ER5 Valve Clearances

[ms51ves3]

I'm adjusting the clearances on the ER5 this weekend, but I'm stumped at what this means in the manual:

https://i15.photobucket.com/albums/a376/ms51ves3/VC.jpg

Any ideas? It's mainly the pictures that are confusing me. What are they showing? Obviously they are showing valves, but why are the valves in the bottom picture rotated 90 degrees? What's the dot on the valves indicate?

[finpos]

...Is showing the position of the cams, not the valves!

f.

[ms51ves3]

[stinkwheel]

Remember you'll need two new o-rings to go round the rocker cover coolant pipes. If you don't use new ones, they will leak.

As said, those pictures show the position of the cams where you should check the clearances. They are marked with two lines and a punch mark.

You rotate the crank until the marks are in those positions. Remember you can be 360 degrees out, that position will appear twice in every cycle. So check the cam lobe is pointing away from the rocker, if it's pointing towards it (valve opening), you need to do another full turn of the crank.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[ms51ves3]

[Itchy]

ESB bolton keep a ton of stuff in stock, they might have them.
____________________
Spain 2008France 2007Big one 2009 We all die. The goal isn't to live forever, the goal is to create something that will. In the end, your life will flash before your eyes. Make sure it is worth watching.

[ms51ves3]

[robocog]

GPZ500...but same eng IIRC
The markings are exactly as the diagram and are of the cam sprockets and are basically showing what position they need to be in when you adjust the clearences

I kind of panicked when I got the cover off as it also involved taking the oil lines off (and was just worried there'd be a gasket or something crushable that I wouldn't get away with re using...but luckily all is pretty straight forward in all honesty)

Ref the o rings for the coolant
I managed to re use mine ...but it wasn't an easy task as they were not in the best of conditions and took much lube (red rubber grease) and swearing to get them in place and not be leaking
(think it took 3 attempts in the end)

I ordered some new O rings online as I couldn't find any locally in that size (which I will have written down somewhere for future ref)

I managed to source some from a place in Wiltshire and they were not stupidly priced and came next day IIRC- if interested I'll find out what website it was I got them from
I'm keeping mine somewhere handy as I know I have pushed my luck re-using the old ones!

Regards
Rob
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Needs a bigger garage...

[stinkwheel]

Any garage workshop will have an o-ring kit with an assortment of o-rings in it. If you take in the old one, they'll be able to sort you out with a new one.

Halfords also sell o-rings.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[robocog]

14mm x ?

I'm sure I looked in at Halfords at the kits and they didn't have an equivalent (and ended up in desperation re-using mine at great hassle)

I'm sure I wrote down the cross section and it wasn't a common size?

Anyway where I got mine from...part way down the page

https://www.gpzzone.co.uk/gpz500s/acatalog/Flexible_hoses__pump__Thermostat__coolant_etc.html

50p each

not connected to the company in any way....just had good service when I bought mine

Regards
Rob
____________________
Needs a bigger garage...

[robocog]

Broke out my packet from the "safe place" and my vernier
(damn its difficult to get an accurate mesurement from an O ring...LOL)

part numbers 670B2014
(and aprox dims)

14mm ID
as good as 2mm dia
so 18mm OD

(I also bought an oil filter at the same time from them so I didn't feel I was buying very expensive O rings)

Regards
Rob
____________________
Needs a bigger garage...

[ms51ves3]

[robocog]

nope deffo 18mm as theres 2 lots of 2mm
Paint diag coming right up...

Regards
Rob
____________________
Needs a bigger garage...

[robocog]

as promised..


Regards
Rob
____________________
Needs a bigger garage...

[ms51ves3]

[ms51ves3]

[robocog]

When I looked I'm sure they were not that common in that exact size
(1/2 mm + or - either on thickness or OD however were)

I found that putting the old ones back on was a bit of a bugger TBH (and it looked like they had "flattened" with pressure against the hole so should have been easy to fit surely...unless it was just a pain because they had gone harder with age/heat cycles??)

If you stray outside the spec (by 1mm overall if going up 1/2mm in thickness) IMHO its going to be impossible without splitting/pinching them AND getting a good seal

Regards
Rob
____________________
Needs a bigger garage...

[robocog]

Thought they were the same engine?
My haynes for the GPZ covers ER5 97-07 and I'm pretty sure it only has one engine section?
If yours is newer perhaps they managed to get the oil to where it needs to be without the oil lines?

When the rocker cover is off you will see (assuming they are the same)
There are "pipes" that are proper in the way under there
Luckily it was drame free on mine (just be careful with not dropping the screws that hold the oil lines on!)
Screws out and the solid pipes just pop out (theres little O rings that do the seal and mine popped back in place once done without any real effort/drama)

Oh yes...watch out when removing the cam cover...theres 2 little dowel/pegs for location that were loose on mine that threatened to drop into the engine...just something to be aware of when taking it off/refitting!

No other gotchas I can think of from when I did mine
It even "burped itself" when I refilled and didn't need topping up (once I got those damned water O rings fitting nicely!)

Regards
Rob
____________________
Needs a bigger garage...

[ms51ves3]

Cheers Rob, Stinkwheel, Finpos and Itchy

[stinkwheel]

The water pipes are a piece of piss to refit if you use new o-rings. You just shove them in.

There are oilways under the rocker cover, you can adjust the tappets with them in place but it can be easier to get the feeler guages in if you remove them (otherwise you need to put a 45 degree bend in the feeler guages). As said, removing and refitting them is not as scary as it looks.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Asimo]

Simply Bearings have the correct sized o-rings in stock but they're rather expensive. Especially since their prices are excluding vat.

[chris-red]

I just treked to the garage in the freezing cold to pull out my O-ring box, the closest I have is 13.6ID 2.4 thick.

If you want I could pop them in the post.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[ms51ves3]

[chris-red]

Sent first class this morning, you should have them tomorrow. Look out for a scrapy 'envolope' with is really a folded over bit of paper with lots of tape.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[ms51ves3]

Cheers Chris