Join Date: Nov 2004
Location: Elk Creek, Kentucky
I sent this reply to a "private message" but others may be able to use the info too...........A manual will give you confidence, and I highly suggest you use one. I assume you can remove the plastic ok. Here are the tough parts you must get right.1) exhaust is in front and intake at rear of head 2)To adjust a tappet you loosen the outer lock nut and turn the inner screw adjuster in or out to get clearance correct. When you tighten locknut back up check that adjuster did not move on you 3) you must have the motor at top dead center (tdc) on compression stroke. To do this you remove the nickle sized cover from the right side of engine case that allows you to see timing marks. Pull the rope very slowly until you see the "T" mark, as you get close the motor will try to spin past it, if it does keep pulling rope till you see the mark again. You must be at TDC to adjust valves. When at TDC the valves should have some play, if not turn motor crank 1 revolution and reset mark and look for clearance again 4) when adjusted I usually pull the rope and spin the crank around 1 or 2 times then reset TDC and recheck the valve clearance. Check manual for clearances, .006 in and .013 ex I think.
I use plain old flat feeler gauages but ones that are bent at the tip are easier. The feeler guage should have slight drag when you insert it between rocker arm and valve stem. When removing plastic it is not necessary to disconnect fuel guage wires which is a bitch. I just take the tank and carefully go under the right side of handle bars and sit it on the front rack still connected. Sometimes its easier to remove the spark plug when you set TDC but I'm lazy and just leave it in. Lastly, you may want to go ahead and buy the O rings to replace the ones (2) under the valve covers.
2003 green Rinny (12,400 miles), "25" Bighorn Radials (white letters out) full of extra slime, water pump mod, no warning labels, E Trex, everything else like Mr. Honda made it. 2000 XR 400r (est 3,500 miles). RIDE RED EVEN IF ITS GOT GREEN PLASTIC!
2013 Yamaha Super Te'ne're' (27,400 miles in 22 months), 1996 Toyota Tacoma 4x4 (392,000 miles) on tight and original motor. 2001 4Runner (82,000 miles).