67224-92E00 Suzuki BRAKE ARM ASSEMBLY

1. Use tool (A) to loosen the nuts on the fuel injection valves and use tool (B) to loosen the nuts on the adapter assemblies in the cylinder head. Remove inner fuel lines (1).
If necessary, use tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with tool (C) to remove the push rods.
2. Put compression on the valve springs with tool (C) and remove push rods (2).3. Push the push rod end of the rocker arms down. 4. Remove the intake valve lifter with tooling (E) as follows: a) Install the 5P2685 Nut and the 5P6601 Collet on the 5P2408 Outer Handle Assembly.b) Install the 5P6599 Inner Handle Assembly in the 5P2408 Outer Handle Assembly.c) Install tooling (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of intake valve lifter.d) Remove intake valve lifters (3) from the cylinder block with tooling (E). 4. Remove the exhaust valve lifters with tooling (E) as follows: a) Install 5P2685 Nut (5) and 5P6601 Collet (6) on 5P2408 Outer Handle Assembly (4). The opening in the cylinder head for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side. b) Install the outer handle assembly in the intake valve lifter side of the cylinder head. Slide the flat area of 5P2408 Outer Handle Assembly (4) through the head casting and install the 5P6601 Collet in the exhaust valve lifter. c) Install 5P6599 Inner Handle Assembly (7) in 5P2408 Outer Handle Assembly (4). Hold the 5P2408 Handle Assembly and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of exhaust valve lifter.d) Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e) Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting and remove it from the intake valve lifter side of the cylinder head. f) Use a magnet and remove exhaust valve lifter (8) from the intake valve lifter side of the cylinder head.5. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2 must be done to intall intake or exhaust valve lifters.
When a valve lifter is removed, a new guide spring must be installed.
1. Install a new guide spring (1) on the valve lifters. 2. Put the intake or exhaust valve lifter in position in 5P2395 Holder (5) of tooling (A). Install 5P2685 Nut (4) and 5P2400 Compressor (3) on 5P2408 Outer Handle Assembly (2). Install the 5P2400 Compressor on the lifter over the guide spring. The opening in the cylinder head for the intake valve lifter is larger than the opening in the exhaust valve lifter side. All tooling and valve lifter must be installed and removed from the intake valve lifter side.3. Install the exhaust valve lifters with tooling (A) as follows: a) Install exhaust valve lifter (6) and the handle assembly in the cylinder head opening on the intake valve lifter side. Slide the flat area of the 5P2408 Outer Handle Assembly through the casting in the cylinder head. b) Put the exhaust valve lifter in the valve lifter bore of the cylinder block. Install 5P6599 Inner Handle Assembly (7) in the 5P2408 Outer Handle Assembly and push the exhaust valve lifter from tooling (A).c) Remove the 5P6599 Inner Handle Assembly from the 5P2408 Outer Handle Assembly. Slide the 5P2408 Outer Handle Assembly to the intake valve lifter side of the cylinder head and remove it.4. Install the intake valve lifters with tooling (A) as follows: a) Install 5P6599 Inner Handle Assembly (7) in the 5P2408 Outer Handle Assembly.b) Install intake valve lifter (8) into the valve lifter bore of the cylinder block with tooling (A). Use the 5P6599 Inner Handle Assembly to push the lifter from tooling (A). Remove tooling (A).
If necessary, use tool (C) to turn the engine so the valves do not make contact with the pistons when the valves are opened with tool (B) to install the push rods.
5. Turn the rocker arms up and use tool (B) to install push rods (9). 6. Install inner fuel lines (10). Use tool (D) to tighten the nuts on the adapter assemblies in the cylinder head and use tool (E) to tighten the nuts on the fuel injection valves to a torque of 30 5 lb.ft. (40 7 N m).end by:a) install valve covers and bases