CAUTION: Valve clearance should be checked with engine cold.

Disconnect negative battery cable. Remove valve cover and gaskets. Rotate crankshaft until No. 1 cylinder is at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with zero mark on timing belt cover.
Valves on No. 1 cylinder should have clearance and be closed. If valves on No. 1 cylinder are not closed, rotate crankshaft one revolution (360 degrees).
Using feeler gauge, measure clearance between rocker arm and valve stem on intake valves on cylinders No. 1 and 2, and exhaust valves on cylinders No. 1 and 3. Adjust valve clearance if not within specification. See VALVE CLEARANCE SPECIFICATIONS table.
Adjust valves by loosening lock nut and turning adjustment screw until correct clearance is obtained. Hold adjusting screw while tightening lock nut, and recheck clearance.
Rotate crankshaft one revolution (360 degrees). Check intake valve clearance on cylinders No. 3 and 4, and exhaust valves on cylinders No. 2 and 4. Valve clearance must be adjusted if not within specification. See VALVE CLEARANCE SPECIFICATIONS table.
On Storm, apply sealant to No. 1 and 5 camshaft bearing cap-to-valve cover areas before installing valve cover and gasket. On all models, reverse removal procedure to install remaining components.

VALVE CLEARANCE SPECIFICATIONS

Application

In. (mm)

Tracker

Exhaust

⁽¹⁾ .006-.008 (.15-.20)

Intake

⁽¹⁾ .005-.007 (.13-.18)

⁽¹⁾	Adjustments made with engine cold.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Valve Clearance