November 28th, 2009, 11:43 PM
Joined: Jul 2009
From: Portland, Oregon - USA
The following is the bare minimum that you have to do to check the valve clearances on your '09 FE 450. Exchanging shims get's more involved and you have to remove the cam chain tensioner (CCT) and camshaft. Still quite straightforward - but you need all the steps including resetting the CCT.
"Checking" the valve clearances on your '09 FE 450:
1. Wash off the engine and clean any loose dirt from overhead hoses, cables, etc.
(You don't want sand and dirt falling into your engine, do you? It's easiest to do if your remove the gas tank first - but that's a whole 'nother story.)
2. Engine needs to be at room temperature: ~ 20 C degrees (68 F degrees)
3. Put the bike on a bike stand (so you can rotate the rear wheel).
4. While rotating the wheel, use the gear shift and put the bike in 6th gear.
5. Pull off the engine vent hose from the top of the valve cover.
5. Remove the valve cover (4 bolts).
6. Put a socket and a breaker bar on the countershaft sprocket (the front spocket on your drive chain).
7. S-l-o-w-l-y, using the breaker bar, turn the rear wheel forward via the countershaft bolt.
9. You should see the camshaft rotating as well in an anti-clockwise direction.
Finding Top Dead Center (TDC):
10. There is a small punch mark on the camshaft gear .... and a corresponding small punch mark on the cam tower itself (next to the small fixing bolt on the camshaft location plate). As you rotate the rear wheel and camshaft .... you should see the two punch marks begin to align.
11. When the punchmark on the camshaft gear is *directly below* and aligned with the punchmark on the cam tower.... you are at Top Dead Center (TDC)! It's that easy!
12. You can now check the valve clearances using a feeler guage:
Temperature: 20 C degrees (68 F degrees)
Exhaust valve clearance: 0.12 -- 0.17 mm (0.0047 -- 0.0067 in.)
Intake valve clearance: 0.10 -- 0.15 mm (0.0039 -- 0.0059 in.)
Record your engine hours, mileage, and your valve clearances. If your clearances are within specification ... then you're done!
13. Re-install the valve cover and torque the mounting bolts to 10 Nm (7.4 lb/ft.)
14. Re-connect the engine vent hose to the valve cover ... and take the engine out of gear.
15. Give a big sigh of relief and go grab a cold Fosters. :^)