Kawasaki J300 - Service manual > Valves

Valve Clearance Inspection

Valve Clearance Adjustment

Valve Removal

Special Tools -
 Valve Spring Compressor Assembly: 57001 -241
 Valve Spring Compressor Adapter,
22: 57001-1202

Valves

NOTE

Valve Installation

Valves

Valve Seat Inspection

Valve Seating Surface Outside Diameter
 Standard:
  Exhaust 23.5 - 23.7 mm (0.925 - 0.933 in.)
  Intake 29.3 - 29.5 mm (1.15 - 1.16 in.)

  • Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper.

    Good [F]

If the width is too wide [G], too narrow [H] or uneven [J], repair the seat (see Valve Seat Repair).

Valve Seating Surface Width
 Standard:
  Exhaust 1.2 mm (0.047 in.)
  Intake 1.2 mm (0.047 in.)

Valves

Valve Seat Repair

Special Tools -
 Valve Seat Cutter Holder Bar [B]: 57001 -1128
 Valve Seat Cutter Holder,
5 [C]: 57001-1208

[For Exhaust Valve Seat]
 Valve Seat Cutter, 45º -
24.5: 57001-1113
 Valve Seat Cutter, 32º -
25: 57001-1118
 Valve Seat Cutter, 60º -
25: 57001-1328
[For Intake Valve Seat]
 Valve Seat Cutter, 45º -
30: 57001-1187
 Valve Seat Cutter, 32º -
30: 57001-1120
 Valve Seat Cutter, 60º -
30: 57001-1123

Valves

If the manufacturer's instructions are not available, use the following procedure.

Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.

NOTE

4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.

NOTE

5. After use, wash it with washing oil and apply thin layer of engine oil before storing.

Marks Stamped on the Cutter

The marks stamped on the back of the cutter [A] represent the following.

60º ........................... Cutter angle [B]
37.5........................ Outer diameter of cutter [C]

Valves

Operating Procedures

NOTICE Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.

Valves

NOTE

Valves

If the outside diameter [A] of the seating surface is too large, make the 32º grind described below.

If the outside diameter of the seating surface is within the specified range, measure the seat width as described below.

Valves

NOTICE The 32º cutter removes material very quickly.

Check the seat outside diameter frequently to prevent overgrinding.

  • After making the 32º grind, return to the seat outside diameter measurement step above.

If the seat width is too wide, make the 60º [A] grind described below.

If the seat width is within the specified range, lap the valve to the seat as described below.

  • Grind the seat at a 60º angle until the seat width is within the specified range.
    • To make the 60º grind, fit 60º cutter into the holder, and slide it into the valve guide.
    • Turn the holder, while pressing down lightly.
    • After making the 60º grind, return to the seat width measurement step above.

      Correct Width [B]

Valves

Valves

Valves

Valves

See also:

 Kawasaki J300 - Service manual > Cylinder Head

Cylinder Compression Measurement Remove the left side fairing (see Side Fairing Removal in the Frame chapter). Warm up the engine thoroughly. Stop the engine. Remove the spark plug (see Spark Plug Replacement in the Periodic Maintenance chapter). Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole.

 Kawasaki J300 - Service manual > Cylinder, Piston