valve/shim/rocker problem

[clb]

Hi guys i have a major problem, was doing the valve clearances the last week, and i have found the the left hand inlet on cylinder 2 has 0.00mm of clearance. The rocker is pressed against the top of the valve bucket, and any shim i put in there is too small and drops below the top surface/level of the valve bucket in which it sits. Im confused and about to give up on the piece of toad as i think the head gaskets also gone as the coolant bubbles like a mofo. help me please

also when i started her up, loads (egg cup amount) of water came out between the link pipes and the down pipes, is this a normal 4 stroke thing to do?

[RedexRobB]

water coming from the exhaust is normal

Have you got the cam in the right position? Have you got the right size shim that you want?

Could be someting missing but i think the shim sit right on top of the valve stem. Is there any wear on the bucket?

[cargo]

ZXR400s do not have "buckets" the rocker runs directly on the shim and the cam runs on the rocker.............

From your discription it shoulds like you might have dropped a valve........................ but then given that you have found a bucket where I know none exsists your discription may not be too accurate or dependable

But more information would be helpful.....................like is it running ? Does it make any strange noise ?

[zimm]

Im assuming by "bucket" you mean the upper valve spring retainer ? ..

sounds like a knackered valve and/or valve seat ..

valve stems stretch
valve heads wear thin
valve seats recess themselves into the head ..

any/all of the above = feck all valve clearance

if the coolants bubbling like hell anyway you've nothing to lose from pulling the head and having a look

[clb]

ok sorry guys, by 'bucket', i mean the small hole in which the shim sits atop the valve, underneath the rocker.
Basically the i reckon the valve stem which sticks up a little bit underneath the shim has been hammered shorter by incorrect clearance. (is this possible)
Catch 22 to this is that there is zero clearance because the rocker is sitting directly on top of the valve in ALL cam positions. Im stumped.
Good news is, im dropping the giraffe thing out. And because im super impatient im just going to jam an L5 engine in there, then get to work on the original L3 motor (unfortunately i use it to commute, and cant really afford to have it out of action for too long because i hate public transport!!)



the left hand diagram is what all the other inlet valves are like, its only the LH inlet on cylinder 2 giving me grief. hope this badly drawn paint diagram explains it
basically ignore the fact that any shim could possibly create the correct clearance in the problem valve, as if you were to put a shim large enough in, this would only make the valve tighter (0.00mm clearance) the rocker is resting atop the valve, meaning the valve has a problem, i have felt the bottom of the rocker and looked at it, comparing it to other rockers on the same inlet line, and it appears to be normal.

to replace this valve what tools would i need? any hints and tips?

lastly the head gasket is definately gone, the coolant came out black....should have been a purple colour, also had an oily shine to the top of it....

thanks for your advice guys!

[cargo]

There is certainly a valve problem...................I'm guessing that the reason why there is zero clearance is that the spring is free or partially free to press up against the rocker because the valve has dropped or is bent or a collet has moved and is jammed somehere.
It could be that when you get the engine out of the frame you'll get a better view of the problem
Sounds like you gasket is gone so you'll need to lift the head off this will give you the chance to remove the offending valve. The only special tool you'll need is a valve spring compressor having said that the valve may well just drop out............then you'll need the compressor to refit it.

If the collets have gone missing you will need to find them.................clearly they will be in the engine somwhere

Your drawing is excellent and explains the problem well...............I only wish others could be so helpfull in explaining problems

I'm sure there is a head removal guide somewhere on the forum

[clb]

thanks, ill be sure to use the search function in order to find the relavent information on head removal/use the H model manual to help. Nice thing is ill be able to take my time on this, as i have another engine on the way

Ill be sure to post pictures up here if i get stuck

Thanks guys