Kawasaki J300 - Service manual > Engine Top End

Valve Clearance Inspection

NOTICE If valve clearance is left unadjusted, the wear will eventually cause the valves to remain partly open, which lowers performance, burns the valves and the valve seats, and may cause serious engine damage.

NOTE

• Valve clearance must be checked when the engine is cold (at room temperature).

 

• Remove:
  Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)
  Timing Inspection Cap [A]
  Alternator Cover Center Cap [B]

• Turn the crankshaft clockwise, and align the "T" mark [A] on the alternator rotor with the groove [B] on the alternator cover.

• Check that the projection [A] and lines [B] on the camshaft sprocket is in position. This shows that the piston TDC is at the end of the compression stroke.

• Using a thickness gauge [A], measure the valve clearance between the adjusting screw and valve stem.
  • Measure the both valves at a time.

Valve Clearance
 Standard:
 Exhaust 0.10 mm (0.0039 in.)
 Intake 0.10 mm (0.0039 in.)

If the valve clearance is not within the specified range, adjust it.

Valve Clearance Adjustment

• Loosen the valve adjusting screw locknut [A] and insert the thickness gauge [B] between the valve and adjusting screw [C], and turn the screw until the adjusting screw stops.
• Tighten the valve adjusting screw locknut.

Special Tool - Valve Adjusting Screw Holder [D]: 57001-1217

Torque - Valve Adjusting Screw Locknut: 8.8 N*m (0.90 kgf*m, 79 in*lb)

• Install the removed parts (see appropriate chapters).

Clutch

Clutch Shoe Wear Inspection

• Remove the clutch outer (see Clutch/Driven Pulley Removal in the Converter System chapter).
• Check the clutch shoes for damage.

  If there is any damaged part, replace it.

• Measure the clutch lining thickness [A].

  If the lining thickness is worn over the service limit, replace the clutch shoe.

Clutch Lining Thickness
 Standard: 4.0 mm (0.16 in.)
 Service Limit: 2.0 mm (0.08 in.)

See also: