Part 5 - Removing the Valve Shims
There seems to be 2 ways to do this. Remove the Cam Shaft or Remove the Rocker Shaft.
I am choosing to take the Rocker Shaft way. I chose this way because removing the Cam Shaft requires the Cam Chain Tensioner to be removed and it appears you need a special tool to reinstall it.
DaleEO used the remove the Rocker Shaft technique, if it is good enough for him it is good enough for anyone. He is a legend.
8mm Allen Key
Long 6mm x 1.00mm Pitch Bolt
I would advise doing 1 rocker at a time so you donít mix anything up.
In my example I am taking the Exhaust Rocker Shaft off. That is the bottom Rocker Shaft. This process would be the same for the top ďInletĒ Rocker Shaft.
Remove the 8mm Allen Key Head Plug in the Side of the Head near the Spark Plug. Put it on a nice clean rag. Bottom Plug for Exhaust Rocker and Top Plug for Inlet Rocker.
Loosen the 2 x Bolts that hold the appropriate Rocker Shaft.
Here is a picture, where you can see the 8mm Allen Key Head Plug and the 2 x Exhaust Rocker Bolts loose.
Remove the Right Hand side (Spark Plug Side) Rocker Shaft Bolt completely. They are different bolts, so donít mix them up. Put it on a nice clean rag.
Screw a clean long 6mm diameter x 1.00mm pitch bolt into the Rocker Shaft. It is actually a Rod that you are screwing into that holds the Rocker Shaft and acts like a Bearing. Screw it in where you removed the Allen Key Head Plug.
Just a few turns will do.
Remove the Left Hand side Rocker Shaft Bolt completely. I left the Left Hand side Rocker Shaft Bolt in so the shaft (or Rod) did not spin while I screwed in the 6mm Long Bolt. I think it is important to not let the Rod spin as I think it will give you different Valve Clearances if the Rod is not inserted the same way as it comes out. The 2 Bolts that you removed go through holes in the Rod to stop it spinning. So it can be inserted 180 Degrees out if you spin it.
Place a Large Rag under the bike below the Head in case the Rocker Shaft falls out. Mine did not fall out but I dropped it when I was trying to remove it. Itís slippery with all the oil on it.
Pull the long 6mm Bolt gently and the Shaft inside the Rocker Shaft Slides out. I did not pull it all the way out, just stop puling when the Rocker Shaft Drops. Don't pull it all the way out as you will not be sure which way it goes back in. Again I reiterate, it can be 180 Degrees out and give you different Valve Clearance Readings. Here is a picture:
Here is a picture of the Rocker Shaft as it drops down. You can keep 1 hand on the Rocker and 1 hand on the 6mm Bolt to do this:
Here is a picture of the Bolts and Rocker Removed. Keep them on a clean Rag.
The Shims stayed in place. I think the oil keeps them there.
I used a magnet to get it out.
Here is a picture of the Shim. Rocker Shaft facing Side
Here is a picture of the Shim. Valve Facing Side.
I could see no marks on the Shim to identify itís thickness. My Micrometers measured 2.92mm (it must be a 2.90mm Shim I think as they donít make a 2.92mm)
I am off tomorrow to buy some Shims ($12.96 each in Australia) and try and reassemble.
I was 0.02mm tight, so I am buying a few to be safe:
60036035275 SHIM D=10/2,75
60036035280 SHIM D=10/2,80
60036035285 SHIM D=10/2,85
60036035290 SHIM D=10/2,90
60036035295 SHIM D=10/2,95
Will post up more tomorrow inc Bolt Torque settings for reassembly.