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Adjusting motorcycle valves

7/30/2014

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How to adjust 4 stroke motorcycle valves by thejunkman
PictureBasic layout of a typical valve adjuster
If your motorcycle makes a “tick-tick-tick” noise from the top of the engine, chances are that the intake and/or exhaust valves are out of adjustment. Here’s how to perform an motorcycle valve inspection. I did this job on a spare horizontal CRR/XR50 (pit bike) clone engine however the same principles apply to most other four-stroke-powered motorcycles with set screw and locking nut adjusters.  Shim over/under bucket type adjustments are measured the same way but the procedure for determining the correct thickness of shims is a whole other process not covered here.

Gain access to the top of the engine as necessary. You might need to remove the fuel tank and or other bodywork. Then you’re almost ready to remove the valve cover, but first clear away any dirt and debris with compressed air or a small brush. Removing the valve cover without first cleaning the area will leave the engine’s top end vulnerable to dirt you might accidentally knock into the engine, and that could cause damage to internal components.

Remove the spark plug and then remove the valve cover(s). Inspect the valve cover seals/gaskets for damage and replace them if necessary upon reassembly. Now you need to set the engine at top dead center (TDC) on the compression stroke so that you can get an accurate measurement of the valve clearances. For most engines you will have to remove the timing plug on the side engine’s crankcase.

While looking through the timing hole, use a wrench or socket to slowly turn the flywheel. Turn over the engine until the line on the flywheel aligns with the the marker — usually an arrow or dot — on the engine case. (Make sure you don’t mistake the engine timing marks as the TDC indicators.) Now the engine is ready for the valve clearance check.

Check the clearance of all valves with a feeler gauge.  If the gauge won’t slide between the valve stem tips and the adjusting screws, rotate the engine one turn to put it on the compression stroke. There should be a slight drag against the feeler gauge as you slide it between the valve stem tips and adjuster screws. If the valves are outside of the motorcycle manufacturer’s specification, adjust them as necessary.

For this engine, I just had to loosen the valve stem lock nut, slide the appropriate feeler gauge in place and adjust it with a wrench until it was in spec. Hold the adjuster with a tappet adjuster tool (available from Motion Pro) and re-tighten the jam nut. Re-check the clearance before moving on to adjust the next valve.

Re-install the valve covers, check and set the spark plug gap and then install it in the engine.


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Bringing new riders into the sport

7/26/2014

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Honda XR100
The "right" first machine can build confidence that will last a life time.
Kawasaki kdx250
As confidence grows, so can the machine
safety gear standee
Proper gear can keep that first ride from becoming the last ride.
thejunkman
Proper techniques come with time, don't rush it.
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Learning to "fail" can keep you from getting hurt
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Two brand new riders, on the "right" bikes, the right gear and the right trail for the first time. We measure the economy of these bikes in "smiles per gallon"

First time rider on Jones Pass by thejunkman
From time to time we all run into or meet new people that are eager to get into the sport, and because most of us are thrilled to share the joys of the sport we all know and love, we are more than happy to introduce and teach the “new blood” all there is to know about riding motorcycles.  Problem is we as the unofficial mentor of this new rider tend to get overzealous and over-estimate the new riders abilities.  This stems from our own excitement about motorcycling.  Over estimating the new rider's abilities can sometimes lead to a less than desirable outcome, in some cases results in a dangerous situation for this “newb”.  Below are some considerations to keep in mind when introducing a new rider to the sport for the very first time.

The RIGHT machine

The right machine is somewhat subjective, as in the right machine for one person could be the wrong machine for someone else.  This topic is too broad to explain in detail here, but a good rule of thumb is to put the “newb” on a small (size/weight) lower performance machine with easy and light handling or operation.  Discourage the new rider to start out on a pure high performance or heavy big bore motorcycle, even though the new rider may have the idea that “I can handle so-and-so” without proper technique the new rider could end up over his/her head and not know what to do.

Get the Gear

Proper safety gear seems like a no-brainer, but surprisingly most new riders fail to remember or know this at the time of purchasing a machine or when they hop on a machine for the first time.  The mentality is usually that “I am just going to putz around and get used to the machine”.  This is when most accidents with injuries happen.  The new rider feels over confident and pushes the limits of their ability.  As the mentor for the new rider, set a good example by ALWAYS wearing your safety gear (especially a helmet, eye protection, gloves, and boots) and encourage the new rider to do the same ANY time they throw a leg over the machine.


Proper Riding Positions and Techniques

This is an often overlooked part of teaching that new rider on your first outing.  Most riders just take them to their favorite trail or area.  This is all well in good if the area or trail is not too difficult (usually not the case with seasoned riders)  Remember what seems easy to you, may be so intimidating to a new rider that it will hurt confidence and retard their learning curve. One of the best places to get a new rider familiar with the machine and technique is a motor sports complex or any area that has a variety of terrain.  I like to use beginner-intermediate motocross tracks as a training ground for new riders.  Why a motocross track?  Motocross tracks have a lot of common obstacles found on most trails all combined into a small controlled area.  Think about it Jump faces are like small hill inclines, some are steep some are not, some have different break over angles.  All this is great for teaching body position and weight distribution  going up and down hills.  Motocross tracks also have different types of corners, some are flat, some are bowls, some are off camber.  Teaching proper line choice and body position around corners in controlled environments like this can make a trip to the trails more confidence inspiring.  Do not force the new rider to ride above their abilities, if they say “No” take a different route or choose a different area.  Confidence is key so don’t push too early.  Pushing usually results in in injuries or can turn off the rider from a future in the sport.

How to Fail

Seems kind of funny to teach a rider how to “fail” but as we all know you don’t always succeed at making a hill or obstacle and you need an exit strategy, especially on very steep hills, slippery slopes, or off camber situations.  Veteran riders instinctively know how to deal with the situation at hand, but to a new rider it is all new to them.  Pick an area that had a moderate obstacle and have the rider practice things like turning around on a hill, backing down a hill, or dismounting from the machine should the situation get that extreme.  Knowing some basic exit strategy’s in controlled environment can lessen the chances of injury or broken parts in a “real” situation on the trail.

Prepare for the worst

Bring some basic first-aid supplies.  You never know what could happen so it goes without saying that you should have some basic supplies to take care of minor scrapes, blisters, bruises, or sprains.  Extra water and some non-perishable food is always a good idea just in case.

Hold off on group rides

Hold off on group rides for a while until the new rider is comfortable with the machine, terrain or their abilities on the machine.  Group riding too soon can be a major step back wards as they might feel anxious or feel like they are holding up the group.  Peer pressure can also fog the new riders judgment of their abilities, thus making them attempt something a little over their head and causing a crash or injury.

Don’t get frustrated

As the “teacher” it is important not to get frustrated with the riders progress.  Doing so shakes the confidence of the rider.  Never show any feelings of frustration, always reinforce the good attributes of their performance.  Highlighting the negatives is not necessary as the rider already knows they made a mistake they don’t need you pointing it out, especially if your in a group.

One last thing:  GO OUT AND RIDE!

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A noob's first ride

7/13/2014

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Everyone has to start somewhere.  This is a brand new rider I took out to show the ropes.  I think he is hooked!  Where are we riding at?  Jones pass in Colorado of course.  Still early in the season and a lot of snow so we could not go over the top and down the back side.  We made several trips up and down to practice negotiating rocks, turns, bumps, braking, shifting, and anything else.  It was a productive day.  See the video below.

First time rider on Jones Pass by thejunkman
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Ask the Junk Man!  #junkask

7/12/2014

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Here is your chance to ask me ANYTHING.  It doesn't have to be motorcycle or technical related.  Ask a question in the comments below (you don't have to register to comment!) and I will make a video answering YOUR questions!  If I get a good response from this you bet there will be more videos in the future.

You may also ask on my facebook page or my Twitter and hashtag #junkask

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    Jon "the junk man" helping to promote responsible riding and recreation whether it be at the track or at the trail. Your source for motorcycle how to videos and much more!

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