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Ian Geary
Original Poster
228 posts
61 months
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Evening all
A bit of advice needed.
I'm giving my ZZR600 its major service (a bit late at 18k)
Valve clearances are generally good, if on the tight side. The specified exhaust clearance is 0.22mm to .31mm
2 exhaust valves are 1mm under the clearance, and 1 is 2mm under.
The rest are all between 0.23mm and 0.26mm
I can probably shuffle some shims around.
But what sort of gap should be aiming for?
In the middle (0.26mm)? or should I set them looser, say 0.30mm, giving more expansion room over the next 15k miles?
Or can I keep them at the low end around 23mm (which would mean less new shims)
The shims haven't changed much compared to their original markings, so the expansion must be in the valve.
The inlet side have tolerance of 0.15mm - 0.24mm, and I've got 3 at 15mm, the rest in the teens apart from 2 in the low 20s.
So again, I can shuffle the shims to even out the gap, but should I be pushing the gap back to the middle of the tolerance range? or can I keep it around the low end?
The bike was running well before I started the service (and I know that statement is just asking for trouble)
cheers
Ian
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RizzoTheRat
8,070 posts
61 months
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Blimey that's a wide range to aim for, mine are all 0.05mm between too wide and too close, and as the shims come in 0.05mm increments (the originals fitted in the factory are 0.01mm increments but it seems I can only buy replacements in 0.05) I just aim for anywhere in the range I can hit.
Your exhausts have tightened up (most likely bedding in to the valve seats) so I'd personally be aiming for the wider end of the tolerance to give them room to tighten a bit more. If you're able to do it by shuffling the shims a bit I'd try and widen the gap on a few of the inlets too.
It's also well worth making a note of all the shim sizes (and which valve they're on), so that next time you do it you know which one's you can swap around or which sizes you need to order.
I found a bloke on e-bay that sells individual shims for about half the price I could get them in shops, but mine does take a very common size, worth a look though if you need several. I also managed to get a couple from my local Yam dealer very cheaply as they were the sizes the workshop had in, if I'd had to order them they'd have cost a lot more.
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Mr2Mike
9,481 posts
124 months
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Ian Geary said: Evening all
A bit of advice needed.
I'm giving my ZZR600 its major service (a bit late at 18k)
Valve clearances are generally good, if on the tight side. The specified exhaust clearance is 0.22mm to .31mm
2 exhaust valves are 1mm under the clearance, and 1 is 2mm under. 1mm and 2mm under the specified tolerance is obviously impossible, do you mean 0.1mm or 0.01mm? As said the shims are only available in increments of 0.05mm anyway, so you don't get a lot of choice as to which end of the range you target.
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Maruchino
852 posts
53 months
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Given that you're gonna have to have the cams out even for just one shim, I would get them all above 0.26/7mm
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Ian Geary
Original Poster
228 posts
61 months
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thanks for the replies
yes, I meant 0.01mm and not 0.1mm.
As the cams are now off, I guess I will get the clearances back past the mid point then.
right - better find some shims sharpish then, as I want the bike back on the road before this nice weather goes.
Ian
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jwoffshore
319 posts
123 months
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I don't know about Kawasaki, but Honda shims are available in 0.025mm increments and are interchangeable with Yamaha ones. The Yam ones only seem to be per 0.05mm, so you can use the Honda shims to get your Yam clearances more accurate.
Might be worth checking if the Kawasaki ones are interchangeable also. I seem to vaguely remember that Suzuki ones are a bigger diameter than Hon/Yam, but presently I only have Old School Suzukis with rocker & screw tappets!
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