900 Valve Adjustment Walk-Thru

[Matt7even]

Ok as promised from my previous post "900 Valve Adjustment Woo's" here is a very abbreviated run down of my experience doing a valve clearance inspection and adjustment on my 900. Now keep in mind I am not the most mechanically inclined person and have never opened an engine before in my life. In fact I am sure the more knowledgeable members on this forum can probably point out mistakes I have made or better ways to do it, (witch I welcome). But the reason I decided to do it myself (all 3 times =) was to learn how witch has made me more confident in taking on other maintenance tasks and customization projects in the future. I hope this helps anyone else like me who is doing there adjustment or thinking of doing it themselves. I must note though that despite the title this is just a visual guide not a step-by-step walk through so you WILL need a service manual if your doing this for the first time. Also some other specialty tools you will need and I highly recommend:

* Hot Cams 9.48mm (2.10 - 2.35mm) Refill Shim Package Hot Cams

* Guage Feeler tool (.05 - .25mm range or higher) angled blades prefered.

* Small Telescopic Magnet


(enjoy =)
































I can only post 10 images per post so I will post the rest below

[Matt7even]

[texrider]

Great job! I can see from your photos it is best to have the correct replacement shims, as they are in a vulnerable position. Enjoy your ride, and the satisfaction of having done that yourself

[Dare]

Wait a minute! I was told by the dealership that the valves on my 900 were non adjustable! That *******! So....how often should they be adjusted?

[LVCigarz]

Thanks Matt, I don't need to make any adjustments yet, but I will be taking off the gas tank soon to install my Fuel Pak. Your photos (first three or four) are going to be very helpful to me.

[Matt7even]

Originally Posted by Dare

Wait a minute! I was told by the dealership that the valves on my 900 were non adjustable! That *******! So....how often should they be adjusted?

Yea it's a shame sometimes how little some stealerships actually know (or care) about the products they sell, especially with a newer model like the 900. That's what makes these forums so great! Your owners manual states they should at least be inspected every 15,000 miles.

[Matt7even]

Originally Posted by texrider

Great job! I can see from your photos it is best to have the correct replacement shims, as they are in a vulnerable position. Enjoy your ride, and the satisfaction of having done that yourself

Yes thats why I would suggest buying a kit or the refill pack of shims listed above. Even if you have a dealership generous enough to give or sell you individual ones you could find yourself taking many trips back and forth trying to find the ones that fit properly.

[Matt7even]

Originally Posted by LVCigarz

Thanks Matt, I don't need to make any adjustments yet, but I will be taking off the gas tank soon to install my Fuel Pak. Your photos (first three or four) are going to be very helpful to me.

Cool Cigarz, Unforchunatly I don't have an image of the fuel hose and how I disconnected/plugged it so just make sure you consult your service manuel.

[MrClean]

You screwed up big time AND right off. You Pumped fuel out of the tank? You should have removed that by twisting your right hand a little longer. 40 miles after that little yellow light comes on you should drive home and you'll be fine. Use a pump? Heretic!!

Otherwise pretty good rundown.

[Matt7even]

Originally Posted by MrClean

You screwed up big time AND right off. You Pumped fuel out of the tank? You should have removed that by twisting your right hand a little longer. 40 miles after that little yellow light comes on you should drive home and you'll be fine. Use a pump? Heretic!!

Otherwise pretty good rundown.

*writes all of that down* =)

[REFUGIO]

Most excellant walk thru.....Great Job

You might find this hard to believe..but I was actually able to...very patiently..do my clearance adjustment/inspection...with the fuel tank still in place....It can be done and yes ...space is tight.

[kc6wfs]

Should get this STICKIED on the write up how to section!!!!

Good job!!!!

[Matt7even]

Originally Posted by REFUGIO

Most excellant walk thru.....Great Job

You might find this hard to believe..but I was actually able to...very patiently..do my clearance adjustment/inspection...with the fuel tank still in place....It can be done and yes ...space is tight.

No kidding Refugio, I think I would rather just attempt to build a ship in a bottle wearing boxing gloves! You get points in my book for difficulty though =).

[Matt7even]

Thanks, How do you go about doing something like that?

[LVCigarz]

Originally Posted by Matt7even

Cool Cigarz, Unforchunatly I don't have an image of the fuel hose and how I disconnected/plugged it so just make sure you consult your service manuel.

Yup, I have the SM and printed the section on tank removal, but your pics show a different angle. It will help.

Thanks again.

[Propdoc]

Thanks so much for the run down, you did an excellent job. I've got to get ready to do this project myself very soon. How much did the shim kit cost?

[jesse web]

Very nice!!! But it looks like an all day thing...

Here is my question to all of you. How do you know when you need a valve adjustment?

What are the symptoms?

I only have 2500 miles on my 900 and i get a sewing machine kinda noise when it warms up and becomes louder with acceleration.

Any ideas? Tks

[Matt7even]

Originally Posted by Propdoc

Thanks so much for the run down, you did an excellent job. I've got to get ready to do this project myself very soon. How much did the shim kit cost?

Thanks, It's about $35 average if you get them off the net. Here is a link Hot Cams

good luck.

[Matt7even]

Originally Posted by jesse web

Very nice!!! But it looks like an all day thing...

Here is my question to all of you. How do you know when you need a valve adjustment?

What are the symptoms?

I only have 2500 miles on my 900 and i get a sewing machine kinda noise when it warms up and becomes louder with acceleration.

Any ideas? Tks

Yea the first time was kinda involved but once you have it down it takes about 2-3 hours to repeat the process. Kawasaki says that you need to at least inspect your valve clearance or get them inspected every 15,000 miles to see if they need adjustment. The sewing machine sound is probably your valves. If so that is a normal sound and will get quieter in time. But as you rack up miles they can tighten up to the point you can barley hear them at all, that's a sign that they may need to be adjusted.

[LVCigarz]

That's funny, its kinda like the male and female mosquito. The males don't drink blood and their wings buzz and you can hear them coming. The female, however, drinks blood and their wings don't buzz. So, when you don't hear anything is when you start worrying.