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Do not attempt to reverse the crankshaft or it may possibly result in wrong valve timing or deformation of chain guide.







Compress


 

 

 
Align

 

 

Adjust the valve clearance. (See page 19.)

 
Install the starter gear cover.

• Apply liquid gasket on the mating faces ® and @.

@

I A CAUTION I

* Make sure that the dowel pin and starter gear cover ®

gasket are fitted without fail.

* Replace the gaskets with new ones.

€Zi 99000-31140: SUZUKI BOND NO. 12078

 
Fit the 0-ring on the VC oil line pipes CD and ®·

I A CAUTION I

I Replace the 0-rings with new ones.

 

 

• Fit the VC oil line pipes to the actuator.

 


 

 
Install the cam chain No.2 guide CD on the cylinder head cover.

• Use the gasket ® without fail.

• Apply thread lock to the attaching screws.

99000-32050: THREAD LOCK " 1322"

Cam chain guide: 3 N·m (0.3 kg-m, 2.0 lb-ft)

 

Position the new gasket on the cylinder head cover.

• Apply liquid gasket to the four cam end caps shown as ®·

99000-31140: SUZUKI BOND NO. 12078

• Fit the dowel pin @ on the cylinder head cover.

• Apply engine oil to each camshaft oil pocket.

• Install the cylinder head cover.

 
The cylinder head cover attaching bolts must be tight­ ened evenly starting from inside in a diagonal fashion.

• Coat engine oil on the sealing surface of the gasket @.

• Fit the gasket ® to the cylinder head cover bolt @ and tight­ en the bolt to the specified torque.

I A CAUTION I

The gasket must be replaced with new one.

 

 

Cylinder head cover bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

 

 


 

 
Fit the 0-ring ® to the fail safe switch (]).

I A CAUTION I

I Replace the 0-ring with a new one.

 

 

• Install the fail safe switch (]) onto the intake right side rock­ er arm shaft.

I A CAUTION I

 
Engage the groove ® of the fail safe switch with the rocker arm shaft end @.

 

• Tighten the fail safe switch cover bolt and the cylinder head side cap bolt to the specified torque.

Fail safe switch bolt: 8.0 N·m (0.8 kg-m, 6.0 lb-ft)

 

 

 
Assemble the oil control actuator @.

 

I A CAUTION I

* Do not attempt to disassemble the oil control actua­ tor.

* The oil control actuator gasket must be installed

with its bead facing down.

 

• Install the oil control hose @.

 
Fit the gasket without fail.

I A CAUTION I

I Replace the gasket with a new one.

 

 

Oil control hose joi nt bolt

Upper: 28 N·m (2.8 kg-m, 21.0 lb-ft) Lower: 28 N·m (2.8 kg-m, 21.0 lb-ft)

 

 


 

LOCATION OF ELECTRICAL PARTS

CD Igniter

® Fail safe switch

@ Oil control actuator solenoid

@ Igniter unit

 

 

 
®

 

 

 

 
OIL CONTROL ACTUATOR SOLENOID INSPECTION

• Check for the coil resistance using a circuit tester.

Tester knob indication: x 1Q range

Actuator solenoid resistance: 14.2-15.2 Q

 

 
Check that the piston operates properly when 12V voltage is applied to the oil control actuator lead wire.

NOTE:

If a click sound is heard when 12V voltage is applied, the pis­ ton is operating properl y.


 







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