Valve Clearance Adjustment

Model(s)

700XS (MaximX)

700XSC (MaximX)

xjcdadmin Mon, 06/14/2010 - 15:41

VALVE CLEARANCE ADJUSTMENT

1 Valve lifter 2 Pad 3 Retainer 4 Spring seat

Valve Clearance (Cold):
Intake: 0.11 -0.20 mm (0.004- 0.008 in)
Exhaust: 0.21- 0.30 mm (0.008- 0.012 in)

Measurement

1. Remove:
• Seat
• Fuel tank
• Horns
• Ignition coil mount bolts (1)

2. Disconnect the spark plug caps

3. Remove:

• Ignition coils
• Spark plugs
• Cylinder head cover
• Left crankcase cover

4. Measure the valve clearance

NOTE:.
Be sure piston is at Top Dead Center (TDC) on compression stroke when measuring clearance.

Valve clearance measurement steps:

•Turn the crankshaft counterclockwise with a 19 mm (0.75 in) spanner.

NOTE:
Valve clearance must be measured when the engine is cool to the touch.

(1) Pickup coil mark

(2) TDC for No. 1 cylinder

(3) Firing range for the No. 1 cylinder

• Align the "T" mark (2) on the timing plate with the pickup coil mark (1) . When the "T" mark is aligned with the stationary pointer (2) . the piston is at top dead center (TDC).

• Measure the valve clearance using a Feeler Gauge (3).
• Record the measured amount if the clearance is incorrect.

Intake Valve (cold): 0.11- 0.20 mm (0.004- 0.008in)
Exhaust Valve (cold): 0.21- 0.30 mm (0.008- 0.012 in)

Measure valve clearance, in sequence, for Nos. 2, 4, and No. 3 cylinders.

Out of specification - Adjust clearance.

Firing Sequence: 1 -2-4-3

[A] Crankshaft counterclockwise turning angle. [Bl Cylinder [C] Combustion

Adjustment

1. Remove carburetors Refer to CHAPTER 3 "ENGINE REMOVAL".

2. Loosen the cam chain tensioner end plug (1)

3. Remove the cam chain tensioner (2)

4. Remove:

•Cam chain guide (Upper) (1)
•Cam cap I3 (2)
•Cam cap E3 (3)
• Dowel pins

5. Remove:

•Cam chain sprocket bolts
•Cam caps
•Dowel pins

•Cam shafts (1)
•Cam chain sprockets (2)

NOTE:
Fasten safety wire to the cam chain to prevent it from falling into the crankcase.

6. Remove:
• Valve lifter (1)
• Pad (2)

Note the installed pad number (3). Round off the value as required:

Pad range		Pad Availability: 25 increments
No. 120 ~ No. 240	1.20 mm (0.047 in) 2.40 mm (0.094 in)	Pads stepped in 0.05 mm (0.002 in) increments
Note: Thickness of each pad is marked on the pad side wall.
• Round off the hundredths digit of the installed pad number to the nearest 0.05 mm increment.
Hundredths digit		Rounded valve
0 or 2		0
5		(NOT ROUNDED OFF)
8		10

7. Select the proper pad from the appropriate chart (next 2 pages, links below)

EXAMPLE:

Installed pad number = 175 (1.75 mm)

Rounded off digit = 175

NOTE:
Pads can only be selected in 0.05 mm (0.02 in) increments.

* Locate the "Rounded off Pad Number" on the chart, and then find the measured valve clearance. The point where these coordinates intersect is the new pad number.

NOTE:
Use the new pad number as a guide only as the number must be verified.

8. Install:
• Pad (1)
• Valve lifter (2)
• Cam shaft
• Cam chain sprocket

Refer to CHAPTER 3 "ENGINE ASSEMBLY"

9. Recheck the valve clearance.

If the clearance is incorrect, repeat all of the clearance adjustment steps until the proper clearance is obtained.

Assembly

1. Reverse removal steps.

Inspect the head cover gasket and replace it if damaged.

2. Tighten:
• Cylinder head cover bolts
• Fuel tank bolts

Head Cover Bolt: 10 Nm (1.0 m.kg, 7.2 ft-lb)

Fuel Tank Bolt: 10 Nm (1.0 m.kg, 7.2 ft-lb)

Exhaust Valve Shim Chart

Model(s)

700XSC (MaximX)

700XS (MaximX)

xjcdadmin Mon, 06/14/2010 - 15:41

EXHAUST

MEASURED CLEARANCE	INSTALLED PAD NUMBER
MEASURED CLEARANCE	120		125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.00-0.02							120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215
0.03-0.07						120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220
0.08-0.12					120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225
0.13-0.17				120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230
0.18-0.20			120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235
0.21-0.30	RECOMMENDED CLEARANCE
0.31-0.32	125		130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.33-0.37	130		135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	725	230	735	240
0.38-0.42	135		140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.43-0.47	140		145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.48-0.52	145		150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.53-0.57	150		155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	730	235	740
0.58-0.62	155		160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.63-0.67	160		165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.68-0.72	165		170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.73-0.77	170		175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.78-0.82	175		180	185	190	195	200	205	210	215	220	225	230	235	240
0.83-0.87	180		185	190	195	200	205	210	215	220	225	230	235	240
0.88-0.92	185		190	195	200	205	210	215	220	225	230	235	240
0.93-0.97	190		195	200	205	210	215	220	225	230	235	240
0.98-1.02	195		200	205	210	215	220	225	230	235	240	VALVE CLEARANCE (cold): 0.21 - 0.30 mm (0.008 - 0.012 in) Example: Installed is 175 Measured clearance is 0.35 mm (0.014 in) Replace 175 pad with 185 pad
1.03-1.07	200		205	210	215	220	225	230	235	240
1.08-1.12	205		210	215	220	225	230	235	240
1.13-1.17	210		215	220	225	230	235	240
1.18-1.22	215		220	225	230	235	240
1.23-1.27		220	225	230	235	240
1.28-1.32	225		230	235	240
1.33-1.37	230		235	240
1.38-1.42	235		240
1.43-1.47	240

Intake Valve Shim Chart

Model(s)

700XS (MaximX)

700XSC (MaximX)

xjcdadmin Mon, 06/14/2010 - 15:41

INTAKE

MEASURED CLEARANCE	INSTALLED PAD NUMBER
MEASURED CLEARANCE	120	125	130	135	140	145	150	155	160	165	170	176	180	185	190	195	200	205	210	215	220	225	230	235	240
0.00-0.02				120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225
0.03-0.07			120	125	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230
0.08-0.10		120	125	130	135	140	145	150	155	160	165	170	175	l80	185	190	195	200	205	210	215	220	225	230	235
0.11-0.20	RECOMMENDED CLEARANCE
0.21-0.22	125	130	135	140	145	150	155	160	166	170	175	180	185	190	19b	200	205	210	215	220	225	230	235	240
0.23-0.27	130	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.28-0.32	135	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.33-0.37	140	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.38-0.42	145	150	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.43-0.47	150\|	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.48-0.52	155	160	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.53-0.57	160	165	170	175	180	18b	190	195	200	205	210	215	220	225	230	235	240
0-58-0.62	165	170	175	180	185	190	195	200	205	210	215	220	225	230	235	210
0.63-0.67	170	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.68-0.72	175	180	185	190	195	200	205	210	215	220	225	230	235	240
0.73-0.77	180	185	190	195	200	205	210	215	220	225	230	235	240
0.78-0.82	185	190	195	200	205	210	215	220	225	230	235	240
0.83-0.87	190	195	200	205	210	215	220	225	230	235	240
0.88-0.92	195	200	205	210	215	220	225	230	235	240
0.93-0.97	200	205	210	215	220	225	230	235	240
0.98-1.02	205	210	215	220	225	230	235	240	VALVE CLEARANCE (cold): 0.11 -0.20 mm (0.004 - 0.008 in) Example: Installed is 175 Measured clearance is 0.24 mm (0.009 in) Replace 175 pad with 185 pad
1.03-1.07	210	215	220	225	230	235	240
1.08-1.12	215	220	225	230	235	240
1.13-1.17	220	225	230	235	240
1.18-1.22	225	230	235	240
1.23-1.27	230	235	240
1.28-1.32	235	240
1.33-1.37	240