Does any one know why the workshop manual says that TDC has to be determined by referring to the normal flywheel marks and the mark on the cam sprocket? Seems to me that TDC is TDC.

The valve clearance is set when the piston is at TDC on the firing stroke with both valves closed. Turn the crankshaft a further 360 degrees to TDC & the cam shaft is on valve overlap, meaning you are coming off the exhaust cam lob & going on to the inlet cam lob, you cannot set the valve clearance in this position because the base circle of the cam lobe is not on the valve rocker & both valves can be open at this point..

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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Thanks Kev. Not trying to be smart because I'm not, just getting old, but I've set screw tappet valve clearances on various bikes for more than 40 years now (Brit stuff at first, then mostly Jap singles from XT500 onwards, and a string of [gasp] 610/570 Huskys), and none that I know of had this feature readily available, so I was curious as to why the Tenere does.

In general, I've just removed the tappet cover, and watched for the inlet valves opening, then set TDC when the flywheel mark next arrives in the port.

So what I was getting at, I guess, is that it's not a requirement to line up the cam sprocket mark, just an aid, and you've cleared it up, so thanks again for that.

Yes it is an aid for the none mechanical mined person. You either set them at TDC on the compression stroke or when the tappet rocker/roller is on the base circle of the cam lobe. Any other way the valve clearance will be wrong.

__________________
Click here to join the XT Supporter's scheme

Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Hi
Sorry to but in , but i thought you lads would have the answer.

I'm doing my valve clearances this week on my 2008 Tenere and would like to know what they should be set at.

Cheers Dazzer

RTFM

In: 0.9-0.13mm
Out: 0.16-0.20mm

Its good to know that most of the maintenance required on these bikes can be carried out by anyone with a basic knowledge of bike maintenance Also all the tools I have used to do all the work I have carried out so far are carried in the tool tube on the bike ,so you wont need to carry a Tool chest with you

Since it appears you've taken the radiator off, do you also carry enough coolant to refill it with you in your tool tube?

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XT660Z - Commuter, Adventurer...Racer?

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Other bikes >> MT-03 / CG125BR-J / ER-6F
Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400

Not if you drain it into a pop bottle first

The Radiator needed a clean !!