How To: Adjust Valves FZ-07 MT-07 XSR Tenere (Part 1)

[Pursuvant]

>> Part 2

Disclaimer - all my mods will kill you and cause athletes foot fungus.

Here's the deal - nobody can do as good of a job adjusting the valves on your bike than you can. Nobody. Just do it. All of us here will help you. "How to" pics from 2019 CP2 689cc CP2 engine.

 

Essential Knowledge

 

Crank Chart

 

 

 

 

 

 

Stone Cold Motor - for adjusting valve clearance

Intake Valve Clearance - 0.11mm - 0.20mm

Exhaust Valve Clearance - 0.24mm - 0.30mm

 

Double Overhead Cams Sketch. The first sketch on left shows the typical operation of the engine - double overhead cams being turned by sprocket/chain on the crankshaft and tensioned by the Cam Chain Tensioner (CCT), rotating in the direction of the arrow - this is the view from the "RIGHT" side of bike (foot brake side). In the second sketch, the CCT has been removed and the slack in the chain could allow the chain to slip off the crank sprocket. The engine is put back in time during reassembly, using the timing marks on the two cams and the rotor timing marks (third and fourth sketch).

rotor timing marks

 

About feeler gauges - don't force. The right size will slide between gap with the same drag as pulling a piece of paper out from under a magazine. Hold the feeler gauge between thumb and forefinger. Don't let the feeler gauge touch the engine case. Use two feeler gauge blades together for cam clearance measures - single blade can give a false sense of resistance because the angle of cam measures. Get blades a little oily. Example -to measure minimum 0.24mm exhaust valve clearance, use 0.15mm & 0.09mm blades together.

 

Prerequisites:

Order Yamaha OEM Service Manual for your bike year/model MT-07, FZ-07, XSR700, Tenere700, any with CP2 motor. Undress your bike for the job – pull the fuel tank panels and fuel tank. TAKE A PICTURE of everything under the tank on both sides once tank is off, before you start removing/moving things to get access to the engine top end. Remove the radiator (drain first), clutch cable guide, coils, spark plugs, cylinder head cover. Put 2 zip-ties around the cylinder #2 Coil On Plug (COP) spark lead wire so you know which is what at reassembly time.

AND PLUG ALL OIL PASSAGES/OPENINGS IN CYLINDER HEAD, SPARK PLUG OPENINGS, AND CAM CHAIN OPENING (when not rotating engine crank) WITH RAGS/SOMETHING BECAUSE ANYTHING CAN ACCIDENTALLY DROP INTO THE MOTOR. IN THIS EXAMPLE RAGS ARE REMOVED TO TAKE CLEAR PICTURES.

 

Key Parts & Tools, if you go all the way. Tip - Order parts ahead of time

Yamaha OEM -

Highly Recommended

1   x   Yamaha Shop Manual, for your bike model

1  x  1WS-11193-01-00 HEAD COVER GASKET

1  x  1WS-12213-00-00 TENSIONER CASE GASKET

Nice To Have

1   x   93210-357A3-00  O-RING Crankcase access cover seal
1   x   90430-08143-00  GASKET, Crankcase cover timing marks bolt gasket
2   x   LMA-R8A9S-00-00 SPARK PLUG NGK LMAR8A-9S
1   x   5SL-12214-00-00 GASKET Tensioner special tool access bolt gasket

 

Tools (All Highly Recommended)
1   x   Mfg Part# FG-02-032 TUSK Feeler gauges
1   x   Mfg Part# 08-0652 Motion Pro magnetic pickup
1   x   Mfg Part# CMMT98348 Craftsman powerful magnetic pickup for buckets
1   x   Mfg Part# 201872 Anytime Tools micrometer

Supplies

Permatex "High Tack" gasket sealant - keeps the valve cover gasket in the valve cover while you struggle getting it back on.

Red Line Assembly Lube - yes because it's red, and you can see that you have used too much, or none at all, because it's red.

 

Measuring Cylinder #1 Valve Clearances

If you have a couple of simple wire marker flags, put one in each cylinder 1 & 2 spark plug openings and let them sit on top of the pistons. When you start rotating the crank these flags make a lot of things clear about the 270 degree offset, Top Dead Center (TDC), BDC, intake and exhaust strokes, and how it is timed to the cam lobes.

 

This is the view from the "LEFT" side of bike (gear shift side). Remove the crankshaft cover and the timing mark access bolt. Only rotate the engine counter-clockwise.

 

Refer to the first row in the Crank Chart "Crank Rotation Degrees 0"

Use a 19mm socket wrench on the crankshaft end nut exposed by removing the crankshaft cover. Rotate slowly the crankshaft counter-clockwise, while looking thru the timing mark bolt opening, and align the rotor timing marks (RED timing mark for clarity).

Cylinder #1 Cams Lobes Facing should "FACE OPPOSITE".

If cam lobes are not facing opposite, rotate the crankshaft counter-clockwise until the rotor timing marks align again. And repeat the check of cylinder #1  Cams Lobes Facing should "FACE OPPOSITE". This is the position for measuring cylinder #1 valve clearance (cylinder #1 TDC compression stroke).

 

Here is the "callout" I will refer to below.

 

Measure cylinder #1 exhaust valves - check the minimum spec of 0.24mm using the 0.15mm & 0.09mm blades together. Continue measuring until satisfied you have measured the current clearance, record results on paper for "Exhaust.C1.V1" & "Exhaust.C1.V2" (the two exhaust valves clearance measures).  Repeat for the cylinder #1 intake valves - check the minimum spec of 0.11mm using the 0.06mm & 0.05mm blades together.  Continue measuring until satisfied you have measured the current clearance, and record results on paper for "Intake.C1.V3" & "Intake.C1.V4" (the two intake valves clearance measures).

Be sure it is clear which valve clearance measure is for which valve - draw a diagram that makes it clear, the cylinder # and the valve# for every measure.

FYI the red in photos is assembly lube - the cams have been in and out multiple times during picture taking, so they got a bit too much smeared a bit too far.

 

Measuring Cylinder #2 Valve Clearances

Refer to the second row in the Crank Chart "Crank Rotation Degrees 270". Make a degree wheel, and cut a hole to fit it onto wrench with the 19mm socket used to turn the crankshaft...

Setup a pointer, to measure the rotation to 270 degrees...

...and rotate the crank counter-clockwise 270 degrees, the required position for measuring cylinder #2 valves clearances. Cylinder #2 Cams Lobes Facing should "FACE OPPOSITE" (cylinder #2 TDC compression stroke). Measure cylinder #2 clearance with the same procedure as used on cylinder #1 measures, and record measures for cylinder #2 exhaust "Exhaust.C2.V5" & "Exhaust.C2.V6" and intake "Intake.C2.V7" & "Intake.C2.V8".

If any valve clearances measures are out of Yamaha specification, continue with the removal of cams and the swapping of new shims into position under the cam lobe buckets described in Part 2.

[M. Hausknecht]

Not for nothing but this 3-part series on adjusting valve clearance is terrific! I've been checking my own valve clearances for a bit (over 25 years) and there are some great suggestions I will definitely incorporate in my procedure. Well done @Pursuvant !!!

[Pursuvant]

2023.02 Walked thru this post editing for clarity, while adjusting my valves.