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Discussion Starter #1
Fail: Did my 1st valve adjustment. Had a mechanic do it last time. Both valves were out of spec by a little bit. Intake valve clearance was almost .001 so i backed it off to .003 like the specs said. I backed the exhuast valve to .005. Made sure the valves stayed put when wrenching the locking nuts on. Put all the covers, tank, fuel line, etc back on and now there's a tapping noise coming from the valves. And there's a tiny hole in the TDC view cap on the stator cover letting oil drip out because i had to gouge my screwdriver in cause the cap was seized up or overtightened by the last mechanic. Any suggestions? Also, if anyone would like to mail some spare TDC view caps or know of any ones not made of plastic, please let me know. IMG_3540.JPG IMG_3541.JPG IMG_3542.JPG IMG_3543.JPG IMG_3544.JPG
 

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Discussion Starter #5
I rotated the part in the middle of the stator cover until the 3 notches showed up in the top view hole. Not sure if the middle notch was supposed to line up with anything but I just left it when i could see all 3 notches and the 2 side ones were lined up with the hole/chamber.
 

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I can't load your pics on a slow Internet connection here, but if I understand right, you used the rotor to find TDC? The thing you should look at when setting to TDC is the little vertical mark on the timing chain sprocket. That mark goes straight up. There is a mark on the cylinder head to line it up. You have to kind of look up from underneath a bit to see it sometimes. That cam chain sprocket rotates at half the speed of the crank shaft, so every two rotations of the crank will be one rotation of the cam chain sprocket. It is likely that you were one rotation out. If that is the case, it would make perfect sense that the valves are making noise now, because when you are a half rotation out, you will be at the top of the exhaust stroke. The cam lobes are lifting the rockers very slightly, and setting valve clearance at that position would make them far too loose when it came around to actual TDC.

Zack
 

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Doh! Oh well, i think i can do everything again in under an hour
1. Remove the spark plug

2. Put a Pencil or something like that in the spark plug hole and make sure it moves with the piston

3. Now try to align that TDC mark. Only make sure you get the TDC when the PENCIL is moving up (This makes sure you are in the Compression stroke)

4. This way you will get the true TDC. otherwise you may end up with the BDC which is most probably your case.
 

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Good advice, but..... as long as the cam sprocket shows TDC, it will never be BDC, right? I wouldn't think there would be a need to risk breaking a pencil off in the spark plug hole. That piston can come up pretty fast if your not careful.

Zack
 

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This method does not require TDC:
 

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Discussion Starter #12
I lined up the cam sprocket middle notch to the tab head on the cylinder when i looked in the inspection window. Also looked in the spark plug hole to make sure it was TDC/compression. Readjusted intake to .004 and exhaust to .006. Checked clearances after tightening nuts. Put everything back on the bike and there's still tapping. I will try the method in the video tomorrow. Third time should do it.
 

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Zack is leading you to the easiest and most accurate way to make sure you're at TDC. Indika666's method will work too. If you have any questions, go review B-dub's base gasket tutorial. It will show the cam chain sprocket method in either the photo's, video's or both. Cam sprocket method is what I've used since my base gasket replacement.
 

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Discussion Starter #16
I used the top mark. I later used the non-TDC method in the video and forgot to put the covers back on when testing the bike for 5 seconds. Doh! This was in the middle of the night. I still heard a tapping noise but maybe that is partly to do with the covers being off. I'll test it again in the morning. This is harder than changing out tubes for me :(
 

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Discussion Starter #17 (Edited)
I will adjust cam chain tension tomorrow. Read some forum discussions on other bikes and people r having the same issue as me. Also said that valve clearances on the high tolerance will be noisier or "tappier". I will do a test ride after my cam chain adjustment in the morning.
 

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Don't forget the old finger covering the spark plug hole to make sure your getting the compression stroke. or use a compression tester if you like and be sure your grounding the spark plug wire
 

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Good advice, but..... as long as the cam sprocket shows TDC, it will never be BDC, right? I wouldn't think there would be a need to risk breaking a pencil off in the spark plug hole. That piston can come up pretty fast if your not careful.

Zack
yep i agree...! you can just put your finger in the spark plug hole and verify its really the compression stroke..! (should feel pressure of piston moving up)

and yes if you don't mind the hassle of taking off the cam sprocket cover, that is the best method....! cam sprocket will always show the TDC..!
 

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Discussion Starter #20
Decided to check the cam chain tensioner and boy was that thing a pain to reinstall. If i did not have a tiny screwdriver to wind up that thing, i would have been screwed. Gonna test ride in a bit.
 
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