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  1. #1

    Ultra 300 valve clearance service manual error?

    Hi all!

    I'm assembling my ultra 300x engine and am currently in process of setting the valve clearance. The service manual states:

    IN: 0.15 - 0.24mm (0.0059 - 0.0094 in)
    EX: 0.47 - 0.55mm (0.0185 - 0.0217 in)

    on the other hand, the formula for calculating the right shim thickness (page 55) states:

    A + B - C = D where

    A: present shim thickness
    B: measured valve clearance
    C: specified valve clearance (mean value = 0,275mm (EX), 0.160 mm (IN)

    Which one is right?

    I don't know HOW they got those mean values but if i calculated correctly, the mean value for the IN side is 0.195mm and 0.51mm for the EX side; or am I missing something?? In my opinion, the formula is WRONG and could mislead someone...

    Thanx

    Alex
    Last edited by ss9940; 11-21-2018 at 02:32 PM.


  2. #2

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    I can give you tons of details if ya want but long story short Grab you a whole box of the hotcams shim kit for $89. Trust me if you try to measure it and get "exactly" the shim you need itll never work.

  3. #3

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    1. Measure current clearance with your feeler gauges.

    2. Figure out how much you need to tighten the gap (thicker shim) or open the gap (smaller shim)

    3. Measure the current shim and go larger/smaller as needed.

    Make sure you actually measure the shim coming out of the hot cams box, even though they're marked and typically close to said marks they're not always 100%

    HCSHIM02 is the shim kit you want...
    Last edited by MWHC; 11-21-2018 at 08:49 PM.

  4. #4
    steve45's Avatar
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    Quote Originally Posted by MWHC View Post
    1. Measure current clearance with your feeler gauges.

    2. Figure out how much you need to tighten the gap (thicker shim) or open the gap (smaller shim)

    3. Measure the current shim and go larger/smaller as needed.
    Don't you want to widen the gap? Don't the valves recede into the valve seat as they wear and close the gap?

    EDIT: Perhaps I misunderstood what you were saying. Do you want the gap in the mid-range? Seems to me that you would want the gap on the wide end of the range.

  5. #5

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    Quote Originally Posted by steve45 View Post
    Don't you want to widen the gap? Don't the valves recede into the valve seat as they wear and close the gap?

    EDIT: Perhaps I misunderstood what you were saying. Do you want the gap in the mid-range? Seems to me that you would want the gap on the wide end of the range.
    There is no "your gap will always get xyz" some gaps get bigger other smaller don't ask me how or why hahaha. When i gap them i try and keep them on the tighter side (gives just that bit more lift) but i beat the hell out of all mine and constantly tear them down for maintenance. On a stock rebuild/freshen up/regular maintenance i would agree with you. Shoot for something in the middle but if you're off just a touch one way or the other dont let it ruin your day.

  6. #6
    steve45's Avatar
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    OK, thanks! Still learning about these 4-strokes.

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