2004 Volusia 800 Correct valve clearance?

179 Views 7 Replies 6 Participants Last post by bry, 15 d ago

dwood1000

Discussion Starter · 16 d ago

I have a 2004 Volusia 800. I have been reading different articles and manuals on valve clearance. Seems to be some confusion. Some manuals say Intake - .003 - .005 and Exhaust - .007 - .009.

But, my Clymer manual says intake .008-.013 and Exhaust .017-.022
Which is the correct setting?

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Rob 61

· #2 · 16 d ago

I'm not sure on the clearance, but I think Clymer has you rotating the engine the wrong direction. Someone who knows should pop in.
Welcome from New Mexico

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Whiskey

· #3 · 16 d ago

Welcome from Kennesaw GA!

I don't have a Volusia service manual, but the valve clearance should be the same as the Boulevard.

Suzuki Service Manuals - Google Drive

drive.google.com

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Skrapiron

· #4 · 16 d ago

The Clymer manual is giving the valve clearance in both METRIC and IMPERIAL measurements.

.008-.013 and .017-.022 is in MILLIMETERS
.003 - .005 and .007 - .009 is in INCHES.

Do not confuse the two.

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dwood1000

Discussion Starter · #5 · 15 d ago

Skrapiron said:
The Clymer manual is giving the valve clearance in both METRIC and IMPERIAL measurements.

.008-.013 and .017-.022 is in MILLIMETERS
.003 - .005 and .007 - .009 is in INCHES.

Do not confuse the two.

I am glad you solved that confusion! I will be checking my valves this weekend.
Thanks for the help.

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HCosta

· #6 · 15 d ago

dwood1000 said:
I have a 2004 Volusia 800. I have been reading different articles and manuals on valve clearance. Seems to be some confusion. Some manuals say Intake - .003 - .005 and Exhaust - .007 - .009.

But, my Clymer manual says intake .008-.013 and Exhaust .017-.022
Which is the correct setting?

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Skrapiron

· #7 · 15 d ago

Unit of measure is expressed in MM first and Inches in parentheses.

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bry

· #8 · 15 d ago

Almost anything you want to know should be in this pinned post

How to guide: Adjusting your valves 101 with pics and vid

Here’s another tutorial for those looking to save some money by adjusting their own valves. Notice: This valve adjustment procedure was performed on a 2002 Suzuki Volusia with naked jugs (i.e. de-paired and de-filtered). Having a pair valve and/or air cleaner installed will require the removal...

www.volusiariders.com

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