First valve shim check at 20,100 miles - Kawasaki Versys Forum
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post #1 of 6 (permalink) Old 01-31-2018, 02:44 AM Thread Starter
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First valve shim check at 20,100 miles

I finally decided to tear the bike down and check my valve clearances as I haven't been getting that great MPGs over the last couple years. Keeping the revs 4500 or below I can get around 50 MPG, but in the 5-6K range it drops off significantly to around 40 so I wanted to see what I could do to make it a little better.
Upon initial measurement:
ALL 4 exhaust valves were @ .18; Quite a bit below minimums of .22
3 of the intake valves were @ .15 and one @.13; Right at and slightly below .15 minimums

Now my question is can I order the new shims now (is there a standard size shim the bike is made with that I can just calculate what size I need from the measurements?) OR do I remove the cams and measure the existing shims to be more accurate BEFORE ordering new?


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Jeff Reichel Palmer, ALASKA
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post #2 of 6 (permalink) Old 01-31-2018, 08:08 AM
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Valve Shim How To

Even though this is a 2015, there is also a MK-1 and MK-2 link in this thread, make sure you print out the PDF in post #3 at the bottom of the 2015 thread, make at least 2 copies, one is working and the other saved for future reference. Your question, as to shims, I have done it 2 times FastEdie at least 5 times, that is sand the shims to fit, follow the posts. FYI the buckets and shims are never exact. What I mean is a 0.15 shim may be spec in position #1 but tight in position #4 cylinder #2, because the bucket is different. Needless to say you should do 1 valve at a time. Lots of good instructions and photos. FYI while your at it follow the Vacuum hose extension modification, the correct size is stated in http://www.kawasakiversys.com/forums...-1-mk-2-a.html , you will probably find the vacuum is spot on once the shim is complete. The only real difference between MK-1 & MK-2 and MK-3 is the plastic removal and air box removal, plus the earlier bikes were easier to work on as no ABS pump / mechanism .


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post #3 of 6 (permalink) Old 01-31-2018, 09:45 AM
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Here's a little toy to help with the math of it all:

https://www.crfsonly.com/calculators...-shim-calc.php

Iff'n you don't feel like sanding things down there are shim kits avalable for about $70-80. The one I bought had 47 sizes, three each. The brand name is Hot Cams. They come in .05 increments.

HTH.
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And most of Canada too, eh?
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post #4 of 6 (permalink) Old 01-31-2018, 12:47 PM
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Jeff - the FIRST time I did Versys valves was here in AZ. I measured everything, removed the shims (all kept SEPARATELY!), then ordered the new shims according to the info, but took my calipers w/ me to the shop when I picked up the new shims, then I measured THEM....

NONE of them were as marked, and I was SOME PI$$ED-OFF! Their mechanic looked at the shims, then invited me to go thru his 'used-shim' collection (from several bikes that use similar shims), so I got EXACTLY the shims I needed, and ever since then I have sanded-down any shims that were 'tight' (using oil on the garnet-cloth) after reading a post from "invader" where he said that is what he does, and I ALWAYS bring them to the HIGH end of the clearance range.

I've PROBABLY 'done' valves that way 7 to 9 times among the 3 Versys.

-
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post #5 of 6 (permalink) Old 02-01-2018, 09:22 PM Thread Starter
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Math Check HELP! Please

So the exhaust valve clearance measurements were ALL the same @ .18mm and the shims were ALL @ 3.09mm So I'm going with a 2.975mm replacement shim to bring the gap to right around .30mm

The Intake valve clearance was @ .15mm X 2 and .13mm X 2 and the shims were @ 3.04mm X 2 and 3.05mm X 2 so will use 2 of the .2975's and 2 of the 3.00 to make all 4 right around .20mm.
I've double and triple checked my math but if anyone sees any discrepancy in my calculations PLEASE LMK before I order the shims!


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Jeff Reichel Palmer, ALASKA
1 Tim 6:11-12 "FIGHT the GOOD Fight"
There is no inappropriate temperature to ride a motorcycle…just inappropriate layers of protection.
2011 ADVersys
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post #6 of 6 (permalink) Old 02-02-2018, 08:46 AM
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I posted up a link to an on line calculator above. Let the computer do the work.

Just change the desired gap to what you want. Easy peasy.

Edit to add: Here is another calculator iff'n you wanna measure gap in inches.

http://www.maultechatv.com/techguide...%20Calculator/

Yeah, if you want true ram air tuning, you better be willing to ram some air! (SteveinSunnyFlorida)

'15 KLE650LT
'99 Concours(with 234,xxx miles on it), sold
'98 KLR650


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And most of Canada too, eh?

Last edited by SteveJ; 02-02-2018 at 08:57 AM.
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