first ever valve clearance experience. Warning... Long post

[TheGazWaz]

Just done my first valve clearance.

First time I’ve ever had the rocker cover off any bike. My previous bikes were shims so I wouldn’t even entertain it but everyone kept telling me how easy VC adjustment was on the bandit I thought I’d give it a go but I did have a few pits to fall down :-

Removed the tank completely. Labelled up all the pipes coming off the pair system and removed. Completely removed the coils to get them out of the way.

Took the four banjo bolts out then the 9 standard bolts. There should have been 10 according to the manual but the front one was missing. Remove all four spark plugs. Then removed the four alan bolts holding the rocker oil feeds on making sure not to lose the rubber rings. Manual says these should be renewed but I didn’t. All bolts removed was about to stick my screwdriver in to pri it open but thought I consult the manual first. Manual states tap around the cover with rubber mallet or block of wood. Did that then I was able to lift the cover.

I really struggle to move the cover from that point so I removed that oblong box thing from the top of the cover. Some kind of air feed from the pair I think. Once that was out of the way the cover came off relatively easy with a bit of wiggling here and there.

Cover off. Inspect the rubber seals. The two Mickey mouse ones were stuck fast to the head and the other two outside ones were stuck to the cover so I thought I’d leave as is. Both Dowels were in place so all is good.

Proceeded to check my clearances. Started with the intakes. I believe 0.10mm to 0.15mm. I opted for 0.13mm. All of my intake valves were so tight I couldn’t even get my 0.10 in there so the job was well worth doing just for that. All but number 1 exhaust side were OK.

Job almost done.

Inspect the rocker gasket and put a dab of gasket maker around the half moons. Proceed to re-install the rocker cover. Got it all in place and lifted each end to shine a torch in there to make sure the four rubber seals hadn’t moved. All OK.

Proceeded to do up all the bolts then...... Oh crap... Standard bolt has just gone down plug hole number 2. The only way I could get to this was to undo all my bolts and remove the cover gain. Thank the heavens for long nose pliers.

Lesson learned, once the cover was back in place I loosely put the spark plugs in then all the bolts. Incidentally I discovered that my torque wrench was way too big to fit into any of these gaps so the whole job was done by feel. Whilst fitting one of the banjo bolts, one of the washers fell off and went down the same number 2 plug hole. Luckily it fell right over the plug top so I was able to get to it.

Refitted the oblong thing on top of the cover then put everything back together and connected it all up. I’d planned to do my carbs as well so I rigged a temporary fuel supply. Started it up and all sounded well. I was well happy that it didn’t go bang.

Walk around the bike looking for any oil leaks then to my horror I felt a puffing of air coming from the rocker gasket on the right hand side of the engine. Upon inspection it became apparent that I’d trapped the gasket. Bum.... Undo ALL the bolts AGAIN. Managed to life the cover enough to get my hands in and sort it without having to remove loads of other stuff.

Been at it for 12 hours as I’d installed new downpipe gaskets the same morning. Feeling tired so didn’t bother with carb balance as I needed to take the bike for a run to make sure it was OK for work the next morning.

Put it all back together. Cleaned myself up, got me gear on and went for a spin. First impression is that the engine is a little more tappy. I’m seeing this as a positive as the intakes were so tight they will have been silent. Now that I’ve loosened them up I can hear them in all their glory.

Got about 2 minutes down the road the bike started chugging and clattering. My first thought was that I’d left something in there and it was now wrapped around my pistons. I quickly turned the bike around and headed home. Got to the bottom of my road and it died. Now... I live on a huge hill so pushing this beast home would have been a mare. I got my phone torch thing going and had a look. The bike was turning over but just not firing. I’d put it down to fuel starvation so looking for hoses that I’d not connected properly. Nope... all was where it should be but I did notice my main fuel line was trapped between the petcock and the frame. It didn’t look kinked or anything but I pushed it through so it sat behind the petcock. Turned the key, hit the starter and vwoooom. Came back to life and all was well again.

Road to work this morning and took it easy. You can only hear the tappets when more or less stationary. It might be placebo but it does feel smoother and less vibration throughout the rev range.

Anyway, that’s my first Valve Clearance job ever and I’m proud. Yes it took me all day but next time will be a lot easier. Not sure how much a garage would have charged me but I bet it would have been best part of £100?

Carb Balance next weekend.

Thanks for ready.

Gary
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Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[weasley]

Good stuff - best way to learn is to do it, so long as you can accept the consequences. Was the engine stone cold when you did it?

Lessons learnt? Maybe stuff a rag in those spark plug holes when the plugs are out (same goes for any open orifice AFAIAC)!

Carb balance should be a doddle after that, and good to do after all the other stuff is sorted (header gaskets, valve clearances etc).
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Yamaha XJ600 | Yamaha YZF600R Thundercat | KTM 990 SMT | BMW F900XR TE

[TheGazWaz]

Cheers Weasley,

Yes.. engine had been stood still for two days.

Good idea with the rags though. I'll do that next time.

Cheers
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Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[pompousporcup...]

sounds very much like my first attempts at it, putting it back together and then pulling it all apart again. all part of learning but frustrating nevertheless.

good on ye for having a go at it

[wodge]

"Warning long post...".

For a minute there i thought Teflon Mike had answered a question on Honda Benleys.....

Glad you sorted it without Tefts help..
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nolidge iz pouwur.
Yamaha RXS100 RS100

[Copycat73]

I recon half a day for a mechanic .. 3.5 hours @ £85 inc vat = £ 297.50
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Whatever I post I have no citation and no intention of providing one..
caveat emptor

[TheGazWaz]

Wow.. that much. Well worth doing yourself then.
____________________
Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[Vincent]

Good job
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Space Is Deep

[Ben90]

Good job doing it yourself I will shamefully admit that I collected my bike today from it's first valve check and spent a days pay on what a mechanic did in 2 and a half hours. I was geared up to do it myself, haynes manual and all, but I bottled it because if they were out of spec I'd have put it back together and pay someone to shim it anyway.
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Yamaha FZ6 S2

[DJP]

I did it a few times on my Bandit 600. In the end, I got it down to about 4 hours. Frankly, I doubt that even a pro-mechanic would be much faster.

If they claimed that they were, I'd doubt that they were doing it properly.

The other thing that bothers me with bike shops doing this is that ideally the bike needs to have stood overnight to make sure that the engine is stone cold to start with.

Hence I don't see how it can be done correctly if you take it in and collect the same day.
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Suzuki Bandit 1250
https://deejayp999.atwebpages.com/index.html
That's http not https

[Pete.]

[Michelle L]

Well done m8 , I got a B6 , its always great to do the job yourself , I been taking my bikes apart since I was in my teens , even now when I do a job I it makes me feel proud of myself so well done..
Doing it yourself you always lean and next time you will be faster..

I have only had my B6 a few months but I have done the valves twice now as the first time I was not happy with them.
I have set mine the same as yours , mine taps on tick over as well.
A tappy bike is a happy bike
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Ride safe , if you can not ride safe , ride free....

[Copycat73]

[Michelle L]

No your right copycat , mine tap on tick over.
But the first time I set them you could hear them riding the bike that is why I went back in and re-set them.

Since then I have done 1000 miles on it , I did take the cover off yesterday to have a check and there all fine so I will leave it now, manual says 7500 check but I will have a look at 3000 miles..
I mean I can have it stripped down in half hour ready to work on anyway so its no big deal.
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Ride safe , if you can not ride safe , ride free....

[Fizzer Thou]

Just getting to this stage to check the clearances can take quite a time,as removal of parts to access the cam cover is time consuming

https://i666.photobucket.com/albums/vv23/WiNot_Rhencullen/Workshop/2013-04-16173638_zps93a3b3dc.jpg

Whenever I check the clearances on any bike I always take my time and arrange for regular cups of tea to be delivered
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Just talk bikes.What else is there?

Always have a 'Plan B'

[Michelle L]

Hi Fizzer

What bike is that in your pic ?, is it a new bandit , my husband always brings me out drinks

I always put paper out on the table so when I take the bolts out I put them back in the same order
I find taking it apart is easy and quick , 30 minuets tops but setting the gaps takes me time and putting it back together takes me longer..
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Ride safe , if you can not ride safe , ride free....

[Michelle L]

You look like your not to far away from me Fizzer , Like ya bikes , I had an FZR once , killed it , it was a nice bike though...
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Ride safe , if you can not ride safe , ride free....

[TheGazWaz]

Ooooerrr. I didn't need to remove my carbs on my B12.

Agreed on the steady supply of tea though.

I really enjoyed doing mine. I shouldn't have done the downpipe gaskets and valves on the same day though. Felt knackered by the end of the day.
____________________
Went like this.. 43 years old(2013) decided to do CBT to get a 125 for new job. Bought 2011 YBR, loved it for three months then hated it because it was too god damn slow. Did DAS 4 months later then bought RF600 Loved it, sold it bought Bandit 1200(K3). EFFIN lOVED IT. Wanted something a bit more sporty so got Triumph Sprint ST 955i (53). Not sporty enough so now on my GSXR 1000 K3 and absolutely love it. 1 year down the line, nearly died way too many times on this bike. Sold it. Had a 6 month break. Missed biking so now, Aug 2019 have a 1999 ZX9r. What a beauty she is too.

[Fizzer Thou]

[bladeblaster]

Did my first ones about a year ago, it was much easier than I had imagined, that was shims and TBH they were a doddle.

Having said that the engine was out making access considerably easier.

[Michelle L]

Smart bike , my m8s got a R6 , he loves it , I like the workshop Fizzer.
Yeah its a bit of a bummer working outside but if something goes wrong with my bike I will always bring it in the house in the winter.
Sod freezing my butt off outside in the cold
____________________
Ride safe , if you can not ride safe , ride free....

[blurredman]

CX500 is a doddle
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CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S, 1979 MZ TS150.
Current: 1973 MZ ES250/2 - 18k, 1979 Suzuki TS185ER - 10k, 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (295cc) - 40k, 1989 MZ ETZ251 - 51k.

[Carvel]

[Fizzer Thou]

[pompousporcup...]

Out of interest, what happens if you adjust clearances and afterwards it tappety taps when on the move?

Do they tap when too tight or too loose?