adjusting valves on 525

[bossman525]

my outlaw is about do to have the valve clearance checked and adjusted. has anybody done this them selves? is it hard to do? also does your warranty cover this to have the dealer do it? i have heard they are pretty simple to do (other than outlawbill's mishap);)

[LT250_JOE]

WARRANTY DOES NOT COVER ADJUSTMENTS. I HAVE NOT DONE MINE YET, BUT I HAVE NO FEAR IN DOING SO. I HAVE DONE HONDAS, SUZUKIS, CHEVYS, FORDS, TOYOTAS, ETC. JUST GET A SHOP MANUAL AND FOLLOW STEPS. IF YOU DONT FEEL COMFORTABLE TRYING YOURSELF THAN DONT BECAUSE IF DONE WRONG IT CAN BECOME VERY EXPENSIVE!

[Evasiveone]

The 525 engine has the screw type valve adjusters so it is very painless. Start to finish, with an oil change took me under an hour. Next time will probably be around 30 minutes for the valve adjustment.

The crank lock bolt to lock at TDC on the front of the engine is too short on the ATV since the case is bigger. However, I used the adjust the intake valves when the exhaust is 1/2 open and adjust the exhaust valves when the intake is 1/2 closed method. It is explained here.
Valve adjust method of 1/2 open, 1/2 closed (http://ktmtalk.com/index.php?showtopic=43498)
This is really painless and simple. You do not even have to drain the oil, however a helper helps to hold the brakes to hold the engine in the right place.

A good angled feeler gauge is a life saver here too. I use this one.
Angled feeler gauge (http://www.motionpro.com/motorcycle/tools/tappet_feeler_gauge_-_spark_plug_gap_tool_for_ktm/)

Hope that helps.

[bossman525]

thanks for the attachment on that evasiveone. it looks pretty simple, the service supervisor at my local dealer is going to come show me and my buddy how to do it so we can do it our selves in the future. it says it's a piece of cake