Suzuki C50/C800 valve adjustment procedure tips

Member

This is not a complete guide on lining up the timing etc, its more to share my findings and how I did it.

Things to remove:

Tank
Gauge cluster
Seats
Air filter and air filter housing
Intake pipe from air filter housing to throttle body
Both side plastic cover panels
Both neck plastic cover panels
Rear left side PAIR valve metal pipe
Throttle body (optional, see guide on rear jug)

Valve adjustment tool - my method.
1 x aluminium flat bar. Screw in and glue two Square Drive Robertson # 2 size. Have one at a 45 degree angle, and one normal (see pic)
1 x aluminium oblong bar. Screw in and glue a single Robertson # 2 size. TAPE SOME STRING TO IT IN CASE YOU DROP IT.
1 x Robertson screw wrapped in gorilla tape and with string. I used this to 'finger tighten' the adjusters in order to do the JPaige method.

Suzuki C50/C800 valve adjustment procedure tips ODRC5Zy

Suzuki C50/C800 valve adjustment procedure tips ODRC5Zy

Suzuki C50/C800 valve adjustment procedure tips YhYAYyu

Suzuki C50/C800 valve adjustment procedure tips 2eUTMLv

Findings on my 20,000 mile bike - no previous history of valve adjustment

Method: JPaige - 90 degree from finger tight plus a few degrees more for exhaust. Approx 55 degrees for intake. Then checked gap with feeler gauges.

Front jug:
Intakes: Both too tight. Adjusted so 0.05mm feeler fits, but 0.06mm does not fit - looser end of the range
Exhaust: Both too tight. Adjusted so 0.09 feeler fits, but 0.10 does not fit.

Rear jug:
Exhaust both too loose. This was surprising. 0.10mm fit, but 0.12 did not. Adjusted so 0.09 fit.
Intake: In spec but on the tighter side, adjusted so 0.05 fit but 0.06 did not.

Change plugs while you're at it, may as well.

Quite surprised at how the front jug was too tight across the board but the rear jug had loosened with time.

Easiest adjustments: Front jug intakes are very easy to access. Front exhaust aren't bad either.

Hardest: Rear jug intakes by far. You can remove the entire throttle body for better access but I managed without. Rear jug exhaust isn't too bad to access really.

Fired up and its ticking away nicely. To be honest it never lost that sewing machine sound to begin with, it doesnt sound much different to me, however i'm running V&H Cruzers which mask it a bit.
Hope this helps.

Valued Member

excellent write up to what can be a bit daunting as regards to rear cylinder, :thumup:really good to have this to reference when time comes.

Member

Thanks. Over on the US forums they make it sound next to impossible but its really not that bad, even therapeutic if you do it out in the sun in a quiet environment.
By the way the gaps are in inch not mm thats my mistake. E.g. 0.09 inch, NOT 0.09mm

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