Help! Valve Adjustment

Today I tested the compression on my 1979 KZ650. Cold and kickstarted, I had 75, 65, 80, and 75.

So, I decided to check the valve clearances to see if I could improve the compression. The clearances I got were (based on feeler gauge sizes): Exhaust - .178, .152, .152, .203, Intake - .102, .063, .076, .102.

Then I checked the shim sizes, based on the numbers written on the shims: Exhaust - 2.60, 2.50, 2.55, 2.50, Intake - 2.55, 2.65, 2.65, 2.50.

I decided to swap shims around so that my clearances were closer to .10 to .15, and I swapped them to this: Exhaust - 2.65, 2.50, 2.55, 2.55, and Intake - 2.50, 2.60, 2.65, 2.50. Based on these changes, I should have the following new clearances: Exhaust - .128, .152, .152, .153, and Intake - .152, .113, .076, and .102.

I made sure to keep the chain tight while pulling buckets to check/replace shims.

When I got it all bolted back up, I rotated the engine a few times to make sure everything was seated. I checked the clearances again... and I couldn't even get my smallest shim between some of these buckets, but the best was .102! I must have done something wrong. My timing chain, before I took off the idler, had some slack in it. Now, it's super tight.

I think that's everything I can remember doing... can you help me? What did I do wrong?

Thank you!

Are the buckets in their original valve? I dont know if they would change that much even with the same shims left in if you had switched the buckets. Apparently it makes adjusting after that more difficult.

did you tighten you cam chain tensioner with a longer bolt if its the auto like my 79 before you took off the idler?

Thanks for getting back with me.

No, the buckets are the exact same at each valve. And I didnt make any adjustments to my chain tensioner.

If the chain is "Super Tight" it is most likely not on the crankshaft sprocket correctly.

Motor Head wrote: If the chain is "Super Tight" it is most likely not on the crankshaft sprocket correctly.

So, I can rotate the engine fine though... Is there a way to verify that's it's not on the crank sprocket correctly?

May locate some info through one of these links about re-setting the tensioner.

www.kz650.info/

jarlef.no/Kawasaki/Series/Z/650/z650files.htm

Good Fortune!

The manual says to stop the tensioner with a longer bolt before removal of the cam shafts. if you took slack off the chain the tensioner may have pushed out too far. You should make sure the chain is on tight (no slack between sprocket and crank)on the exhaust side and then timed right with the intake. if the chain is still too tight you may have to tighten the tensioner down with a longer bolt and take it off to see if that is the problem.

Im also curious about the differences in spec too though. I did the same exact thing, rearranging shims and buying two new ones to put it in theoretical spec, but upon inspection only one was at .152! it runs like a rocket though and the spark plugs look MUCH better still.