Were my cams installed incorrectly? Valve clearance woes...

[Tarwetijger]

Hmm, good luck with that! You've seen my topic, right? I used Wynn's injection cleaner (a.o.) to get the carbon off.

I read on the first page of this topic that you also ordered two new inlet valves. Why is that exactly?

[JL]

Hmm, good luck with that! You've seen my topic, right? I used Wynn's injection cleaner (a.o.) to get the carbon off.

I read on the first page of this topic that you also ordered two new inlet valves. Why is that exactly?

Yes, I've been following your thread while waiting for my parts to arrive. Quite funny that we are both doing it at the same time! Regarding my valves - I've got a '96 model with almost 100,000 km on the clock and had no clearance on my inlets when I checked them. When I had a mechanic adjust them last time I was told he had to order very thin shims. It seems that valve stretch is a common issue with the early models, so figured I may as well install new inlet valves (all 6) while I was at it and replace all the valve stem seals as well. And then figured I'd do the rings and a cylinder hone. Will try some brake cleaner tomorrow on a rag and perhaps buy some injector cleaner if I'm not having any luck!

[Tarwetijger]

Ah, I misread; not two but six new valves. Expensive! But makes sense.

[JL]

I decided to take my head, valves, seals and (very glazed) cylinder block to a local head workshop today after having a chat with the friendly chap who runs the place. May as well get the tricky bits (at least for me) done properly since I've come this far. He pulled one of the inlet valves out while I was there - HOLY CRAP!!! Here's a pic for everyone:

At least the seat looked ok, should have the head ready next week sometime, will update then. Glad I didn't just put new shims in!

[Tarwetijger]

Whoah! No wonder you needed very thin shims!

[HansJ]

ooops....

I think we finally can kill the myth of having soft valve seats, and blame it on the valves, or?

[JL]

Well, aren't I chuffed - my first ever rebuild and I didn't kill my bike! After waiting for an eternity, finally got all the parts and now have a trx with a fresh top end. Feels like a stranger at the moment though after riding the xs650 for the last 4 months - so much more power, different riding position and so nimble. And so much smoother! All seems to be well so far, fired it up last night and took it for a burn, and rode to work today. No problems aside from some leaking coolant as I didn't tighten a hose clamp properly. Definitely more valve noise, guess that's because it now has proper clearances. So satisfying to have done the work myself (aside from head work, and having a friend help lower the cylinder block over the pistons), it was daunting, but in the end was not too difficult, even for a first timer armed with the workshop manual and Haynes. Worst part was tightening head nuts - felt like an eternity waiting for the torque wrench to click. And then going to replace the gear change shift shaft oil seal, and discovering some cracked clutch plates which meant I had to wait for replacements before firing her up!

Now that it's back on the road Aww yeah!!!

[Tarwetijger]

Haha, you're really satisfied aren't you! I know the feeling.
Good job, and now enjoy!

[JL]

Haha, you're really satisfied aren't you! I know the feeling.
Good job, and now enjoy!

Oh yeah! It's so funny that I began ordering parts before you started and yet you beat me to the rebuild!

[Tarwetijger]

Don't be too jealous, my engine was leaking oil.
It was the valve cover, which isn't as bad as a head gasket I suppose.
So, don't forget to use gasketing (is that the correct word? liquid gasket we would call it) on the valve cover! I heard they even to this in the factory, despite the rubber valvecover seal.

[JL]

I used a new seal this time around - the old one was pretty cracked and was covered in gasket which I removed. Didn't use any when I put it on, but I'll keep an eye on it. It seems ok so far and has stopped the leak I was getting through the spark plug area and out through the drain hole. More concerning is the leaking left side carb to radiator/thermostat hose I will have to check tomorrow ... Probably didn't show up before as the coolant pipes on the right carb were completely clogged to the point of not even being able to blow air through them!