2003 Suzuki w/ bad engine... Any advice?

**greg0187** · 02-16-2011, 12:13 PM

After going back and looking at some of your pics (hard to tell for sure) Im guessing you wont get any clearance no matter what the position is. The intake cam lobes look shiny all the way around like they are constanly riding on the shim whereas the exhaust does not.

**fupabox** · 02-16-2011, 03:34 PM

I think you are correct in assuming that combustion chamber deposits would cause a loose instead of a tight clearance...I think I mis-stated what I meant by carbon build up in the head..I was referring to the coked/burnt oil on all the internal surfaces..it may be built up under the lifters as well causing the loss in clearance..it definitely looks as though the engine has missed a few oil changes or idled a lot..hopefully not stretched valve stems.shims generally have a tighter clearance than regular adjustable rockers inorder to ensure the shims remain in place. Is there any scoring on the shims ?

**DYNOBOB** · 02-16-2011, 07:15 PM

No clearance at any point. I'm going to pull the intake cam and see what it leaks then and what shims are in there now. The problem is if you cant get a gauge in you cant figure out what size shim you need. I guess you put in the thinnest shim they make and see where you are.

I wouldn't say the shims or lobes look abnormally worn. Can valve stems stretch?

Bob

**fupabox** · 02-16-2011, 11:09 PM

I know they can stretch on high rpm street bikes...so I guess these little engines would semi-qualify in that category ..Although myself I have never had a stretched valve stem(serious knocking on wood..don't upset the engine gods) My bet is still build on up under the shim cups and on the tops of the spring retainers

**DYNOBOB** · 02-23-2011, 10:20 PM

Today I pulled the cams and did another leakdown. All cylinders now below 20%. Pulled the shims/buckets, a lot of oil crud under the buckets. Cleaned everything, recorded shims, put together. Still can't get a gauge in the intakes. Going to order the thinnest shim avail (about 12 thou thinner) and see what happens. Hoping they give me at least 7-9 thou clearance.

**DYNOBOB** · 02-26-2011, 10:14 PM

Some pics.

**fupabox** · 02-26-2011, 11:06 PM

wow..that poor little truck definitely missed a few oil changes...has the cleanout given you any clearance?? oops..never mind..the answer is in the previous post still

**DYNOBOB** · 03-02-2011, 07:50 PM

Installed the new shims and got correct valve clearance back. Compression is now around 200psi on all cylinders. Waiting on new water pump to put it back together. Leaving for BikeWeek Friday so it will be a couple weeks before it's running.

Thanks to everyone for your input and links to manuals.

Bob

**greg0187** · 03-03-2011, 07:53 AM

Who did you end up sourcing shims from? Expensive? I heard that they can be a bit overpriced for some vehicles. Recommend to the owner he sell it.

**DYNOBOB** · 03-17-2011, 10:18 PM

I ordered the shims and special tools from the local Jacobson/Cushman Turf dealer. Shims were between $10-15 each. The killer was the special tools needed to remove the shims w/o pulling the cams...$377.00 for two little pieces of machined metal you can hold in the palm of your hand. Without them you have to hang the motor, remove the lower x-member, front drive shaft, oil pan, harmonic bal and front timing chain cover to pull the cams...

I got the truck put back together yesterday and it started up like a new car. Runs & idles perfect and has great power. Waiting on an air filter and new water pump(back ordered) and it will return to owners. Finally Supra is back in its place in the garage

Now I can get some stuff done on my truck before next trip to TN Apr 1st...

Bob

**fupabox** · 03-17-2011, 10:50 PM

Glad it all worked out for you..good job

**greg0187** · 03-18-2011, 09:25 PM

So... They are expensive. What part of TN this time?

**DYNOBOB** · 03-18-2011, 09:29 PM

Norris/Coal Creek Rec Area again. You ever been there?

**greg0187** · 03-18-2011, 09:47 PM

No i haven't. I heard its beautiful out there though. parents looked at some property on the lake there but down here you don't always get year round water. Im usually running around the cookville area. Got approx 5000 acres to run around on in white county up on bon air mountain.

**DYNOBOB** · 04-01-2012, 11:36 AM

UPDATE: ONE YEAR LATER...

The little Suzuki has quit running again. Picked it up Fri and checked the compression. Now at 64,120,175psi. All were near 200psi after the repairs last year. Haven't checked the valves yet but I suspect the intakes are tight again. It seems like it should run w/ 120 and 175 compression though...

Does anyone have thoughts on where to source a quality reman or used head? I've called Jacobsen/Cushman but they only sell the head in individual parts.

.