Robert:

The one I found the off cam was supposed never to have been pulled down.

It's easy to check. With the plugs out and the rocker covers off to check the lash, turn the crank and watch the rockers. Going in forward rotation you'll see the exhault open, and then as it's closing you will see the inlet start to open. If the cam is timed correctly you will see the two valves equally open when you feel the crank move the pistons past TDC. The two cylinder's overlap points should be exactly one turn of the crank from one to the other.

Ifthe engine is new, with the rockers unworn, you can do an accurate valve adjustment using a feeler strip. If the rockers have any wear you can not. The end of the valve stem will wear, and a groove will wear in the rocker. This is aggravated by oil deposits and gum build up on the rocker face. You might get a good feel with a 0.002" strip, and still have 0.005" actual valve lash. The only way to know for sure what the clearance is requires using a dial gauge. The two pictures attached show the overall set up, this is on an FA-80, but it's the same for all Saito enginesx, whether one, two, three, or five cylinders. The second shot is the plunger of the dial gauge sitting on the rocker arm, as close to being in line with the valve as you can set it. By reaching under the valve end of the rocker with a small screwdriver you can lift the rocker, and read the actual lash.

Now. How many people have that dial stand? And how many are willing to ship their engines to me to have them adjusted? Right. There's a better way, a consistent way, and it's easy.

With the piston at TDC and the valves in the overlap position, turn the crankshaft exactly one turn. If you want to try your feeler gauge go ahead, then set it down and do not pick it up again until it's time to put it away. Loosen the locknut on the adjuster screw, and with your allen key turn the screw back and forth, make sure it turns freely. You noticed, as you turned it in it got a little snug at one point. Look at the valve as you turn the screw in. You will see the valve start to open as you keep turning it. Back the screw out to where it's free again, and turn it back in until you are just at the point where the valve would start opening if you kept going. this should be exactly zero clearance. Hold the screw right there, and tighten the locknut. The threads will distort a little, and if you got the screw just right before you tightened it you will have right at your 0.001" lash. Practice it, do it five or more times to get the feel. Once you have it you will find this method is very consistent, your valves will be as close as they can be done without using the dial gauge. After you do one side switch and do the other cylinder. You will be able to wiggle the rockers and feel the clearance. Easy, fast, and accurate.

Hope this helps you find the problem.

Bill.