My Official Valve/Head Thread

[Guest]

Hey guys,

I going to be doing a valve adjustment and some general loving on my head pretty soon. I'm getting the parts/tools together that I'm going to order and had a couple questions. I figured I'd have more questions when I start it (or at least pictures!) so I'll start my official thread

Firstly, my bike is missing the metal covers that go on the outside over the ends of the camshafts, overtop of the "D" plugs. They were missing when I got it. Do I need these? Apart from being nice and shiny, I imagine they may be protecting the plastic "D" plugs from weathering? They're not too expensive, but I'm on a very tight budget. Four new ones will cost me $67.

My Purchase List:
-Valve Shim Tool (Z1, $14)
-"D" Plugs (Z1, $13)
-25 blade metric feeler gauges (Z1, $14)
-Cyc Head Gasket (GSSuzuki, $16)
-Breather Gasket (GSSuzuki, $6)

I'm also replacing all the bolts, and the oil separator mesh things in the breather. It's probably fine, but they're really cheap and I like to be complete.

I'm also ordering some other stuff not associated with the head, such as petcock gasket, clutch/throttle cables, lube/lube tool, various nuts and bolts (I like to replace *ALL* the nuts/bolts just because they are probably originals on there and stressed over the years). Do you guys recommend a cable lube tool like this one? I plan on replacing all the cables soon.

http://www.z1enterprises.com/ItemDetails.aspx?item=EM84-81190

I've shopped around on various sites. Z1 seems to be the best, but they don't have everything. GSSuzuki seems to be the cheapest source of OEM parts.

Anyway, thanks! And I'll definitely post some pictures.

[jsandidge]

Suzuki Parts Monster

I have found Suzuki Parts Monster to be cheaper for OEM parts. Everything else I get from Z1.

[azr]

Great project, just remember you'll need to resynch your carbs after you do this job so organize how or who will do that for you as well. As for bolts, are you putting in S/S allen heads? pretty cheap sets for sale out there.

[cowboyup3371]

Z1 doesn't post everything on their site but can get everything. You'll just want to give them a call or even send Jeff.Saunders a PM as he's one of their employees or owners...something like that

[eil]

Firstly, my bike is missing the metal covers that go on the outside over the ends of the camshafts, overtop of the "D" plugs. They were missing when I got it. Do I need these? Apart from being nice and shiny, I imagine they may be protecting the plastic "D" plugs from weathering? They're not too expensive, but I'm on a very tight budget. Four new ones will cost me $67.

No, you don't strictly need them, they're just ornamentation. You should be able to get used ones a little cheaper from eBay if you aren't terribly picky about condition.

[srg]

So I finally got around to popping the head off and adjusting the valves. Most of them are in spec, it looks good in there.

..............1......2......3.......4
Exhaust..0.07..0.05..0.04..<0.04
Intake....0.07..0.05..0.04....0.07

I planned on replacing #3 intake and exhaust, and the #4 exhaust. After my calculations, I basically need two 2.60x shims. The shop near me doesn't have the "x" sized shims for fine-tuning it, nor does my OEM supplier. Anyone know where I can get *NEW* shims? I checked Z1, CycleReCycle, and my OEM supplier. None have the "x" size. Should I just give up and go with the regular sizes?

Is it better running on the tighter (less clearance) side or the loose (more clearance) side? Does it differ for the intake and exhaust?

Anyway, thanks guys!

[Nessism]

They don't sell the half size shims, but if you measure each shim with a micrometer, you can often find half sizes (assuming you have a few to choose from).

[srg]

I got a few shims from Z1, hopefully I can find something to fit. I also got new OEM bolts and gaskets for the head cover and the breather, as well as new "D" fittings.

Should I use a dab of grease over the D fittings to ensure a good seal? White lithium grease? Wikipedia says it has a drip temp of 350° to 400° F...the head shouldn't get that hot, so it should be alright?

Also, would white lithium grease be a good general lube for things like the pedals and the clutch push assembly thing?

[srg]

Valve cover gasket came shipped folded in half. I'll sit a textbook on top of it to flatten it out. But this shouldn't affect it, will it? I was sort of upset when I unpacked it.

[eil]

No, they should not have folded it when they shipped it. That's why it comes with an additional piece of cardboard inside the package, to deter folding.

Is it just bent or did is there an actual crease in the gasket? If it's just bent, it's probably serviceable. You can straighten it out with a textbook like you said. Or in the worst case, a smidgen of gasket adhesive can help hold it down during installation. If there is a crease, it will probably never seal well so call up your vendor and have them ship you another. If they won't, order one from somewhere else and never buy from them again.

[tkent02]

I'm curious who sent them like that?

[Wester Cooley]

Folded the valve cover gasket in half to ship it. That hilarious!!!!!

Guess thats one way those mail order parts suppliers cut costs. Hire ex burger flippers from Mickey D's instead of someone with a brain to do their shipping.

In my 41 years of being around motorcycle dealerships, I have never seen anybody fold a gasket in half to save on shipping costs!!!!

[srg]

G&S Suzuki. It was literally folded in half inside the USPS flat-rate envelope. There is a crease in the gasket. The one side is slightly torn up.

I just looked closer at it. It's ruined.

[eil]

Yep, that's bad. Call them up and (politely) see if they will make it right. Hopefully they're eager to do so. If not, you might mention this thread and remind them that this forum sends them quite a lot of business.

[tkent02]

I don't think we send them much business anymore. I have only heard bad remarks about G&S since about a year ago when they stopped selling good parts cheap and started the lying about orders, the endless delaying, more lying about the delaying and now the folding of gaskets.