Valve clearance/carbon deposit on plugs

Restoring clearance on the valves may require moving two shim sizes. You might want to keep this in mind when placing your shim order. Also, after installing a thinner shim make sure to double check the clearance to confirm that you fixed the problem.

So for the 650 it's more complicated, but I don't need any special tools other than a caliper to measure the shims (assuming the etched measurement is worn off)? I don't want to waste money on unneeded shims so I suppose I'll remove, measure, order then install/remeasure?

gcphoto wrote: I don't want to waste money on unneeded shims so I suppose I'll remove, measure, order then install/remeasure?

Your problem is the "0" clearance valves. The real reading is not likely zero, but some negative number that feeler gauges can't measure.

When you take the shims out, you can measure (or read) what shims you have. But then you will be guessing how much thinner they need to be to start picking up a gap again.

Aside from having a "shim kit" at hand, I can think that if you had just one real thin shim, placed it in a "0" valve, then you will get a reading to math out the real shim it needs.

That's one way of doing it. I like to have the next sizes down for future use. Odds are you will need one of the smaller ones, perhaps more.
Steve

It's likely you have to do the valve check twice on the valves that measure 0. As mentioned use a thinner shim than you think to get a positive number as a gap then calculate what you really need as a shim. I would use a decent magnet if you don't have a suction device.
Hth

If you go to Wiredgeorge's site he has the 77 kz650 shop manual in his downloads on page 5 of the Kawasaki files
www.vintagebikeforum.org/
You will probably have to join to see it though, no big deal
JD

bluezbike wrote: I.... I would use a decent magnet if you don't have a suction device.
Hth

There is a theoretical risk bringing magnets around engine parts.

In this instance, if a shim becomes magnetized from being in proximity of a magnet, then it will pick up any metal out of the oil and hold on to it, then the cam will swing by and wear on the metal..in theory.

I don't know how big a risk this is in the real world, but I demagnetize any tools I use around the shims & cams as standard practice.

Did not realize it might be a problem, thank you......what do you do to demagnetize your tools?

Pulling a shim out with a small magnet isn't a problem. If it worries you then you can use tweezers. I for one am not that paranoid.
Steve

This is coming from the guy who made his own shims out of beer cans. :laugh:

Don't give a false impression. I shimmed up my cams with beer can shims. If you're going to quote me PLS get it right. :woohoo:
Steve

bluezbike wrote: Did not realize it might be a problem, thank you......what do you do to demagnetize your tools?

You probably recognize it; sold an most HW stores. $5 thing for the tool box.



Cheers
Chris