Since my 500i is going into the dealer's for the ball joint recall, I was thinking it's a good time to have him adjust the valve clearance...But do I really need to? It seems to run fine (170 miles), seems like it is well broken in, no strange noises at all....The motor seems to be perfect - why mess with a good thing? I looked in the manual, there is no requirement for valve adjustment in the maintenance schedule. I really dont think I'm going to have anything done...Maybe after I've rolled on about 500 miles or so, I will notice a need for this service. I'd appreciate any comments on this ASAP, since it's going to the dealer's this week. TKS!

 

Let it go, You'll be fine. The valves might need to be adjusted at around 1000 miles. That is when my 500 seemed to change in engine sound, and I seemed to have just a little more Umph in it. So my advice would be to let it get a few more miles on it. M ake sure it's good and broke in.

 

I agree with minehunter. I always wait until at least 500 miles. I just adjusted mine the other evening and it has over 700 on it. I have done several of the 400 and 500 Cats and I haven't had one need to be adjusted until 4-500 miles. The 250 and 300 is another story.

 

My '02 300 4x4 has 262 miles on it. How are they a different story? Do they need it sooner or more often? [img]i/expressions/face-icon-small-confused.gif[/img]

 

does anyone know where to get a sevice manual for the 2002 375 4x4 yet? I looked at alot of dealers and no one has any yet!!

 

Its a good idea to at least check the adjustment after the break-in period, to make sure everything is optimum, and I like to check every 500 miles thereafter. Too much gap means a valve isn't opening as far as it could, meaning slightly less performance, and no gap means the valve isn't closing all the way - decreasing compression and causing deposits on the valve seat. These two extremes are rarely the case, but worth bothering for.

I just checked the valves on my 400 last weekend - it has around 500 miles - the exhaust valves were .009, one intake was .004, and the other intake was .002
I need to adjust them, but I don't know the specs - can anybody (Mudcat maybe) tell me the exact clearance for intake and exhaust?? I have no shop manual for this machine, all I need is the numbers.

I have to say, the Cat is the easiest Bike I've ever accessed valves on. You can have the tank off in minutes, and access to the rocker arm covers couldn't be more convenient.

 

You can have any dealer order your service manual, it runs less than $50.
The #s for the 400 Cat are:
intake 0.05-0.10mm
exhaust 0.17-0.22mm

This info is also on your vehicle emisions sticker on the front bumper support left side on the 02s. I can't remember where it is on the 01s. The 250 and 300 has it visible from the rear above the engine on the frame.

The 300 and 250 seem to need valve adjustments more often than the 400 and 500. I have heard of people not adjusting them and burning the valve seat. I adjust our 250s at about 100 hours, I don't have a speedo so I go by the hour meter. It seems like they are always out of adjustment when I check them. But it is a real simple job, only takes about 1 hour now that I have done it so much.

 

Thanks mudacat. Is your 250 set up anything like the '02 300 (engine, plastic, gas tank, etc.)? What does it involve? Do I have to take the tank off and stuff to get in there? Also, I've got about 265mi on it. Not usre how this would translate to hours, but is it too soon to have it done? Thanks again!

 

Yes the 250 is set up just like the 300 except for different bore and stroke. You need to remove the plastic side panels and fuel tank as well as the intake snorkle. I would not hesitate to adjust the valves on the 300, at least pop the plugs off and check them. I would suggest a factory service manual, they cost less than $50. They have a lot of info and if you are planning on doing simple work on your quad it is good to have. You can get them at your dealer and one manual covers all models from 250 2x4 to the 500 autos and manuals.

 

Mudcat, nice pics! I like that Windrock! I wish I had someplace to go like that. Does the cylinder head need to be removed to do the valves, or do you go thru the inspection caps on either side of the head? I'm sure I can do them myself, I just like to know what I'm getting into and what to expect before I do it. I usually don't hesitate to work on my stuff myself and when I'm done, I don't have extra srews laying around. Usually! [img]i/expressions/face-icon-small-happy.gif[/img]