Check and adjust the valves every 250 hours or a every year To keep the engine starting and running properly.
A common symptom will be that the engine will be hard to start, or will slowly turn over as if the battery is weak or the starter is dragging. This indicates the intake valve is closing to soon, which means the rocker arm is to loose and must be adjusted back to specifications. Below is the procedure to
Check and adjust the valves on a Kawasaki engine FJ400-D.
NOTE: THIS PROCEDURE IS DONE WITH THE ENGINE COLD
Rocker Cover Removal
Tool List Qty
Ratchet ——————- 1
Extension 6″ ————- 1
Socket, 10 mm ———– 1
1. Remove the four bolts (5) securing the rocker cover.
Remove the rocker cover (2) and the gasket.
If the valve clearance is incorrect, adjust it.
Valve Clearance Inspection
Turn the crankshaft to the proper direction until the piston is at TDC of the compression stroke.
Valve Clearance Inspection
Tool List Qty
Allen Bit, 3 mm —————— 1
Ratchet —————————- 1
Extension 6″ ———————- 1
Feeler Gauge ———————- 1
Wrench, 14 mm ——————- 1
Torque Wrench, in. lbs ———– 1
NOTICE
Valve clearance must be checked when the engine is cold (at room temperature).
With the rocker cover removed, Place the piston at TDC of the compression stroke turning the crankshaft in its rotational direction.
Then check the valve clearance with a feeler gauge (7), measure the valve clearance between the rocker arm (8) and the valve stem end.
Valve Clearance (when cold): Inlet, Exhaust 0.10 – 0.15 mm (0.004 – 0.006 in.)
Loosen the lock screw (10) using the 3 mm Allen bit and the adjusting nut (11). Insert the feeler gauge (7) between the rocker arm and the valve stem end and move the adjusting nut (11) until the feeler gauge begins to bind between the rocker arm and the valve stem end.
Hold the adjusting nut (11) in place using a wrench and tighten the lock screw (10) to the specified torque 61 in. lbs (6.9 Nm).
CAUTION
DO NOT overtighten.
Remeasure any clearance that was adjusted. Readjust if necessary.
Replace the Rocker Cover (6), gasket and the four bolts (5). Tighten the bolts to secure the cover in place.
