7) Time to get the wiring out of the way! Its pretty idiot proof stuff.
All the plugs are
colour coded but none the less its good practice to take a reference pic in case it all goes pear shapep. Simply unplug it all and move the looms off to the side. I just popped them behind one of the tank mounting lugs to keep em out of the way. 8) Next up is to drain the coolant. On the left engine cover, undo the 5 bolts. A 10mm and 8mm socket gets the job done. Dont forget to pop off the gearshift lever. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 4 oI 22 26/10/12 21:21 Then undo the drain bolt and remove the radiator cap and drain it all out. 9) With that done the thermostat is the next piece to come out. With two 10mm wrenches undo its mounting bolts. Also undo the bolt with the grounding wire on it (10mm socket) and take all 3 coolant hoses off. With a bit of jiggling it'll fit out the right hand side of the bike. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... S oI 22 26/10/12 21:21 12) Now there's plenty of room to get the job done so we can get down to business ;) The cam cover is held on with 8x giant bolts. So undo them in the standard diagonal pattern so you dont warp the cover then place it aside. It may need a tap or two with a rubber mallet to knock the seal loose. Its also a rather snug fit on the two coolant 'nozzles' so keep that in mind as your removing it. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 7 oI 22 26/10/12 21:21 14) With the cams in this position the intake and exhaust valves for cylinder 1 (the left most cylinder), the intake valves of cylinder 2, and the exhaust for cylinder 3 can now be checked for clearance. You just slide the feeler gauge in between the bottom of the cam lobe and the shim bucket and move it back and forth. There should be a slight resistance. Read the value on the feeler gauge and this gives you your clearance. The service limits are .17 to .27mm for the intake and .2 to .3mm on the exhaust side. Thankfully mine were all on the tight side so it seems they were dont not that long ago! VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 9 oI 22 26/10/12 21:21 15) With the 22mm spanner rotate the engine 1 revolution until the notches on the cams are facing inward. Then read the clearance on the remaining valves using the same method. 16) Hopefully yours are all in spec and you can just go ahead and follow the reverse of this procedure to put everything back together (dont forget the RTV silicone on the cam cover gasket) BUT if the clearances are above the limit then there's more work to do.. Depending on which valves need doing you may only have to remove one cam or both. Im removing both here as i have to take the head off eventually to change the head gasket. Just keep that in mind. Undo the 6x bolts holding on each cam holder, undoing them diagonally so you dont warp anything and set them aside somewhere clean. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 10 oI 22 26/10/12 21:21 19) With some basic maths you can work out what size shim you need. My local suzuki dealer stocked the shims but thankfully i didnt need them. The thickness of the existing one will be printed on top of the shim. However you can measure it if its unreadable. Work out what thickness shim you need, buy it, then pop it back on top of the valve. as such (put a bit of oil on it too) Then put the shim bucket back on too with a little bit of oil as well. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 13 oI 22 26/10/12 21:21 24) Pop the exhaust cam back in (its the one with the E stamped on the end, Make sure you install the cam with the notched end to the right of the engine if you are sitting on it) then make sure the number 1 arrow is flush with the top of the gasket surface. 25) I took this pic wrong and the intake cam is in the wrong position, but ive corrected it in the picture with a seamless photoshop lmao. Pop the chain over both cams and count the number of chain pins between the 2 mark on the exhaust cam and 3 mark on the intake cam. it should be 16 pins. Making sure the exhaust cam 1 mark is pointing to the gasketed surface the entire time.. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 18 oI 22 26/10/12 21:21 26) Everything should now be in time, make sure you dont move anything! 27) Fill the cam holders with some new engine oil, coating it liberally then pop them back on, taking note they go on in order (A is left exhaust side D is intake right side) and torque them to 0.8kg-m - 1.2kg-m doing them up diagonally so you dont warp em. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 19 oI 22 26/10/12 21:21 28) Now take the cam chain tensioner that came off and wind the screw in the back all the way in clockwise, the rod should pull in. make sure it moves smooth or you'll have to replace it. Wind it all the way clockwise with a flat blade screwdriver and while holding the screwdriver in place do up the two bolts with a 10mm socket. just a bit more then finger tight for now and let the screwdriver release the tensioner, it should pop out and tension the chain. You can check it by pushing the cam chain at the top between the two sprockets. Then torque the cam chain tensioner bolts up to 0.6-0.8kg-m 29) fill the oil pockets (where the shim buckets are) with a bit of fresh engine oil. about 50ml is plenty. VaIve cIearances on suziki across (Ions oI pics) - Aus... hIIp://www.aussiesIreeIbikes.com/Iorum/showIhre... 20 oI 22 26/10/12 21:21