Usethenewgaskettopreventoilleakage.

•Installtheclutchcoverandtightenitsboltstothespecifiedtorque.

~Clutchcoverbolt:10N·m(1.0kgf·m,7.0lb-ft)

NOTE:

*Fittheclamptothebolt®asshown.

..Fitthegasketstothebolts@asshown.

CYLINDERHEAD

•FitthedowelpinsandthenewcylinderheadgasketG)tothecylinder.

ACAUTIONI

Usethenewgaskettopreventgasleakage.

•Placethecylinderheadonthecylinder.

•Installthecylinderheadsidebolt~andgasket~andtightenittothespecifiedtorque.

~Cylinderheadsidebolt:14N·m(1.4kgf·m,10.0lb-ft)

NOTE:

~Themetalsideofthegasket®facesout.

*Installthecylinderheadsideboltbetweenthecamchain.

NOTE:

Wheninstallingthecylinderhead,keepthecamchaintaut.

•Tightenthecylinderheadbolts(M10)tothespecifiedtwo-steptorquewithatorquewrenchsequentiallyanddiagonally.

~Cylinderheadbolt(M10):Initial:25N·m

(2.5kgf·m,18.0lb-ft)Final:46N·m

(4.6kgf·m,33.3lb-ft)

NOTE:

~Installthewasherstothecylinderheadbolts{M10)asshown.

*Applyengineoiltothewashersandthreadportionoftheboltsbeforeinstallingthecylinderheadbolts.

^"111_[

•Tightenthecylinderheadboltstothespecifiedtorque.\

C!JCylinderheadbolt(M6):10N·m(1.0kgf·m,7.0lb-ft)^"'

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~

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•FitthegasketG)andtightenthewatertemp.gauge.

(!JWatertemp.gauge:18N·m(1.8kgf·m,13.0lb-ft)

•Installthethermostat.(c:::75-10)

•Installthethermostatcover.

(!JThermostatcoverbolt:10N·m(1.0kgf·m,7.0lb-ft)

NOTE:

_-

Fittheclamptothebolt®·

•Installthewaterhose.(c:::78-24)

CAMSHAFT

•Turnthecrankshaftcounterclockwisewiththeboxwrenchandaligntheline:f;Jonthestarterclutchwiththeindexmark@ofthevalvetiminginspectionholewhilekeepingthecamchainpulledupward.

'ACAUTIONI

Pullthecamchainupward,orthechainwillbecaughtbetweencrankcaseandcamdrivesprocket.

IACAUTIONI

Toadjustthecamshafttimingcorrectly,besuretoaligntheline~iwiththeindexmark@andholdthispositionwheninstallingthecamshafts.

•Thecamshaftsareidentifiedbytheembossedletters.

•Beforeplacingthecamshaftsoncylinderhead,applymolyb-denumoilsolutiontotheirjournalsandcamfaces.

_{•Applyengineoiltothecamshaftjournalholders.}

^{W1MOLYBDENUMOILSOLUTION}

NOTE:

Beforeinstallingthecamshaft,checkthatthetappetsareinstalledcorrectly

•Pullthecamchainlightly.

•Theexhaustcamshaftsprockethasanarrowmarked"1"®·Turntheexhaustcamshaftsothatthearrowisalignedwiththegasketsurfaceofthecylinderhead.

•Engagethecamchainwiththeexhaustcamshaftsprocket.

•Bindthecamchainandthesprocketwithaproperwireclamp

G)topreventthecamchaindisengagementwhileinstallingthecamshaftjournalholders.

•Theotherarrowmarked"2"'§)shouldnowbepointingstraightup.Startingfromtherollerpinthatisdirectlyabovethearrowmarked"2"@.countout14rollerpins{fromtheexhaustcam•shaftsidegoingtowardstheintakecamshaftside).

Engagethe14rollerpin©onthecamchainwiththearrow

marked"3"ontheintakesprocket.

•BindthecamchainandthesprocketwithaproperwireclampQitopreventthecamchaindisengagementwhileinstallingthecamshaftjournalholders.

G)--

NOTE:

Thecamchainshouldnowbeonallthreesprockets.Becarefulnottomovethecrankshaftuntilthecamshaftjournalholdersandcamchaintensionadjusteraresecured.

-

•Installthedowelpins.

•Installthecamshaftjournalholders,intakeandexhaustandcamchainguide.

•Fastenthecamshaftjournalholdersevenlybytighteningthe

camshaftjournalholderboltssequentiallyanddiagonally.

NOTE:

"Damagetoheadorcamshaftjournalholderthrustsurfacesmayresultifthecamshaftjournalholdersarenotdrawndownevenly.

^{~Eachcamshaftjournalholderisidentifiedwithacast-onletters}

®·

•Tightenthecamshaftjournalholderboltsinascendingorderofnumbers(seebelow)tothespecifiedtorque.

~Camshaftjournalholderbolt:10N·m

_{(1.0kgf·m,7.0lb-ft)}

IACAUTIONI

Thecamshaftjournalholderboltsaremadeofaspecial

..... materialandmuchsuperiorinstrength,comparedwithothertypesofhighstrengthbolts.

Takespecialcarenottouseothertypesofbolts.

Camchaintensionadjuster

•Retractthepushrodbypushingtherachet.

•InstalltheballG)tothecamchaintensionadjuster.

•Installthenewgasket~.

IACAUTIONI

Usethenewgaskettopreventoilleakage.

•Installthecamchaintensionadjusterandtightenthemountingbolts.

(!JCamchaintensionadjustermountingbolt:1ON·m

_{(1.0kgf·m,7.0lb-ft)}

•Installthespring@.

•Installtheoilhoseasshowninillustration.(c:::::rNextpage)

•Installthegasketsandtightentheunionbolt.

(!JOilhoseunionbolt:12N·m(1.2kgf·m,8.7lb-ft)

•Installthegasketsandthecamchaintensionadjustercapbolt.

NOTE:

Clicksoundisheardwhenthecamchaintensionadjustercapboltisinstalled.

•Tightenthecamchaintensionadjustercapbolttothespeci•

fiedtorque.

(!JCamchaintensionadjustercapbolt:23N·m

_{(2.3kgf·m,16.5lb-ft)}

IACAUTIONI

Afterinstallingthecamchaintensionadjuster,checktobesurethattheadjusterworkproperlybycheckingtheslackofcamchain.

•Cutthewireclamps.

•Afterinstallingthecamchaintensionadjuster,rotatethecrank•

shaft(someturns),andrecheckthepositionsofthecamshafts.(c:::::r3-96)

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•TightenthevalvetiminginspectionplugG)tothespecifiedtorque.

_{(!)Valvetiminginspectionplug:11N·m(1.1kgf·m,8.0lb-ft)}

CYLINDERHEADCOVER

•Pourengineoilineachoilpocketinthecylinderhead.

NOTE:

-

Besuretocheckthevalveclearance.(er2-8)

•Installthedowelpins.

•Installthe0-rings.

•Installthenewgasketstothecylinderheadcover.

•ApplySUZUKIBOND"12078"tothecamendcapsofthegas•

ketsasshown.

~99000-31140:SUZUKIBOND"12076"

)ACAUTIONI

Usethenewgasketstopreventoilleakage.

•Placethecylinderheadcoveronthecylinderhead.

•Fitthenewgasketstoeachheadcoverbolt.

ACAUTIONI

Usethenewgasketstopreventoilleakage.

•Tightentheheadcoverboltstothespecifiedtorque.(!)Headcoverbolt:14N·m(1.4_kgf·m,10.0lb-ft)

PAIRVALVE

•InstallthePAIRreedvalve1).(C::::7'8-22)

•ApplyTHREADLOCKtothebolts,installthePAIRvalveandhose.(C::::7'8-22)

~99000-32050:THREADLOCK"1342"

C!JPAIRreedvalvecoverbolt:10N·m(1.0kgf·m,7.0lb-ft)

STARTERMOTOR

•Applythegreasetothe0-ring.

,099000-25010:SUZUKISUPERGREASE"A"

•Installthestartermotor.

C!JStartermotormountingbolt:10N·m(1.0kgf·m,7lb-ft}

•Installthesparkplugs.{c:::::/2-5)