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Suzumi MOL y paste






 

• The ex ha ust ca mshaf t ca n be d isti ng uished from that of t he i nta ke by the em bossed letters " EX" (for ex haust) as aga i nst letters " I N " (for i ntake). Si m i l a rl y, the right end ca n be d isti ngu ished by the notch CD at the rig ht end.

 

 

• Wit h " CD /1 ma rk a ccu ratel y l i ned u p wit h the ti mi ng ma rk, hold the camshaf t stead y a nd lig htl y pu l l u p the cha i n to remove the sl ack between the cra n k sprocket a nd ex ha ust sprocket.

• Exhaust sp rocket bea rs a n a rrow ma rked " 1" i nd icated as CD. Tu rn over the exhaust camshaf t so t hat the a rrow poi nts fl ush wi t h the gasketed su rface of the cyl i nd er head. E ngage

the ca m cha i n wi th th is sprocket.


 

 

 

 

 

 

EX. n n•I N.

 
1st

 

CD


 

 


The other arrow marked " 2" is now pointing straight upward. Count the chain roller pins toward the intake camshaft, starting from the roller pin directly above this arrow marked " 2" and engine with the 20th roller pin. Engage the cam chain with intake sprocket, locating the 20th pin at the above the arrow marked " 3" on the intake sprocket.

NOTE:

The cam chain is now riding on all three sprockets. Be careful not to disturb the crankshaft until the camshaft journal holders and cam chain tensioner are secured.


 

 

 
20th


 


20 pins


 

 
Cam chain

guide


 

 

 
Each camshaft journal holder is identified with a cast-on letter. Install the dowel pins to each camshaft journal holder.

• Place the cylinder head oil pipe CD to the camshaft journal

holders.

NOTE:

Fit the washer to each oil pipe union bolt ®·

 

 
Secure the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially. Try to equalize the pressure by moving the wrench diagonally from one bolt to another and from one camshaft journal holder to another, to push shafts down evenly.

NOTE:

Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.

 
Tighten the camshaft journal holder bolts to the specified torque.

Tightening torque: 8 - 12 N-m

(0.8 - 1.2 kg-m, 6.0 - 8.5 lb-ft)

CAUTION:

The camshaft journal holder bolts are made of special material and much superior in strength compared with other type 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.

 

 
Turn the slotted end of the cam chain tensioner to lock it with a screwdriver in the clockwise direction.

• Install the cam chain tensioner on the cylinder.

 

Tightening torque: 6 - 8 N·m

(0.6 - 0.8 kg-m, 4.5 - 6.0 lb-ft)

09911-73730: " T" type hexagon wrench (5 mm)

 

 
Turn back and pull out the screwdriver from the cam chain tensioner. As the cylinder turns, the tensioner rod is advanc­ ed under spring force and pushes the tensioner against the cam chain.

NOTE:

The cam chain tensioner is maintained at the proper tension by an automatically adjusted tensioner. Before installing the cam chain tensioner, inspect the smooth movement.


 

 

CAUTION:

 
After installing the cam chain tensioner, check to be sure that the tensioner work properly by checking the slack of cam chain.

• Pour about 50 ml (1.69 US oz) of engine oil in each oil pocket in the head.

NOTE:

Turn the crankshaft and check that all te moving parts such as cam follower, camshaft, work properly.

CAUTION:

Be sure to check and adjust the valve clearance. (Refer to page 2-5.)

 

 

 
Coat SUZUKI BOND NO. 1207B lightly to the portion around mating surface between upper and lower crankcases as shown in the Fig.

(For U.S.A. model)

99104-31140: SUZUKI BOND NO. 1207B

(For the other models)

99000-31140: SUZUKI BOND NO. 1207B

 

• Install the dowel pin, a new gasket and starter clutch cover.

• Tighten the cover bolts securely.

 

CAUTION:

Use a new gasket to prevent oil leakage.

 

 
Apply SUZUKI BOND NO. 1207B to the four cam end caps of the gasket as shown in the Fig.

(For U.S.A. model)

99104-31140: SUZUKI BOND NO. 1207B

(For the other models)

99000-31140: SUZUKI BOND NO. 1207B

 

 

 
Place the dowel pins CD and cylinder head cover on the cylinder head.


 

 

Seat the six gaskets to each exact position.

 


CAUTION:

Replace the gaskets with new ones to prevent oil leakage.

 

NOTE:

Apply engine oil to the gasket surfaces.

 

 

 
Tighten the cylinder head cover bolts to the specified torque.

 

Tighteni ng torque: 8 - 12 N-m

(0.8 - 1.2 kg·m, 6.0 - 8.5 lb-ft)

 

CAUTION:

When replacing the intake pipe, use a new 0-ring to prevent sucking air from the joint.

 

 






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