ZZR11 Valve clearance check, cam inspection

chameleon · Post by **chameleon** » Fri Mar 31, 2006 5:00 pm

Busy day today for chameleon, Got the cover off and am about to check shim clearance. Cams look great, that's a nice start

I have the manual + a great write up on the proccedure that Goanna-38 wrote out for me a little while back. Would hate to do this shit without the support of the forum.
Thanks KSRC

bonester · Post by **bonester** » Fri Mar 31, 2006 6:22 pm

Cams lookin good there Chameleon! Better than my 1200 cams at 18000km....
ZZRs are piss easy to change shims on too- BTW the service manual says to remove the timing cover to time engine for valve clearance measurement. I discovered after a while (duh!) that there is an inspection window in the timing cover that does the trick, but doesn't bugger the gasket. Guess Kawasaki is trying to sell more gaskets. (I found that if I timed the engine by looking at the cams it wasn't accurate enough although a lot of people do.)
Busa, ZX12, and Blackbird need cam removal to change shims- love the ZZR setup!

chameleon · Post by **chameleon** » Sat Apr 01, 2006 7:44 am

bonester wrote: (I found that if I timed the engine by looking at the cams it wasn't accurate enough although a lot of people do.)

What do you mean "time the engine"? Can you adjust the timing like on the old bikes? I didn't know that, thought it was preset or automatically adjusted in some way? Or perhaps I just didn't think

Well I'll suss out the manual on that and check it. Most of the shims are way out of spec, well below the 1/2 way mark in the allowable range. I only have 3 that are above

, none that are too loose. I have one EX with no clearance whatsoever and it will be a trick to get that shim out to measure it. O well, nearly 8am so I better get the tools back out and bumble on if I want to get the replacements before the shops shut.

Strika · Post by **Strika** » Sat Apr 01, 2006 8:23 am

chameleon wrote:
bonester wrote: (I found that if I timed the engine by looking at the cams it wasn't accurate enough although a lot of people do.)
What do you mean "time the engine"? Can you adjust the timing like on the old bikes? I didn't know that, thought it was preset or automatically adjusted in some way? Or perhaps I just didn't think Well I'll suss out the manual on that and check it. Most of the shims are way out of spec, well below the 1/2 way mark in the allowable range. I only have 3 that are above , none that are too loose. I have one EX with no clearance whatsoever and it will be a trick to get that shim out to measure it. O well, nearly 8am so I better get the tools back out and bumble on if I want to get the replacements before the shops shut.

I think he may be refering to pulling the little engine side cover off, where the end of the crank sits, which has positioning markers to designate top dead centre etc., Personally I wouldn't worry about this unless you have slotted cam wheels and are wanting to advance or retard the timing. Provided you ensure the cam lobe is reversed from it's fully depressed position on the valve it should be perfect.

chameleon · Post by **chameleon** » Sat Apr 01, 2006 9:33 am

Ahhhh! I see. Yes I checked the manual and found no reference to adjusting timing, all done electronically no doubt. I used the window method, though goanna suggested using the marks on the cam but as long as the lobes are up that's the way to do it hey

I had 13 shims out of wack but I can reuse 5 so I only need eight. 8 of the little bastards will cost me upwards of $70

O well, I saved a few hundred I guess, and I know the job will be done "right". Touch wood

bonester · Post by **bonester** » Sat Apr 01, 2006 2:04 pm

I meant putting the engine in the correct place for measurement- two different measurement 'timings' are needed.

chameleon · Post by **chameleon** » Sat Apr 01, 2006 2:43 pm

redundant post removed

chameleon · Post by **chameleon** » Wed Apr 05, 2006 2:25 pm

no more trips to the bike dealers and I can carry several on tour. You can get down and adjust the shims with the OEM tool kit under the seat and a set of feelers if you need to

Mind you a small socket set helps

Strika · Post by **Strika** » Tue Apr 11, 2006 8:25 am

What did the shim kit set you back Chameleon??? and where did you purchase it????? Handy little kit that!!!!

chameleon · Post by **chameleon** » Tue Apr 11, 2006 1:51 pm

$150 from serco at capalaba

mike-s · Post by **mike-s** » Tue Apr 11, 2006 1:55 pm

I bought a dynojet kit directly from serco, ordered it early on the tuesday, was in my hands on Friday arvo

.