TECH TIP

ADJUSTING VALVE CLEARANCES

In the previous issue of “Inside Team Green” (Issue 3) we covered the first part of TOOLS NEEDED:
our two part series, and explained how to properly check valve clearances on your
● 8mm socket wrench ● 5/8 spark plug wrench ● Feeler gauges
250F 4-Stroke motor. In this issue we will pick right up where we left off and explain
how to adjust your valve clearances if one or more of your valves are out of tolerance.
● 10mm socket wrench ● 6mm Allen ● Calipers
However, we will begin with a little refresher course on valve clearances. ■ ● 12mm socket wrench ● Flat Blade screw driver ● Pin magnet

Step 5: Remove
the tappet on
any valve or
valves that need
adjusting using a
pin magnet

Refresher: Valve clearance is the distance between the

Step 6: Remove
cam lobes (A) and the lifters or tappets (B).
the valve shim.
The shim often
TEAM GREEN RECOMMENDED VALVE CLEARANCE
(Stock cams) sticks to the
Step 2: Remove cam cap bolts and cam caps. Be care-ful inside of the tap-
● Intake - (.004 to .006) or metric (.17 to .22) that the dowel locator pins do not fall in the motor. pet. However,
● Exhaust - (.007 to .009) or metric (.1 to .15) if it doesn’t you
* If the valve clearance is not within the specified will have to use
range, adjust it. the pin magnet
once again to
[NOTE] As always, remove any necessary body work remove it.
(seat, tank, shrouds, etc.) so that you have good clear NOTE: If you are adjusting more
access to the top-end of the motor. In our examples, than one valve at a time, mark and
we will be working on a motor that has been record the locations of the tappets
removed from the frame. Adjusting the valves can and shims so that they can be rein-
easily be done with the motor still in the frame. It is stalled in their original locations.
not necessary to remove it.
Picking up right where we left off in the previous is- Step 7: Now that
sue, we currently have the valve cover removed, the spark the shim is re-
plug out, timing inspection cap off, and the motor set at moved, clean the
top-dead-center on the compression stroke. The motor Step 3: Remove two cam position rings, (they look like shim to remove
must be set to top-dead-center on the compression stroke piston rings cut in half) Note: intake side is smaller than any dust and oil
in order to check and or adjust the valve clearances (refer
the exhaust side. and measure the
to the last issue of “Inside Team Green” or your service
man-ual on setting your motor to top-dead-center). thickness of the
After checking all four valve clearances on our removed shim.
motor, we have determined that our left side intake
(clutch lever side) valve clearance is too tight and
needs to be adjusted.
Step 8: Select a replacement shim thickness using the
following calculation.

A = (B – C) + D

[A] Replacement shim thickness (the shim needed

Step 1: Start by removing the cam chain tensioner.
This will relieve the tension on the cam chain and
allow you to remove the cams. Do so by first remov-
ing the center 12mm socket bolt, washer, spring and
rod. Then, remove the two smaller 8mm socket bolts
to remove the entire chain tensioner body.
Step 4: Remove Cams. In order to do so, you will have
to rotate each cam toward the cam chain and slip
them out. Note: Even though you may only need to
adjust the cam clearance on one of your cams, it is a
good idea to take the time and remove both so that
you can inspect the tappets for any excessive wear.
to obtain the correct valve clearances)
[B] Measured Valve Clearance (current clearance
not within spec)
[C] Specified valve clearance (target or proper
clearance we are trying to obtain)
[D] Present shim thickness (incorrect shim re-
moved from motor)
NOTE: Repeat [Step 8] on any and all valve clearance
that need adjustment.

Step 9: Before installing the new replacement shim,
measure it to make sure that it is the correct thick-
ness supposed to be.
Step 16: Before installing the cam chain tensioner,
NOTE: When installing the cams, refer to the figure inspect the o-ring [A] and replace if needed. Release the
above. Check that the engine is still at top-dead-center. stopper [D] and push the pushrod [B] into the tensioner
Starting with the exhaust cam, align the marks on the body [C] fully.
cam sprocket (Figure D&E) with the cylinder head (F) and
place the chain onto the sprocket. Repeat the procedure
on the intake cam along with the punchmarks. You can
verify the cam position by counting a total of 8 pins from
A to C.

Step 17: Install the tensioner body with the stopper

Step 10: Begin reassembly of head. Put replacement or facing up and tighten the smaller 8mm tensioner
corrected shims back in place. Use some engine oil to mounting bolts to the correct torque specification.
hold the shim in place. Torque - Camshaft Chain Tensioner Mounting Bolts:
9.8 N.m(1.0kgf-m,87ft-lb)

Step 14: Once your sure that the cams are positioned
properly, lightly oil cam cap bolts and tighten to the
specified torque in the correct tightening order.
NOTE: Uniformly tighten all cam
cap bolts. Bolts (A) are longer than
the rest. After applying entine oil
to the seat and thread, tighten ac-
Step 11: Replace tappets cording to thesequence numbers
on the camshaft caps (1-4).
Torque - Camshaft Cap Bolts: Step 18: Next, install the spring and rod into the ten-
9.8N-m(1.0kfg-m,87in-lb) sioner body and finish off by tightening the 12mm
cap bolt and washer to the tensioner body. Torque
-Camshaft Chain Tensioner Cap Bolt: 20 N-rn (2.0
kgf-m, 15ft-lb)

Step 12: Apply lubrication to any cam contact locations

and tappets.

Step 13: Replace cams, cam position rings, and cam
caps (Be sure to replace the cam caps in their original
location).
Step 15: Recheck valve clearances to ensure that they
are now within specification. If valves are still out of
specification, repeat valve adjustment process and
recheck clearances til they are within specification.
- Once valve clearances are adjusted properly and
within specification the cam chain tensioner is ready
to be reinstalled.
Step 19: Using a 14mm socket wrench turn the fly-
wheel counter-clockwise a number of times to ensure
that the motor turns over properly and that all valves
and cams are turning and functioning properly. Also
recheck that the cam timing is still correct.
Step 20: Job complete.... Reassemble motorcycle and
have fun!

Material courtesy of Team Green News USA