Suzuki DR650 Valve Adjustment Page

VALVE CLEARANCE

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.

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.

VALVE CLEARANCE

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

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