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www.motorcyclespecs.co.za/model/suzu/suzuki_dr400s%2080.ht 1980. Engine. Air cooled, four stroke, single cylinder, SOHC, 2 valves per cylinder ....Valve adjustment can be done without a feeler gauge and the CDI has ..
There is a specific procedure for setting valve clearance . I highly recommend getting a repair manual for the correct specs & procedure. The engine must be at TDC with the #1 cylinder on the compression stroke , that will allow you to adjust ONLY certain valves , then you have to turn the engine one turn to TDC again only now #1 will be on the exhaust stroke & the rest of the valves can be adjusted . it's important that you know the difference between the two !
There is no adjustment. The clearance is pre-set by the valve length and tappet length. If the valve seat is worn the clearance becomes non-existant. .020-0.30 clearance for both intake & exhaust will work okay.
make the engine runs for about 30minutes before adjusting the valves, valve clearances: intake valve = 0.20mm(0.008 in) exhaust valve = 0.25mm(0.010 in) for reference only when the engine is cold, valve clearances: intake valve = 0.25mm(0.010 in) exhaust valve = 0.30mm(0.012 in) engine specs: mitsubishi 4g13 1.3L (if you have same engine)
Valve clearance ideal setting is 0.10mm however as ideal replacement size shims are not always available use tolerance 0.05 to 0.2mm inlet and exhaust Procedure remove tappet cover rotate motor to tdc compression (inlet valve lobe pointing to rear wheel and exaust lobe to front wheel) measure clearance if no clearance depress cam bucket hold down by wedging a screwdriver or suitable tool (allen key) between cam bucket and cam remove shim measure with micrometer an relace with a shim 0.15 thinner depress valve remove wedge and measure clearance (if any) repeat procedure 4 each cylinder if clearance to large replace shim with a thicker one till clearance is in spec
make sure engine is warmed up. Put cylinder one at top dead center,remove the valve cover,loosen all adjustment lock nuts,adust intake and exhaust valves on cyl #1 and intake valve on #2 and exhaust valve on #3. now rotate crankshaft 360 degrees clockwise, now adjust intake valves on cyl#3 and cyl #4 and exhaust valves on cyl #2 and cyl #4.now tighten lock nuts and install valve cover. specs are intake valves 25mm clearance and exhaust 28mm clearance, use a feeler gauge,heres a picture to show you where to check clearance.
with the cylinder set at top dead center compression. using a feeler gauge between the tappets and the valves there should be .002-.003in clearance on the intake valves, and .006-.007in. clearance on the exhaust valves. thank you.