Suzuki TLS/TLR

[Gixxerthou]

How to change shims

Note: Once Cams are removed do not rotate engine, only rotate as neccessary with cams locked down and only work on one cam at any time so alignment of timing is not disturbed.

Check you have correct clearances for the model of bike.

This task was carried out on a TLR and openings are:

Inlet valves 0.10 to 0.20

Exhaust valves 0.20 to 0.30

Sometimes shims can be swapped around to prolong usage, simple mathematics and taking your time will help you carry this task correctly. Shims can be purchased in half a thou (0.05) sizes minimum to reduce over sized clearences. If your slightly baffled with the size you need, write down the clearences you have for the shims to be replaced and go to the local dealer with the shim or shims and they will measure them with a micrometer for you to order the new sizes required.

IF YOU DONT KNOW WHAT A FEELER GAUGE IS DON'T ATTEMPT THIS YOURSELF!

Remove tank, plastics, seats, radiator so access to the cylinder heads are possible and remove head covers and spark plugs.

Check clearences between cam lobe and shim using a feeler guage to remove cams for replacement of shims, firstly paint a mark to the side of the cam wheels level with the top of the engine casting to ensure re-alignment after removal is successfull.

Carefully remove cam bracket covers ensuring not to drop the anti slip plate bearings that are seated to the casting,

(View when cams are removed)

Lift out cam and you may find some of the slip bearings are not there, dont panic as for a strange reason Suzuki seem not to bother installing all possible bearings, just check none have dropped on the head and put cam in a clean place.

Remove shim by pulling them upwards, a handy tool to have is a rubber sucker as shown below to remove the shims as they are well fitted and slippy. (pinch one from a kids "bow n arrow" set)

Now replace shims with required new items and assembley is in reversal order of this page, firstly making sure you align the painted lines you made on the cam wheels with the engine case.

DON'T forget to use threadlock for the cam bracket cover bolts.

Originally submitted by MadManc U.K.

Copyright The Thumperzone 2008