video- 07+ 400-Valve Clearance Inspection - Page 2 - Suzuki Burgman Forum
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post #11 of 12 (permalink) Old 04-22-2011, 02:50 PM
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Location: Winter Haven, FL (Central Florida) ***TRAVEL STOP***
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Re: video- 07+ 400-Valve Clearance Inspection

OK, thanks, I'll try that.

I can't imagine that you would not dig into this thing for a couple of days instead of trust your memory, LOL.

I'll let you know how that suggestion turns out.



I turned the flywheel around again to the timing mark and the sight picture is different. Here is what I see DIFFERENT for the next person doing this:

You will turn the TDC to the TDC mark correctly, go to measure the valve clearance and what you will see when the TDC mark is correct but you need to turn the TDC one more time to the NEXT TDC is:

the cam lobe will be approaching the tappet from the top moving toward the bottom to make contact with the tappet. You can not measure it this way.

from the cam lobe contacting the tappet, turn the TDC mark ONE more time around and:

You will see what looks like a small square nut welded to the cam shaft, no cam lobe in sight, and the small square nut will be centered right in the middle of the tappet and you will slide the feeler gauge from the top (seat side) between the nut and the tappet, testing for fit until the next feeler gauge does not fit.

VERY simple.

I had done it the wrong way about 4 times and just unluckly in turning the TDC mark to the wrong place 4 times. Again, the TDC right place is when you look at the cam and tappet you see what looks like a little square nut centered right in the middle of the tappet and the feeler gauge slides very easily under it adn it is very easy to see with a mechanics mirror and the feeler gauge will go all the way from entry to exit and you will have a good sight picture of it.

You may need to stack feeler gauges i.e. .17+.04 stacked together = .21 because there is not a .21 in my feeler gauge stack, but I do have a .17 and a .04 = .21 and the .20 slipped through easily so Ineeded a little bit more thickness, but the .18 + .04 =.22 would not go through.


Bob Weis

intake .15 left side .13 right side
exhaust .21 left side .20 right side

Bob Weis, Winter Haven (Central), FL, Red 400K8 "Rebekah"
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post #12 of 12 (permalink) Old 07-21-2016, 10:38 AM
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It looks like you stopped the TDC with the sprocket's '1' on top, whereas it should be '3' in accordance with the manual.

Just did mine, after measurements had revealed some tight specs, went for the adjustment, and although didn't find any change in performance or engine sound whatsoever, the thing that bothered me was a very narrow lash interval those valves operate in.

Things happening pretty fast there, so who knows what can occur if a valve misses the boat. Besides, tech guys suggest.

The whole job took a bit more than half a day. Considering that i did the first check earlier, it took a whole day. In a prepared garage it might take what QM assigns for it. But i don't have such a garage.

My advice would be if get to the checking, do the adjustment once your there, because the most difficult part is probably the access, i.e. removing all the stuff and dressing it back.

Got the Hot Cams kit and was a bit disappointed with the 0.05 increments. Having closed the journal, realized that those shims could be sanded with small grain paper to the desired value, but didn't want to open it back again.

Might want to take additional measurements, as you may find the OEM shim sizes a little bit surprising. E.g. mine read 162 but the measured size was 1.64. Assuming device error, the measured replacement shim size was 1.61 vs claimed 1.60.

Do one cam at a time -- it's easier to keep everything in original position this way.

It could be done with floorboard on, but air cleaner element bracket will be more challenge. In principle, it even can be left in situ as air cleaner has a pivoting mount point. I just like more space to move around.

All in all the job is doable for a non-mechanic like me. Whether it's worth doing i can't say for sure, but i'd better never know

Burgman 650 '04 Exec black (too much a scoot)
Last true 400.
Suzuki DL1000. (gone but still most miles)
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