I would give the project all day....an entire weekend day with an overnight cure of the sealer.  You want plenty of time to clean up the parts before you put them back on.  Wash the bike a day or two before you start the job and take it for a quick ride to dry it out.

I know others have used different forms of RTV - but the Suzukibond is made for the job and I believe it cures slower and gives you more time to get the job done before it sets up.  It also seems to have more solids in it, and it does not dry shiny.  You also just need a very thin amount of sealer - you should not see a big gob of it squeezing out as you tighten the head cover.  Don't buy orange or copper colored RTV.....it looks awful!  I believe the Suzuki Bond is about $ 20 a tube - you can also use Three Bond which is a bit cheaper. http://www.bikebandit.com/threebond-liquid-gasket-1194

I have never done the plug repair with the engine in the frame - so I can't help you figure out how to wiggle the head cover in and out of the frame.

You do not need to do anything to the clutch when working on the tensioner.  Buy a gasket for the exhaust header and a gasket for the clutch cover just in case you need them......and an O-ring for the clutch shaft is not a bad idea.  Clean and apply sealant to the rubber grommet where the neutral light comes out of the case.

Don't do this!  

Coaxial wrote on 04/23/14 at 07:35:13:


Nope. Looks like Dave thought you were doing some head work. Your valve covers have little rubber O-rings so you don't need gaskets or sealant. I did both, it will take you a good Saturday for sure if it's your first time. Be sure you have your exhaust gaskets (get two in case you need to stack them for a tight seal) and your clutch cover gasket, oil and filter, a dab of RTV to put around the little wires that go into the back of the clutch cover (oil leaks there). Mix up some transmission fluid and acetone 50/50 for "nuts-off" it works better than store bought stuff. Dose your exhaust bolts all around (don't forget the ones behind the muffler at the frame) a couple times the night before you start.  Remove the bolts at the engine first before you drop the rest of them, you don't want the weight of the exhaust hanging on your engine case. When re-installing, get the exhaust basically hung in place and pretty close before you start tightening down the engine bolts. Use some anti-seize on them and your exhaust bolts, it'll make you life easier down the line.

Cut our a piece of cardboard and draw your clutch cover then poke your bolts into the carboard piece where they go so you can keep track of the long and short and gasketed bolts.

When you take the clutch cable off there is a little tab you have to bend. Be sure you pay attention to the clutch cable assembly and put it back right before you put the clutch cover back on, otherwise you'll need to pull the clutch cover to get it on again.

On the valves, once you are sure you are at TDC, get your .0003 to .0006 feelers and check the clearances. If the 0003 doesn't fit they're too tight and need adjusting. If it fits, go up a size. If you get to .0006 then it's too loose and you need to adjust. Anything in between is in spec and don't mess with it. Don't go loosening everything up and adjusting  unneccesarily.

Take it slow. Take pictures along the way, don't trust your memory about how things go back.  Good luck!

S-P wrote on 04/23/14 at 07:59:00:


Whoops, you mean .003 to .006 (inches)

I use .004 and .005"

4 has to fit, 5 shouldn't.

I was careful and re-used the clutch cover gasket...still no leaks after a long road trip...

remember to smear a tiny bit of sealant on the washers with rubber centers (clutch cover) I believe 3 or 4 of the cover bolts have these

verslagen1 wrote on 04/23/14 at 08:57:30:


Yep, that's exactly what I meant. Danged twitchy fingers... I shouldn't try to type sober.  

Gents:

I opened up the top of the engine and checked the valve clearance.  Evidently they are way off or I am doing something wrong.  I got the TDC right, I'm pretty sure.  But it appears I have 1/8 inch to much clearance.  Is this even possible?  As always, your help is appreciated.  Thanks.

pg wrote on 04/27/14 at 16:52:02:


hmmmm... sumpins not right.... 1/8 I doubt the bike would have been runnin.