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Discussion Starter #1
Hi,

I've owned 3 previous DL1000s, got a fourth (the others are sold). I've done a ton of valve adjustments on them, so was a bit casual with this one. I removed the rear intake cam without actually checking to see it was aligned with the hashmarks, it was at TDC (R/T in view window). I realize I should have checked, marked it and taken photos, but I've done this so many times without issue I didn't think of it.
So I've removed the intake cam, replaced the shims, and I find absolutely no hashmarks on the cam at all. More over, despite the exhaust cam being in the correct position, it has hash marks that aren't lined up. I have not removed it yet, and they're way off?
The best I can think of doing is replacing the intake cam in the exact opposite position of the exhaust, as that is how they were when they came out, by appearance anyway. Does anyone have a better suggestion for making sure the intake cam is properly aligned that doesn't involve the hash marks on the end of the cam? Or why the exhaust seems to be not on the hashmarks despite it definitely being at TDC and on the correct stroke (Cams are in B position)?
Thanks for any suggestions. Yeah, I should have checked first. Downloading photos, will post as soon as I get 'em.
 

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I don't have your model service manual. Do you have one and are you using the exact manual procedure? My suspicion would be you are using the wrong marks on the rotor.
 

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Discussion Starter #3
Procedure

R/T is definitely visible through the rather awkward to access viewing port, which should be TDC, and as I said the cams were in the "B" position (as they are in the manual), so that should be good. The lack of hash marks on the end of the Intake cam is weird. Just looking for ideas to align it another way.
 

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Did you let the cam chain off the sprockets and let it just hang? I have read that doing that can let the chain off the bottom sprocket which messes things up a bit. I always zip tie the chain to one sprocket, make a mark on both sprockets and chain, tension chain up with a bungie when removing one sprocket at a time so I don't get lost in the forest.

So neither sprocket has any marks...on either side? is this an Iraqi DL560?? ;)
 

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Caution!

At least on my 2002 DL1000, the R/T mark is only used for measuring clearance (on the rear cylinder). The F/T mark should be used for aligning the camshafts, on both the front and rear cylinders. (And F/T should be used for measuring clearances on the front cylinder too.)

And yes, I agree that this is pretty insidious.
 

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Are you sure the cams are OEM and not aftermarket or from another Suzuki model?
 

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Discussion Starter #10
I am not sure the cams are original, I kind of suspect what you say is correct Tac Pro. The manual I have does say to align it when the R/T is showing, so I didn't do it at the F/T but am about to do the front so I'll see if that helps, but as I said, there's no hash marks on the intake cam, so I'll only be able to see if the rear cam aligns properly. I'm afraid a video won't help, other than I should have manually marked the cams before removing them, just never had to previously on other Stroms, but I won't make that mistake in the future.
 

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To remove and install the rear cams you must be on the F/T marks. The R/T marks are only for checking clearances. Post up some pictures of it.
 

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Discussion Starter #12
Jim,

My problem is there is no hashmarks on the intake came, and I'm wondering if there is another way to align it. I've had a few people look just to see if I'm blind and they are very faint, but no luck. There are pictures on the first page. Thanks.
 

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Discussion Starter #14
Blaustrom, all the other cams have markings. I think I have it figured out, I know where the cam should be at R/T, and I've found a ton of photos where you can see where the cam lobe is in relation to the hash mark, I can count gear teeth from the edge of the lobe, so I think I've found the right spot, and the cam appears correct when at R/T, in the B position, so I think I'm good. Thanks for everybody's help, if I do this again I'll score the cam with a dremel, it's marked with pen now.
 
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