09116-08101 Suzuki BOLT

1. Loosen adjustment screws (3) to have maximum valve clearance.2. Remove six bolts (2) and washers that hold the rocker shaft in position.3. Remove rocker shaft assembly (1). 4. Remove push rods (4). 5. Remove O-ring seal (5) from rear support bracket. The O-ring seal (5) must be installed new each time the head bolt is removed from the rear support bracket.Install Rocker Shaft And Push Rods
1. Install a new O-ring seal in the rear support bracket of rocker shaft. 2. Install push rods (1).3. Put rocker shaft (2) in position on the cylinder head.
The dowel pins (3) on each end of the rocker shaft and arms must be in alignment with the holes in the cylinder head. If the pins and holes are not in alignment when the bolts are tightened, damage to the rocker shaft and arms can be the result.
4. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the rocker shaft in position. Install the six bolts and washers. 5. Tighten all bolts (4), (5), (6), (7), (8), (9) in number sequence to a torque of 115 lb.ft. (155 N m). Tighten bolts again in number sequence to a torque of 185 13 lb.ft. (250 17 N m). Last, tighten the bolts again (hand turn only) in number sequence to a torque of 185 13 lb.ft. (250 17 N m).6. Make adjustments until the intake valve clearance is .015 in. (0.38 mm) and the exhaust valve clearance is .025 in. (0.64 mm).end by: a) install valve coverDisassemble Rocker Shaft
start by: a) remove rocker shaft and push rods 1. Remove O-ring seal (1) from the rear support bracket. A replacement of the O-ring seal must be made each time the head bolt is removed from the rear support bracket. 2. Remove retainer ring (6), washer (5), spring (4) and washer (3) from each end of rocker shaft. Remove rocker arm (2). 3. Remove pin from rear support bracket with a hammer and punch. Remove rear support bracket (7) from shaft.4. Remove remainder of rocker arms, springs, washers and brackets.5. Check the bore in the bearings for the rockers. The diameter with new bearings must be .7263 .0005 in. (18.448 0.013 mm). The maximum permissible clearance between the shaft and bearings (worn) must not be more than .008 in. (0.20 mm).6. Check the condition of the plugs in the ends of the rocker shaft. If the plugs have damage, use new parts for replacement. Plugs that have damage can cause loss of oil pressure.Assemble Rocker Shaft
1. Install rocker arms (5), brackets (1), washers (4) and springs (2) on the rocker shaft.2. Install rear support bracket (6) on rocker shaft. Make sure hole in rear support bracket is in alignment with hole in rocker shaft.3. Put pin (3) in position in the bracket. 4. Install pin (3) through bracket and shaft with a hammer.5. Pin (3) must extend .378 in. (9.60 mm) above the bracket. 6. Install O-ring seal (7) in the rear support bracket. Install rocker arm (8), washer, spring, washer and retainer ring on the rocker shaft.7. Install the plugs in each end of the rocker shaft if they were removed.8. Put clean engine oil on all the parts after the rocker shaft is assembled.