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Old 10-25-2012, 11:29 AM   #6112
RoninMoto's Avatar
Joined: May 2010
Location: In the mountains?
Oddometer: 1,695
Originally Posted by Mini Trail View Post
I finally got my new rockers and the intake is TIGHT. I expected to have to adjust the valves but I don't exactly know where to start. Is there a way to estimate the shims particularly when they are tight? They aren't cheap.
What you will need:
-A set of calipers for measuring the shim you remove.
-a shim kit About the same price as 1 hour of shop time at your local KTM shop?
-strong magnet (easiest way to remove the shims, like you use when you drop a socket into a motor and have to fish it out)
-Feeler gauge.

1. Measure the clearance and note the one(s) that is/are tight.
2. Use the feeler gauge to see about how far out they are.
3. Pull the cam out and so your rockers are loose. Its a good Idea to ziptie the timing chain to the cam gear so you don't loose the place.
4. Using the magnet, remove the shim.
5. Measure it with the calipers and find replace with the shim you need.
6. Re-install the cam and check your valve clearance again to see if you have correct clearance.

Last time we did the valves shims on my 08 we installed them loose.. around .11 mm. They are more noisy when they are loose but seem to tighten over time. I don't want to have to do valve shims in Siberia next summer.
Noah 08 KTM 690 ADV. 125,000 km. 42 countries. 5 continents and counting.
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