KTM Valve Adjustment Without Swapping Shims

Valves wear to be tighter, not looser. So generally valve adjustment requires thinner shims to open up necessary clearance. I figured, why not resize my own shims? Here's where I gave it a go.
2010 KTM 530 EXC Champions Edition.
This procedure should apply to 2008+ KTM 450/530/500 motorcycles, and really, anything with valve shims.

[@EMFRocks]

Thank you for your time to record this, much appreciated.

[@colindgrant]

My pleasure! I hope it was helpful.

[@geebopbaluba1591]

Very good idea! Thanks for this and I’m going to use this on my 530 exc-r

[@geebopbaluba1591]

Just got through with checking the valve clearance and all 4 were spot on and this 2008 530 exc-r has really been taking care of with only 200 hours on it so I’m very pleased with it.

[@peterpedant]

15:29 Don't forget to install the rocker shafts with the indent mark facing up.

[@WillysRubicon]

Really great videos. Thank you! One question on your radiator fan. Can you give me some background on this? I am worried I might be over stressing the factory stator if I add a fan with headlight, etc.

[@colindgrant]

Thanks! I don't know a lot about the fan, it was already installed when I purchased the bike. I can tell you that it is DC and runs off the battery. It turns on when a thermal switch determines water is getting hot, but I can flip a switch to keep it turned off. The headlights run on AC, only while the bike is running. The highest stress on your stator would be a completely dead battery, fan on, and headlight on. I don't think it would be an issue. If these bikes have a charging regulator between stator and battery then it definitely wouldn't be an issue.

[@WillysRubicon]

@@colindgrant thanks for the feedback

[@nwyoda8792]

I put a trail tech 100 watt stator in to help with bigger lights and my fan. works great and worth it!

[@colindgrant]

@@nwyoda8792 Thanks for the follow up post! Nobody ever does that, I sure appreciate it!

[@miro_s]

Thanks for this. Can you explain the mechanics of why valves get tight and not loose? I would have thought wear on the shim and rocker arm could easily make them loose…

[@colindgrant]

Hey, you're welcome. When valves slam closed 100s of millions of times, they actually beat up their seats and close slightly farther into the head over time. Meanwhile the cam and rocker wear is so slight that they are effectively unchanged. So you need a smaller shim over time to make up the difference. We're talking about thousandths of an inch, 10ths of millimeters, so it's small, but important for keeping your engine running well.

[@miro_s]

@@colindgrant thanks. Makes sense

[@rogerhupp3115]

Excellent!

[@colindgrant]

Glad you liked it!

[@tothepoint4240]

Hey man, pretty helpful video. Thank you for sharing!

[@colindgrant]

I appreciate that, glad it was helpful!

[@trailwayfilms]

Hi. What grade of flatting paper would you say each side of the sanding stone is? I don't have access to one but I have lots of sandpaper at work

[@colindgrant]

Totally guessing here. I'd say 400 and 800 grit. Wet/dry sandpaper will work. Use some thin oil and a flat backing surface. 3M Trizact is pretty amazing stuff so if you can get your hands on that, I recommend using a super high grit (like 3000) for the final polish. Put some good assembly lube on them when you reinstall them, as there will naturally be some wearing in that takes place once you start it up. Good luck!

[@trailwayfilms]

@@colindgrant cool I have access to all of those. Cheers

[@hughiemaceachern5282]

U probably know by now but valves in them bikes a really good seldom go tight

[@johnnygalvan1344]

Was the bike running perfectly fine before tinkering with the valve adjustments?

[@colindgrant]

Yes it ran very well, but it was a used bike so I didn't know the last time they had been checked.

[@johnnygalvan1344]

@@colindgrant my bike stopped running on me while I was riding on the freeway in 6th gear , I checked spark and gas was good , everything was turning in the gearbox , I took it in and they tell me it has low compression. It will be my first time rebuilding the top end . My dots for tdc are in the same spots as yours that’s why I was wondering if your bike was running before the adjustments. My bike is a 2009 exc 450 ktm . Do you think it has something to do with my Torque limiter? Or flywheel bearing ? Why it’s not firing up

[@colindgrant]

@@johnnygalvan1344 if it stopped running while on the freeway, then something happened. Low compression could come from loss of oil or a head gasket failure. But if it stopped running while you were riding it I wouldn't suspect the starter.

[@johnnygalvan1344]

@@colindgrant wouldn’t I still be able to start it if it was also a kick start ?

[@johnnygalvan1344]

@@colindgrant starter or stator ?

[@59plexi]

did you put the trail fan on or is it stock?

[@colindgrant]

I bought the bike used and it was already on there.

[@nwyoda8792]

Its aftermarket

[@alexandre8598]

Hi, why don't you use the top dead center bolt on the right side of the transmission cover? Some people use it, some other not... Thank you!

[@colindgrant]

I read about that, but the notches on the timing pulley just make it so easy to visually see when you're at TDC, that I didn't bother with the bolt you mentioned. I think if I needed to lock the motor in place at that position, I would use the bolt. Thanks for commenting!

[@SootyHunt]

Maddddd