Refer to “engine top side disassembly” .
Refer to “engine top side assembly” .
Caution identify the position of each removed part. Organize the parts in their respective groups (i.E., Intake, exhaust, no. 1 Or no. 2) So that they can be installed in their original locations. |
Disassembly
Caution be careful not to damage the tappet sliding surface with the special tool. |
Special tool
(a): 09919–28620 (sleeve protector)
(b): 09916–14522 (valve lifter
attachment)
(c): 09916–14510 (valve lifter)
: 09916–84511 (tweezer)
Assembly
Assembly is in the reverse order of disassembly. Pay attention to the following points:
Caution replace the gaskets with new ones. |
Tightening torque cam chain tension adjuster service cap (a): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft) oil gallery plug (cylinder head) (b): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)
Caution replace the o-rings with new ones. |
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
Tightening torque intake pipe bolt (c): 8.5 N·m (0.85 Kgf-m, 6.5 Lbf-ft)
Caution use new o-ring to prevent oil pressure leakage |
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
Tightening torque bypass hose union (d): 12 n·m (1.2 Kgf-m, 8.5 Lbfft)
Note the air bleeder hole “b” of the thermostat faces upside. |
Tightening torque thermostat cover bolt (e): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)
Tightening torque ect sensor (f): 18 n·m (1.8 Kgf-m, 13.0 Lbf-ft)
Caution
|
Caution do not reuse the removed oil seal. |
M/o: molybdenum oil (molybdenum oil solution)
Caution when inserting the valve, take care not to damage the lip of the oil seal. |
M/o: molybdenum oil (molybdenum oil solution)
|
Caution
|
Special tool
(a): 09916–14510 (valve lifter)
(b): 09916–14522 (valve lifter
attachment)
(c): 09919–28620 (sleeve protector)
: 09916–84511 (tweezer)
|
Note
|
Air bleeding from brake fluid circuit
Air trapped in the brake fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full
braking performance of the brake caliper. The presence
of air is indicated by “sponginess” of the brake lever and
also by la ...
Rear brake disc inspection
Brake disc thickness
Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if defect is found.
Special tool
(a): 09900–20205 (micrometer (0 –
25 mm))
Brake disc thickness
service ...
Schematic and routing diagram
Cooling circuit diagram
Water hose routing diagram
Thermostat air bleeder hole
Cushion
O-ring
Radiator heat guard
: be careful not to damage the pawls when removing.
Yellow
marking
White
marking
Clamp end
should face downward
...