albums/d41/friedad1/Picture029.jpg


Now remove the hoses from the cam cover and take the cam cover off. Now take out your two inspection cover plugs on the stator cover(I have my stator cover off doing other things, but it is definately not needed). Then set the motor to TDC lining up with the marks on the flywheel. Only turn the motor CCW! The marks should line up on the cams with one mark pointing up and another mark even with the head deck. If the cam marking aren't like I described, you are on the wrong stroke and need to turn the motor over more.
http://i32.photobucket.com/albums/d41/friedad1/Picture031.jpg



Here is a pic of the cams how they should be.
http://i32.photobucket.com/albums/d41/friedad1/Picture032.jpg


And now I'm checking the clearance on the cams. Use a feeler gauge for this job. Mine did not need adjustment so I didn't pull the cams out.
http://i32.photobucket.com/albums/d41/friedad1/Picture033.jpg

Valve Clearances
Intake: 0.10-0.20mm (0.0039-0.0079in)
Exhaust: 0.20-0.30mm (0.0079-0.0118in)

[Quadprorider]

The black plastic cover that is underneath of the gas tank and over top of the cam cover.......Would you think that it would be ok if you were to remove that cover? Just trying to find some ways to make checking over the fittings around the motor a little bit easier.

But anyways, thanks for taking your time to write this little ariticle up. You might want to think about posting this on ********.com or ***********.com also.

Thanks again, Nick.

[z400clone]

Originally posted by Quadprorider
The black plastic cover that is underneath of the gas tank and over top of the cam cover.......Would you think that it would be ok if you were to remove that cover?


I guess I just assumed that people would remove it as you can't get the cam cover off without the black heat cover off. But yes, I removed the black cover as it just pops right up. I fixed it in the thread so it's more clear. Thanks

[Quadprorider]

Originally posted by z400clone
I guess I just assumed that people would remove it as you can't get the cam cover off without the black heat cover off. But yes, I removed the black cover as it just pops right up.

Sorry I guess I worded that wrong........

Would you take that cover off and not put it back on? I mean take it and throw it away? Or in other words does it have a purpose? If so what?

Sorry about the confusion again, Nick.

[z400clone]

It holds the fuel valve assembly in place. The fuel valve is not mounted to anything so this holds it. And I'm assuming it keeps heat off the gas tank. It's not worth tossing for the few OUNCES you would lose.

[slief]

Thanks for the informative post and for taking the time to include pictures. What if any gaskets need replacing when checking the valves? It would be good to have those in advance.

[z400clone]

No new gaskets needed. The cam cover is a rubber gasket that can be used again and again with no problems.

You won't need any parts to do this job other than possibly some shims. I can't say for sure, but I'm expecting the shim to be 9.48mm in diameter. Can anyone confirm this?

[dg95]

Is there anything tricky to getting the stator cover off? Like things to be careful with?

[z400clone]

Originally posted by dg95
Is there anything tricky to getting the stator cover off? Like things to be careful with?
Not that I can recall, but REMEMBER, I just had mine pulled for another reason. You don't need to pull yours for this job.

[LTR450_#67]

Thanks Clone I'm gonna check mine this weekend sometime since I won't be racing due to a severe ankle sprain at my last race.

later

#67

[KWAD GAWD]

Originally posted by Quadprorider
Sorry I guess I worded that wrong........

Would you take that cover off and not put it back on? I mean take it and throw it away? Or in other words does it have a purpose? If so what?

Sorry about the confusion again, Nick.
This is there for a reason. It's a heat shield, it keeps your gas from getting hot. Some pro racers keep their gas in a refrigerator, and also add heat resistant tape or shielding to the bottom of their tanks for this purpose. Cool gas is good, hot gas is bad. So.... leave it on.