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Suzuki 800 Intruder Club & Forum

A UK Site Dedicated To The Suzuki C800, VL800, VX800, M800, VZ800, VS800, C50, M50 Model Intruder / Boulevard / Marauder
 
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 Valave Clearances VZ800 M800 2008

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ippikin
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PostSubject: Valave Clearances VZ800 M800 2008   Sun Apr 14, 2013 12:49 pm

HAve spent the morniung in the workshop with the idea of checking the valve clearances on my VZ800. What a bastard of a job; I got so far as getting the tank off, the air filter housing off, the front cylinder chrome trim off the top of the front cyclinder R side, and by lots of fiddling (and praying that I wasn't going to drop the inner (cos you can hardly get to it) bolt), the exhaust tappet cover on the front cylinder. Peering in to the hole, the tappet clearances are so deep that I could not see them, let alone check them. The idea of doing this another 3 times did not appeal so I have chickened out and put it all back together again.
It looks like to get any sort of access to this one you would need to remove the radiator..... but then what about the inlet valves? And the rear cylinder.
In the Haynes manual it says "engine removed for clarity" which is highly useful.
I can't believe this is so difficult!
HAs anyone done the job on this bike? Does anyone have any tips about getting this done or shall I bite the bullet and find a friendly mechanic (but I don't really trust anyone else with my bikes).

Frustrated.
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Mr Intruder
Suzuki800.com Founder ... & ... Senior Administrator
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Sun Apr 14, 2013 7:53 pm

I will be doing this job myself over the next few weeks, so will be able to give real insight into any issues and how to get around them.
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simbo
.. Mechanical Tart .. .. Site Moderator ..
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Sun Apr 14, 2013 9:22 pm

I read somewhere it's easier to do the valves with a bent feeler gauge to gain access.
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ippikin
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Mon Apr 15, 2013 12:03 am

Thanks Dave. I will be very interested to hear how you get on. In cool reflection I may have given up too soon and better light required!
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ippikin
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Mon Apr 15, 2013 9:29 am

simbo wrote:
I read somewhere it's easier to do the valves with a bent feeler gauge to gain access.

Thanks Simbo....... it looks like it is almost essential!
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ippikin
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Wed Apr 24, 2013 8:20 pm

Getting somewhere now; I have had to remove the rubber thing that goes from the top of the air filter to the top of the engine, and disconnected lot of hoses and wires and have actually managed to get all the inspection covers off now. The intake cover of the rear cylinder is the worst!
~Went to take out the spark plugs but haven't got a spanner in the tool kit. Saturday morning ear marked for checking clearances now if I can get the plugs out!
This is not an easy job; leave yourself plenty of time...... you do not want to be rushing this!
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ippikin
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Fri May 03, 2013 3:35 pm

After much head scratching and cursing I have come to the conclusion that the only way to get to the intake valves is to remove the throttle body. What a pain! Also access with the feeler gauges is so crap that I think the only way to do it is to loosen the lock nut and adjuster off, slide the appropriate size feeler gauge under and then adjust to snug with the feeler gauge in situ.
~Will be attempting this at the weekend I hope.
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ippikin
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Mon May 06, 2013 12:08 am

Just finished putting my bike all back together after finally adjusting the valve clearances and feeling rather pleased with myself at finally having done it....... thought I had set the exhaust clearances to 0.2mm and the intake ones to 0.09mm ......... went to put the feeler gauges away and found that the 0.1mm gauge had (just for badness) stuck to the back of the 0.09mm gauge!! Thus meaning that my intake clearances are now 0.19mm....... suggested range is 0.08mm to 0.13mm. Arrrrghhh!
~So .... it looks like I shall have to redo the intake ones... actually not too bad a job now I know the trick is to remove the throttle body.... this gives you easy access to the intake valves.
~I just can't believe it... what a stupid mistake. Still we all learn by experience!
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simbo
.. Mechanical Tart .. .. Site Moderator ..
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Mon May 06, 2013 10:16 am

Glad you've sorted it Grob, good tip on the throttle bodies I bet finding the gauges stuck together was a spanner throwing moment
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captain crash
Mentally Deficient lunatic ..... & ..... Site Moderator
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Mon May 06, 2013 11:11 am

Good on you Grob, great tip. What a shitter about the gauge but at least you will do that one quickly
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Mr Intruder
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Mon May 06, 2013 8:10 pm

Glad your nearly there mate, we all learn by these little hiccups, although it would be nice if sometimes we didn't have too.
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ippikin
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Wed May 08, 2013 3:49 pm

Finally all done and yes, it's much quicker the second time round. New plugs as well.... and there is a definite improvement in her perfomance! Had a really fun ride just now..... not sure what's made the difference but what the hell! Happy days!
I will post a few tips discovered on this journey later, along with some pics when I get the time.
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Mr Intruder
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PostSubject: Re: Valave Clearances VZ800 M800 2008   Wed May 08, 2013 5:08 pm

Good man.
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