Yeah, that is the furthest out of spec. I have ever heard of on a Kawi 1400 engine (C or ZX). I too am somewhat suspect; perhaps you were measuring the clearance on the clearance ramps rather than the true 'back side' (smallest diameter) of the cam? Not throwing rocks at you, just very curious about the 0.003" deviation, especially since it is so consistent.
And yep, it is a pretty involved job doing a valve check / lash adjustment on this bike. Once you get all her clothes off, you find she is wearing petticoats, suspenders everywhere and wrapped in wires and hoses.
You may want to consider doing yourself a favor and putting rubber hoses on each throttle body vernturi nipple and routing them to the left side of the bike- honest, it will save you a ton of time and effort the next time you balance the throttle bodies. I am assuming you ARE balancing the T.B's while this far into the engine.....
It is not a particularly difficult job but it is quite involved, and must be done in a pretty specific order. Methodology is the key to success IMO.
Best of luck with this project.
Brian
8.5 years, 43,428 miles. First day.
I had no idea it was going to be this difficult to do. It took two of us 5 HOURS just to get to the point of measuring the valve clearance and then the shims and buckets and then stopped (because we are exhausted and I will have to order lots of shims). My garage is a disaster. And there are so many freaky mounts and connectors and crap, I am scared we will never get it back together.
1in .002/.002 2in .005/.005 3in .002/.002 4in .002/.002
1ex .007/.007 2ex .007/.007 3ex .007/.007 4ex .008/.007
My mechanic friend says that might explain the running problem I am having at low speed/throttle. Only 3 of 16 valves are in spec, and 1 of those barely.
13 buckets were 0.106, 2 were 0.105 and 1 was 0.107
Shims were all between 0.089 and 0.093 (most in the middle of that range).
It was necessary to remove the right engine mount. The lower bolt which was supplied for the Canyon Cages was extremely tight and hard to move. IT BROKE IN THE MOUNT after about 1 turn. So that is going to be a huge pain in the ass, I'm sure.