I gotta 06 klx250s with 9500 miles on it. i bought the bike last year with 4000 miles on it and the valves checked good then . Decided it was time for another check. If i remember correctly the exhausts are supose to be .15-.24 mm and intakes are between .10-.19 mm .

On my bike the front two (exhaust) measure at .15 mm , one is a bit tighter but i can still get the .15 under it.

The back two (intake) are very tight . The smallest feeler gauge i have is a .04 mm and i cant get it under. This cant be to good. I am assuming the the clearance is 0.
With that being said i havent tore into the bike yet so i dont know the the size of the shim in there . My question is with both the exhaust .15 can i shim it so i dont have to tear into it again in a few thousand miles . And for the intakes im kind of stumped on what to do.

Thanks

 

For starters, you're sure you have the cams in the correct position for valve adjustment, right? That's a pretty big change for the intake in 5000 miles. Assuming everything is in the correct position, can you still easily rotate the intake buckets under the cam to indicate that the cam lobe isn't touching the bucket? In other words, to tell that you at least have some clearance?

 

Also, my tutorial on clearances may help:

https://www.kawasakiforums.com/forum...acement-35136/



I will assume ya done everything right..... so I'd suggest you get that clearance addressed ASAP. If the valve holds open a wee bit but still fires, you are headed towards valve burning issues.

 

Yes you can change the shims on the exht to the loose side of the spec, while you address the intake situation.
I agree, I would double check you are on TDC on the compression stroke when measuring your clearances before proceeding.

 

tjw, did you develop any starting issues since your last valve check?

 

Thanks guys . I did turn the engine over and made sure the T was showing but the valves did not look like theywere in the same place as the one pictured in you pictures. I will go out again and make sure i am at TDC on the compression stroke. Thanks KLXrelic
TNC- I havent had any starting issues what so ever. The bike was hard to start just recently before i jetted it and put the pipe on . but since then it starts very easy. When its cold it still need the choke to start

 

you need to pass the t at times to get to tdc...

 

i should also add..that on my first valve adjustment at around 8,900 miles, my inlet clearance was also 0.04 mm...exhaust clearance was also slightly below the minimum clearance...my theory was that inlet clearance dimish more rapidly, so replaced the shims to have more clearance for the inlet and replaced the shim for the exhaust to remain on the tighter side of clearance...bike ran like a champ after..

after 15,000 miles, i'm starting to have slight engine cut out issues the first few miles after a cold start...engine sometimes cuts out when downshifting for slowing down in the morning...once engine is hot, no issues...my new theory is my exhaust shims are out of spec (last time I checked, my exhaust clearance was at the minimum 0.14 mm for both..manual said to leave it, so I left it and I didn't have any shims ready at the time)...

 

Thanks for all the replies . I ended up not being all the way at tdc. I rotated the engine a tiny bit more and was able to get .16 on the inlets and both of the exhausts are at .15 , one is a bit tighter then the other but i could still get a .15 in there easily I will run it a few thousand more miles and check again then most likley adjust the exhaust .

 

is there a topic on checking the valves after doing the marcel cam mod ???