SuzukiSavage.com - THAT was a chore!

justin_o_guy2

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East Texas, 1/2 dallas/la.

THAT was a chore!
11/23/16 at 14:47:54

The timing plug was in there Solid... After shaping a piece of mild steel and watching it bend, I grabbed a mower blade outta the junk pile. After some slicing and filing, since it was a few thousandths too thick, and an 18" crescent wrench, it popped loose.. About four hours,,
Now, the question is, what is the plug gap Sposeta be?
The iridium plug looks kinda funky,, I need to find the plug color pictures..

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5112 Manteca , CA Gender:	Re: THAT was a chore! Reply #1 - 11/23/16 at 15:00:32 Should have called cheapnewbie for advice !
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: THAT was a chore! Reply #2 - 11/23/16 at 15:17:12 If I remember correctly, the plugs come pre-gapped. and it's either .035 or .029 I think the iridium is .029 reading plugs in the index
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Kenny G

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Re: THAT was a chore!
Reply #3 - 11/23/16 at 15:19:25

Justin,

Just the other day I broke a chunk off of the back side of the timing cover trying to get it off. I am thinking anyone trying to take this cover off might want to think about purchasing a can of Freeze off.
https://www.amazon.com/gp/product/B000TFTH00/ref=ox_sc_sfl_title_4?ie=UTF8&ps...

Here is a link to the spark plug color:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1126253987

When I measured my spark plug the gap was .033 and somewhere on here, or the internet, I found the gap was supposed to be .031 to .035. I left mine exactly where it was at .033.

I set the valves at a snug .004.
I had to make feeler gauges to fit my hands and the engine.

I went for a ride today and the engine sounds good and there are no parts missing.

Kenny G

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: THAT was a chore! Reply #4 - 11/23/16 at 15:20:27 0.031-0.035" per owners manual
Back to top	There's no problem that a full tank of gas and a sunny day can't fix! 2008 S40, Rotella T 15W-40 w/ZDDP added, Dyna, 140/90-15, Battery Tender Jr., Seat lift, #52.5/150/3 washers, Raptor IP Logged

justin_o_guy2

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East Texas, 1/2 dallas/la.

Re: THAT was a chore!
Reply #5 - 11/23/16 at 15:41:56

Mmmmkay, good to go on the plug..
But daggummitt I forgot the valve adjustment tolerance..

I'm gonna go pop the covers and hope the lash is here when I get back..

Thanks guys, it's much appreciated..
I should have kept the manual when I sold the bike.
Dude's not even riding it but wouldn't even call me when I told his mom I wanted to buy the fork brace and manual back..

Phhhht..

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The people never give up their liberties but under some delusion.- Edmund Burke.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: THAT was a chore! Reply #6 - 11/23/16 at 16:45:49 So, the PDF manual says See Table Six for correct valve lash adjustments. WHY NOT JUST TELL WHAT THEY ARE? Adjust intake to!!###===/// Adjust exhaust to!!###===/// But NOOOO, I gotta go find Table 6.. And Turn engine clockwise,, no, I don't think so..
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Kenny G

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Re: THAT was a chore!
Reply #7 - 11/23/16 at 16:47:35

Justin,

Verslagen has a great post in the technical section for valve adjustment.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1325991352

I think the valve clearance is in the .003 to .006 range.
I set my valves at a snug .004.
Before I do this again I want to get someone to weld a handle onto a 10mm socket so I can do the intake valves without so much hassle.

Kenny G

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: THAT was a chore! Reply #8 - 11/23/16 at 16:50:47 Yeeehawww! .003 to .005" I saw that reference to A tight four but I gotta see the range ,, and, now it's off to the races..
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5112 Manteca , CA Gender:	Re: THAT was a chore! Reply #9 - 11/23/16 at 19:41:46 Yeah they are a PITA no matter what tools you use ! It's good that you took the time to do it,good job,now you don't have to do it in the spring time! Have a safe trip !
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justin_o_guy2

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Re: THAT was a chore!
Reply #10 - 11/23/16 at 20:31:04

I have trouble keeping the adjustment from changing while I tighten the nut. I have an offset screwdriver, but just a tiny bit of rotation is an obvious change in the adjustment..
I gotta build something, and Verslagen has a really good idea going,,

Ohh, and BTW, the 05 NEEDED adjustment. And the rocker threads were sloppy on the adjusters. This one is an 02 model and as far as I can tell, it's just superior. The adjusters felt good, the brakes are worlds apart.. I'm totally pleased with this bike..

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The people never give up their liberties but under some delusion.- Edmund Burke.

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Kenny G

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Re: THAT was a chore!
Reply #11 - 11/23/16 at 21:29:31

Justin,

I made a copy of Verslagen's screwdriver and that works really well.

As soon as I find a welder I am going have a tappet wrench that will work on either the intake or exhaust valves.

When I get the tappet wrench finished I will post a picture.

One thing I found that helped was leaving the feeler gauge in place while I tightened the locknut.

My Norton was easy to adjust the valves that I cannot believe how difficult the Japs can devise simple adjustments. With the Norton I didn't even have to take the tank off.

Kenny G

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: THAT was a chore! Reply #12 - 11/23/16 at 21:44:54 I hafta leave the feeler gauge in, I have to slide it and check the adjustment.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: THAT was a chore! Reply #13 - 11/23/16 at 22:07:45 I'm looking to supersize it. the fender washer I have now is 1.25" in diameter. I want 2.5", but I've found some 2" so I'll try those.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: THAT was a chore! Reply #14 - 11/23/16 at 22:13:02 Verslagen, I found that if I fold 2 of the edges up on the fender washer it is a little easier for me to hold while tightening the lock nut. Kenny G
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