how to change valve cover gasket

[Nessism]

so let's say you wanted to *only* replace the valve cover gasket (on a 1983 GS650G to be specific ), do you just skip the valve adjustment and put everything back together?

Not unless you want your valves to burn, or you have done a valve adjustment recently.

[Fenixgoon]

Not unless you want your valves to burn, or you have done a valve adjustment recently.

so what kind of tools am i gonna need for that? it's about time i get my christmas list started, it seems

[Steve]

Your manual should give you an idea of the tools necessary. You do have a manual, don't you?

If you don't, you can download one from BassCliff's little site.

One tool that is not mentioned in the Suzuki manual is the Excel spreadsheet I have developed that will help you figure out what shims you need and will also keep track of them from one service to the next. Toss an e-mail my way with a request and I will reply with the spreadsheet attached.

.

[BassCliff]

so what kind of tools am i gonna need for that? it's about time i get my christmas list started, it seems

Hi Mr. Fenixgoon,

Feel free to read the valve adjustment guide on my website. Then we'll see if you have any questions. I like using the tappet depressor tool, some don't. Have you inventoried your shims yet? If you keep track of your clearances and what shims you have installed, it makes it easier to plan ahead and order or swap for the shims you will need. After "guesstimating" the sizes you'll need, you can have a small selection of shims on hand, then you don't have to wait for the right size shims to arrive in the mail. No down time!

Also, for those of you with an '82 GS850G, count your valve cover bolts. As Mr. Steve mentioned, sometime in '82 the valve covers changed from a 16 bolt pattern to a 19 bolt pattern. Be sure to order the right part.

Thank you for your indulgence,

BassCliff

[NES07DEZ]

so let's say you wanted to *only* replace the valve cover gasket (on a 1982 GS850L to be specific ), do you just skip the valve adjustment and put everything back together?

[cromwell1234]

Listen, ***JUST DO THE VALVE ADJUSTMENT***, its like changing your oil but leaving the old oil filter on for a few years--makes no sense---everyone is just trying to help!! you'll be happy later!!

[Fenixgoon]

Hi Mr. Fenixgoon,

Feel free to read the valve adjustment guide on my website. Then we'll see if you have any questions. I like using the tappet depressor tool, some don't. Have you inventoried your shims yet? If you keep track of your clearances and what shims you have installed, it makes it easier to plan ahead and order or swap for the shims you will need. After "guesstimating" the sizes you'll need, you can have a small selection of shims on hand, then you don't have to wait for the right size shims to arrive in the mail. No down time!

Also, for those of you with an '82 GS850G, count your valve cover bolts. As Mr. Steve mentioned, sometime in '82 the valve covers changed from a 16 bolt pattern to a 19 bolt pattern. Be sure to order the right part.

Thank you for your indulgence,

BassCliff

BassCliff,

My tool inventory is virtually nonexistent. I need to order some tappet feelers to measure the valve clearances. Where do you install shims, exactly? I didn't see anything offhand regarding that in the valve adjustment guide.

Also, where can I get a valve cover gasket? I can't seem to find it online anywhere. I guess I'm just glossing over it when going through the parts diagrams on bikebandit. On a sad note, Z1 enterprises is currently out of float bowl gaskets

[Steve]

From the Bike Bandit Cylinder Head Cover fische:

You are looking for part #2

http://www.bikebandit.com/suzuki-motorcycle-gs650gd-1983-cylinder-head-cover/o/m6091sch233143

[BassCliff]

BassCliff,

My tool inventory is virtually nonexistent. I need to order some tappet feelers to measure the valve clearances. Where do you install shims, exactly? I didn't see anything offhand regarding that in the valve adjustment guide.

Also, where can I get a valve cover gasket? I can't seem to find it online anywhere. I guess I'm just glossing over it when going through the parts diagrams on bikebandit. On a sad note, Z1 enterprises is currently out of float bowl gaskets

Hi,

Look on pages 17 and 18 of my valve adjustment guide and you will see pictures like this:

Check the clearance like this:



Remove/install shim here (in the "bucket" under the cam lobe):



If you are interested in a Real Gaskets reusable silicon gasket, go here:

http://www.realgaskets.com/files/motorcycle.htm#suzuki

For your GS650G the part# is RG-GS650-1.

If you want an OEM Suzuki gasket, the part number is 11173-34212. It's #2 in this picture from www.alpha-sports.com:



Check the list of vendors in the mega-welcome for most of our favorite online resources.

Thank you for your indulgence,

BassCliff

[Fenixgoon]

BassCliff,

Thanks for the great pictures! I have many more questions for everyone though, if you guys don't mind me picking your brains more

With regards to valve adjustments, how do I measure anything finer than the tappet feeler I'm using? The valve clearances on my GS650 (clymer manual) are listed as 0.03-0.08mm (0.001-0.003 inches), and the smallest tappet feelers available from Z1 Enterprises are 0.002-0.003 inches. Is there any point to buying a single tappet over a card of 6? Is there a better tool for the job? I know spark plug gap sets have very fine increments.

Also, I noticed that the valve shims come in sets of 5. I'll need a shim for each valve, correct?

Is it worthwhile getting a pair of calipers? Well, I'll probably need those for the float bowls on the carbs, come to think of it.

That's all I have for now I think. Thanks in advance to everyone, once again!

[Steve]

... if you guys don't mind me picking your brains more

Actually, we would rather have you asking questions than making silly mistakes.

With regards to valve adjustments, how do I measure anything finer than the tappet feeler I'm using? The valve clearances on my GS650 (clymer manual) are listed as 0.03-0.08mm (0.001-0.003 inches), and the smallest tappet feelers available from Z1 Enterprises are 0.002-0.003 inches.

As nice as the metric feelers might be, you can also get a set in standard units. The 0.0015" feeler is about 0.0381mm. If that won't fit, you will want to be changing the shim anyway. It won't hurt to be just a little over spec, but you definitely don't want to be under spec. Remember that .003", which is your maximum clearance, is only the thickness of a piece of paper. Many like to use metric feelers to make the math easier, but you have a copy of my spreadsheet, so it won't be a problem for you.

Is there any point to buying a single tappet over a card of 6? Is there a better tool for the job? I know spark plug gap sets have very fine increments.

You will need at least two feelers, one for the maximum size, the other for the minimum size. Many times it's nice to have the ones in between, so get the variety pack. I have the fan-fold set that goes from .0015" to .025". The increments might be small, but spark plug gaps are usually about ten times too big to be considered for valve clearance use.

Also, I noticed that the valve shims come in sets of 5. I'll need a shim for each valve, correct?

I was going to ask you where you were finding them in sets of five, but I think I found it. Z1 sells shims for about the best price, and they are shown in groups of five in the catalog, but they are sold individually. You already have a shim for each valve, but you won't necessarily need a new one for each valve. Look at the clearances you have, look at the shims you have. You might be able to move shims around to minimize the number of shims you need to buy. But ... DON'T TURN THE ENGINE OVER IF ANY OF THE SHIMS ARE NOT INSTALLED.

Is it worthwhile getting a pair of calipers? Well, I'll probably need those for the float bowls on the carbs, come to think of it.

YES, it's worth getting calipers. Besides setting the float levels, they are also handy for measuring any shims that have had their sizes worn off. Many other uses, but those are probably the most-used ones for general maintenance.


.

[NES07DEZ]

what are the torque requirements on the 1982 850 L.
for the valve cover I am confuse in the manual it says 5 to six ft pounds.
and on some other threads it says 1.5 ounce pounds.
what is the difference and what is exsacly the foofpounds.

[willie]

Hey BassCliff...thanks for posting the link to realgaskets. what a score! and they're practically in my backyard. looks like Christmas has arrived early. Yee haw!
Willie in TN

[Nessism]

what are the torque requirements on the 1982 850 L.
for the valve cover I am confuse in the manual it says 5 to six ft pounds.
and on some other threads it says 1.5 ounce pounds.
what is the difference and what is exsacly the foofpounds.

6.5 ft-lbs if using the stock valve cover gasket, 15 in-lbs if using a Real Gasket

[Fenixgoon]

after reading the guide on valve adjustments, i have a few quick questions about measuring clearances and removing valve shims (if required):

1) when measuring the clearances, it seem like the cam lobes were in both vertical and horizontal orientations. Which one is correct, or does it need to be both to measure either the intake or exhaust valve clearances?

2) when removing shims, is a tappet depressor tool required? if so, are said tools acquired easily?


Thanks in advance