Cylinder head removal - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum

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Old 03-15-2010, 07:50 AM   #1 (permalink)
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Default Cylinder head removal

Hi all

'07 M50. I'm in process of removing the read cylinder head (in order to take out *something* that fell into the cylinder through the spark plug hole ), and I'm kind of stuck trying to understand the procedure - specifically, this part:

"After unlocking the ratchet, push the cam chain tension adjuster rod fully. Insert the special tool between the ratchet and the adjuster body." (Page 3-14 of the service manual).

I've read on the forum that no special tools are really required to do this, one can manage with a small screwdriver.

Can someone who have done this before, point me out how to unlock the **** thing? What to push, where to insert the screwdriver etc. Below is the picture of the cylinder in its current state.

Thanks!

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Old 03-15-2010, 08:48 PM   #2 (permalink)
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Are you sure that you can't get it back out the spark plug hole? They make some neat tools for retrieving lost items. Small pair of mechanical fingers, magnets, sticky ended flexi rods, etc.....
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Old 03-15-2010, 11:22 PM   #3 (permalink)
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yeah i would get me a small magnet before i tore it apart.
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Old 03-16-2010, 12:54 AM   #4 (permalink)
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Hi guys,

Thanks for your replies. I don't think a magnet will help because it's a piece of plastic chopstick that I need to take out. Worse yet, I can't even detect it inside the cylinder. I've been fumbling in the cylinder with a piece of wire for a couple hours but to no avail. Not a sign of it yet I know for sure it's there. I think maybe it got stuck to the ceiling of the cylinder. Anyway I'm just one step now from removing the head and it makes it especially frustrating that I'm stuck with that chain tensioner.
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Old 03-16-2010, 09:43 AM   #5 (permalink)
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I figured it out. The ratchet is the small thingie between the spring and the other thingie with the letter "R" on it (or probably "F" for the front cylinder, I'm not sure, I only dismantled the rear one). To get the tension adjuster rod out of the way for the head removal, one needs to push the ratchet down (towards "R") using a screwdriver for example, and then push the rod (which is inside the spring) fully down. To keep it in depressed position, something must be inserted between the ratchet and the base (marked with "R"). Suzuki recommends "09918-53810: Chain tensioner lock tool". I used a long 2mm Allen wrench. I don't recommend it though 'cause it has the potential to break easily, but I couldn't find anything suitable. Anyway that's how I did it. Hope it will help someone.
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Old 03-16-2010, 12:01 PM   #6 (permalink)
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Stop eating Chinese food around the bike!!!
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Old 03-16-2010, 05:07 PM   #7 (permalink)
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Haha I will

I should probably also stop following advices without putting any thought into what's being adviced. There wasn't clearly any sense to try and put something (in my case, a chopstick) into that cylinder to find TDC. The proper procedure for finding correct position for valve adjustment seems to be as described in this post http://www.volusiariders.com/viewtop...374579#1374579. Finding TDC alone doesn't give any indication as to whether it's TDC of the compression stroke or the exhaust stroke. Had I thought it through earlier, I couldn've saved me 10 days of not riding and about 20 hours of work
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Old 03-20-2010, 04:46 AM   #8 (permalink)
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so Levi, did you get it out?
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Old 03-20-2010, 09:48 PM   #9 (permalink)
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The easiest way to find TDC for a cylinder is to watch the valves..After the intake closes, it's at TDC.

Regardless, you don't need to be at TDC to set them. If you want to set the intakes, just rotate until the exhaust are compressed (which ensures the intake are open)..Then rotate and when the intake are compressed, exhaust are open!
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