[Davydo]

My z500 is overdue for a valve adjustment, I feel confident I can accomplish this, but not sure where the indicators are for TDC. Also, I think I can just remove the access cover in the back to get to the top of the cylinder head to remove the valve cover. Need some input and advise, thanks!

[NMKawierider]

My z500 is overdue for a valve adjustment, I feel confident I can accomplish this, but not sure where the indicators are for TDC. Also, I think I can just remove the access cover in the back to get to the top of the cylinder head to remove the valve cover. Need some input and advise, thanks!

The service manual has all you need in it.

[Davydo]

My z500 is overdue for a valve adjustment, I feel confident I can accomplish this, but not sure where the indicators are for TDC. Also, I think I can just remove the access cover in the back to get to the top of the cylinder head to remove the valve cover. Need some input and advise, thanks!

The service manual has all you need in it.

Where can I get a service manual for the z500? The one on this site I can’t seem to download?

[NMKawierider]

My z500 is overdue for a valve adjustment, I feel confident I can accomplish this, but not sure where the indicators are for TDC. Also, I think I can just remove the access cover in the back to get to the top of the cylinder head to remove the valve cover. Need some input and advise, thanks!

The service manual has all you need in it.

Where can I get a service manual for the z500? The one on this site I can’t seem to download?

The good original copy we had went corrupt...we don't know why but it's gone. Aside from getting one from on-line all I have is this very bad copy of the ZForce 500 service manual. Much of it is hard to read but..you are welcome to it.

https://documentcloud.adobe.com/link/track?uri=urn%3Aaaid%3Ascds%3AUS%3Aac34c0c3-c2d4-42c9-880c-0f9215116c14

[Davydo]

My z500 is overdue for a valve adjustment, I feel confident I can accomplish this, but not sure where the indicators are for TDC. Also, I think I can just remove the access cover in the back to get to the top of the cylinder head to remove the valve cover. Need some input and advise, thanks!

The service manual has all you need in it.

Where can I get a service manual for the z500? The one on this site I can’t seem to download?

The good original copy we had went corrupt...we don't know why but it's gone. Aside from getting one from on-line all I have is this very bad copy of the ZForce 500 service manual. Much of it is hard to read but..you are welcome to it.

https://documentcloud.adobe.com/link/track?uri=urn%3Aaaid%3Ascds%3AUS%3Aac34c0c3-c2d4-42c9-880c-0f9215116c14

Thanks NMK!

[Davydo]

So from millimeter to inches I get .002-.004 intake clearance and .007-.008 exhaust clearance?

[NMKawierider]

So from millimeter to inches I get .002-.004 intake clearance and .007-.008 exhaust clearance?

Looks right except I thought there was a bit more of a range then one on the exhaust. Anyway try to stay in the middle of any range. Do it dead cold..meaning it hasn't run in at least 6 hours. 

EDIT: I just did the conversions for the 800s and it says...002-005 on the intakes and 004-007 on the exhausts. Might do a double check

[Davydo]

So from millimeter to inches I get .002-.004 intake clearance and .007-.008 exhaust clearance?

Looks right except I thought there was a bit more of a range then one on the exhaust. Anyway try to stay in the middle of any range. Do it dead cold..meaning it hasn't run in at least 6 hours. 

EDIT: I just did the conversions for the 800s and it says...002-005 on the intakes and 004-007 on the exhausts. Might do a double check

Says .05-.10 mm intake and .17-.22 mm exhaust. Conversion to inches is .0019685-.00393701 intake and .00669291-.00866142 exhaust.

[NMKawierider]

So from millimeter to inches I get .002-.004 intake clearance and .007-.008 exhaust clearance?

Looks right except I thought there was a bit more of a range then one on the exhaust. Anyway try to stay in the middle of any range. Do it dead cold..meaning it hasn't run in at least 6 hours. 

EDIT: I just did the conversions for the 800s and it says...002-005 on the intakes and 004-007 on the exhausts. Might do a double check

Says .05-.10 mm intake and .17-.22 mm exhaust. Conversion to inches is .0019685-.00393701 intake and .00669291-.00866142 exhaust.

Ah..just use the thousands number..ie .001-.003 and .006-.008

[Davydo]

So from millimeter to inches I get .002-.004 intake clearance and .007-.008 exhaust clearance?

Looks right except I thought there was a bit more of a range then one on the exhaust. Anyway try to stay in the middle of any range. Do it dead cold..meaning it hasn't run in at least 6 hours. 

EDIT: I just did the conversions for the 800s and it says...002-005 on the intakes and 004-007 on the exhausts. Might do a double check

Says .05-.10 mm intake and .17-.22 mm exhaust. Conversion to inches is .0019685-.00393701 intake and .00669291-.00866142 exhaust.

Ah..just use the thousands number..ie .001-.003 and .006-.008

10-4 Thanks!

[Davydo]

I finally adjusted my valves this weekend, nothing to it...the only issue I had was initially lining the TDC mark on the crank to the mark on the case. I found that mark on the case inside the tach sensor hole at the bottom opposite the crank shaft mark, it was hard to see without adequate lighting. Everyone of the valves were tight and I could not get a .076 filler which was too thin between any of the valves and adjusters. Is this normal for them to be so tight after 500 initial miles?? And what causes them being too tight?  Anyway I adjusted them .107 for intake (.08-.12 mm specs) and .157 for exhaust (.12-.18 mm specs) reassembled and took for a ride. All seemed fine.

[NMKawierider]

Well, valves loose lash or gap when either the valve sinks farther in the seat or the stem stretches. Most often it's the valve setting farther in the seat and that's caused by one of two main issues- one, Kawasaki had this a few years ago, soft valve seats and valves. Or, most often, particle ingestion. As the valves close on this grit, it erodes the seats into a surface that looks pitted or sand blasted. That allows the valve to beat it's way into the seat faster. It most always leaves the valve(s) with a broken seal so a leak-down test can confirm a seat problem. If you ran it a while with the stock air filter this would account for it and it should stop after the Unifilter was installed. Check them again 4-500 miles. If they are about where you left them you should be good.

On the other side of the coin the lash gets larger when the cam and or rockers wear or just wear-in as well as the valve top & adjuster. All but one on my 800 were loose when I first checked them at 300 miles. The one that was tight had a seizing roller. I fixed that and the next two times I checked them all were stable so I've left them alone for a while now.   

[Davydo]

Well, valves loose lash or gap when either the valve sinks farther in the seat or the stem stretches. Most often it's the valve setting farther in the seat and that's caused by one of two main issues- one, Kawasaki had this a few years ago, soft valve seats and valves. Or, most often, particle ingestion. As the valves close on this grit, it erodes the seats into a surface that looks pitted or sand blasted. That allows the valve to beat it's way into the seat faster. It most always leaves the valve(s) with a broken seal so a leak-down test can confirm a seat problem. If you ran it a while with the stock air filter this would account for it and it should stop after the Unifilter was installed. Check them again 4-500 miles. If they are about where you left them you should be good.

On the other side of the coin the lash gets larger when the cam and or rockers wear or just wear-in as well as the valve top & adjuster. All but one on my 800 were loose when I first checked them at 300 miles. The one that was tight had a seizing roller. I fixed that and the next two times I checked them all were stable so I've left them alone for a while now.

Thanks NMK, I purchased the machine from a guy earlier this year and it had 120 miles on it then. He rode on trails in eastern North Carolina, red clay mud and dust etc.  It had the original stock filter when I checked it over, but it was in good condition, the foam prefilter had some dust on it but thats it. I at that point installed the uni filter and have maintained it as best I could since.  the over head clean and my engine oil is still clear and hasnt been changed since the other guy had it serviced at 100 miles. I thought I was doing something wrong about TDC because I expected to have loose valves too.  I hope I don't have any serious troubles down the road and I'll check them again like you recommended at the 1000 miles mark.   

[Davydo]

I was roving the site and found Marbella's Buggies post on 9/15/2018 and their comment about the 100,000 kms and all the issues they had with the zforces and one that stood out to me was the no valve clearance when they went to adjust them. Also by the dusty conditions and clogged filters, they probably had experienced some valve seat erosion that had caused a loss of valve clearance maybe? I guess i'm not the only one...

[NMKawierider]

I was roving the site and found Marbella's Buggies post on 9/15/2018 and their comment about the 100,000 kms and all the issues they had with the zforces and one that stood out to me was the no valve clearance when they went to adjust them. Also by the dusty conditions and clogged filters, they probably had experienced some valve seat erosion that had caused a loss of valve clearance maybe? I guess i'm not the only one...

Yep...