Pm me your email and preference if it is any good to you. Pdf by bigboy292000 on thumpertalk neduros tire changing class adv rider snap, crackle, pop by bugginsdr return to. Seems easy, ive watched the videos and read clymers. An absolutely free and advertisementfree website dedicated to the maintenance and enjoyment of the kawasaki klr650 motorcycle. Best of all, it has been custom configured for you and your motorcycle. Reduced power intake and exhaust valves that are not adjusted to open and close at the proper times degrade an engines ability to make maximum power. Loose is better than tight but im hoping they will stabilize soon. In this motorcycle tutorial you will learn how to check and then adjust the valves on a kawasaki klr650 motorcycle.
I done my last valve check at 6000km do i need to check them at 12000kms. Valve adjustment question i have now adjusted my valves 3 times unsuccessfully in three days on my 2015 dr650. Saturday, sep 20 2014 38 miles before taking the bike out on a ride i want to adjust the clutch. Want to know how to check and adjust the valve clearance on a suzuki vstrom dl650. This meant that the actual valve clearance was somewhere in between 0. Allow you to access the lower portion of the gas tank when gas level is low.
Suzuki dr650 valve check and adjustment tutorial hd youtube. Go back to the crankshaft and keep turning it counterclockwise, this time until the r line on the generator rotor appears in the timing inspection hole. Getting the bike torn down to where i could check the clearances was pretty easy but i will admit i was getting pretty nervous about going any farther and doing the adjustments until i did a little searching and found blacklabs thread supplemental guide to dl650 valve adjustment, thanks whistler and greywolf. This is so you will be able to rotate the engine by turning the wheel with your hand. Our new damper assembly o r shock consists of a damper unit and spring and is built to exacting specifications usin g the. Major camshaft manufacturers recommend setting valves cold, to avoid erroneous adjustments on lifters that may be pumped up if you are setting valves on a. The high speed valve has less effect as you turn the base valve setting clockwise to the right. The mighty suzuki dr650 a ural gear up and a bmw hp2 enduro in the dirt. Dl650 valve adjustment notes and tips page 4 stromtrooper.
The most serious result of incorrect valve lash adjustment is damage to the valves and related components. Service manual for2007 suzuki boulevard m109r also known as suzuki intruder m1800r and suzuki vzr1800 motorcycles. Some of the tools youll want need are, a feeler gauge min range. Once youve done that, watch this video and get ready to do a valve check on the klr and then a valve adjustment.
This manual includes spe it is strongly recommended that the chapter. The biggest news for the 1991 years dr650 range was the introduction of the dr650rse with electric start with automatic decompression system. If the valve lash is set incorrectly too much clearance, or not enough, the engine may respond by running rough at idle, particularly while warming up. I thought id make a quick tutorial on how to adjust the valves on a suzuki dr650. Oil change valve adjustment posted on by dieseldave24v.
No clutch free play no clutch free play got bike this way. Then, replace the bucket and coat it with a light layer of engine oil to keep everything nice and lubed up. For info and valve adjustments see valve adjustment. Zenseekers dr650 maintenance page oil changevalve adjustment posted on. How to take apart the stock suzuki dr650 carb for simple carb mods credits. May 08, 20 i thought id make a quick tutorial on how to adjust the valves on a suzuki dr650. Make sure you wrote down exactly which valve intake l, intake r, exhaust l, exhaust r had which measurement. Introduction eau10080 congratulations on your purchase of the yamaha xt250xxt250xc. After hellas, kevin from warp9 kindly sent me a new rear wheel bearing and brake pedal even though the old ones, im pretty sure, would have lasted a tad. The service manual states turn the crankshaft until the t line on the magneto rotor is aligned with the center of the hole. Like, i had to back them off a halfdozen turns before i got enough room to insert a. March 15, 2010 i really cant improve upon what the suzuki service manual explains as, how to perform a valve check, and valve adjustment on the dl650.
However, my situation is a little different then the average dl650 owner. Race techs complete shock shaft assemblies for dr650 and klr650. This is the most functional high speed valve found on any stabilizer. Aug 06, 2019 lucy, my 2011 suzuki dr650, has already been thoroughly abused during its three years on the road traveling the americas. Our new damper assembly or shock consists of a damper unit and spring and is built to exacting specifications using the finest materials. I can do a dropbox link to download, email it but it is a big file or send it by we transfer. What are the problems caused by bad valve adjustment. Gents i have a pdf copy of a suzuki manual for the 03 burgman if anyone needs it. Mojave damper shock for the dr650 cogent dynamics inc. We carry a range of suzuki dr650 parts that are made by the top manufacturers in the industry and are priced at an extreme value. It is a rather simple process with the right tools, and if you dont have them, i show how to make some makeshift.
I am doing the 600 mile adjustment on my buddys dr650 and the intake side seems absolutely too tight. Suzuki dr600s 19851989, dr650 19902009 factory service repair manual pdf. This model is the result of yamahas vast experience in the production of fine sporting, touring, and pacesetting racing machines. Suzuki dr650 valve check and adjustment tutorial hd i thought id make a quick tutorial on how to adjust the valves on a. This prevents the valve stem from wearing against the edges of the number and keeps the number itself from wearing off thanks to astute reader brian for that tip. The rse was 15 kg 33 lbs heavier than the rs, the electric starter, larger battery 12 ah instead of 5 and more effencive alternator 200 w intead of 180 caused the extra weight. Do not test the high speed valve while the bike is on a. Thats because i dont have any fairings on my bike anymore. Your suzuki dr650 has stood the test of time with a lightweight, winning design that makes this dualsport bike perfect for on or offroad riding. The book calls for 1015 mm of free play measured at the ball end of the lever. Page 1 page 2 page 3 group index page 4 component parts and work to be done page 5 symbol page 6 general information page 7 warningcautionnote page 8 page 9 suzuki dr650set 96 model right side page 10 engine oil page 11 information labels page 12 page specifications page 14 page 15 country or area page 16 periodic. Dr650 valve check adjust how to procedure with photos. Is the intake valve the one nearest to the carbs and exhaust nearest to exhaust pipe or vice versa. Piston to valve clearance must also be checked prior to final.
The photo in the manual, while barely visible, does show the line centered up. Setting the clearances loosely causes parts of the valve mechanism to hammer together, damaging valves and creating a knocking or rattling sound. Apr 14, 2016 im doing a valve adjustment on my 2011 tc449. Do tappy valves indicate the valve clearance is too tight narrow or too loose wide. Service manual 2007 suzuki boulevard m109r, a great reference for the repair and maintenance. You will need to remove the bodywork of the bike first. Automatic petcock allows fuel to flow into carb without engine turning over. Once the bracket is off and you can move it down, unhook them from the carb i learned this after i took my cables off already. Service manual, fix motorcycle yourself with a repair manual. Valve adjustment is an important routine maintenance task that is beyond the skill or comfort level of most riders, but isnt that difficult to do. Dear valued customer, thank you for purchasing your new cogent dynamics m otorcycle damper assembly for the suzuki dr650 motorcycle. Our easy to follow step by step illustrated tutorial. It is a rather simple process with the right tools, and if you. Suzuki dr650 valve check and adjustment tutorial hd.
The only possibility, other than a defective camshaft when the bike was new, is that the cam chain was so loose the slack bound up around the sprocket causing enough pressure to break the shaft. Periodic maintenance chart, clutch cable adjustment, throttle free play, brake bleeding, engine idle speed, drive chain adjustment, rear brake inspection, front brake pads, engine oil, spark plug, air filter servicing, spark arrestor, tires, valve clearance, compression test. When doing the adjustment is it better to be in the lower range 0. What spec should i set the valve clearances to in order to reduce some of the valve tap. Conversely, it has more effect as you turn the base valve to the left. In normal operation, there is no way the chain or valve springs could break a shaft. Click link below to see the pdf file with very good pictures. Oil changevalve adjustment posted on by dieseldave24v. Put the bike on the centrestand, remove both spark plugs, and put it in top gear.
West with the night you can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing. Here is a nice pictorial on how to adjust the valves on a dr650. View and download suzuki dr650se shop manual online. Acces pdf clymer manual dr650 clymer manual dr650 top 10 car emergency items learn the musthaves to keep in your car in case of emergencies. I just checked my valves last night, for the first time since buying my bike. At 6000kms i fitted iridium plugs, so can i leave well enough alone and keep riding. Dr650 valve adjustment and top dead center adventure rider. The latest challenge in the maintenance series is an oldschool endurodual sport bike. Technical articles and maintenance procedures with accompanying photos to further clarify the process make this very much a diy resource for almost every level of mechanical skill. Lucys got warp9 wheels, footpegs, and levers which were clearly built to last and withstand some serious beating. Heres what boosted my suzuki dr650 reliability the most. A cold engine is a lot more comfortable to work on. Each assembly includes a gold valve, rebound adjustment, and a rebound separator valve.