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ENGINE 40
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1. ENGINE 3 49 PISTON RING TO GROOVE CLEARANCE J Using a thickness gauge measure the side clearances of the 1st and 2nd rings If any of the clearances exceeds the limit replace both piston and piston rings Piston ring to groove clearance J Service Limit 1st 0 18 mm 0 0071 in A 2nd 0 15 mm 0 0059 in amp J Piston ring groove width Standard 1st 0 93 0 95 mm 0 0366 0 0374 in 4 i J 1 55 1 57 mm o7 2 0 0610 0 0618 in 2 Lo 2nd 1 01 1 03 mm it 0 0398 0 0406 in 3 i Oil 2 51 2 53 mm 0 0988 0 0996 in 4 Piston ring thickness Standard 1st 0 86 0 91 mm 0 034 0 036 in 1 38 1 40 mm 0 054 0 055 in 2nd 0 97 0 99 mm 0 038 0 039 in I 09900 20803 Thickness gauge 09900 20205 Micrometer 0 25 mm J PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings measure the free end gap of each ring using vernier calipers Next fit the ring in the cylinder and measure each ring end gap using a thickness gauge If any ring has an excess end gap replace the ring J Piston ring free end gap Service Limit 1st 7 0 mm 0 28 in 2nd 8 1 mm 0 32 in 09900 20101 Vernier caliper l 3 50 ENGINE Piston ring end gap Service Limit ist 0 7 mm 0 03 in 2nd 0 7 mm 0 03 in 09900 20803 Thickness gauge PISTO
2. INCORRECT 3 102 ENGINE NOTE When checking the cam drive idle gear sprocket 4 position at its gear tooth top or root bring the eye level as shown in right illustration Tighten the cam drive idle gear sprocket shaft to the specified torque F cam drive idle gear sprocket shaft 40 N m 4 0 kgf m 29 0 Ib ft CAM CHAIN TENSION ADJUSTER Install the front cam chain tension adjuster to the following pro cedure NOTE The cam chain tension adjusters are distinguished by the shapes For No 1 Front cylinder 2 For No 2 Rear cylinder Turn in the cam chain tension adjuster bolt 3 fully ENGINE 3 103 Compress the cam chain tension adjuster rod fully by releasing the ratchet J From this position turn out the cam chain tension adjuster bolt until locking the cam chain tension adjuster rod 4 Now the cam chain tension adjuster is ready to install J NOTE Turn out the cam chain tension adjuster bolt while compress ay ing the cam chain tension adjuster rod s J p e Install the new gasket D CAUTION Use the new gasket to prevent oil leakage J 3 104 ENGINE e Install the cam chain tension adjuster as shown and tighten its mounting bolts to the specified torque Cam chain tension adjuster mounting bolt 10
3. 3 82 ENGINE Install the gearshift cover NOTE Fit the clamp to the bolt Apply grease to the oil seal lip before installing the gearshift cover AH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others GENERATOR ROTOR Install the cam drive idle gear shaft and cam chain w Degrease the tapered portion of the generator rotor assembly Degrease pey and also the crankshaft Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry Crankshaft Install the key e Install the generator rotor together with the starter drive gear Install the generator rotor bolt CAUTION Make sure that the one way clutch on the crankshaft is fitted into the generator rotor properly ENGINE 3 83 e While holding the generator rotor with the special tool tighten the bolt to the specified torque Generator rotor bolt 140 N m 14 0 kgf m 101 0 lb ft GB 09930 44541 Rotor holder PRIMARY DRIVE GEAR Install the thrust washer onto the crankshaft NOTE The chamfer side of the thrust washer faces the crankcase side e Install the key Install the primary drive gear assembly and washer NOTE The convex side of the washer 3 faces outside Fa Crankshaft Install the primary dr
4. Never reuse the bearing cap bolt Apply engine oil to the bearing cap bolts e Tighten the bearing cap bolts as following two steps Conrod bearing cap bolt Initial 35 N m 3 5 kgf m 25 5 Ib ft Final After tightening the bolts to the above torque tighten them 1 4 of a turn 90 Check the conrod movement for smooth turning CLUTCH CLUTCH DRIVE PLATES NOTE Wipe off engine oil from the clutch drive plates with a clean rag Measure the thickness of drive plates with a vernier calipers If each drive plate is not within the standard range replace it with anew one Drive plate thickness Standard No 1 2 92 3 08 mm 0 115 0 121 in No 2 amp No 3 3 72 3 88 mm 0 146 0 153 in 09900 20102 Vernier calipers 35 N m 3 5 kgf m 25 5 lb ft 35N m kgt m 25 5 lb ft Measuring thickness ENGINE 3 55 Measure the claw width of drive plates with a vernier calipers Replace the drive plates found to have worn down to the limit Drive plate claw width No 1 and No 2 Standard No 1 13 85 13 96 mm 0 545 0 550 in No 2 amp No 3 13 90 14 00 mm 0 547 0 551 in z 09900 20102 Vernier calipers CLUTCH DRIVEN PLATES NOTE Wipe off engine oil from the clutch driven plates with a clean rag Measure each driven plate for distortion with a thickness gauge and surface plate Replace driven plates
5. Conrod big end oil clearance Standard 0 040 0 064 mm 0 0016 0 0025 in Conrod big end I D specification I D specification 48 000 48 008 mm 1 8898 1 8900 in 48 008 48 016 mm 1 8900 1 8904 in O D specification 44 992 45 000 mm 1 7713 1 7717 in 44 984 44 992 mm 1 7710 1 7713 in 44 976 44 984 mm 1 7707 1 7710 in 09900 20202 Micrometer 25 50 mm ENGINE 3 53 Bearing thickness Color Part No Thickness 4 Gblar ene Green 1 476 1 480 mm 12164 16G00 0A0 0 0581 0 0583 in Black 1 480 1 484 mm 12164 16G00 0B0 0 0583 0 0584 in Brown 1 484 1 488 mm 12164 16G00 0C0 0 0584 0 0586 in Yellow 1 488 1 492 mm 12164 16G00 0D0 0 0586 0 0587 in CAUTION Bearing must be replaced as a set BEARING ASSEMBLY When fitting the bearings to the bearing cap and conrod be sure to fix the stopper part A first and press in the other end J Apply molybdenum oil solution to the crank pin and bearing surface Ey MotyBpENuM OIL SOLUTION 3 54 ENGINE When fitting the conrods on the crankshaft make sure that D codes of the conrods face each cylinder intake valve sides NOTE The shape of the conrod is not symmetrially right and left CAUTION
6. Apply SUZUKI SUPER GREASE to the O ring and install it AAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply THREAD LOCK to the thread and install the PAIR reed valve cover sa 99000 32050 THREAD LOCK 1342 ENGINE 3 35 CAMSHAFT CYLINDER HEAD CAUTION Be sure to identify each removed part as to its loca tion and lay the parts out in groups designated as No 1 No 2 Exhaust Intake so that each will be restored to the original location during assembly CAMSHAFT All camshafts should be checked for runout and also for wear of cams and journals if the engine has been noted as giving abnor mal noise vibration or lack power output Any of these condi tions may be caused by camshafts worn down or distorted to the service limit The camshafts can be identified by the engraved letter No 1 Front intake camshaft INF and I Intake No 1 Front exhaust camshaft EXF and E Exhaust No 2 Rear intake camshaft INR and I Intake No 2 Rear exhaust camshaft EXR and E Exhaust CAM WEAR Worn down cams are often the cause of mistimed valve opera tion resulting in reduced power output The limit of cam wear is specified for both intake and exhaust cams in terms of cam height H which is to be measured with a micrometer Replace camshaft if it wears
7. Do not drop the snap ring pin and washer into the crankcase Hold the generator rotor with the special tool 09930 44541 Rotor holder CAM DRIVE IDLE GEAR SPROCKET e While holding the generator rotor remove the cam drive idle gear sprocket nut J J J ENGINE 3 29 Insert a suitable bar into the holes of primary drive gears to align the teeth of scissors gears Remove the cam drive idle gear sprocket and cam chain Remove the key PRIMARY DRIVE GEAR e Hold the generator rotor with the special tool 09930 44541 Rotor holder While holding the generator rotor remove the primary drive gear nut CAUTION This bolt has left hand thread Turning it counter clockwise may cause damage Remove the washer e Remove the primary drive gear assembly 2 3 30 ENGINE Remove the key and thrust washer GENENRATOR ROTOR While holding the generator rotor with the special tool remove its bolt C 09930 44541 Rotor holder e Install the special tool to the boss Remove the generator rotor by turning the special tool while holding the generator rotor with the special tool 09930 30450 Generator rotor remover bolt Remove the key and starter driven gear 2 Remove the cam drive idle gear shaft 3 and cam chain ENGINE 3 31 GEARSHIFT e Remove the gearshift cover Remove the gasket
8. mark faces upward MAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others CAUTION Use the new O ring to prevent air from sucking through the joint e Apply engine coolant to the new O ring and install the water union 3 48 ENGINE CYLINDER PISTON INSPECTION CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Cylinder distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge CYLINDER BORE Inspect the cylinder wall for any scratches nicks or other dam age Measure the cylinder bore diameter at six places Cylinder bore Standard 98 000 98 015 mm 3 8583 3 8589 in PISTON DIAMETER Using a micrometer measure the piston outside diameter at 10 mm 0 4 in from the piston skirt end If the measurement is less than the limit replace the piston Piston diameter Service Limit 97 880 mm 3 8535 in 09900 20204 Micrometer 75 100 mm PISTON TO CYLINDER CLEARANCE As a result of the previous measurement if the piston to cylinder clearance exceeds the following limit replace both cylinder and piston Piston to cylinder clearance Service Limit 0 12 mm 0 0047 in
9. CONROD CRANK PIN BEARING INSPECTION Loosen the bearing cap bolts and tap the bearing cap bolt lightly with plastic hammer to remove the bearing cap J CAUTION Never reuse the bearing cap bolt Remove the conrods and mark them to identify the cylinder position e Inspect the bearing surfaces for any sign of fusion pitting burn or flaws If any replace them with a specified set of bearings J CONROD CRANK PIN BEARING SELECTION e Place plastigauge axially on the crank pin avoiding the oil hole at TDC or BDC side as shown in the illustration Tighten the bearing cap bolts as the specified manner 09900 22301 Plastigauge J 09900 22302 Plastigauge NOTE Never rotate the crankshaft or conrod when a piece of plasti gauge is in the clearance 3 52 ENGINE Remove the caps and measure the width of compressed plas tigauge with envelope scale This measurement should be taken at the widest part Conrod big end oil clearance Service Limit 0 080 mm 0 0031 in e If oil clearance exceeds the service limit select the specified bearings from the bearing selection table e Check the corresponding conrod D code number A 1 or Z Check the corresponding crank pin O D code number 1 2 or 3 stamped on the left crank web Bearing selection table Crank pin O D 8 1 a ae Green Black Brown Black Brown Yellow
10. 4 09930 73120 Starter torque limiter socket 2 Set the starter torque limiter to the special tools and vise as shown in the illustration e If the slip torque is not within the specification replace the starter torque limiter with a new one ENGINE 3 65 J STARTER CLUTCH DISASSEMBLY e Remove the starter clutch securing bolts by holding the rotor with the special tool 09930 44541 Rotor holder REASSEMBLY P3 e Install the starter clutch in the proper direction NOTE When installing the starter clutch onto the rotor face the flange side of the one way clutch to the rotor The arrow mark 8 must face to the engine side Apply engine oil to the starter clutch Apply THREAD LOCK SUPER to the bolts and then tighten them to the specified torque with the special tool Starter clutch bolt 25 N m 2 5 kgf m 18 0 Ib ft QJ 99000 32030 THREAD LOCK SUPER 1303 09930 44541 Rotor holder INSPECTION Install the starter driven gear to the starter clutch Check that the starter driven gear turns in the opposite direc tion of the arrow mark on the rotor while holding the gener ator rotor The gear never turns in the direction of the arrow J e If there is anything unusual replace the one way clutch J Inspect the starter driven gear bushing for any damage 3 66 ENGINE GEARSHIFT GEARSHIFT SHAFT GEARSHIFT ARM DISASSEMBLY Remove the fo
11. N m 1 0 kgf m 7 0 Ib ft e Release the cam chain tension adjuster by turning in its bolt NOTE Click sound is heard when the cam chain tension adjuster rod is released e Tighten the cam chain tension adjuster bolt 8 to the specified torque Cam chain tension adjuster bolt Front 23 N m 2 3 kgf m 16 5 Ib ft CAUTION After installing the cam chain tension adjuster check to be sure that the adjuster work properly by checking the slack of cam chain REAR CAM DRIVE IDLE GEAR SPROCKET e For the rear cam drive idle gear sprocket installation the crankshaft setting position must be set at the same position TDC of compression stroke as the front one The procedures are also the same as the front cam drive idle gear sprocket installation CAUTION When checking the cam drive idle gear sprocket posi tion remove the cam chain slack at the cam chain guide side by holding it by hand ENGINE 3 105 REAR CAM CHAIN TENSION ADJUSTER J Install the rear cam chain tension adjuster to the following proce dure Disassemble the rear cam chain tension adjuster J Compress the cam chain tension adjuster rod by releasing the J ratchet Install the new gasket 1 CAUTION J Use the new gasket to prevent oil leakage e Install the cam chain tension adjuster as shown and tighten its mounting bolts to the specified tor
12. Remove the push rod Remove the engine sprocket cover 40 Remove the speed sensor 4D Jd Remove the engine sprocket nut while depressing the brake pedal 3 6 ENGINE e Loosen the rear axle nut e Loosen the chain adjusters by loosening the lock nuts Remove the engine sprocket and washer Disconnect the engine ground lead wire D Remove the mufflers L amp R e Loosen the front exhaust pipe mounting bolts 9 e Remove the front exhaust pipe Remove the rear exhaust pipe Remove the oil cooler 8 C7 5 20 Disconnect the starter motor lead wire 9 and oil pressure switch lead wire ENGINE 3 7 3 8 ENGINE e After removing the pinch bolt 2 remove the engine mounting bolt 2 Remove the engine mounting bolt 2 e Remove the engine mounting nut 25 20 ENGINE 3 9 e Loosen the engine mounting thrust adjuster lock nut 09940 14990 Engine mounting thrust adjuster socket wrench e Loosen the engine mounting thrust adjuster 2 Loosen the pinch bolt 2 e Gradually lower the engine assembly by removing the bolts CAUTION Be careful not to damage the frame and engine when removing the engine from the frame 3 10 ENGINE ENGINE INSTALLATION Remount the engine in the reverse order of engine removal t Pay attention to the following points NOTE The engine mounting nuts are self loc
13. and Rear cam chain guide 3 38 ENGINE CYLINDER HEAD Remove the pin and O ring Remove the tappets and shims by fingers or magnetic hand e Using special tools compress the valve spring and remove two cotter halves from the valve stem 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers Remove the valve spring retainer and valve spring D Pull out the valve from the other side ENGINE 3 39 Remove the oil seals and spring seats 9 CAUTION Do not reuse the removed oil seals CYLINDER HEAD DISTORTION Decarbonize the combustion chambers Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several places indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylin der head Cylinder head distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE STEM RUNOUT Support the valve with V blocks as shown and check its runty with a dial gauge The valve must be replaced if the runout exceeds the limit Valve stem runout Service Limit 0 05 mm 0 002 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm VALVE HEAD RADIAL RUNOUT Plac
14. and dowel pins Draw out the gearshift shaft e Remove the gearshift cam plate 3 Remove the gearshift cam stopper Remove the engine sprocket spacer 5 3 32 ENGINE Remove the crankcase bolts Separator the crankcase into 2 parts right and left with the crankcase separating tool tox 09920 13120 Crankcase separating tool NOTE Fit the crankcase separating tool so that the tool arms are in parallel with the side of crankcase The crankshaft and transmission components should remain in the left crankcase half When separating the crankcase tap the end of the counter shaft with a plastic hammer e Remove the dowel pins ENGINE 3 33 e Remove the gearshift fork shafts gearshift forks 7 and J gearshift cam I Remove the countershaft and driveshaft e Remove the crankshaft 3 34 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD COVER DISASSEMBLY Be sure to identify each removed part as to its loca tion and lay the parts out in groups designated as No 1 No 2 Exhaust Intake so that each will be restored to the original location during assembly Remove the camshaft position sensor Remove the PAIR reed valve cover 2 INSPECTION e Inspect the PAIR reed valve for the carbon deposit e If the carbon deposit is found in the reed valve replace it with anew one REASSEMBLY
15. between 4th to 7th position from the clutch sleeve hub Set the numbers of driven plate to the standard specifications when replacing the driven plates with the new ones DRIVEN PLATE Factory setting No 1 driven plate Standard 7 pes 5 8 pcs No 2 driven plate Standard 2 pcs 1 4 pcs o DRIVE PLATE No 1 drive plate 8 pes No 2 drive plate 2 0mm 2 3mm No 3 drive plate a 0081 g ERN No 1 driven plate No 2 driven plate 2 8 mm 3 8 mm 3 8mm 0 11 in 0 15 in 8 0mm 0 15 in 0 31 in No 3 drive plate NOTE Apply molybdenum oil solution to shaft of clutch drive cam before installing Clean the excess oil firmly ENGINE 3 91 CLUTCH COVER J e Install the gasket and dowel pins CAUTION Use the new gasket to prevent oil leakage e Install the clutch cover I NOTE Set the impeller shaft end to the cam drive idle shaft NOTE Fit the clamp to the bolts Fit the dowel pin Apply engine coolant to the O ring e Install the water pump case 3 92 ENGINE e Install the starter idle gear spacer 3 and shaft NOTE Apply engine oil to the shaft e Install the bushings into the crankcase and generator cover NOTE Apply molybdenum oil solution to the inside of the bushings MoLyBDENUM OIL SOLUTION e Fit the washers onto the starter torque limiter e Ins
16. camshafts on cylinder head apply molybde num oil solution to their journals and cam faces Apply engine oil to the camshaft journal holders Ey MoLyBDENUM OIL SOLUTION Place the No 1 front camshafts intake and exhaust Align the engraved lines A on the camshafts so it is parallel with the mating surface of the cylinder head cover Check that the cam faces are located as shown e Install the dowel pins 3 108 ENGINE e Install the camshaft journal holders intake and exhaust e Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally Try to equalize the pressure by shifting the wrench in the above manner to fasten the shafts evenly NOTE Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly Each camshaft journal holder is identified with a cast on letters e Tighten the camshaft journal holder bolts to the specified torque Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 lb ft CAUTION The camshaft journal holder bolts are made of a spe cial material and much superior in strength compared with other types of high strength bolts Take special care not to use other types of bolts instead of these special bolts To identify these bolts each of them has a figure 9 on its head e Recheck the No 1 Front camshaft positions i
17. drive gear CAUTION The removed O ring must be replaced with a new one Remove the top drive gear bushing washer and 3rd 4th drive gears e Remove the snap ring with the special tool 09900 06107 Spring ring pliers Remove the 5th drive gear 7 and its bushing 3 58 ENGINE Driveshaft Remove the washer and 1st driven gear 2 Remove the 1st driven gear bushing washer and 5th driven gear Remove the snap ring with the special tool 09900 06107 Spring ring pliers Remove the washer 4th driven gear 7 and its bushing Remove the washer 3rd driven gear 0 and its busing 4 ENGINE 3 59 Remove the washer J e Remove the top driven gear 3 by removing the snap ring 09900 06107 Spring ring pliers Remove the snap ring with the special tool J 09900 06107 Spring ring pliers Remove the 2nd driven gear 5 its bushing 6 and washer D REASSEMBLY Assemble the transfer in the reverse order of disassembly Pay attention to the following points NOTE Always use new snap rings J Before installing the gears coat lightly engine oil to the shafts and gears CAUTION Never reuse a snap ring After a snap ring has been J removed from a shaft it should be discarded and a new snap ring must be installed When installing a new snap ring care must be taken not to expan
18. leakage Place the cylinder head covers on each cylinder head e Fit the gaskets to each head cover bolt CAUTION Use the new gaskets to prevent oil leakage After applying engine oil to the gaskets tighten the head cover bolts to the specified torque Head cover bolt 14 N m 1 4 kgf m 10 0 Ib ft SPARK PLUG e Install the spark plugs 09930 10121 Spark plug wrench set e Install the valve timing inspection plug ENGINE 3 113 D Apply engine oil to the new O ring and install the generator cover plug CAUTION Use the new O ring to prevent oil leakage STARTER MOTOR J Install the new O ring to the starter motor CAUTION Use the new O ring to prevent oil leakage Apply grease to the O ring AH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others e Install the starter motor NOTE Fit the clamp to the bolt e Install the thermostat
19. 3 60230 Journal bearing remover installer Set the special tool as shown to remove the crankshaft journal bearings NOTE Remove the crankshaft journal bearings in only one direction from inside to outside of each crankcase half e Gradually press out the bearing with the special tool by using the hand press CAUTION The removed bearings must be replaced with new ones NOTE Using the hand press is recommended to remove the crankshaft journal bearings However the crankshaft journal bearings can be removed by using with the following special tools 09924 84510 Bearing installer set 09924 74570 Final drive gear bearing remover installer e Set the specified crankshaft journal bearings to the special tool CAUTION Before setting the bearing apply enough engine oil to the special tool and bearings When setting the bearing align the bearing side with the engraved line A and also the bearing edge with the mating surface of the special tool 09913 60210 Journal bearing remover installer set or 09913 60240 Journal bearing remover installer NOTE Journal bearing remover installer 09913 60240 is included in Journal bearing remover installer set 09913 60210 e Tighten the special tool bolt to the specified torque Special tool bolt 23 N m 2 3 kgf m 16 5 Ib ft CAUTION Before installing the bearings lightly shave off t
20. 3 73 I CRANKCASE CRANKSHAFT BEARING CRANKCASE CRANKSHAFT BEARING INSPECTION e Inspect the crankshaft journal bearings for any damage If any replace them with a specified set of bearings e Inspect the crankshaft journal for any damage J Measure the crankshaft journal O D with the special tool Crankshaft journal O D Standard 47 985 48 000 mm 1 8892 1 8898 in 09900 20202 Micrometer 25 50 mm CRANKCASE CRANKSHAFT BEARING SELECTION Select the specified bearings from the crankcase bore I D code The crankcase bore I D code A B or C is stamped on vJ the inside of each crankcase half Bearing selection table I D code A I D specification A 52 000 52 006 mm Green 2 0472 2 0475 in 52 006 52 012 mm Bearing p 2 0475 2 0477 in Bick 52 012 52 018 mm 2 0477 2 0479 in Brown Bearing thickness Color code J Color Part No Thickness Green 1 996 1 999 mm 12229 06G00 0A0 0 0786 0 0787 in Black 1 999 2 002 mm 12229 06G00 0B0 0 0787 0 0788 in Brown 2 002 2 005 mm 12229 06G00 0C0 0 0788 0 0789 in CAUTION J Bearing must be replaced as a set 3 74 ENGINE CRANKSHAFT JOURNAL BEARING REPLACEMENT Use the special tool to replace the crankshaft journal bearings The replacement procedure is as follows 0991
21. 44 Paint the engraved line on the cam drive idle gear sprocket e Install the cam drive idle gear sprocket onto the front cylinder head and engage the cam chain on it Align the engraved line on the cam drive idle gear sprocket with the embossed line on the cylinder head e Install the cam drive idle gear sprocket shaft copper washer 3 and thrust washer 2 ENGINE 3 101 Check and correct the positions of the F T line on the gen erator rotor and cam drive idle gear sprocket CAUTION When checking the positions remove the cam chain slack at the cam chain guide side by holding the J cam drive idle gear sprocket by hand NOTE A Due to special valve train mechanism aligning of the three ele ments the engraved line embossed line and the gear tooth root on the cam drive idle gear sprocket can occur once every other rotation of crankshaft INCORRECT CORRECT CAUTION Root of tooth If the engraved line does not align the embossed J line O turn the crankshaft 360 1 turn to bring the F T line on the generator rotor to the index mark of the valve timing inspection hole again and reinstall the cam drive idle gear sprocket to the correct position as shown CAUTION Pull the cam chains upward or the chain will be caught between the crankcase and the cam drive sprocket when turning the crankshaft
22. ENGINE 3 1 CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE 3 2 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL ENGINE INSTALLATION ENGINE DISASSEMBLY J ENGINE TOP SIDE ENGINE BOTTOM SIDE ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD COVER CAMSHAFT CYLINDER HEAD CYLINDER PISTON INSPECTION CONROD CRANKSHAFT CLUTCH iniisa TRANSMISSION GEARSHIFT FORK PRIMARY DRIVE GEAR m STARTER TORQUE LIMITER STARTER CLUTCH GEARSHIFT CRANKCASE CRANKCASE CRANKSHAFT BEARING GENERATOR COVER CLUTCH COVER GEARSHIFT COVER ENGINE REASSEMBLY ENGINE BOTTOM SIDE ENGINE TOP SIDE 3 2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame Refer to the page listed in this section for removal and reinstallation instructions ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION Generator rotor 3 30 3 82 Gearshift 3 31 3 80 ENGINE RIGHT SIDE PARTS REMOVAL INSTALLATION Clutch cover 3 25 3 91 Clutch 3 25 3 86 Oil pump driven gear 3 28 3 86 Primary drive gear 3 29 3 83 Cam drive idle gear sprocket 3 28 3 84 Gear position switch 3 27 3 85 Oil sump filter 3 28 3 85 Oil pressure switch 3 67 3 67 Oil jet 3 68 3 68 and 95 ENGINE CENTER PARTS REMOVAL INSTALLATION Cylinder head cover 3 17 and 20 3 112 Cams
23. N ADJUSTER After loosing the spring holder bolt remove the cam chain tension adjuster Front cylinder head Nose FRONT CYLINDER HEAD e Remove the cam drive idle gear sprocket by removing its shaft copper washer and thrust washer 2 NOTE Do not the drop the thrust washer into the crankcase e Remove the cylinder head bolts and cam chain tensioner mounting bolt Remove the cam chain tensioner STARTER MOTOR e Remove the starter motor e Remove the cylinder head nut e Loosen the cylinder nuts Remove the oil cooler mounting bracket ENGINE 3 19 3 20 ENGINE Remove the cylinder head bolts e Remove the cylinder head NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally To identify each cylinder head mark the cylinder as the front and rear cylinder head uses the same part FRONT CYLINDER Remove the cylinder head gasket dowel pins 2 and cam chain guide 3 e Remove the cylinder NOTE Firmly grip the cylinder at both ends and lift it straight up If the cylinder does not come off lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose Remove the cylinder base gasket and dowel pins FRONT PISTON e Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase Remove the
24. N PIN AND PIN BORE Using a small bore gauge measure the piston pin bore inside diameter and using a micrometer measure the piston pin out side diameter If the difference between these two measure ments is more than the limits replace both piston and piston pin Piston pin bore I D Service limit 22 030 mm 0 8673 in 09900 20602 Dial gauge 1 1 000 mm 1 mm 09900 22403 Small bore gauge 18 35 mm Using a micrometer measure the piston pin outside diameter at three positions Piston pin O D Service Limit 21 980 mm 0 8654 in 09900 20205 Micrometer 0 25 mm CONROD CRANKSHAFT CONROD SMALL END I D Using a small bore gauge measure the inside diameter of the conrod small end Conrod small end I D Service Limit 22 040 mm 0 8677 in 09900 20602 Dial gauge 1 1 000 mm 1 mm 09900 22403 Small bore gauge 18 35 mm If the inside diameter of the conrod small end exceeds the limit replace the conrod ENGINE 3 51 CONROD BIG END SIDE CLEARANCE J Check the conrod side clearance by using a thickness gauge If the clearance exceeds the limit replace conrod or crankshaft Conrod big end side clearance Service Limit 0 50 mm 0 020 in J 09900 20803 Thickness gauge Conrod big end width J Standard 21 95 22 00 mm 0 864 0 866 in Crank pin width Standard 44 17 44 22 mm 1 739 1 741 in 09900 20205 Micrometer 0 25 mm
25. Visually inspect the gear teeth for wear and damage If they are worn replace the gear with a new one PRIMARY DRIVE GEAR DISASSEMBLY Disassemble the primary drive gear by removing the snap ring 09900 06107 Spring ring pliers Snap ring Spring washer Scissors gear Spring Primary drive gear PRIMARY DRIVE GEAR REASSEMBLY Set the springs into the grooves e Install the scissors gear 2 NOTE Align the hole of the primary drive gear with the hole of the scis sors gear e Install the spring washer not to cover the holes of the gears NOTE The convex side of the washer faces upward 3 64 ENGINE Install the snap ring completely with the special tool 09900 06107 Spring ring pliers CAUTION Never reuse a snap ring When installing a new snap ring care must be taken not to expand the end gap larger than required to slip a snap ring over the gear After installing a snap ring always insure that it is completely seated in its groove and securely fitted STARTER TORQUE LIMITER STARTER TORQUE LIMITER INSPECTION CAUTION Do not attempt to disassemble the starter torque lim iter The starter torque limiter is available only as an assembly Check the slip torque with the special tools Slip torque Standard 22 45 N m 2 2 4 5 kgf m 16 0 32 5 lb ft 09930 73110 Starter torque limiter holder
26. bdenum oil solution all around and along the full stem length without any break CAUTION When inserting each valve take care not to damage the lip of the oil seal EJ MoLyBDENUM OIL SOLUTION Color 3 46 ENGINE e Install the valve spring with the small pitch portion facing cylinder head A P s _ Paint Large pitch portion ao UPWARD T Put on the valve spring retainer and using the valve lifter a press down the spring fit the cotter halves to the stem end f and release the lifter to allow the cotter to wedge in 7 between retainer and stem Be sure that the rounded lip of EO the cotter fits snugly into the groove O in the stem end 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers CAUTION Be sure to restore each spring and valve to their origi nal positions e Install the tappet shim and tappet to their original position NOTE Apply engine oil to the shim and tappet before fitting them When seating the tappet shim be sure the figure printed sur face faces the tappet Apply engine oil to the O ring and install it ENGINE 3 47 Install the pin J INTAKE PIPE WATER UNION J Remove the intake pipe Remove the water union e When installing the intake pipe apply grease to the O ring NOTE UP
27. bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase Replace the bearing in the following procedure if there is any thing unusual Play 3 70 ENGINE Remove the oil seal retainer Remove the oil seal CAUTION The removed oil seal must be replaced with a new one e Remove the oil seal with the special tool 09913 50121 Oil seal remover CAUTION The removed oil seal must be replaced with a new one e Remove the bearing retainers ENGINE 3 71 I Remove the bearings with the special tool 09921 20240 Bearing remover set NOTE If there is no abnormal noise the bearing removal is not neces sary J Install the bearings with the special tool 09913 70210 Bearing installer set NOTE v The sealed side of the driveshaft bearing must face outside 3 72 ENGINE e Install the bearing retainers NOTE When installing the bearing retainers apply THREAD LOCK to the screws GZ 09900 32050 THREAD LOCK 1342 we e Install the oil seals with the special tool 09913 70210 Bearing installer set e Apply SUZUKI SUPER GREASE to the oil seal lip w MAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the oil seal retainer we _ ENGINE
28. bolts to the specified torque F Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 Ib ft CAUTION The camshaft journal holder bolts are made of a spe cial material and much superior in strength compared with other types of high strength bolts Take special care not to use other types of bolts instead of these special bolts To identify these bolts each of them has a figure 9 on its head e Recheck the No 2 Rear camshaft positions intake and exhaust Engraved line Engraved line No 2 Rear cylinder head lt lt FRONT ENGINE 3 111 e After installing the No 2 Rear camshafts rotate the genera a tor rotor 360 degrees 1 turn and recheck the positions of the camshafts CAUTION Be sure to check the positions of the F T line on J the generator rotor engraved line on the cam drive idle gears sprockets and the engraved line on the camshafts J FRONT gt No 1 Front cylinder TDC of compression stroke 3 112 ENGINE e Pour engine oil in each oil pocket in the front and rear cylinder heads CAUTION Be sure to check the tappet clearance CYLINDER HEAD COVER e Install the new gaskets to each cylinder head cover Apply SUZUKI BOND to the cam end caps of the gaskets as shown 99104 31140 SUZUKI BOND 1207B CAUTION Use the new gaskets to prevent oil
29. d cable guide OIL PUMP DRIVEN GEAR e Install the washer and pin e Install the oil pump driven gear by installing the snap ring wa 09900 06107 Spring ring pliers NOTE The boss of the oil pump driven gear faces crankcase side CLUTCH Install the thrust washer onto the countershaft NOTE The chamfer side of thrust washer faces crankcase side Install the needle bearing and spacer 2 onto the counter shaft Apply engine oil to them w ENGINE 3 87 e Install the primary driven gear assembly 3 onto the counter G v shaft NOTE When installing the primary driven gear assembly align the teeth of the primary drive gears by inserting a suitable bar to a the holes of them Be sure to engage the oil pump drive and driven gears pri mary drive and driven gears Install the thrust washer e Install the clutch spring support bolts to the specified torque Clutch spring support bolt 23 N m 2 3 kgf m 16 5 lb ft Install the clutch drive cam driven cam onto the clutch sleeve hub NOTE Align the punched mark on the clutch drive cam with J punched mark on the clutch driven cam Apply molybdenum oil solution to shaft of clutch drive cam amp before installing to the clutch sleeve hub D 73 90 J Install the clutch sleeve hub with the clutch drive cam and driven cam 6 Install the washer and clutch
30. d the end gap larger than required to slip the snap ring over the shaft J After installing a snap ring always ensure that it is completely seated in its groove and securely fitted 3 60 ENGINE e When installing a new snap ring pay attention to the direction of the snap ring Fit it to the side where the thrust is as shown in the figure CAUTION When installing the 3rd and 4th driven gear bushings on to the driveshaft align the shaft oil holes A with the bushing oil hole gt Thrust Sharp edge 000000000000000 3 62 ENGINE GEARSHIFT FORK GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge check the gearshift fork clearance in the groove of its gear The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action Shift fork to groove clearance Service Limit 0 50 mm 0 020 in 09900 20803 Thickness gauge 09900 20102 Vernier calipers If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Shift fork groove width Standard 5 0 5 1 mm 0 197 0 201 in Shift fork thickness Standard 4 8 4 9 mm 0 189 0 193 in Checking thickness ENGINE 3 63 PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR INSPECTION
31. e between the cylinder head and the thrust washer Cam drive idle gear sprocket thrust clearance Standard 0 15 0 29 mm 0 006 0 011 in Cam drive idle gear sprocket shaft 40 N m 4 0 kgf m 29 0 Ib ft 09900 20803 Thickness gauge ENGINE 3 45 If the thrust clearance exceeds the standard range adjust the thrust clearance by the following procedures e Remove the thrust washer and measure its thickness with a micrometer e Change the thrust washer with the other washer if the thrust clearance is incorrect e Perform the thrust clearance measurement described above once again checking to make sure it is within standard GS 09900 20205 Micrometer 0 25 mm Unit mm in pico Thrust washer thickness A Blue 1 38 1 42 09181 15182 0 054 0 056 Yellow 1 28 1 32 09181 15181 0 050 0 052 Light blue 1 18 1 22 09181 15176 0 046 0 048 Light green 1 08 1 12 09181 15172 0 043 0 044 Brown 0 98 1 02 09181 15166 0 039 0 040 J mark 0 88 0 92 09181 15164 0 035 0 036 CYLINDER HEAD REASSEMBLY e Install the valve spring seats e Apply oil to each oil seal and press fit them into position with the valve guide installer 09916 44910 Valve guide remover installer CAUTION Do not reuse the removed oil seals Insert the valves with their stems coated with moly
32. e the dial gauge at right angles to the valve head face and measure the valve head radial runout If it measures more than the limit replace the valve Valve head radial runout Service Limit 0 03 mm 0 001 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm 3 40 ENGINE VALVE FACE WEAR Visually inspect each valve for wear of its seating face Replace any valve with an abnormally worn face The thickness T decreases as the wear of the face advances Measure the thickness and if the thickness is found to have been reduced to the limit replace it Valve head thickness T Service Limit 0 5 mm 0 02 in 09900 20101 Vernier calipers VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Measure the valve stem deflection in two directions X and Y perpendicular to each other by positioning the dial gauge as shown If the deflection measured exceeds the limit see below then determine whether the valve or the guide should be replaced with a new one Valve stem deflection IN amp EX Service Limit 0 35 mm 0 014 in L 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM WEAR If the valve stem is worn down to the limit as measured with a micrometer where the clearance is found to be in excess of the limit indicated replace the valve if the stem is within the limi
33. er pump case WATER PUMP DISASSEMBLY C7 5 14 CLUTCH e Remove the clutch cover Remove the gasket and dowel pins Hold the generator rotor with the special tool 09930 44541 Rotor holder e While holding the generator rotor remove the clutch spring set bolts and springs diagonally Remove the pressure plate 2 3 26 ENGINE Remove the thrust washer bearing and clutch push piece Remove the clutch push rod e Remove the clutch drive and driven plates Remove the wave washer 7 and wave washer seat 8 e Unlock the clutch sleeve hub nut While holding the clutch sleeve hub with the special tool remove the clutch sleeve hub nut GB 09920 53740 Clutch sleeve hub holder ENGINE 3 27 Remove the washer Remove the clutch drive cam 0 clutch driven cam and clutch sleeve hub NOTE The clutch drive and driven cams should be replaced as a set Remove the thrust washer 3 J e Remove the primary driven gear assembly 49 Remove the needle roller bearing spacer 6 and thrust washer GEAR POSITION SWITCH e Remove the gear position switch J Remove the gear position switch contacts and springs 2 3 28 ENGINE OIL SUMP FILTER Remove the oil sump filter OIL PUMP e Remove the oil pump driven gear by removing the snap ring 09900 06107 Spring ring pliers e Remove the pin and washer NOTE
34. f the crankshaft the driveshaft and the countershaft rotate smoothly e Install the engine sprocket spacer 1 onto the driveshaft CAUTION Use the new O ring to prevent oil leakage NOTE The grooved A side of the engine sprocket spacer faces crankcase side Apply grease to the oil seal lip and O ring MAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others GEARSHIFT e Install the gearshift cam stopper its bolt 2 washer 3 and return spring NOTE Apply a small quantity of THREAD LOCK to the gearshift cam stopper bolt and tighten it to the specified torque GZ 99000 32050 THREAD LOCK 1342 Gearshift cam stopper bolt 10 N m 1 0 kgf m 7 0 Ib ft J J J ENGINE 3 81 Check the gearshift cam stopper movement e Make sure that the gear position is neutral e Install the gearshift cam stopper plate after aligning the gear shift cam pin with the gearshift cam stopper plate hole 8 e Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque Gq 99000 32050 THREAD LOCK 1342 F Gearshift cam stopper plate bolt 10 N m 1 0 kgf m 7 0 Ib ft Assembly the geafshift shaft gearshift arm e Install the gearshift shaft as shown Install the dowel pins and gasket CAUTION Use new gasket to prevent oil leakage
35. g bolt Remove the cam chain tensioner e Remove the cylinder head nuts Remove the cylinder head nut Loosen the cylinder nuts Remove the cylinder head bolts Remove the cylinder head NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally To identify each cylinder head mark the cylinder as the Front and Rear REAR CYLINDER e Remove the cylinder head gasket dowel pins 2 and cam chain guide e Remove the cylinder NOTE Firmly grip the cylinder at both ends and lift it straight up If the cylinder does not come off lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose Remove the cylinder base gasket and dowel pins REAR PISTON Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase Remove the piston pin circlip e Remove the piston by driving out the piston pin NOTE Scribe the cylinder number on the head of the piston ENGINE 3 23 3 24 ENGINE ENGINE BOTTOM SIDE OIL FILTER Remove the oil filter with the special tool 09915 40610 Oil filter wrench Remove the generator cover Remove the gasket and dowel pin Remove the starter torque limiter and starter idle gear 3 Remove the bushings from the crankcase and generator cover ENGINE 3 25 Remove the wat
36. gauge 18 35 mm Camshaft journal O D Standard IN amp EX 21 972 21 993 mm 0 8650 0 8659 in 09900 20205 Micrometer 0 25 mm ENGINE 3 37 CAMSHAFT RUNOUT Measure the runout with a dial gauge Replace the camshaft if the runout exceeds the limit Camshaft runout Service Limit IN amp EX 0 10 mm 0 004 in 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm CAM GEAR AND AUTOMATIC DECOMP Inspect the cam gear teeth for wear and damage Inspect the automatic decomp for damage and smooth opera tion If there are unusual replace the camshaft assembly and cam chain as a set CAUTION Do not attempt to disassemble the cam gears and automatic decomp assembly They are unserviceable CAM CHAIN TENSION ADJUSTER The cam chain tension adjusters are maintained at the proper cam chain tension automatically Unlock the ratchet and move the push rod in place to see if it slides smoothly If any stickiness is noted or ratchet mecha nism is faulty replace the cam chain tension adjuster assembly with a new one Front cam chain tension adjuster 2 Rear cam chain tension adjuster CAM CHAIN GUIDE AND CAM CHAIN TENSIONER Check the cam chain guide and tensioner for wear and damage If they are found to be damaged replace them with the new ones Front cam chain tensioner 2 Rear cam chain tensioner Front
37. h 36 mm 1 4 in For 5th driven gear width 40 mm 1 6 in For 6th driven gear width A 40 mm 1 6 in Painted ENGINE 3 79 e Fit the dowel pins Apply grease to the O ring and install it MAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others CAUTION Use the new O ring to prevent oil leakage e Clean the mating surfaces of the left and right crankcase halves Apply SUZUKI BOND to the mating surface of the left crank case 99104 31140 SUZUKI BOND 1207B NOTE Use of SUZUKI BOND is as follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply any bond to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film 3 80 ENGINE e When securing the right and left crankcase halves tighten each bolt a little at a time to equalize the pressure Tighten all the securing bolts to the specified torque values Crankcase bolt M6 11 N m 1 1 kgf m 8 0 Ib ft M8 26 N m 2 6 kgf m 19 0 lb ft CAUTION Do not drop the O ring into the crankcase when assembling the right and left crankcase halves NOTE After the crankcase bolts have been tightened check i
38. haft 3 18 and 21 3 106 Cylinder head Front 3 19 3 96 Cylinder Front 3 20 3 95 Piston Front 3 20 3 93 Cam chain tension adjuster 3 18 and 22 3 102 and 105 Oil filter 3 24 3 93 Starter motor 3 19 3 113 t ENGINE 3 3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame wash the engine using a steam cleaner Engine removal is sequentially explained in the following steps Reinstall the engine by reversing the removal procedure Remove the under cowling 76 5 Drain engine oil 72 14 Drain engine coolant 772 17 Remove the seat 476 7 Disconnect the battery lead wire Remove the radiator 775 5 Lift and support the fuel tank 474 65 Remove the air cleaner C7 4 75 Remove the throttle body 7 4 76 3 4 ENGINE Disconnect the engine coolant temperature sensor lead wire coupler 1 Disconnect the gear position switch 2 side stand switch HO2 sensor and camshaft position sensor lead wire cou plers Remove the rubber heat shield A Remove the spark plug caps Disconnect the generator lead wire coupler 6 and signal gen erator lead wire coupler 7 after removing the screws e Remove the gearshift lever ENGINE 3 5 Bind the clutch lever with a rubber band to prevent the clutch release cylinder piston from coming out Remove the clutch release cylinder
39. he sharp edge part of the crankcase chamfer by using an oilstone and wash the crankcase bore with enough engine oil ENGINE 3 75 09913 60210 09913 60240 Sharp edge 3 76 ENGINE Set the bearings installed in the special tool to the crankcase half as shown CAUTION Be sure the bearing protruded side faces the crankcase bore Align the special tool mating surface with the line mark on the crankcase NOTE The upper and lower bearings are same Apply enough engine oil to the special tool and the bearings and then set the special tool carefully e Gradually press in the bearing into the main journal bore by using the hand press until the special tool stops the special tool 09913 60230 Journal bearing remover installer Bearing NOTE Using the hand press is recommended to install the crankshaft journal bearings However the crankshaft journal bearings can be installed by using the following special tools 09924 84510 Bearing installer set 09924 74570 Final drive gear bearing remover installer ENGINE 3 77 After installing the bearings check the bearing surface for any scratch or damage GENERATOR COVER DISASSEMBLY AND REASSEMBLY e Remove the generator stator e When installing the generator stator or crankshaft position sensor apply THREAD LOCK
40. he gearshift lever as shown Gearshift lever height Standard 60 70 mm 2 4 2 8 in After installing the engine route the wire harness cables and hoses properly C7 8 14 Adjust the following items Engine oil 472 14 Engine coolant 2 19 Engine idle speed C7 2 16 Throttle cable play 2 16 Engine oil capacity Oil change 2 7 L 2 9 2 4 US Imp qt Oil and filter change 2 9 L 3 1 2 6 US Imp qt Engine overhaul 3 3 L 3 5 2 9 US Imp qt a ENGINE 3 17 ENGINE DISASSEMBLY ENGINE TOP SIDE Remove the spark plugs C7 2 6 e Remove the thermostat Remove the valve timing inspection plug 1 and generator cover plug 2 FRONT CYLINDER HEAD COVER Remove the front cylinder head cover 1 3 18 ENGINE Turn the crankshaft to bring the F T line on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown NOTE At the above condition the No 1 Front cylinder is at TDC of compression stroke and also the engraved lines A on the cam shafts are parallel with the mating surface of the cylinder head cover FRONT CYLINDER CAMSHAFT Remove the camshaft journal holders CAUTION Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally e Remove the camshafts NOTE Do not drop the dowel pins into the crankcase FRONT CAM CHAIN TENSIO
41. ive gear nut NOTE This nut has left hand thread The L mark on the nut faces outside 3 84 ENGINE e Hold the generator rotor with the special tool 09930 44541 Rotor holder e While holding the generator rotor tighten the primary drive gear nut to the specified torque Primary drive gear nut 115 N m 11 5 kgf m 83 0 Ib ft e Install the cam chain and key CAM DRIVE IDLE GEAR SPROCKET e Insert a suitable bar to the holes of the primary drive gears and align the two gears e Install the cam drive idle gear sprocket 1 NOTE Align the punched marks A on the cam drive idle gear sprocket and primary drive gear e Install the washer and nut ENGINE 3 85 Hold the generator rotor with the special tool 09930 44541 Rotor holder While holding the generator rotor tighten the cam drive idle gear sprocket nut to the specified torque F cam drive idle gear sprocket nut 70 N m 7 0 kgf m 50 5 Ib ft CAUTION Before tightening the cam drive idle gear sprocket nut be sure to engage the front and rear cam chains to each sprocket OIL SUMP FILTER Clean the oil sump filter using compressed air e Install the oil sump filter NOTE The projection of the oil sump filter faces to the bottom GEAR POSITION SWITCH Install the springs and gear position switch contacts 3 86 ENGINE Install the gear position switch an
42. king Once the nut has been removed it is no longer of any use Be sure to use new nuts and then tighten them 3 to the specified torque t ENGINE 3 11 Before installing the engine assembly install the spacer A J collar and engine thrust adjuster 3 12 ENGINE e Put the drive chain on the driveshaft Gradually raise the engine assembly and align all the bolt holes e Install the engine mounting bolts and tighten them tempo rarily Tighten the engine mounting thrust adjuster lock nut to the specified torque with the special tool m Engine mounting thrust adjuster 12 N m 1 2 kgf m 8 5 Ib ft Engine mounting thrust adjuster lock nut 45 N m 4 5 kgf m 32 5 lb ft 09940 14990 Engine mounting thrust adjuster socket wrench After tightening the engine mounting bolt tighten the pinch bolt Engine mounting bolt A 55 N m 5 5 kgf m 40 0 Ib ft Engine mounting pinch bolt 8 23 N m 2 3 kgf m 6 5 lb ft ENGINE 3 13 Tighten the engine mounting bolt to the specified torque 55 N m 5 5 kgf m 40 0 Ib ft Q Engine mounting bolt Tighten the engine mounting nuts O and bolt to the specified torque Engine mounting nut D 93 N m 9 3 kgf m 67 6 Ib ft Engine mounting bolt 55 N m 5 5 kgf m 40 0 Ib ft Engine mounting nut P 55 N m 5 5 kgf m 40 0 Ib ft After tightening the bo
43. llowing parts from the gearshift shaft gearshift arm 2 Washer Plate return spring Snap ring Washer Gearshift shaft return spring Snap ring Gearshift cam drive plate Washer 09900 06107 Snap ring pliers GEARSHIFT SHAFT GEARSHIFT ARM INSPECTION Check the gearshift shaft gearshift arm for wear or bend RETURN SPRINGS INSPECTION Check the return springs and for damage or fatigue GEARSHIFT SHAFT GEARSHIFT ARM REASSEMBLY e Install the following parts to the gearshift shaft gearshift arm as shown in the right illustration Washer Plate return spring Snap ring Washer Gearshift shaft return spring Snap ring Gearshift cam drive plate Washer 09900 06107 Snap ring pliers NOTE When installing the gearshift shaft return spring position the stopper of the gearshift arm between the shaft return spring ends CRANKCASE OIL PUMP e Remove the oil pump ENGINE 3 67 e Rotate the oil pump by hand and check that it moves smoothly If it does not move smoothly replace the oil pump assembly CAUTION Do not attempt to disassemble the oil pump assembly The oil pump is available only as an assembly Install the oil pump OIL PRESSURE REGULATOR e Remove the oil pressure regulator e When installing the oil pressure regulator apply engine oil to the new O ring Check the operation of the oil
44. lts tighten the pinch bolt H to the specified torque Engine mounting bolt 55 N m 5 5 kgf m 40 0 Ib ft Engine mounting pinch bolt H 23 N m 2 3 kgf m 16 5 lb ft Install the new washers and tighten the union bolt to the spec ified torque Oil cooler hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Install the new gaskets Front amp Rear 3 14 ENGINE e Install the exhaust pipes and mufflers NOTE Apply THREAD LOCK to the bolt L amp R Ga 99000 32050 THREAD LOCK 1342 Apply PERMATEX 1372 Apply PERMATEX 1372 mem Nm kgf m i t ASDODS 23 2 3 16 5 P 25 2 5 18 0 ENGINE 3 15 e Adjust the brake pedal height Brake pedal height A Standard 55 65 mm 2 17 2 56 in e Install the gearshift arm as shown Gearshift arm angle 8 Approx 17 5 e Install the engine sprocket and washer Apply THREAD LOCK SUPER to the engine sprocket nut and tighten it to the specified torque while depressing the brake pedal F Engine sprocket nut 115 N m 11 5 kgf m 83 0 Ib ft Gq 99000 32030 THREAD LOCK SUPPER 1303 e Tighten the speed sensor rotor bolt 3 16 ENGINE Apply SUZUKI SUPER GREASE to the push rod and install it Install the clutch release cylinder AH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Adjust t
45. ly Install the 45 cutter attachment and T handle Using the 45 cutter descale and clean up the seat with one or two turns Inspect the seat by the previously described seat width mea surement procedure If the seat is pitted or burned additional seat conditioning with the 45 cutter is required NOTE Cut only the minimum amount necessary from the seat to pre vent the possibility of the tappet shim replacement INTAKE EXHAUST 60 ok Valve seat Valve seat ENGINE 3 43 If the contact area is too high on the valve or if it is too wide use the 15 60 cutters for exhaust side and 30 60 cutters for intake side to lower and narrow the contact area If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area After the desired seat position and width is achieved use the 45 cutter very lightly to clean up any burrs caused by the pre vious cutting operations CAUTION DO NOT use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish and not a highly polished or shiny fin ish This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation Clean and assemble the head and valve components Fill the intake and exhaust ports with gasoline to check for leaks If an
46. m chains upward and install the cam chain tension ers into each cylinder head For No 1 Front cylinder head For No 2 Rear cylinder head NOTE When installing the cam chain tensioners insert the their holder ends 1 into each guide cast on the cylinder When installing the No 1 Front cam chain tensioner through it rear side of the rib J Tighten the cam chain tensioner mounting bolts to the speci fied torque F Cam chain tensioner mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft REAR Nos2 F 3 100 ENGINE FRONT CAM DRIVE IDLE GEAR SPROCKET e Turn the crankshaft counterclockwise with the box wrench and align F T line on the generator rotor with the index mark of the valve timing inspection hole while keeping the camshaft drive chain pulled upward CAUTION Pull the cam chains upward or the chain will be caught between crankcase and cam drive sprocket CAUTION To adjust the camshaft timing correctly be sure to align F T line with the index mark and hold this position when installing the cam drive idle gears sprockets front and rear Apply molybdenum oil solution to the cam drive idle gear sprocket bearing its shaft and thrust washer 2 E MoLyBDENUM OIL SOLUTION NOTE The thickness of thrust washer must be selected for each cylinder head THRUST WASHER SELECTION CF 3
47. nd rear the indents on the piston heads must be located to each exhaust side e Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase Install the pistons front and rear Install the piston pin circlips CAUTION Use new piston pin circlips to prevent circlip failure which will occur with a bend one CAUTION When turning the crankshaft pull the cam chains upward or the chains will be caught between the crankcase and the cam drive sprocket NOTE End gap of the circlip should not be aligned with the cutaway in the piston pin bore 2nd ring Lower side rail Top ring IN Spacer amp ENGINE 3 95 OIL JET Apply engine oil to the new O rings e Install each of the oil jets front and rear CAUTION Use the new O rings to prevent oil leakage CYLINDER Coat SUZUKI BOND lightly to the mating surfaces at the part ing line between the right and left crankcases as shown NOTE When replacing the stud bolt apply SUZUKI BOND to the thread of the crankcase side 2 99104 31140 SUZUKI BOND 12078 e Fit the dowel pins and new gaskets 1 to the crankcase front and rear CAUTION Use the new gaskets to prevent oil leakage Apply engine oil to the sliding surface of the pistons and cylin ders NOTE The cylinders can be distinguished by the embos
48. nstalling the cylinder head bolts e After firmly tightening the cylinder head bolts M10 tighten the cylinder head nuts bolts and cylinder nuts F Cylinder head nut M8 A 25 N m 2 5 kgf m 18 0 lb ft Cylinder head nut M6 10 N m 1 0 kgf m 7 0 lb ft Cylinder head bolt M6 10 N m 1 0 kgf m 7 0 lb ft Cylinder nut M6 D 10 N m 1 0 kgf m 7 0 Ib ft 3 98 ENGINE Place the front cylinder head on the cylinder NOTE When installing the cylinder head keep the cam chain taut e Tighten the cylinder head bolts M10 to the specified two step torque with a torque wrench sequentially and diago nally Cylinder head bolt M10 Initial 25 N m 2 5 kgf m 18 0 Ib ft Final 47N m 4 7 kgf m 34 0 lb ft NOTE Install the washers to the cylinder head bolts M10 as shown Apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts After firmly tightening the cylinder head bolts M10 install the cylinder head nuts bolts and oil cooler mounting bracket 1 Tighten the cylinder head nuts bolts and the cylinder nuts Cylinder head nut M8 25 N m 2 5 kgf m 18 0 Ib ft Cylinder head nut M6 F 10 N m 1 0 kgf m 7 0 lb ft Cylinder head bolt M6 10 N m 1 0 kgf m 7 0 Ib ft Cylinder nut M6 H 10 N m 1 0 kgf m 7 0 Ib ft wt i w s wf a amp ENGINE 3 99 e Pull the ca
49. ntake and exhaust Engraved line No 1 Front cylinder head FRONT C gt wi we i we a ENGINE 3 109 NO 2 REAR CAMSHAFTS Install the No 2 Rear camshafts intake and exhaust in the fol lowing procedure e From the position where the No 1 Front camshafts have now been installed rotate the generator rotor 360 degrees 1 turn and align the F T line on the generator rotor with the index mark of the valve timing inspection hole NOTE At this position the engraved line on the cam drive idle gear sprocket is inside the cylinder head and not visible Place the No 2 Rear camshafts intake and exhaust Align the engraved lines on the camshafts so that it is par allel with mating surface of the cylinder head cover Check that the cam faces are located as shown e Install the dowel pins 3 110 ENGINE e Install the camshaft journal holders intake and exhaust Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally Try to equalize the pressure by shifting the wrench in the above manner to fasten the shafts evenly NOTE Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly Each camshaft journal holder is identified with a cast on letter Tighten the camshaft journal holder
50. piston pin circlip e Remove the piston by driving out the piston pin NOTE Scribe the cylinder number on the head of the piston REAR CYLINDER HEAD COVER Remove the rear cylinder head cover 1 e ENGINE 3 21 e Turn the crankshaft to bring the F T line mark on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown NOTE At the above condition the rear cylinder is at ATDC 90 on expansion stroke and also the engraved lines on the cam shafts are parallel with the mating surface of the cylinder head cover CAUTION Pull the front cam chain upward or the chain will be caught between the crankcase and cam drive idle gear sprocket when turning the crankshaft REAR CYLINDER CAMSHAFT Remove the camshaft journal holders CAUTION Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally Remove the camshafts NOTE Do not drop the dowel pins into the crankcase 3 22 ENGINE REAR CAM CHAIN TENSION ADJUSTER After loosing the spring holder bolt remove the cam chain tension adjuster REAR CYLINDER HEAD Remove the cam drive idle gear sprocket 1 by removing its shaft copper washer and thrust washer 2 NOTE Do not drop the thrust washer into the crankcase e Remove the cylinder head bolts and cam chain tensioner mountin
51. pressure regulator by pushing on the piston with a proper bar If the piston does not operate replace the oil pressure regulator with a new one OIL PRESSURE SWITCH e Remove the oil pressure switch e When installing the oil pressure switch apply SUZUKI BOND to the thread Oil pressure switch 14 N m 1 4 kgf m 10 0 Ib ft 27 99104 31140 SUZUKI BOND 1207B 3 68 ENGINE OIL JET Remove the oil gallery plug Remove the oil jet with a suitable bar Remove the oil jet Check the oil jets for clogging If they are clogged clean their oil passage with a proper wire or compressed air Fit the new O ring to the oil jet CAUTION Use the new O ring to prevent oil leakage NOTE Apply engine oil to the O ring when installing the oil jet e Install the oil jet with a suitable bar ENGINE 3 69 Tighten the oil gallery plug to the specified torque Oil gallery plug M8 18 N m 1 8 kgf m 13 0 lb ft Apply engine oil to the new O ring and install it Apply THREAD LOCK to the screw and tighten it to the speci fied torque Piston cooling oil nozzle screw 8 N m 0 8 kgf m 6 0 Ib ft G2 99000 32050 THREAD LOCK 1342 e When replacing the gearshift arm stopper bolt apply THREAD LOCK SUPER to it Gearshift arm stopper bolt 23 N m 2 3 kgf m 16 5 Ib ft Gq 99000 32030 THREAD LOCK SUPER 1303 BEARING OIL SEAL Rotate the
52. que F Cam chain tension adjuster mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft e Install a new O ring spring and cam chain tension adjuster bolts and tighten them to the specified torque NOTE Apply grease to the O ring before installing W EH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Cam chain tension adjuster bolt Rear 7 N m 0 7 kgf m 5 0 Ib ft J NOTE Click sound is heard when extending the cam chain tension adjuster rod CAUTION 7 After installing the cam chain tension adjuster check to be sure that the adjuster work properly by checking the slack of cam chain 3 106 ENGINE CAMSHAFT e Rotate the generator rotor 720 degrees 2 turns and align the F T line on the generator rotor with the index mark of the valve timing inspection hole e Recheck the position of the engraved lines A on the front and rear cam drive idle gears sprockets No 1 Front cylinder TDC of compression stroke NO 1 FRONT CAMSHAFTS At the above condition install the No 1 Front camshafts intake and exhaust in the following procedure es t tU wy 4 ENGINE 3 107 NOTE SNE exp ANR EX The cam shafts are identified by the engraved letters No 1 Front intake camshaft No 1 Front exhaust camshaft No 2 Rear intake camshaft No 2 Rear exhaust camshaft NOTE Before placing the
53. rom the combustion chamber and always turn the reamer handle clockwise VALVE SEAT WIDTH Coat the valve seat uniformly with Prussian blue Fit the valve and tap the coated seat with the valve face in a rotating man ner in order to obtain a clear impression of the seating con tact In this operation use the valve lapper to hold the valve head Cylinder head 3 42 ENGINE The ring like dye impression left on the valve face must be continuous without any break In addition the width of the dye ring which is the visualized seat width must be within the following specification Valve seat width WW Standard 0 9 1 1 mm 0 035 0 043 in 09916 10911 Valve lapper set If either requirement is not met correct the seat by servicing is as follows VALVE SEAT SERVICING The valve seats for both intake and exhaust valves are machined to four different angles The seat contact surface is cut 45 INTAKE EXHAUST 45 N 615 or N 626 N 615 or N 626 60 N 211 N 211 16 N 615 30 NOTE The valve seat contact area must be inspected after each cut 09916 21111 Valve seat cutter set 09916 24210 Valve seat cutter N 615 09916 24480 Solid pilot N 140 5 5 09916 24810 Valve seat cutter N 626 09916 27710 Valve seat cutter N 211 e Insert the solid pilot with a slight rotation Seat the pilot snug
54. sed letters F and R F Front No 1 cylinder R Rear No 2 cylinder 3 96 ENGINE Hold the piston rings in proper position and insert each of the pistons into the respective cylinders NOTE When installing the cylinders keep the cam chains taut The cam chain must not be caught between cam drive sprocket and crankcase when turning the crankshaft Tighten the cylinder nuts M6 temporarily NOTE Fit the clamp to the front cylinder nut CYLINDER HEAD e Pull the cam chains out of the cylinders and install the cam chain guides NOTE There are the guide holders for the bottom ends of each cam chain guide cast in the crankcase Be sure that the cam chain guides are inserted properly e Fit the dowel pins and new cylinder head gaskets 2 to the cylinders front and rear CAUTION Use the new gaskets to prevent gas leakage e Place the rear cylinder head on the cylinder NOTE When installing the cylinder head keep the cam chain taut Tighten the cylinder head bolts M10 to the specified two step torque with a torque wrench sequentially and diagonally Cylinder head bolt M10 Initial 25 N m 2 5 kgf m 18 0 Ib ft Final 47 N m 4 7 kgf m 34 0 Ib ft ENGINE 3 97 NOTE Install the washers to the cylinder head bolts M10 as shown a2 Apply engine oil to the washers and thread portion of the bolts before i
55. sleeve hub nut 3 88 ENGINE NOTE The convex side of the washer faces outside Tighten the clutch sleeve hub nut to the specified torque with the special tool Clutch sleeve hub nut 95 N m 9 5 kgf m 68 5 Ib ft 09920 53740 Clutch sleeve hub holder Lock the clutch sleeve hub nut with a center punch e Install the spring washer seat and spring washer 40 onto the clutch sleeve hub correctly e Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order No 3 drive plate being inserted first Refer to page 3 90 NOTE Insert the outermost No 2 drive plate claws to the other slits of clutch housing as shown INSIDE OUTSIDE Washer ENGINE 3 89 e Install the clutch push rod into the countershaft e Install the clutch push piece bearing 3 and thrust washer J e Tighten the clutch spring set bolts diagonally to the specified torque while holding the generator rotor with the special tool Clutch spring set bolts 10 N m 1 0 kgf m 7 0 lb ft 09930 44541 Rotor holder 3 90 ENGINE No 1 drive plate No 2 drive plate Direction of outside gt D 4 AJ NOTE O The No 2 driven plate should be installed
56. t then replace the guide After replacing valve or guide be sure to recheck the clearance Valve stem O D Standard IN 5 475 5 490 mm 0 2156 0 2161 in EX 5 455 5 470 mm 0 2148 0 2154 in 09900 20205 Micrometer 0 25 mm NOTE If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in valve guide servicing ENGINE 3 41 VALVE GUIDE SERVICING Using the valve guide remover drive the valve guide out toward the intake or exhaust camshaft side 09916 44910 Valve guide remover installer NOTE Discard the removed valve guide subassemblies Only oversized valve guides are available as replacement parts Part No 11115 32E70 e Re finish the valve guide holes in cylinder head with the reamer and handle 09916 34580 Valve guide reamer 09916 34542 Reamer handle Oil the stem hole too of each valve guide and drive the guide into the guide hole with the valve guide installer and attach ment 09916 44910 Valve guide remover installer 09916 53340 Attachment CAUTION Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head e After fitting the valve guides re finish their guiding bores with the reamer Be sure to clean and oil the guides after reaming xo 09916 34550 Valve guide reamer 09916 34542 Reamer handle NOTE Insert the reamer f
57. tall the starter torque limiter with the washers Install the dowel pin and gasket CAUTION Use the new gasket to prevent oil leakage ENGINE 3 93 e Install the generator cover OIL FILTER v Apply engine oil lightly to the O ring e Install the oil filter turning it by hand until feeling that the O ring contacts the mounting surface Then tighten it 2 turns with the special tool 09915 40610 Oil filter wrench ENGINE TOP SIDE PISTON e Install the piston rings in the order of oil ring 2nd ring and 1st tst ring J ring NOTE 1st ring and 2nd ring differ in the shape m Z i VAA 2nd ring Be sure to bring the concave side of 1st ring to top when fit ting it to the piston 2nd middle ring has letters RN marked on the side Be sure to bring the marked side of the 2nd ring to top when fit ting it to the piston J The first member to go into the ring groove is spacer 1 After placing the spacer fit the two side rails 2 Side designations top and bottom are not applied to the spacer and side rails you can position each either way Raa 3 94 ENGINE Position the gaps of the three rings as shown Before inserting each piston into the cylinder check that the gaps are so located Apply a light coat of molybdenum oil solution to the piston pin ET morvenenum OIL SOLUTION NOTE When installing the pistons front a
58. to the generator stator set bolts Gq 99000 32050 THREAD LOCK 1342 CLUTCH COVER OIL SEPARATER Remove the oil separator GEARSHIFT COVER OIL SEAL INSPECTION Inspect the gearshift shaft oil seal for damage or wear on the lip If any defects are found replace the oil seal with a new one OIL SEAL REPLACEMENT Remove the gearshift shaft oil seal CAUTION The removed oil seal must be replaced with a new one Install the new oil seal with the special tool 09913 70210 Bearing installer set NOTE Apply grease to the oil seal lip to prevent damage when install ing the gearshift cover AAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others 3 78 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly vu NOTE Apply engine oil to each running and sliding part before reas sembling ENGINE BOTTOM SIDE CRANKSHAFT e Install the crankshaft into the left crankcase half NOTE Coat lightly molybdenum oil solution to the crankshaft journal bearings ET morvenenum oiL SOLUTION CAUTION Never strike the crankshaft with a plastic hammer when inserting it into the crankcase e Install the countershaft assembly and driveshaft assembly e Install the gearshift forks and gearshift cam NOTE Identify the gearshift forks as follows For 3rd 4th drive gear widt
59. which exceed the limit Driven plate distortion Service Limit 0 10 mm 0 004 in 09900 20803 Thickness gauge CLUTCH SPRING FREE LENGTH Measure the free length of each coil spring with a vernier cali pers and compare the length with the specified limit Replace all the springs if any spring is not within the limit Clutch spring free length Service Limit 26 7 mm 1 05 in 09900 20102 Vernier calipers CLUTCH BEARING Inspect the clutch release bearing for any abnormality particu larly cracks to decide whether it can be reused or should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing NOTE Thrust washer is located between the pressure plate and the bearing Measuring claw width Measuring distortion 3 56 ENGINE TRANSMISSION CONSTRUCTION 1st driven gear 5th driven gear 4th driven gear 3rd driven gear 6th driven gear 2nd driven gear Driveshaft Countershaft 5th drive gear 3rd amp 4th drive gear 6th drive gear 2nd drive gear F ENGINE 3 57 DISASSEMBLY CAUTION Be sure to identify each removed part as to its loca tion and lay the parts out in groups designated as Drive and Driven so that each will be restored to the original location during assembly Countershaft e Remove the O ring 2nd drive gear 2 and top
60. worn down to the limit Cam height 4 Service Limit IN 37 48 mm 1 476 in EX 36 08 mm 1 420 in 09900 20202 Micrometer 25 50 mm 3 36 ENGINE CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place Use the plastigauge to read the clearance at the widest portion which is specified as follows Camshaft journal oil clearance Service Limit IN amp EX 0 150 mm 0 0059 in 09900 22301 Plastigauge 09900 22302 Plastigauge NOTE Install camshaft journal holder to their original positions Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 Ib ft NOTE Do not rotate the camshaft with the plastigauge in place Remove the camshaft holders and read the width of the com pressed plastigauge with envelope scale This measurement should be taken at the widest part If the camshaft journal oil clearance measured exceeds the limit measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal Replace the camshaft or the cylinder head depending upon which one exceeds the specification Camshaft journal holder I D Standard IN amp EX 22 012 22 025 mm 0 8666 0 8671 in 09900 20602 Dial gauge 1 1 000 mm 1 mm 09900 22403 Small bore
61. y leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing A WARNING Always use extreme caution when handling gasoline NOTE After servicing the valve seats be sure to check the tappet clearance after the cylinder head has been reinstalled C7 2 8 Contact area too high and too wide on face of valve Contact area too low and too narrow on face of valve 3 44 ENGINE VALVE SPRING The force of the coil spring keeps the valve seat tight Weak ened spring results in reduced engine power output and often account for the chattering noise coming from the valve mecha nism Check the valve springs for proper strength by measuring their free length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not fall within the range specified replace it Valve spring free length IN amp EX Service Limit 41 2 mm 1 62 in Valve spring tension IN amp EX Standard 197 227 N 35 6 mm 20 1 23 1 kgf 35 6 mm 44 3 51 0 Ibs 1 40 in EB 09900 20102 Vernier calipers CAM DRIVE IDLE GEAR SPROCKET THRUST CLEARANCE Install the cam drive idle gear sprocket 1 its shaft 2 copper washer 3 and thrust washer to each cylinder head Tighten the shaft 2 to the specified torque Use a thickness gauge to measure the thrust clearanc
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