Ok I just called the owner...great guy by the way, and he said he never touched the valves, just oil and trans oil. So with that being said I agree with you Stig I doubt they would of sent it out NEW like this, but then again the plug was WAYYY off too.
So here is my fear (even though the test ride went well):
#1. I may of not been at TDC since I did not pull on the rocker arms checking for movement (however I did pull the plug and put my socket extension down there to see if the piston was near the top, which it was).
#2. I did not use the torque specs provided for the valve adjuster. Since it is so difficult to get it to spec
(trying to hold the adjuster with a needle nose) I got it close and snugged the adjuster nut. Then I would use the (next size up gap .005) gauge to see if it still fit, if it did I then used just the wrench and tightened 1/32ish of a turn to the right (since the nut carries the adjuster rod with it...thus making a smaller gap). I when the .005 no loner fit in knew I was close and adjusted very carefully until the .004 could fit and the .005 could not.
I'm just having a hard time believing this scoot was this far out of spec and I am always fearful the motor will blow. Please let me know your thoughts of the above. If I have to take it apart again I will, to check TDC...getting the proper torque spec seems impossible, but I don't have any other tricks unless they make a tool for the adjuster rod (to hold it).
...and again THANK YOU for your help!!!
OK, with Zombie riding shotgun we will get this sorted!
Your specs were too tight. Still some movement there - but too snug. Who knows why --- maybe the dealer at the first major servicing (200 or 600 miles) set the valves when the scoot had not been sitting overnight. In other words: owner brings in scoot for service. Waits in waiting room. Dealer lets engine cool some, then sets the valves. EVERYbody I respect as a mechanic says to ONLY do valves on a COLD engine ("overnight sitting" in the service bay)
Who knows?
But you are about to insure that they are perfect!
#1 Take the valve cover off again, spin the engine and look for those 3 holes to line up as shown. Now, grab that nut and pull/push on it. Got movement? No? Spin again 360 degrees. Line up the sprocket's 3 holes. Try for movement now. Got movement? Super....
#2 Now slip the .004 blade in there. I like what you're doing --- if the .004 fits and the .005 does not. You are good to go.No matter how or what you do with that center rod or the surrounding lock-nut....when you're all done messing with it and snugging things up IF THE .004 has a nice fit - You are GOOD TO GO!
I never torque little nuts like that - I do not own an expensive fine adjusting torque wrench. Look at the nut - use your noggin and snug it. We're not trying to snap anything off - just a good snug tightening is perfect.
If you suspect that you did the orginal valve set at the wrong 360....Do the straw in the spark plug hole thing again to see when the piston is at its highest AND look at those 3 sprocket holes.
Rotate engine forward > check > look > feeler gauge blades....take your time. No rush.
Consider doing this: once you've got everything spun to the proper place and valves all adjusted. Take off that disc by the fan, look in there with a flash light - find the marks stamped in the metal. Study that TDC image...maybe even use a touch of white-out paint to make things easier to spot the next time. MY TDC marks are so faint they are really hard to see. I applied a bit of white paint to both places.
Let us know how it's going....Zombie is pacing in his back yard - missing supper.
As my 13 yr old daughter tells me :"You can do this thing, Pops."
Stig
