My Versys-X 300 has 7755 miles on it ......... time for the first valve check and shim. I have a late model Ninja 300 shop manual and proceeded with the tear down. As you might imagine, everything is tightly packaged and a lot of stuff has to be moved/removed to access the removal of the valve cover.
The body work is easily removed via the instructions on page 566 of advrider.com on the regular Versys-X 300 thread. The removal of the gas tank is somewhat of a pain due to the fuel coupling being snaked through the frame and the connector for the fuel pump having a very short harness-----not much room to work with my full size hands.
Next, remove the spark plug wire leads, stick coils, right radiator hose/thermostat from the engine and radiator, valve cover breather/related plumbing, and finally the very tightly frame constricted valve/head cover. You will have some minor loss of coolant when the radiator hose is removed. I topped it off when it was re-installed.
I positioned the crank/cams properly for a clearance check and found the left cylinder #1 exhaust valves to be .001 under spec at .008. The right cylinder #2 were at minimum spec of .009 for both. The intakes on #1 were .007 and .008 and the #2 cylinder were .007 and .007---right at the minimum.
Kawasaki calls for these specs:
Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)
Intake 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
I marked the cams, cam chain, removed the cam chain tensioner, cam caps, etc. and removed the cams, lifter buckets, and shims for each valve. I found the following shims:
Cyl #1 Exhaust shims 2.73 and 2.75 Cyl #2 Exhaust shims 2.73 and 2.70
Intake shims 2.80 and 2.78 Intake shims 2.80 and 2.80
I ordered two packets of 5 Hot Cams shims in size 2.75 and 2.65 as i wanted to be near max on intake and exhaust clearances. The shims arrived yesterday and I began to measure each shim thickness to ensure they were as marked. Some were and some were not!!!! Like previous shims I have encountered and measured....they can be mis-marked and a couple of thousandths off.
I placed what I believed to be the correct shims in place and remeasured with the cams/cam caps re-torqued to spec. I found the right exhaust clearance on Cyl #1 to be too large at .012-----everything else was good. So, the cams were removed and the proper shim installed.
I began to put everything back together.........checking and re-checking the timing of the cams/crank, re-checked the valve clearance after everything was torqued to proper spec, and found the valve clearances to be:
Cyl #1 Exhaust .011 and .011 Cyl #2 Exhaust .010 and .011
Intake .095 and .009 Intake .095 and .009 Just where I wanted them.
The further assembly was time consuming due to the tight fitment of everything.....but it did go together with no extra pieces or parts!!!
I install the fuel tank, hook up everything fuel related, and turn the bike on to start it.
It would not start!!!! but, did keep back firing. I couldn't believe it as everything had been checked and re-checked multiple times as I assembled everything. I made a last ditch effort and switched the wiring leads to the stick coils-----thought I had them separated properly when disassembled?????........hit the start switch and the mighty X-300 started instantly and began to purr like a kitten!!!
I finished up the install of the bodywork and took it for a short, couple blocks ride.........ran just like it did before the valve shim. Only now, I know everything is in spec and should be good for quite some time.