XJ1100 valve clearances

[HalfCentury]

I bought a metric feller gauge at NAPA. Below are the measurements.

It looks to me that #4 intake and exhaust each need to move two sizes.
#1 exhaust needs to move one size. The rest look good.

#4 intake is a little worrisome. Could it be an actual valve problem? Or just incompetent PO?

The bike runs like a scalded dog. No complaints about any part of the power band.


Exhaust spec 0.21 - 0.25mm
1..........2...........3.........4
0.20----0.25-----0.23----0.16



0.14-----0.15-----0.13----0.05
1...........2..........3..........4
Intake spec 0.11 - 0.15mm

[trbig]

Valve problems usually mean massive clearances on your measurements. Just put 'em back in spec.. The #4 ex will be slightly over, but it won't hurt anything. They get closer as they wear. Gap them to the high side and ride it a loooooonnng time.

P.S. You might need a carb synch when your done to get everything back good.

[HalfCentury]

For sure a carb sync is on the menu. I already have the differential bottles ready for the sync.

I am debating tearing the carbs down or not. There are absolutely no problems now with starting, idling or running as is. No leaks, no drips, no stinky carb smell in the garage.

One petcock does need a refurbish. Probably will do both at the same time.

[trbig]

Differential bottles?

Although a good carb clean wouldn't hurt, if it starts/runs well, run a bit of seafoam through it and ride it a while. But slowly, silt does start to gather in the bottoms of your bowls just due to the fuel these days, even if you run inline filters. (Highly suggested)

[HalfCentury]

Here is a photo of my DIY differential bottles. I got the idea from a web search back in 2008.

The fluid moves to the stronger vacuum pull. You adjust for zero motion of the fluid. Zero motion = exact vacuum match.

It cost me $20 for the windshield washer hose and other assorted parts.



I agree concerning filters. My XJ650 carbs had rust particles everywhere. But that bike had a rusty tank inside and it ran like crap when I bought it.

[HalfCentury]

I pulled all but one of the shims. #3 exhaust will not let me set the sim bucket tool properly. I may have to resort to a zip tie at some future date if the clearance gets too tight on #3 exhaust.

It looks like I need to order 2 of the Y285 and 1 of the Y270.


Exhaust spec 0.21 - 0.25mm
1..........2...........3.........4
0.20----0.25-----0.23----0.16
Y290----Y295----????----Y295


Y280-----Y280----Y275----Y280
0.14-----0.15-----0.13----0.05
1...........2..........3..........4
Intake spec 0.11 - 0.15mm

[motoman]

Here is a photo of my DIY differential bottles. I got the idea from a web search back in 2008.

The fluid moves to the stronger vacuum pull. You adjust for zero motion of the fluid. Zero motion = exact vacuum match.

It cost me $20 for the windshield washer hose and other assorted parts.



I agree concerning filters. My XJ650 carbs had rust particles everywhere. But that bike had a rusty tank inside and it ran like crap when I bought it.

Guess that sorta set-up would work.........times two more for final balance of the carb pairs.

[HalfCentury]

The bottles are moved from carb pair to carb pair. No need for any more than one set of bottles.

[trbig]

But you'll still need to isolate the carbs with a YICS tool.

[HalfCentury]

But you'll still need to isolate the carbs with a YICS tool.

Thanks for the reminder. I have not seen the tool in a while other than in the mirror. I bought the YICS tool in 2008 when I was refurbishing the XJ650. Two major home moves later, its around somewhere....

[HalfCentury]

The #3 exhaust shim turned out to be a major PITA. I ended up removing a significant amount of meat from the shim bucket hold down tool. The screw hole needed enlarging by 2X+. Even so, it required 10+ tries to place the tool and actually have the bucket immobilized.

I called it quits last night after over an hour of failed attempts. This morning I gave it a fresh try and after a few fails I got the %$@#& shim to pop out. Its a Y300 which was a surprise making it the thickest one of the bunch.

Now I have a complete map and will not have to pop any out next time a clearance becomes tight.

Exhaust spec 0.21 - 0.25mm
1..........2...........3.........4
0.20----0.25-----0.23----0.16
Y290----Y295----Y300----Y295


Y280-----Y280----Y275----Y280
0.14-----0.15-----0.13----0.05
1...........2..........3..........4
Intake spec 0.11 - 0.15mm

[HalfCentury]

Here is what I ended up with after the adjustment

Exhaust spec 0.21 - 0.25mm
1..........2...........3.........4
0.25----0.25-----0.23----0.25
Y280----Y295----Y300----Y285


Y280-----Y280----Y275----Y270
0.14-----0.15-----0.13----0.15
1...........2..........3..........4
Intake spec 0.11 - 0.15mm

#1 exhaust does not make any sense unless I measured incorrectly originally. I replaced the Y290 with a Y285 and the measurement was 0.19mm which is tighter than I measured with the Y290 that was in place. I swapped in a Y280 which came out of #4 intake. That resulted in 0.25mm which is pretty much ideal.

I am not interested enough to put the Y290 back in and re-measure. Maybe after I clean the carbs before buttoning it all back up.

Its weird that some of the clearances were found at the high side of in-spec while #4 intake was less than half of the lowest in-spec number.

The only thing that makes sense is that a lazy mechanic just never did the #4 intake and exhaust and lied about checking those clearances.