Project Organized By:

Yermo

PROJECT: Mileage 10599 - Oil Change Valves Cover Clutch grommet oil leaks

This is an open project.
This project is ongoing.

On Bike:

DR
2004 Suzuki DR650SE
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Yermo
3 years ago
I placed an order with ProCycle for:

Factory shop manual
An additional set of feeler gauges
Better valve adjustment tool. 

We'll see how long it takes to get here.
Yermo
3 years ago
The Dunlop Trailmax Mission tires made a much better impression on me than I was expecting.

The bike was surging a bit but then again the gas in the tank is over a year and a half old.

I would like to find a way to improve the use of shop supplies (I use way too many gloves and paper towels) in addition to becoming a bit more efficient. It seems to me like these projects take many more hours than they "should" or maybe "could". 
Yermo
3 years ago
Need: 

9 mil extra large nitrile gloves. 

No Mar tire lubricant
Photo #165871
Yermo
3 years ago

(We probably have enough for one or two more tire changes.) 
Yermo
3 years ago
Yermo
3 years ago
Done at midnight.
Yermo
3 years ago
Tires came iff easily enough but the new front tire is putting up a huge fight.

Photo #165864
Yermo
3 years ago

Yermo
3 years ago
#tools needed:

Better valve adjustment tool for the DR.

2nd set of feeler gauges for the DR. 
Yermo
3 years ago
Intake valves are super loose but we are unable to get a full sized feeler gauge in there to measure the existing gap.

Fortunately, I remembered that I had the dedicated procycle feeler gauges in my DR toolkit along with the adjuster tool.

The sizes on the procycle tool do not match the gap values in the book.

Intake:
tool: .10 .13
book: .08 .13

Exhaust:
tool:.15 .20
book: .17 .22
Yermo
3 years ago
buffalo, I got some more work done. The oil seals and clutch lever seal (what ever it's called) have been replaced.

As it turns out there was no need to remove the right hand cover. The clutch lever seal needs to be picked out as there is no access to it from the inside.
Photo #165093
Yermo
3 years ago

Photo #165082
Yermo
3 years ago

Photo #165080
Yermo
3 years ago

Photo #165076
Yermo
3 years ago

So that cost me a bit of time. I had to reuse the cotter pin for the rear brake lever but it was in pretty good shape. I put a new cotter pin in for the rear master cylinder linkage. 

At this point all that's left is valve adjustment, plugs, and tires.

See the photos tab.
Yermo
3 years ago
buffalo, I have to look. If I remember I have a clutch cover gasket that I got when I did the NSU switch fix on my bike.

I don't think I'm going to get anything done on the bike today since I didn't sleep. I hope to get back to it tomorrow. Thanks for dropping off the seal. 
buffalo
3 years ago
Looks like I actually already have the seal--I'd just forgotten about it. The only bit missing now is the clutch cover gasket--and that might come off intact.
buffalo
3 years ago
I believe the O-ring oil seal that *should* be in the parts bag should be correct for the oil pipe going into the head. As for the valve cover itself, it doesn't have a gasket--It's sealed with liquid gasket sealant. I can order the valve adjustment cover gaskets if they're leaking. I've read that they should be changed every other valve adjustment, which should roughly be about every 16000 miles. Thanks for all the work you've put in today!
Yermo
3 years ago
Timing cover successfully removed. It was /really/ on there and was significantly more difficult to remove than the one on my bike. 

Timing inspection port cover came off without issue.

Oil drained. Oil Filter Replaced.

I held off removing the clutch cover since the seal is still on order. 

I removed the tank and inspected the top of the engine. There are two oil leaks we need to address: 

We are going to need the gaskets for both valve adjustment inspection caps, or whatever they are called. (These are the small covers, not the whole valve cover.)

https://www.bikebandit.com/oem-parts/detail/suzuki/1117...;

Sadly BikeBandit is way too slow. 

Photo #165017
Yermo
3 years ago

.The oil line heading into/out of the valve cover is leaking really badly. I did not take it off to see if the seals we have are the ones for this. If not, we will need it

Photo #165022
Yermo
3 years ago

Photo #165021
Yermo
3 years ago

. There's another leak that I cannot tell where it's coming from so my plan is to make sure the valve cover bolts are torqued to the correct values. 
Photo #165018
Yermo
3 years ago

I spent quite a bit of time cleaning the top of the engine as well as I could so that we'll be able to see if replacing the seals addresses the oil leak and, just as a matter of principle. "If you don't clean your parts, you're just an amateur." Tom Cutter once told me. I've taken that to heart. 

My plan is to at least adjust the valves and replace the spark plugs tomorrow. Once we get the clutch seal in I'll do that. 

buffalo, if you like  I can order the seals we need.