How to measure/inspect and adjust valve clearances on a Suzuki motorcycle?
📍Not as difficult as it seems! Every motorcyclist with straight arms and a minimal set of tools can handle this.
Sequence of actions (relevant for most motorcycles):
1️⃣ Need to dismantle: Crankshaft window cover, fuel tank, air box, throttle ramp, ignition coils with interfering wiring elements, valve cover.
2️⃣ Aligning the crankshaft mark with the mark on the side engine cover, measure the first group of valves, rotate the crankshaft 360 degrees, and measure the second group of valves. Record the actual values in the table! Set the crankshaft mark so that the marks on the camshaft gears with values 2 and 3 are parallel to the cylinder head.
3️⃣ Next you need to dismantle: Timing chain tensioner, camshaft pastels, camshafts, glasses along with valve adjusting washers. STRICTLY IN THE ORDER IN WHICH THEY ARE INSTALLED! You can't mix it up! ⚠
4️⃣ You can start measuring each adjustment puck with a micrometer. Be sure to write down the thickness of each washer!
Based on the obtained values, you need to calculate the required thickness of each washer, at which the valve clearance will be ensured within the allowable gap according to the motorcycle service manual.
5️⃣ Next, either adjusting washers of the required thickness are purchased (the number on the puck indicates its thickness), or the existing washers are adjusted to the required size using the turning/grinding method.
📌 As a rule, during operation, the valve clearance tends to decrease, and therefore the thickness of the washers will have to be reduced/ground off.
6️⃣ Install adjusted washers, cups, camshafts, secure pastels, clearly set marks, MAKE A COLD RUN of the engine by manually rotating the crankshaft!
Next, carry out a control check/measurement of the valve gaps, and if all the gaps are within the tolerance limits, assemble everything in reverse order ✅ You can go!
Good luck with the repair & maintenance!✌🏼
Leave your questions and suggestions in the comments! ❣️👇🏼
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00:00 Intro
00:05 Removing the crankshaft window cover
01:01 Crankshaft mark
01:05 Removing the fuel tank and mounted plastic
01:56 Lifting the tank onto a stand
02:15 Airbox removal plan
02:40 Fuel tank removal plan
03:06 Dismantled (Tank + Airbox + Ignition coils)
03:37 Disconnecting wiring connectors
04:15 Dismantling the PAIR system
04:57 Preparing to remove the valve cover
05:38 Life hack for tearing off valve covers
05:56 Justification for the need to remove the throttle ramp
06:44 The process of dismantling the throttle ramp
07:52 Throttle ramp block removed
08:56 Recommendation for self-service of a motorcycle
09:57 Archive of sad service experiences in motorcycle services
11:04 Illustrations of measuring valve clearances from the manual
11:24 Hard-to-reach camshaft bolt
12:33 The process of dismantling the camshafts
13:56 Removing the timing chain tensioner
14:19 Camshafts removed (+Explanation)
15:31 Order of camshaft pastels
15:44 Order of camshafts
16:19 Table for recording and calculating valve clearances
18:15 Life hack for measuring the gaps of inaccessible valves
19:43 Covering a disassembled engine
19:58 Micrometer - a tool for measuring thickness
20:12 The process of grinding valve shims
21:04 Epic Fail! Dropped a dipstick into the timing chain shaft
24:34 Cold continuation
24:55 Visual explanation of the tactile gap comparison lifehack
25:34 Features of working with a timing chain tensioner
27:00 Location of marks before assembling the timing belt
27:36 Installing camshaft pastels + Timing chain tensioner springs
28:04 Control cold engine run
28:32 Control measurement of adjusted valve clearances
29:53 I hope I explained it clearly! Like for the effort!
30:03 Degreasing the head plane & valve cover
30:27 You cannot rotate the crankshaft with an automated tool!
31:55 Overview of the build process
34:43 Problem installing frame reinforcement brace
35:24 Outro
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