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Discussion Starter #1 (Edited)
So I got around to measuring my clearances and this is what I found.
Cylinder 1 Outside EX Valve 0.23mm --- shim 2.7432mm
Cylinder 1 Inside EX Valve 0.23mm ----- shim 2.794mm
Cylinder 2 Inside EX Valve 0.20~0.21mm shim 2.8448mm ****
Cylinder 2 Outside EX Valve 0.23mm --- shim 2.8194mm


Intakes were all in comfortable spec 0.18mm.


According to the chart, my out of spec EX valve should have a shim of 2.80mm.

Now my question is, what about the other 3? I rather have them be adjusted as well since they are so close to being out of spec so what shims would they need?Or should I not even bother with them for now? :thanx:
 

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You can get 7.48mm diameter shims (same as Versys) in 0.025mm increments (instead of only 0.050mm increments), in 2.50mm to 3.50mm thicknesses.

You should get:

2.725
2.775
Reuse your 2.794mm shim here
2.800

Suzuki 2004-2005 RM-Z250 shims $9.04 Retail ($7.66)
Kawasaki 2006-2011 KX-250F shims $9.40
(Versys shims 0.050mm increments $12.36)

Shim ------- Suzuki # ----- Kawasaki #

2.700mm - K9218-00175 - 92180-0175
2.725mm - K9218-00176 - 92180-0176
2.750mm - K9218-00177 - 92180-0177
2.775mm - K9218-00178 - 92180-0178
2.800mm - K9218-00179 - 92180-0179
2.825mm - K9218-00180 - 92180-0180
2.850mm - K9218-00181 - 92180-0181
2.875mm - K9218-00182 - 92180-0182
2.900mm - K9218-00183 - 92180-0183
2.925mm - K9218-00184 - 92180-0184
2.950mm - K9218-00185 - 92180-0185
2.975mm - K9218-00186 - 92180-0186
3.000mm - K9218-00187 - 92180-0187
3.025mm - K9218-00188 - 92180-0188
3.050mm - K9218-00189 - 92180-0189
3.075mm - K9218-00190 - 92180-0190
3.100mm - K9218-00191 - 92180-0191

http://www.partshark.com/custompage.asp?pg=suzukiparts (Enter part #)
 

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Discussion Starter #3
I knew you would be the one to post, thanks invader!
 

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Discussion Starter #5
What you edit? I may have not seen the post till you edited.
 

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Invader, Thanks for the list. One of my winter projects if the do the valves on both bikes and this will help a lot.
 

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Your other option, WallCrawl, would be to thin your 1st, 2nd, and 4th shim down by 0.030mm, and your 3rd shim by 0.045mm... I did it by hand with wet fine emery cloth on a hard flat surface. I think it was fasteddiecopeman who also managed to thin his shims down.
 

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Your other option, WallCrawl, would be to thin your 1st, 2nd, and 4th shim down by 0.030mm, and your 3rd shim by 0.045mm... I did it by hand with wet fine emery cloth on a hard flat surface. I think it was fasteddiecopeman who also managed to thin his shims down.
Yup - several times!

:thumb: - :thumb:
 

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Discussion Starter #9
Traded for the right ones, I was thinking of thinning but this was easier. Next time maybe, thanks for all the help as well, I wouldn't have any confidence to try and do this stuff without this forum :yeahsmile::thanx:
 

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Shims are surface hardened. Sanding them down removes the hard layer.
waltermitty, that's crucial information you are giving here. If sanding removes the hardened surface it does definitely not sound like a good option.

Or does the hardening go deeper than what most need to take off?

How does grinding affect parallelity & squareness..., is that not important, as well?

Need some comment on this pls :feedback:
 

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I can't address the surface hardening, but sanding with fine emery over a sheet of glass, using a circular motion, should result in an even surface.
 

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I also sanded my shims down. Sure, I saved a decent amount of money (pretty amazing how much those little things add up to), but it was a royal pain in the you know what!

Do it by hand, if anybody is going to do it. Can't let the heat build up and anneal the metal. Not sure what would happen then...

Mine have been good for a few thousand miles, so I know it is working fine so far.
 

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What ever hardening they MIGHT have, I haven't worried about.
First - the shims are between the valve-stem end and the underside of the bucket, unlike for instance, KLR shims which are DIRECTLY contacted by cam lobes; and
Second - IF they were "HARDENED" I don't think you would be able to work them down on emery cloth.
 
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