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Hoof Hearted?
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717 Posts
Discussion Starter · #1 ·
First, I apologize for no pictures with this thread. This being my first venture under the valve covers precluded the photographic distraction. I knew it would take me a while (6 hours including the 60 min. trip to the store...more on that later) so I'm sure I will be able to do this in 2-3 hours next time...and I'll take pictures then. Also understand that I would consider myself to be an amateur wrencher with just enough wrench time to be dangerous.

Everything had gone well...first time removing tank...no problem...had maybe a gallon of gas. Rear jug chrome valve cover cover (as opposed to the valve cover itself) came off fine. Then 3 of the 4 front jug chrome cover bolts came out fine...it was only that right rearmost bolt where Kawasaki engineers thought it would be funny to weld a mount to the frame right above the bolt to which is bolted a mount for what looks like a breather valve. The breather valve mount was easily removed as it had only 1 bolt but the welded mount precluded socket access without a universal...which I didn't have. So, to the store. Had it off in about 5 minutes upon returning.

Everything else went smooth until...here's the "amateur wrenching" part...I dropped one of the shims and it fell down into the case on the cam chain side of the engine! Fortunately...actually downright lucky for me, I could see it. My trusty telescoping magnet did the rest...WHEW! Big lesson here...ALWAYS STUFF A RAG DOWN AROUND THE CAM CHAIN SIDE OF THE JUG WHEN CHANGING SHIMS! I did this and, of course, I didn't drop any more shims.

The rest of the adjustment went smooth, the bike fired up perfectly and ran as smoothly as it always does this a.m. on the commute.

As for needed adjustments, here's the scoop:
Rear jug: Intake...ok
Exhaust...a bit under spec...used a 2.40 on one and a 2.45 on the other
Front jug: Intake...a bit under spec...used a 2.50 on one and a 2.55 on the other
Exhaust...ok

I think it is interesting that the only valves that needed adjustment were the rearmost of each jug...both intakes on the front and both exhausts on the rear. Coincidence? I'm thinking so but I'd be really interested if anyone else might have an idea. BTW, my bike has just under 22k miles.

Anyway, don't be afraid to adjust your own valves even with limited wrenching skills like mine. Just get a shim kit, a good set of feelers and one of those small telescoping magnets to go along with your socket set. It's amazing how much confidence one gains after performing a task like this.
 

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IBA#34418
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6,329 Posts
Where did you order your shim kit from?
There was another post on here about the 900 valve adjustment. I used the link he provided. Can't remember where it was. It wasn't the entire kit. It was a refill. I would suggest getting one that tops out at 2.50 and gets smaller from there.
 

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Hoof Hearted?
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717 Posts
Discussion Starter · #5 ·
Clean,

I ordered this shim kit. Yeah, it was a bit pricey but, considering the cost of having a shop do it, I've already paid for the kit and then some. Also, the plastic cases (2 come with this shim kit) are very nice and make organization easy.

Now I should buy a nice micrometer to measure the shims I removed...the markings on them were not decipherable.
 

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Workin' to ride
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559 Posts
Thanks for the great post Dog. Congrats on the job coming out perfect. I haven't decided if I'll tackle that one or not. Depends on how much time I have when it comes time. Thanks again.
 

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IBA#34418
Joined
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6,329 Posts
Valve clearance adjustment is done by replacing existing shims with a thicker/thinner shim. I'm coming up on 7500, I think that's the first time it's due on the 900.
No every 15000 miles. They call for a plug change every 7500
 

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Hoof Hearted?
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717 Posts
Discussion Starter · #16 ·
Nevermind. Just did some more reading. Doesn't look like something I'll tackle myself. :|
Deuce,

Don't shortchange yourself, man...it's really not that difficult. In reality, this is the first time I've ever done a valve adjustment on ANY vehicle. After this, I'm confident enough to tackle other things as well...stator, coolant system repairs, pretty much anything outside of the cases.

Now, splitting the cases? That where I'll be drawing the line.

Man, if I were near Ohio, we'd knock that thing out and go throw down a few brews!
 

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Hoof Hearted?
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717 Posts
Discussion Starter · #18 ·
Thanks for the great post Dog. Congrats on the job coming out perfect. I haven't decided if I'll tackle that one or not. Depends on how much time I have when it comes time. Thanks again.
jawbreaker,

Knowing that you will put your bike away for the winter, I may be close to my next adjustment before you are ready for your first at which time I'll snap some pics as mentioned above. In the meantime, check out this great thread. This helped me significantly...thanks Matt7even if you're still hanging around.
 

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Registered
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15,327 Posts
Deuce,

Don't shortchange yourself, man...it's really not that difficult. In reality, this is the first time I've ever done a valve adjustment on ANY vehicle. After this, I'm confident enough to tackle other things as well...stator, coolant system repairs, pretty much anything outside of the cases.

Now, splitting the cases? That where I'll be drawing the line.

Man, if I were near Ohio, we'd knock that thing out and go throw down a few brews!
Well, I'm in NC so come on up. ;) :lol:

Getting to them isn't my concern. Knowing if they need replaced does.
 
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