Adjusting valve clearances (Suzuki DRZ 250, 1996-2007) [Information for owner: Maintenance]

The valve clearance is adjusted by replacing the shims with thicker or thinner ones.

Remove the intake and exhaust camshafts (section 3-9).

Remove the pusher and washer by hand or with a magnet (section 3-22).

Check the numbers on the shim. These numbers indicate the thickness of the washer, as in the picture on the right.

Select a washer that will provide the required clearance. There are 21 standard sizes of washers, thickness from 1.20 to 2.20 mm in increments of 0.05 mm. Install the selected washer (1) on the valve stem with the number facing the pusher. Before installing the washer, measure it with a micrometer to ensure the correct size. To select washers, use the selection table.

Note.

Apply molybdenum grease to both sides of the washer before installation.

When installing the washer, make sure that the number on the washer faces the pusher.

Attention! Install the camshafts according to the instructions. (section 3-59 to 3-61).

After installing the washers and camshafts, rotate the crankshaft so that the camshaft cams press on the tappets (this will allow the grease to be squeezed out from the contact points and allow for correct measurements). Rotate the crankshaft and recheck the clearance to ensure it is within specifications.

Reinstall the cylinder head cover. (section 3-62).

Washer selection table (inlet)

WASHER No (12892-05С00-ХХХ)

WASHER SET No (12800-05820)

How to use this table:

I. Measure the clearance on a cold engine.
II. Measure the thickness of the existing washer.
III. Compare the gap in the vertical column with the size of the existing washer in the horizontal column.

Example:

The valve clearance is 0.23 mm.
The thickness of the existing washer is 1.70 mm.
The washer to use is 1.8mm.

Washer selection table (release)