Valve clearance misery, help needed!

Hi, the &%¤&%¤ valves changes clearance just to &/%/ me off!.

I checked my valve clearances, all fine (0,1 - 0,15 mm) except intake on cyl 1 (valve 5) which was 0,05-0,1). So I remove the cam, change the shim on valve 5 from 2,40 to 2,35 and put the cam back. I lubed all the bearings and tightened all camcap bolts in the correct order to the correct torque. Double checked chain timing. Turned the engine a couple of turns and rechecked the clearances, and to my utter confusion I now have no clearance on valve 5 and not on 7 either! 6 and 8 as before. Ok so I guess I made it wrong, disassemble all, recheck all the bearing surfaces, relube, check that every camcap and bolt is in the right place, tighten bolts with fingers and torque them in correct order (double check order and torque) ok to be sure, I torque a little lower. Recheck camshaft is on correct, measure again, 5 and 7 no clearance.

At this point I almost drove a hammer through the window. So ok recheck procedure in factory manual and compare to Haynes: no difference.

I just have no idea whatsoever what might have happened and no idea what to try next. So I beg to the kzrider forum gurus, please help!!!

the only two things that come to mind are the shims under the bucket, I am guessing that is so on your bike, are not seating correctly, or you have used some heavy grease in the reassembly and it has changed the clearance

Did you measure the replacement shims to make sure the numbers that are printed on them are correct? Are you making sure the cam lobe is opposite of the valve bucket when you take the reading? Do not use grease on the shim, use engine oil. Are you using the same feeler gause every time. There are not that many reasons why your clearances would do that.

Thanks guys for the replies, I removed the cam once again yesterday night and You were right, the shim was not correctly seated. How that happened is beyond me, but it had. I did not have time to reinstall and measure but I am pretty certain that was it. Thanks again.

Wilde wrote:

...I did not have time to reinstall and measure...

Too busy replacing the window? :laugh:

Sorry, just kidding. I know valve adjustments can be frustrating. Luckily there were no windows in the basement where I did it.

Honestly, in my teens I almost drew a screwdriver into my friend when he laughed when I could not get the chainlink on correct on my 50cc bike. I actually saw stars before my eyes of adrenalin...

Clearances measured now and they are spot on, also invested in a high quality torque wrench, about $120...

Glad to hear it's solved!

I went through the same experience once, come to find out a shim marked .235 was actually the next bigger size, so it happens.

I had a similar problem. However, my issue was that I hadn't correctly torqued the bolts before initialy measuring the clearances. Once I did that, all was good.