I adjusted the valves (twice) and put them at about .004" and now theres some heavy lugging along with the normal click.  I adjusted at TDC after the intake valves close and I've been riding it around for about 10 miles or so and it hasn't exploded... but it just seems to be louder than it was before I adjusted and its enough to cause me a good deal of concern.

Might this be a problem due to the loose cam chain?

Bobbert wrote on 03/19/09 at 18:47:02:

Remove the timing plug to locate TDC on the compression stroke.  The other TDC is the top of the exhaust stroke.  Check the rockers by hand (finger) for some movement between the rocker and the valve and you will be right on if the pointer is aligned in the timing window exactly with the cutout in the cover.  Always rotate ccw (counter clockwise) when turning the crankshaft (17mm hex socket) the normal rotation of the engine. Don't reverse direction if the indicator is off just rotate around again twice.

Bobbert is a friend of mine.  We put in a verslagen 1 holer last year and it's run out of adjustment.  and he's noted that and opened her up for visual confirmation.

BTW, I taught him to adjust his valves.  He picked it up fast, which was good cause after I did one I was ready to collapse.  After doin' his cam chain with him, I was fadin' rapidly.  Came down with somthin'.

So I trust his opinion, is he says so, it's loud.

LMAO!

Bobbert wrote on 03/19/09 at 18:47:02:

I checked the valve lash yesterday on my 2008 S40.  I guess Suzuki refer to it as the "first service".  Here is what I found.  Both exhaust valves measured .003" and both intake valves measured .002".  Those thicknesses are measurable but difficult due to the paper thin feeler gage.  I left all settings as I found them.  The intake are perhaps a tad close but with the insurance factor that the clearances will increase by .004" at running temperature they should be just fine and especially the intake running cooler.  The re-torquing of the cylinder head I left alone, perhaps at another time.  Lets see what happens if anything.

justin_o_guy2 wrote on 03/22/09 at 10:54:36:

Justin, I'll be watching mine closely.  The head bolts (4) are 9 mm diameter studs with hex acorn nuts with AF dimensions of 14mm hex.  The 9 mm are special metric sizes, difficult to find and probably made for Suzuki as a speciality item.  Perhaps there was limited space for a  10mm or even a 12 mm fastener and this 9mm comprimises the clamp load of the cylinder head to the cylinder block.

Bobbert wrote on 03/29/09 at 11:06:00:

I think the decomp just opens the exhaust just enough not to seat.  We can look at it when you're here.