Valve Adjustment help! Exhaust cam doesnt line up correctly.

[jax]

EDITED TITLE AS THIS BEGAN AS HELP FIGURING OUT SHIM SIZES.....NOW I NEED HELP FIGURIN GOUT THE TIMING MARKS. PLEASE GO TO PAGE 2 AND CHIME IN AT THE REPLY WITH THE PICTURES.


Hello guys,


Finally getting the old FZR out to ride since spring is around the corner and I want to get it in tip top shape to save money on gas.

I went ahead and pulled the valve cover and checked the valve clearances. I am having trouble deciphering what my Chilton manual says about replacing the shims. This is what I have.

IN = intake valve, EXH = Exhaust Valve.......the number next to it will be the size shim it currently has installed or if it says " in spec " that means that particular valve is within the spec per the book. Can someone help me with this please?


Cyl1

IN .12mm ( in spec ) EXH .15mm Shim 174
IN .12mm (in spec ) EXH .15mm Shim 164

Cyl2

IN .09mm Shim 169 EXH .15mm Shim 161
IN .08mm Shim 172 EXH .15mm Shim 162

Cyl3

IN .10mm ( in spec ) EXH .16mm Shim 159
IN .09mm Shim 178 EXH .16mm Shim 160

Cyl4 Intake Exhaust

IN .16mm Shim 158 EXH .16mm Shim 159
IN .09mm Shim 178 EXH .16mm Shim 159

[racerd14666]

the easy way to break it down is this, thicker shim less clearance thinner shim more clearance. the number on the shim corresponds to the thickness in thousands, so just subtract the clearance you need that is in spec (and you want to go with the most clearance you can so you dont have to adjustment as soon) so i would still swap shims on the ones that are in spec cus there on the tight end and remember the shims you can buy only end in 5 or 0

Cyl1

IN .12mm ( in spec ) EXH .15mm Shim 174 160 would give you to .29mm
IN .12mm (in spec ) EXH .15mm Shim 164 150 would give you .29mm

Cyl2

IN .09mm Shim 169 160 shim = .18mm clearance
IN .08mm Shim 172 160 shim = .20mm clearance

you get the idea

[dobr24]

The formula is as follows:
A+B-C= D
Where:-
A is the measured clearance
B is the current installed shim size
C is the desired clearance (given by the manual)
D is new shim size

That easy
Example
160+160-150=170 shim. Get it?

[racerd14666]

thats complicated

current shim size - the clearance you out of spec to be in spec = new shim size

[yamaha_george]

The formula is as follows:
A+B-C= D
Where:-
A is the measured clearance
B is the current installed shim size
C is the desired clearance (given by the manual)
D is new shim size

That easy
Example
160+160-150=170 shim. Get it?

D,
neat but :-

Example
0.160thou + number160shim - 0.150thou = number 170 shim.

OR
in simple figures :-
(160 +160)= 320-150= 170
170= 170 numbered shim

[jax]

Thanks guys. After being able to not rush yesterday I finally sat down after a good meal ( home made Chicken enchiladas topped with melted white cheese and mild red salsa ) and read through the chilton manual. So far I think I have It down. This is what I need. Correct me if I am wrong. I took into account the rounding off of numbers that the manual said to do. New shim sizes to the left.

Cyl1 Need Shim

IN .12mm ( in spec ) EXH .15mm Shim 174.............in ( in spec ) Exh Shim 165
IN .12mm (in spec ) EXH .15mm Shim 164..............in ( in spec ) Exh Shim 155

Cyl2

IN .09mm Shim 169 EXH .15mm Shim 161............. in Shim 165 Exh Shim 150
IN .08mm Shim 172 EXH .15mm Shim 162...............in Shim 165 Exh Shim 150

Cyl3

IN .10mm ( in spec ) EXH .16mm Shim 159............. in ( in spec ) Exh Shim 150
IN .09mm Shim 178 EXH .16mm Shim 160.............. in Shim 175 Exh Shim 150

Cyl4 Intake Exhaust

IN .16mm Shim 158 EXH .16mm Shim 159............. in ( in spec ) Exh Shim 150
IN .09mm Shim 178 EXH .16mm Shim 159.............. in Shim 175 Exh Shim 150

[jax]

after doing a search on the web to confirm my finding I found this shim calculator that works really well.

http://vicdzen.narod.ru/main_eng/


another question. the specs are as follows.


Intake ( .11 - .20mm )
Exhaust ( .21 - .30mm )

Ideally do I want to be on the low or high end of that number?

[dobr24]

I always shoot for the mid to loose end.

[racerd14666]

you want them as loose as you can get them so you can go longer in-between valve adjustments but you want each pair of valves to be as close to each other and dont forget to sync your carbs after

[yamaha_george]

after doing a search on the web to confirm my finding I found this shim calculator that works really well.

http://vicdzen.narod.ru/main_eng/

Guys,
I thought we has a reference program for doing just that in the WIKI but i cannot spot it!!!

anyone?

If not I will add that one Thanks Jax.

[jax]

Looks like Im just going ot go ahead and go by what the chilton says per my measurements. When I measured with the feeler gage I did it to where there was a positive drag but not to the point where I had to jamb it in there.

I need

Qty 6 150

Qty 3 165

Qty 2 175

Qty 1 155


Wasn't there a shim swap thread here? Also, I guess i will have to get someone to sync my carbs since I don't have a sync tool.

Here is a list of shims that would be up for grabs once I do my adjustment.

158
159 x 2
160
161
162
164
169
172
178 x 2
174

[yamaha_george]

Looks like Im just going ot go ahead and go by what the chilton says per my measurements. When I measured with the feeler gage I did it to where there was a positive drag but not to the point where I had to jamb it in there.

I need

Qty 6 150

Qty 3 165

Qty 2 175

Qty 1 155


Wasn't there a shim swap thread here? Also, I guess i will have to get someone to sync my carbs since I don't have a sync tool.

Here is a list of shims that would be up for grabs once I do my adjustment.

158
159 x 2
160
161
162
164
169
172
178 x 2
174

Jax,
yes there was a SHIM swap thread, and the WIKI does have this:-

http://fzronline.com/wiki/doku.php?id=h ... clearances

Thanks to my Northern connection for that :-}

[jax]

OK. Now I am totally confused. So my intake valves on Cyl 1 are right at the borderline too tight.

The measurement is .12mm ( specs are .11 to .20 ) I have a shim 172. Does this mean I can go with a 170 or 165 to get that into mid or high range of the spec?



OK..........throw all my numbers out the window. I'm going to recalculate and see which shims I can re-use and swap over to minimize costs. Im going to calculate for mid range. ( .15mm intake ) ( .25mm exhaust )

Will post my numbers here later.

[yamaha_george]

Jax,
If your head hurts try this one:-

http://www.logicminds.biz/motorcycles/shimulator/

[jax]

Jax,
If your head hurts try this one:-

http://www.logicminds.biz/motorcycles/shimulator/

I tried that one but I guess it doesnt like firefox as the new shim sizes wouldnt populate.

I actually made my own shim calculator using excel. I just used .15 and .25 as the sizes I want to get to. Subtracted my measured from the current shim sizes that I have and got my new shim sizes.

I can swap some shims around from cylinder to cylinder. Going up or down +- .001 shouldnt hurt since I will still be within spec because I calculated the mid range.

Found a place on ebay that sells the shims for $4 a piece but I still have to buy 12 of them. Not bad considering my local shops want $8 plus tax.