Suzuki DR650 Valve Adjustment Page

 

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Suzuki DR650 Valve Adjustment Page

 

Suzuki DR650

 


Valve Adjustment

Valve adjustment is an important routine maintenance task that is beyond the skill or comfort level of most riders, but isn't that difficult to do.

 

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Pre 1996 DR650 Valve clearance specifications:

IN. 0.08 - 0.13mm (0.003 - 0.005in)
EX.   0.08 - 0.13mm (0.003 - 0.005in)

 

1996- DR650 Valve clearance (when cold):

IN. 0.08 - 0.13mm (0.003 - 0.005in)
EX.   0.17 - 0.22mm (0.007 - 0.009in)

 

 


Valve Clearance 1990-1995 DR650

Here are the instructions from the Suzuki Pre '96 DR650 Maintenance Manual:

 

VALVE CLEARANCE

Inspect Initial 1,000km (600miles, 2 months) and

Every 6,000km (4,000miles, 12 months

 

Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power.  At the distances indicated above, check and adjust the clearance to the specification.

 

Valve clearance specifications: 0.08 - 0.13mm
(IN. and EX.)   (0.003 - 0.005in)

 

The procedure for adjusting the valve clearance is as follows:

 

NOTE:

Valve clearance is to be checked when the engine is cold.  Both intake and exhaust valves must be checked and adjusted when the piston is at Top-Dead-Center (TDC) on the compression stroke.

 

  • Remove the frame covers, seat and fuel tank.

  • Remove the spark plug and valve inspection caps, intake and exhaust.

  • Remove the valve timing inspection plug and magneto cover cap.

  • Turn the crankshaft counterclockwise with the box wrench to set the piston at T.D.C. on the compression stroke.  (Turn the crankshaft until the "T" line (1 on image to right) on the magneto rotor is alighted with the center of the hole on the magneto cover.)

  • Insert the thickness gauge into the clearance between the valve stem end and the adjusting screw on the rocker arm.

 

09900-20803: Thickness gauge

 

  • If clearance is off the specification, bring it into the specified range with the screwdriver.

  • Securely tighten the lock nut after adjustment is completed.

 

CAUTION:

Both right and left valve clearances, should be as closely set as possible.

 

  • reinstall the spark plug, valve inspection caps, valve timing inspection plug and magneto cover cap.

 

 

DR650 Plugs and Intake

 

DR650 Top Dead Center

 

DR650 Valve Check

 

DR650 Valve Adjustment

 

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Valve Clearance 1996- DR650SE

Here are the instructions from the Suzuki 1996 DR650 Maintenance Manual:

 

VALVE CLEARANCE

Inspect Initially at 1,000km (600 miles, 2 months) and
Every 12,000km (7,500 miles, 24 months thereafter.

 

The valve clearance specification is different for intake and exhaust valve.

 

Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is disturbed by removing it for servicing.

 

Valve clearance (when cold):

IN.: 0.08-0.13 mm (0.003-0.005 in)

EX.: 0.17-0.22 mm (0.007-0.009 in)

 

NOTE:

Valve clearance is to be check when the engine is cold.  Both intake and exhaust valves must be checked and adjusted when the piston is at Top-Dead-Center (TDC) on the compression stroke.

 

  • Remove the frame covers, seat and fuel tank.

  • Remove the spark plug and valve inspection caps, intake and exhaust.

  • Remove the valve timing inspection plug and magneto cover cap.

  • Turn the crankshaft counterclockwise with the box wrench to set the piston at T.D.C. on the compression stroke.  (Turn the crankshaft until the "T" line on the magneto rotor is aligned with the center of hole on the magneto cover.)

  • Insert the thickness gauge into the clearance between the valve stem end and the adjusting screw on the rocker arm.

 

Tool

09900-20803: Thickness gauge

09917-14910: valve clearance adjusting driver

 

  • If clearance is out of specification, bring it into the specified range.

  • Securely tighten the lock nut after adjustment is completed.

 

CAUTION

Both right and left valve clearances, should be as closely set as possible.

 

  • Reinstall the spark plug, valve inspection caps, valve timing inspection plug and magneto cover cap.

 

 

 

 

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