Got my valve cover gasket and o-rings, shim tool, intake boot o-rings and side cover emblems.
Clearances:
LH Ex = <.038 w/2.75 shim (bucket does not move freely)
RH Ex = <.038 w/2.75 shim (bucket moves freely)
LH In = <.038 w/2.70 shim (bucket moves freely)
RH In = <.038 w/2.70 shim (bucket moves freely)
Swapped LH Ex shim with 2.70, now has .12 clearance (that math doesn't seem right?)
Swapped RH Ex shim with 2.70, still has <.038 clearance
I ordered (3) 2.65 shims and (3) 2.60 shims plus (1) 2.30 for future clearance checks
I expect that the 2.65's will give me good clearances, but I got the 2.60's just in case. Should have them Friday.
(http://i820.photobucket.com/albums/zz124/me181/under_tank_zpscb10d5a2.jpg)(http://i820.photobucket.com/albums/zz124/me181/parts_on_the_floor_zps3e8fe67f.jpg)
And I got '96 black side cover emblems to replace scratched silver ones. The black looks so cool on the silver engine!!
(http://i820.photobucket.com/albums/zz124/me181/stator_cover_zps565cf2ed.jpg)
Will post an update after my shims come in.
Mike
I love the black side covers! How much did you pay for them and where did you order them from ?
I got them from ronayers.com, part number 68233-01D00, $12.57 each. They were from a 1996 model with the black engine.
Mike
Thanks, I've seen them everywhere for around that price. It kills me to buy stickers for that cost haha
Thanks!
Sent from my iPhone using Tapatalk (http://tapatalk.com/m?id=1)
Congratulations on the way you are maintaining your machine's cleanliness and overall orderly look. Nice.
Thanks noworries! This bike was a straight mess 3 months ago when I bought it. It sat unused in a parking lot in the Florida sun for a year or more and then sat in a storage shed for another year before I bought it. It has 11.5k miles and appeared to have never been cleaned or serviced! I'll bet I've got the better of 50 hours or so spent just cleaning and polishing :cookoo:
And robfriedenberger, those emblems are so far the coolest looking 25 bucks I've spent yet!
Mike
Yeah, it doesn't add up!
Couple of suggestions....
Measure the shims with a dial or digital caliper...just because they are stamped with a certain size, doesn't mean they are actually that size...ya gotta measure...and measure in a couple places...might vary.
Also, any oil under the shim will temporarily give a false reading, as the shim is "floating" up on the oil...should rotate the engine a couple turns to squeeze out excess oil....
Also ya gotta be clean....any crumb that falls under the shim will mess up everything.
also measure with the same cam orientation every time, as shown in the manual..
If the gap is less than your thinnest feeler, then you can't use that as a starting point...gotta go to smaller shim and bigger gap, to figure out where to start, and go from there
Quote from: HotrodScamp on January 21, 2014, 12:39:15 PM
Got my valve cover gasket and o-rings, shim tool, intake boot o-rings and side cover emblems.
Clearances:
LH Ex = <.038 w/2.75 shim (bucket does not move freely)
RH Ex = <.038 w/2.75 shim (bucket moves freely)
LH In = <.038 w/2.70 shim (bucket moves freely)
RH In = <.038 w/2.70 shim (bucket moves freely)
Swapped LH Ex shim with 2.70, now has .12 clearance (that math doesn't seem right?)
Swapped RH Ex shim with 2.70, still has <.038 clearance
I ordered (3) 2.65 shims and (3) 2.60 shims plus (1) 2.30 for future clearance checks
I expect that the 2.65's will give me good clearances, but I got the 2.60's just in case. Should have them Friday.
(http://www.mikefurtado.com/images/bikes/under_tank.jpg)(http://www.mikefurtado.com/images/bikes/parts_on_the_floor.jpg)
And I got '96 black side cover emblems to replace scratched silver ones. The black looks so cool on the silver engine!!
(http://www.mikefurtado.com/images/bikes/stator_cover.jpg)
Will post an update after my shims come in.
Mike
Its quite odd to me that all your screws are in plastic cups.....I love the idea, but I think my wife would have a heart attack when she saw some thing like that. Usually mine end up in cardboard marked or in a magnetic screw bowl full of a bunch of others lol
Shims came in today!
(http://i820.photobucket.com/albums/zz124/me181/shims_zpsd5a5c23b.jpg)
The three on the right are the two 2.75's and one 2.70 I have removed, the rest are the ones I ordered from http://www.z1enterprises.com/ (http://www.z1enterprises.com/) Kudos to Z1 for fast shipping and great prices.
Got out the digital caliper and measured old and new shims. Many times over. The three shims I removed all measured consistently .01mm under and all 7 new shims measure exactly on spec.
Tomorrow I'll pop in the three 2.65's and check clearances again. The intakes should be fine, they had 2.70's with <.038mm and the buckets moved freely, so if I assume .02mm on those, I should end up around .07mm on the intakes. The right exhaust with a 2.70 also had less than .038mm so a 2.65 should bring me in spec there. The left exhaust has an original 2.70 and the clearance measured .12mm, though the math didn't work out for that swap, as long as it measures a consistent .12mm, I'll go with it.
Assuming all goes well, I'll button it up and go for a spin!
robfriedenberger: I've used clear plastic cups for holding fasteners and small parts on just about every project I've ever done. I use a separate cup for each small area of the project so it's really easy to remember where everything goes. If there's really complicated stuff, or left and right (like carb parts) I mark it on the cup with a sharpie.
twocool: Did all the measuring and the removed shims were all .01mm under, but not enough to account for the discrepancy. I did rotate the engine 4 or 5 revolutions before I measured the new clearance as well as before I measured the original clearance, so it shouldn't be float. The only thing that's been close enough to the head since I opened the valve cover is a blue paper shop towel I put in the center of the head in case I dropped anything. I've also used one to cover the open head while I'm not working on it. I'll do another careful round of measurements tomorrow and post my results.
Are you checking clearances with engine on the timing marks like the shop manual describes? Not doing so is the only reason I can think of for the inconsistency of the LH EX measurements. Put them on the marks after you change the other 3 shims to check clearances if you're not doing that already.
http://www.gs500.net/gallery/data/500/gs500signalgenerators.jpg
http://www.gs500.net/gallery/data/500/GS_ValveAdj.jpg
If the motor wasn't spun around a few times before you checked this would cause inconsistency of the measurements.
Cool!
You are doing this project like a real pro! At this point, forget about what the valve clearances "were"...it only matters what they "are now"...so put in your new shims.....rotate the engine.... set the cams positions as per the manual, and measure......if in spec...you're done...if not change shims, repeat the process, and then your done.
I Like your plastic cups....in our airplanes shop, we buy those baking tins for muffins...12 spots on each for small parts....we run some masking tape to label each depression...sometimes a plane is apart for a day, or a week or even a year before it is re-assembled...easy to forget what each hardware is for without sorting and labels!
Cookie
Quote from: HotrodScamp on January 24, 2014, 09:20:11 PM
Shims came in today!
(http://i820.photobucket.com/albums/zz124/me181/shims_zpsd5a5c23b.jpg)
The three on the right are the two 2.75's and one 2.70 I have removed, the rest are the ones I ordered from http://www.z1enterprises.com/ (http://www.z1enterprises.com/) Kudos to Z1 for fast shipping and great prices.
Got out the digital caliper and measured old and new shims. Many times over. The three shims I removed all measured consistently .01mm under and all 7 new shims measure exactly on spec.
Tomorrow I'll pop in the three 2.65's and check clearances again. The intakes should be fine, they had 2.70's with <.038mm and the buckets moved freely, so if I assume .02mm on those, I should end up around .07mm on the intakes. The right exhaust with a 2.70 also had less than .038mm so a 2.65 should bring me in spec there. The left exhaust has an original 2.70 and the clearance measured .12mm, though the math didn't work out for that swap, as long as it measures a consistent .12mm, I'll go with it.
Assuming all goes well, I'll button it up and go for a spin!
robfriedenberger: I've used clear plastic cups for holding fasteners and small parts on just about every project I've ever done. I use a separate cup for each small area of the project so it's really easy to remember where everything goes. If there's really complicated stuff, or left and right (like carb parts) I mark it on the cup with a sharpie.
twocool: Did all the measuring and the removed shims were all .01mm under, but not enough to account for the discrepancy. I did rotate the engine 4 or 5 revolutions before I measured the new clearance as well as before I measured the original clearance, so it shouldn't be float. The only thing that's been close enough to the head since I opened the valve cover is a blue paper shop towel I put in the center of the head in case I dropped anything. I've also used one to cover the open head while I'm not working on it. I'll do another careful round of measurements tomorrow and post my results.
:woohoo: Finished my valve adjustment and carb sync!
Final clearances:
LH Ex = .12 w/2.70 shim
RH Ex = .14 w/2.60 shim
LH In = .05 w/2.65 shim
RH In = .07 w/2.65 shim
So I cleaned up the valve cover and got some gasket goo:
(http://i820.photobucket.com/albums/zz124/me181/valve_cover_zpsd18494ac.jpg)(http://i820.photobucket.com/albums/zz124/me181/gasket_goo_zps5f01a2f2.jpg)
Put the valve cover back on and buttoned it all up:
(http://i820.photobucket.com/albums/zz124/me181/valve_cover_on_zps15faf122.jpg)(http://i820.photobucket.com/albums/zz124/me181/back_together_zpsa6ccedf4.jpg)
Started right up! A very little valve clacking to be heard and a little popping in the exhaust. I went for a 2 mile ride. The stalling symptom is completely gone! Still a little hesitation, but noticeably less. So back to the garage for carb syncing. All I've got is my dad's 40+ year old vacuum gauges.
(http://i820.photobucket.com/albums/zz124/me181/vacuum_gauges_zpsa3dc10d5.jpg)
I put the gauges on and soon found out that I couldn't get a stable reading until almost 9000 rpm! I took a full turn and a half out to balance the gauges. Just as I hit the balance point the popping exhaust stopped. I took the gauges off, put everything back together and went for another ride. :woohoo:
The difference in how the bike runs is absolutely amazing! No more stalling. No more hesitation/surging. Noticeably more power through the entire RPM range. I'm so happy I could shaZam! myself! :icon_eek:
Now we're back home after a 20 minute ride and I couldn't be happier! Tomorrow should be a great day for a nice long ride :thumb:
(http://i820.photobucket.com/albums/zz124/me181/back_home_zpsd0b58eec.jpg)
:cheers:
Good results on the valve clearances. :thumb: Did the LH EX bucket turn freely after the shim change?
Thanks Jack! All the buckets turned freely with the new shims after turning the crank a few times while I was checking the new clearances. I turned it several times and re-checked all the clearances and the measurements were consistent each time. I couldn't be happier with the results!
:woohoo: :woohoo:
Success!!!
(http://i820.photobucket.com/albums/zz124/me181/out_and_about_zps89bd0233.jpg)