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Feb 14th 2016, 02:28 PM   #1
 
  Jan 2016
  Spokane

ZX6R runs like a soup can full of rocks after valve adjustment

Over winter I redid my valves, and after getting everything together she runs like shit. Clearly I did something wrong here, I'm just hoping someone can tell me what it was and save me some time. My humble intuition tells me that i got the timing off when i put the camshafts back in, which is entirely possible since Kawasaki kindly placed the timing marks so that they face the inside of the frame. Video for your viewing pleasure:


Edited by Jonas on Feb 14th 2016 at 02:33 PM
Feb 14th 2016, 03:21 PM   #2
 
  Jan 2016
  Newcastle, WA

  1995 Suzuki Katana
By "redid my valves" are you saying remove and replace? Full head work done? Or just an adjustment?
Feb 14th 2016, 03:36 PM   #3
 
  Jan 2016
  Spokane

Oh, sorry, I just pulled the camshafts and swapped shims. It's almost impossible to see the timing marks on the camshafts, and one of my sharpie marks got smudged.
Feb 14th 2016, 04:00 PM   #4
 
  Jan 2016
  Spokane

I checked all my electrical and vacuum connections and they look good. Tried removing the powercommander and no difference. While I was shimming valves I also cut the cat out of the headers and welded it back together, but no leaks or anything that I can find. Bike doesn't throw any codes...
Feb 14th 2016, 06:00 PM   #5
 
  Jan 2016
  Newcastle, WA

  1995 Suzuki Katana
You did check the gap before removing the camshafts, right? Then checked then after reinstall?

For that matter, why did you remove them in the first place? No need if all you are doing is checking and changing shims...

Edited by skjeflo on Feb 14th 2016 at 06:03 PM
Feb 14th 2016, 06:30 PM   #6
 
  Jan 2016
  Newcastle, WA

  1995 Suzuki Katana
Quote:
Originally Posted by Redkat600
Shim under bucket yo.....gotta pull cams.
I see, oh wise one....

I was basing my judgement on my history with valves and a rundown that I found online and.....didn't read far enough into the process.

For the OP, if you think that noise is because of bad cam placement then STOP! I believe you have an interference engine and valves can and will hit pistons if your timing is too far out.

Also found this, which sound kind of like yours?
https://youtu.be/U-U-O7dAiAU

Might also want to check in with these guys: http://www.zxforums.com/

Always learning!
Feb 14th 2016, 10:35 PM   #7
 
  Jan 2016
  Spokane

I pulled and reinstalled the tensioner after putting camshafts back in so that's good.

I did check clearances after putting in new shims and reinstalling the camshafts.

On the whole interference engine thing I figured after it ran for a minute while I looked for exhaust leaks any damage was already done. I just ran it to see if I could get an FI light and to check my vacuum/electrical lines. I'll watch that video tomorrow, my phones almost dead.

Maybe the timing chain jumped a link on the timing sprocket and it got out of sync that way....guess she's coming back apart again regardless. Thanks fellas.
Feb 15th 2016, 07:25 AM   #8
DGA
 DGA's Avatar
Moderator
 
  Jan 2016
  PDX

  An Ape and a Husky
Cams on those bikes can be a bitch to line up right, due to where the frame sits. I was doing the same job on my friends and I kid you not that it took me about 30-60 minutes to get the cams just right, because you just can't see the marks from the frame.
Feb 15th 2016, 07:40 AM   #9
 FeralRdr's Avatar
 
  Jan 2016
  The Rider's Seat

Quote:
Originally Posted by Jonas
I pulled and reinstalled the tensioner after putting camshafts back in so that's good.

.......
Yes,.... but did you reinstall it correctly? What Brertt was asking, was when reinstalling the tensioner, did you make sure to push the tensioner's push rod back into the tensioner's housing.



The idea is to have the push rod not apply any tension to the chain when reinstalling the tensioner. When next installing the cap bolt and spring, the push rod will be pushed back out, and the chain tension will then be properly set.
Rusty Nail and Arnbo like this.
Feb 15th 2016, 09:26 AM   #10
 Pavement Tested's Avatar
 
  Jan 2016
  Seabeck

  '08 GSX1300R, '06 GSX-R 750, '17 KTM 690 Duke
If there was an interference issue you would have noticed it when turning the engine over by hand like the manual tells you to do.

You did that, right?
Feb 15th 2016, 02:56 PM   #11
 
  Jan 2016
  Spokane

I did reset the pushrod of the CCT when I reinstalled it.

I also did turn the engine over by hand about ten times to make sure the CCT would be able to adjust itself and to make sure everything was settled when I did the final check on valve clearances. Didn't feel like I was smashing any valves.

I really want to know why Kawasaki didn't just stamp the timing marks on both sides of the camshaft sprockets. I would punch lines on the other side but I suspect the sprockets are gonna be harder than my punches...

How would I tell if I have one camshaft timed wrong vs both? I'm trying to figure out if the chain is off on the timing sprocket or if just one of the camshafts isnt timed right.
Feb 15th 2016, 03:05 PM   #12
DGA
 DGA's Avatar
Moderator
 
  Jan 2016
  PDX

  An Ape and a Husky
Simple...line up the engine at #1 TDC and the marks should be parallel with the machined portion of the head and valve cover mating surface while the arrows point at each other. Now the not so simple thing, actually doing it.

What I suspect happened is that one cam rotated while the other was stationary when the chain was taking up slack initially. That is if you had them lined up right. Only thing left to do is line them up again. One thing that I found very useful was a mirror to check my work in a tight spot.
dragracer1951 and Rusty Nail like this.
Feb 15th 2016, 03:05 PM   #13
 Parilla125's Avatar
 
  Jan 2016
  SeaTac

WHENEVER something runs worse you always go back and ask "What was the last thing I did?" In this case it was valves complete with removing the cams. Do it over. Or REALLY check everything closely.
If you do not you run the risk of bending valve's (if you have not already) or worse. Something is wrong. Do it over.
Feb 15th 2016, 03:42 PM   #14
 dragracer1951's Avatar
Moderator
 
  Jan 2016
  Bremerton

  07 XB12 Buell Lightning
If the valves touched anything, it would die.
Immediately.
So, there's that little bit of good news.
Feb 15th 2016, 03:50 PM   #15
 Parilla125's Avatar
 
  Jan 2016
  SeaTac

Depends on how many touched and got bent and how much. Been there, done that...
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