48K Valve Clearance Checks (Pic heavy) - Wrist Twisters
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post #1 of 53 Old 07-08-2012, 01:47 PM Thread Starter
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48K Valve Clearance Checks (Pic heavy)

My bike crossed over 48K miles a couple of weeks ago. I did the easy maintenance items last weekend and saved the big stuff for today.

Drained the coolant at the drain plug, looks like the bike is taking a piss:



Removed the section of coolant hose containing the radiator cap:



Still a lot of crap in the way:



Next removed the coils and tied them back out of the way. No need to disconnect any wires, but good idea to number the plug wires:





Disconnected and tied back the Pairs and Crankcase vent hoses



Used tie wraps to tie back misc wires and hoses that were kinda hanging loose in the way...pretty clear now.



Pull the cover to reveal some blood n guts:



Checked the valve clearances using the procedure in the service manual:



Here's one that's easy to see (#1 Exhaust)



Now the bad news #2 Intake was on the tight side at 0.004" (Spec is 0.006" +/- 0.001"). This means I had to remove the intake side camshaft and re-shim. Not as bad as it sounds. First I removed the camshaft retainer:



Then the camshaft, and the shim bucket for #2 Intake with the bad reading



Usually the shim will stick to the bucket, so remove it carefully to keep from dropping it into the engine:



Measured the shim that was pulled out at 0.079" wanted to open it up to the high side of the clearance, so the formula in the manual gives you 0.076" for the new shim. New shim installed:



Cam shaft re-installed:



I rechecked the clearances and they were all the same except the bad one was 0.007" which is the high side of the range like I wanted. This is a very opportune time to replace your spark plugs: This is how easy it is to get to #3 with all the crap out of the way:



Iridiums with 16K miles on them:



Valve cover back in place. It helps to prop it up an inch or so, to put some sealant into the half moon areas, then drop it and bolt it up:



Put the hoses, coils, etc back in place, filled up the cooling system, and buttoned everything up. It's always satisfying when it fires right up after having it torn apart. Ran it for a few minutes, topped off the coolant, changed the oil, and a quick wash and she is ready to ride.


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post #2 of 53 Old 07-08-2012, 02:01 PM
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Great pictures! I still need to check the valve clearances on my 919 (25k miles now) but am afraid to do so since I've never done it. hopefully I can find someone local who would be willing to help me with the project soon.

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post #3 of 53 Old 07-08-2012, 02:02 PM
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Great write up.

There is a kit you buy with a bunch of different sized shims, right? Are there any special tools needed?

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post #4 of 53 Old 07-08-2012, 02:09 PM
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Page bookmarked! Thanks marylandmike, this will come in handy in a year or so.

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post #5 of 53 Old 07-08-2012, 02:15 PM
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Quote:
Originally Posted by MF1VE View Post
Page bookmarked! Thanks marylandmike, this will come in handy in a year or so.
+1! Thanks Mike!

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post #6 of 53 Old 07-08-2012, 02:18 PM
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Awesome! I plan on doing this pretty soon, much appreciated!

I also have the following questions:
Quote:
Originally Posted by TheBeeDeeGee View Post
There is a kit you buy with a bunch of different sized shims, right? Are there any special tools needed?
oh and what kind of sealant would be recommended to use when putting the valve cover back in place?

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post #7 of 53 Old 07-08-2012, 02:46 PM Thread Starter
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Quote:
Originally Posted by TheBeeDeeGee View Post
Great write up.

There is a kit you buy with a bunch of different sized shims, right? Are there any special tools needed?
Quote:
Originally Posted by philth View Post
Awesome! I plan on doing this pretty soon, much appreciated!

I also have the following questions:


oh and what kind of sealant would be recommended to use when putting the valve cover back in place?
I ended up buying a Hot Cams shim kit off E-bay a couple of years ago. It was $80, but it could also be used on other bikes and it's nice not having to try to find the right size and leave your bike in pieces. The kit has 3 shims in every size across a pretty wide range. The only special tools really is a set of feeler gages and a micrometer helps. If you have to re-shim, you will need to measure the old and new shims. I bought a cheap 0-1" one at harbor freight for around $20.



For sealant I use Permatex Ultra Black. It's available pretty much everywhere here. You only need a little bit on the half moons. I have used it for all three of my valve clearance checks and haven't had any leaks.



Thanks all for the positive comments.

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post #8 of 53 Old 07-08-2012, 03:02 PM
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I like that HotCams kit. What diameter valve stems does the 919 have?

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post #9 of 53 Old 07-08-2012, 03:06 PM Thread Starter
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Quote:
Originally Posted by MF1VE View Post
I like that HotCams kit. What diameter valve stems does the 919 have?
Here's one on Ebay...looks like 7.48mm. And that's just box 1 of 2. There is another box that goes up to 3.5 mm.

HOTCAMS HOT CAMS VALVE SHIM KIT 7.48MM HONDA 919 02-04 | eBay

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post #10 of 53 Old 07-08-2012, 06:54 PM
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sweet! all the info is very much appreciated [and the pics too]!

the feeler guages, any kind will do? or is there a recommended set out there for the 919?

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post #11 of 53 Old 07-08-2012, 09:33 PM
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Thanks Mike! I Bought the bike last September with 8k on the clock. I'll hit 20k this week. I plan to do the valve check when I install the new +3" MotionPro cables real soon.
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post #12 of 53 Old 07-09-2012, 04:18 AM Thread Starter
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Quote:
Originally Posted by philth View Post
sweet! all the info is very much appreciated [and the pics too]!

the feeler guages, any kind will do? or is there a recommended set out there for the 919?
Just a regular set of feeler gages. Service manual has the specs in inches and mm so either units will work.

Quote:
Originally Posted by Ken Phenix View Post
Thanks Mike! I Bought the bike last September with 8k on the clock. I'll hit 20k this week. I plan to do the valve check when I install the new +3" MotionPro cables real soon.
Your welcome. Good luck with both. The valve clearances may be child's play compared to the throttle cables from what I hear.

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post #13 of 53 Old 07-09-2012, 11:21 AM
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thats pretty impressive that only one valve was slightly out of spec.

And to be honest... only being one notch slightly tight... i would of left it for another 16k.

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post #14 of 53 Old 07-09-2012, 11:32 AM
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Quote:
Originally Posted by nd4spdbh View Post
thats pretty impressive that only one valve was slightly out of spec.

And to be honest... only being one notch slightly tight... i would of left it for another 16k.
Actually no. Tighter valves are worse than loose valves. Mike made the right call to adjust it since it was past spec on the tight side.

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post #15 of 53 Old 07-09-2012, 11:38 AM Thread Starter
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Quote:
Originally Posted by nd4spdbh View Post
thats pretty impressive that only one valve was slightly out of spec.

And to be honest... only being one notch slightly tight... i would of left it for another 16k.
Leaving it alone did cross my mind. But the adjustment is pretty easy compared to what it took to get to that point (removing everything). Plus I would have to be paranoid for the next 16K.

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post #16 of 53 Old 07-09-2012, 01:49 PM
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MM, I'm severely disappointed.

You of all people are STILL running with STOCK bars and PAIR valve system unmolested.

How. DARE. you.
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post #17 of 53 Old 07-09-2012, 03:20 PM
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Quote:
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Actually no. Tighter valves are worse than loose valves. Mike made the right call to adjust it since it was past spec on the tight side.
i would be concerned if it was that tight at the initial 16k check and would adjust it.

But at 48k its found home and one of 8 intake valves on the slightly tight side of the fence isnt much for concern in my book.... now had it been tighter than what it was at... then ya id change it...

that said.... its pretty impressive that at 48k miles thats all this motor needs haha.

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post #18 of 53 Old 07-09-2012, 03:37 PM Thread Starter
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Quote:
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MM, I'm severely disappointed.

You of all people are STILL running with STOCK bars and PAIR valve system unmolested.

How. DARE. you.
It's OK I have a PAIRS Commander Module installed, and those are Renthal Ultra-Stock Chrome bars, BIG improvement.

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post #19 of 53 Old 07-09-2012, 04:32 PM
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Quote:
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MM, I'm severely disappointed.

You of all people are STILL running with STOCK bars and PAIR valve system unmolested.

How. DARE. you.
says the guy who is giving up his 919..... HOW. DARE. YOU!

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post #20 of 53 Old 07-09-2012, 04:49 PM
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Mike makes it look easy.

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post #21 of 53 Old 07-09-2012, 06:07 PM
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Quote:
Originally Posted by nd4spdbh View Post
i would be concerned if it was that tight at the initial 16k check and would adjust it.

But at 48k its found home and one of 8 intake valves on the slightly tight side of the fence isnt much for concern in my book.... now had it been tighter than what it was at... then ya id change it...

that said.... its pretty impressive that at 48k miles thats all this motor needs haha.
True enough! My paranoia of valves tighter than spec comes from owning a ninja 250 and seeing what a set of valves running tighter than spec can do to an engine.

Quote:
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says the guy who is giving up his 919..... HOW. DARE. YOU!
QFT!

edit: and a month before the official 919 track day (shoot out)..... pansy...

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post #22 of 53 Old 07-09-2012, 06:15 PM
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Quote:
Originally Posted by Pvster

True enough! My paranoia of valves tighter than spec comes from owning a ninja 250 and seeing what a set of valves running tighter than spec can do to an engine.

QFT!

edit: and a month before the official 919 track day (shoot out)..... pansy...
Yeah, I needed a bigger bike to make it an even playing field.

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post #23 of 53 Old 07-09-2012, 06:39 PM
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where is said track day.... ill come and kick all your guys' asses.

And yeah tight valves are definitely much worse than loose ones.... but im talking at almost zero lash.

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post #24 of 53 Old 07-09-2012, 07:05 PM
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Quote:
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where is said track day.... ill come and kick all your guys' asses.
https://www.wristtwisters.com/forums/...ers-29580.html

Bring it! The more, the merrier! I can put you up overnight at my place and then ride over to meet up with g00gl3it and his friend before heading north and meeting up with mike and andrew.

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post #25 of 53 Old 07-09-2012, 07:09 PM
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Quote:
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where is said track day.... ill come and kick all your guys' asses.
You would, too. You get way more time to ride than most of us do.

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post #26 of 53 Old 08-04-2012, 06:04 AM
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So it's my turn to do my first valve inspection. This thread is great for getting me familiar with it before I get n there...thanks! The only thing I don't see that the manual talks about is the can chain tension relief tool. Did you make your own, or adjust without relieving the tension?

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post #27 of 53 Old 08-04-2012, 06:15 AM Thread Starter
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Quote:
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So it's my turn to do my first valve inspection. This thread is great for getting me familiar with it before I get n there...thanks! The only thing I don't see that the manual talks about is the can chain tension relief tool. Did you make your own, or adjust without relieving the tension?

I cheated, used a small screwdriver, which you turn clockwise to relieve the tension, once turned I used a small clamp to hold it. it rests against the airbox to keep from rotating. I'm not really sure you need it just to check clearances, but if you have to remove a camshaft to adjust, you will need to use it.


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post #28 of 53 Old 08-04-2012, 06:31 AM
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Quote:
Originally Posted by marylandmike View Post
I cheated, used a small screwdriver, which you turn clockwise to relieve the tension, once turned I used a small clamp to hold it. it rests against the airbox to keep from rotating. I'm not really sure you need it just to check clearances, but if you have to remove a camshaft to adjust, you will need to use it.

Ingenious! Thanks. Gonna swap out plugs and put some PAIR plates on while I have it all ripped apart. Thanks again for the detailed information.

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post #29 of 53 Old 08-04-2012, 06:39 AM Thread Starter
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Ingenious! Thanks. Gonna swap out plugs and put some PAIR plates on while I have it all ripped apart. Thanks again for the detailed information.
Great time do do both. Good luck!

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post #30 of 53 Old 08-09-2012, 07:47 AM
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I'm assuming this is the right kit for an '06, even though the listing says 02-04, but the $70 price tag is enough to ask someone here to verify this before I pull the trigger. Look right?

HOTCAMS ENGINE VALVE SHIM KIT HONDA 919 CB900F 02-04 | eBay

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post #31 of 53 Old 08-09-2012, 08:24 AM Thread Starter
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Looks right to me. Shouldn't be any difference in the years.

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post #32 of 53 Old 08-09-2012, 01:24 PM
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Quote:
Originally Posted by marylandmike View Post
Looks right to me. Shouldn't be any difference in the years.
Thanks for the double check. Ordered... PAIRs plates are on the way... now for the spark plug decision (which I don't want to derail this thread on!! I know where the spark plug threads are)

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post #33 of 53 Old 08-09-2012, 03:11 PM Thread Starter
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Quote:
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I know where the spark plug threads are
They are between the ceramic piece and the electrode.

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post #34 of 53 Old 08-09-2012, 05:47 PM
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post #35 of 53 Old 08-16-2012, 04:20 AM
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Can you post the formula to choose the right shim in case shim replacement needed. I am in Vietnam so I use the mm instead of inch.
Appreciate your help

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post #36 of 53 Old 08-16-2012, 04:31 AM Thread Starter
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Here you go:
Attached Images
File Type: jpg Shim.JPG (45.4 KB, 106 views)

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post #37 of 53 Old 08-16-2012, 05:33 AM
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thank you, mate
Cheers

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post #38 of 53 Unread 07-15-2019, 03:47 AM
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I know, grave dig.
Thanks Mike. First valve clearance check for my 919 at 28000km. Two inlet clearances are out of spec. I've ordered the Hot Cams kit. Increments of .005mm will get me out of trouble. I haven't lifted the inlet cam yet since I'll wait till the kit arrives then redo the check and sort it all out at once.
The pics in this post and others on this site plus the write ups has been excellent reference material against the workshop manual.
Cheers fellas.
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post #39 of 53 Unread 07-15-2019, 11:03 AM Thread Starter
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Quote:
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I know, grave dig.
Thanks Mike. First valve clearance check for my 919 at 28000km. Two inlet clearances are out of spec. I've ordered the Hot Cams kit. Increments of .005mm will get me out of trouble. I haven't lifted the inlet cam yet since I'll wait till the kit arrives then redo the check and sort it all out at once.
The pics in this post and others on this site plus the write ups has been excellent reference material against the workshop manual.
Cheers fellas.
Nice work. Adjusting the shims will be a piece of cake compared to getting where you are now. When you reinstall the bolts for the camshaft retainer, lube them with motor oil and take it slow. I messed up the threads in one of the holes and had to run a tap down the clean it up. Glad the pics helped. I read a lot of other folk's threads on here before getting up the courage to do it.

Getting ready for my 7th valve clearance check soon (112K miles)
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post #40 of 53 Unread 07-15-2019, 04:17 PM
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Mike. Point taken in regards to the camshaft retainer. I noticed there is a process in the manual regarding a sequence for the bolt removal and install.
Will lube threads and go easy, thanks for the heads up.
A couple of questions.
How did you hold your cam chain up?
And did you mark your cam chain and sprocket before removal of shaft?
Also 112k miles is epic.
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