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Help Valve Clearance Inspection

Discussion in 'Kawasaki 250cc In-line 4's' started by DanoHosko, Mar 29, 2020.

  1. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Beautiful thanks @Frankster

    With regards to the cam chain, I'll be honest it's not a job i particularly want to undertake unless absolutely necessary

    - the chain seems to be much tighter at both TDC markings on the crank, between the two theres a noticeable drop in tension
    - chain itself looks in good condition
    - there is a noticeable rubbing mark on the rocker cover underside

    I'll measure the chain hopefully tonight, I'm expecting its going to be deemed out of spec though...

    If i do it, I'd be tempted to go for the 'break the chain' method i think, providing i can do this without messing up the timing beyond repair....
     
  2. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Removing the camchain isn't fun.
     
  3. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Can someone confirm, chain is too far worn?

     
  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Yeah mate than chain has passed its glory days.
     
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  5. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Agree. Sorry bud. That thing is going to leave some nasty marks on your cam cover real soon.
     
    Last edited: Mar 31, 2020
  6. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Haha damn, i thought as much, might paint her yellow and call her the Lemon...
    I'm gonna try changing the chain like Linkins FZR250 sticky then i reckon

    https://tinyurl.com/uowdcvg

    Do we recommend a pre-split chain such as the above, or an endless one then split it?
     
    Last edited: Mar 30, 2020
  7. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Pre-split is better as it will have all the hardware needed to rejoin included. You just need a good chain breaking and riveting kit to peen the pin once you've fitted the new chain.

    Joining the new chain to the old one and feeding it through is the best way to do the job. Use lockwire or small zipties.
     
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  8. DanoHosko

    DanoHosko Well-Known Member Premium Member

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  9. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    They are all made in China and have been used by forum members.
     
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  10. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Ah ok bud, I've read issues with material hardness, maybe I'll try and diy harden the bits aha
     
  11. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    hi again guys,

    Couple more questions:
    Most of my shims measure 7.85mm there abouts, had a couple measure at 7.4mm
    Are the 8mm ones from Precisionshims ok for the ZXR250?


    The one that read less than 0.03mm (Inlet 1-1); what should i do about that? basically the smallest feeler gauge i have is 0.03mm and it wouldn't fit. Should I assume that there is 0 clearance or assume 0.02mm clearance and get the new shim based on that?

    Cheers!
     
  12. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Assume there is zero clearance. Select a shim that will give you near to the maximum clearance spec. Re-assemble and measure clearance again.

    EDIT: You need to measure the inside area of your valve spring retainers. If they are ~7.85mm, then you need to use those diamater shims.
     
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    Last edited: Mar 31, 2020
  13. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Awesome, thanks for the advice bud!


    Wow in my infinite wisdom i nearly ordered the wrong size shims and would of been reducing the clearance, dodged up my spreadsheet...


    Below is new shim sizes planned

    _20200401_102248.JPG
     
    Last edited: Apr 1, 2020
  14. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    G'day DanoHosko
    Just wondering when you were checking your shims, did your shim buckets have wear on them. I have just been checking mine
    & every bucket I pulled seems to have wear on it. Just want to know if this is normal. I have done my dirtbikes
    before but havn't seen this.

    ZXR bucket.JPG
     
  15. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    @PilbaraGuy hey mate, mine all look the same as yours does, measures 19.9mm round, 14.5mm tall

    DSC_0242.JPG
     
  16. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Cheers mate.
    I wasn't sure if my project had been neglected & been staved for oil or if this was normal. The symptoms of mine were it would only run for a while then when up to temp would not restart...
     
  17. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Ah ok is that why you were checking valve clearances?
    I couldn't comment too much, pretty new to the 250 and mine hasn't run properly since i got it either haha (doesn't idle but runs above 6k fine), im hoping clearances and cam chain and the carb overhaul will get her done
     
  18. PilbaraGuy

    PilbaraGuy Active Member Contributing Member

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    Yeah I got my ZXR as a non runner project. Couldn’t get it to run so have reco’d carbies, hoses, vac plumbing. I thought it was spark breaking down so tested all electrical. OK. Bit the bullet & checked valves & found almost all out of spec. Hopefully no valves burnt out.
    I picked it up cheap so I pay the price!


    Sent from my iPhone using Tapatalk
     
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  19. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Ahh sounds very similar situation to me then haha
    I havent replaced any vac lines though, but the ones I've blown into dont seem to leak...
     
  20. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    You have to be pragmatic about these things. 30 plus year old motorcycle and a high performance engine to boot.
     
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