Here are some of the maintenance methods we’ve received from the Webike Community "MOTO HACK Maintenance" campaign that we’d like to refer to. Maybe you have an idea you'd like to try!
In this issue, I'm going to introduce the maintenance HACK from Webi-man who rides ZRX1100.
Motorcycle introduction and its maintenance
About the motorcycle
It is a 20+ year old ZRX1100. I maintain it myself and ride it in good condition. The engine is also in great shape.
Working process
Valve clearance measurement and adjustment
Plug hole gasket replacement
Working hours
About 5 hours
Working difficulty
Medium level of difficulty
Items to use
Parts Number: 11009-1725
Brand: Kawasaki
Parts name: Gas Kettles, Spark Plugs
Parts Number: 92025-1870-1985
Brand: Kawasaki
Parts Name: Shims
*I didn't buy it this time because I could use the shim I had on hand.
Learn more about the work
1. First, remove the fuel tank.
2. Drain the coolant and remove the thermostat and water hoses.
*The service manual states that the thermostat should not be removed.
3. Remove the plug cap.
*It looks like I didn't have to pull the plug, but I did.
4. Unscrew the six-cylinder head cover bolts and remove the cylinder head cover.
5. The crank needs to be turned, so remove the pickup coil cover.
6. Rotate the timing rotor to align with the upper dead center.
7. Measure the clearance between the shim and the rocker arm with a thickness gauge.
*When No. 4 is the upper dead center, the EX valve of No. 2 and No. 4 and the IN valve of No. 3 and No. 4 are measured, and when No. 1 is the upper dead center, the rest can be measured.
*Standard value for valve clearance
EX: 0.18-0.24mm, IN: 013-0.19mm
8. The shims are picked out using a pickup tool or other tool and the thickness is measured with a micrometer.
9. Replace any valve shims that do not fit the standard values with the appropriate thickness.
10. Again, measure the valve clearance and check if it is within the standard value.
11. Put the cylinder head covers and other removed items back in place, add coolant and you're done.
- The tips and tricks of the operation, etc.
It is a thickness gauge, but it measures the clearance by inserting various thickness plates into the gap.
Apply engine oil to the board and insert it into the gap, and if it feels neither too tight nor too loose, it is the thickness. It is said to feel like cutting a sweet bean jelly. Do it a few times and you'll get a feel for it.
If you have dropped shims in the cylinder bed, never start the engine unattended.
Also, if you don't have shims of a suitable thickness, you may be tempted to cut it down, but the manufacturer tells you not to do it, so don't do it. The ring on the cylinder head bolt must be replaced.
In the last photo, I dropped the rings in the grass and couldn't find one, so you can see only 5 rings, but I have replaced them all properly.
Advice
I thought I was on the threshold of working on the engine, but it's manageable. This work reduced the tappet striking noise and made the engine feel smoother. In this case, I also replaced the plug hole gasket while I opened the cylinder head. This is not a place that you can easily open up, so I think it would be a good idea to plan it out so that you can work on it all at once as much as possible.
Thank you, Webi-man, for posting this valuable maintenance HACK! You will receive 1,500 points to be used at Webike!
See KAWASAKI Moto Index Page
See Accessories for KAWASAKI ZRX1100