09403-10313 Suzuki CLAMP

Inspection and Adjustment of Valve Clearance
Inspect and adjust valve clearance when the engine is cold. (1) Inspecting valve clearance(a) Inspect the valve clearance in the firing order by turning the crankshaft 240° in the normal direction to bring each piston to the top dead center on the compression stroke. (b) Attach a socket and ratchet handle to the crankshaft pulley tightening nut, and turn the crankshaft.(c) When the No. 1 piston is at the top dead center on the compression stroke, the "0" line stamped on the circumference of the crankshaft pulley is aligned with the pointer of the timing gear case, and the inlet and exhaust valves are not lifted off their seats by the pushrods. (d) Insert a feeler gage between the rocker arm and valve cap to inspect the clearance.
Checking top dead center cylinder of No. 1 piston compression stroke (1)
Checking top dead center cylinder of No. 1 piston compression stroke (2)(2) Adjusting valve clearance(a) Loosen the lock nut, insert a feeler gage between the rocker arm and valve cap, and while measuring the clearance, tighten or loosen the adjusting screw until the feeler gear moves slightly tight.(b) After adjusting the clearance, securely tighten the locknut, and inspect the clearance again.
Adjusting valve clearanceBleeding of Fuel Injection Pump
(1) Loosen the air vent plug of the fuel injection pump by about 1.5 turns.(2) Move up and down the priming pump cap.(3) Tighten the air vent plug when no air bubbles appear in the fuel coming out of it. Before tightening the last air vent plug, lock the priming pump cap of the fuel feed pump by turning it clockwise while pushing it down.(d) Bleed the right-hand fuel injection pump in the same way as the left-hand one. (a) If all the vent plugs are tightened before the priming pump cap is locked, the fuel pressure acts on the fuel feed pump to make it impossible to return the priming pump cap to the original position.(b) Thoroughly wipe off any fuel spilled from the air vent plugs with a cloth or the like.
Bleeding fuel injection pumpInspection of Fuel Injection Timing
The fuel injection timing varies with the output, speed and other engine specifications. Be sure to check it according to the specification sheet.(1) Checking top dead center of No. 1 piston on compression stroke(a) Apply a special tool or turning socket to the crankshaft pulley tightening nut, and turn the crankshaft in the normal direction of engine rotation or clockwise when seen from the front of the engine.(b) Stop turning the crankshaft when the "0" line stamped on the circumference of the crankshaft pulley is aligned with the pointer of the timing gear case. (c) Move the rocker arms of the inlet and exhaust valves of the No. 1 cylinder up and down to check that the pushrods are not lifting both of the inlet and exhaust valves off their seats or that the inlet and exhaust valves both have no clearance.
Checking top dead center of No. 1 piston on compression stroke(2) Inspecting fuel injection timing(a) Bring the piston to the top, and check the top dead center.Remove the delivery valve holder from the No. 1 plunger of the fuel injection pump, remove the delivery valve, spring and stopper, and install the delivery valve holder alone.(b) Install the spare injection pipe to the No. 1 plunger. Face the other end of the pipe downward so that the flow-out condition of the fuel can be clearly seen.(c) Position the crankshaft at about 60° before the top dead center of the No.1 piston on the compression stroke.
Inspecting fuel injection timing (1)(d) Feed the fuel by priming the pump, and slowly turn the crankshaft in the normal direction while allowing the fuel to flow out of the injection pipe.(e) Turn the crankshaft more slowly when the flow of the fuel out of the injection pipe is about to stop, and stop turning the crankshaft when the flow of the fuel out of the fuel injection pipe is stopped.(f) Check that the line stamped on the crankshaft pulley and the pointer indicate the fuel injection timing.
Inspecting fuel injection timing (2)Adjustment of Fuel Injection Timing
When the fuel is injected earlier than normal, turn the fuel injection pump away from the crankcase. When the fuel is injected later than normal, turn the fuel injection pump toward the crankcase.
Adjustment of fuel injection timingInspection And Adjustment of V-Belt Tension
Inspect the V-belt for the mount of deflection when it is strongly pressed down on with the thumb at the center of its span. Adjust the V-belt to proper tension by loosening all of the bolts securing the alternator and installing the alternator at an appropriate angle.
Inspection and adjustment of V-belt tensionAdjustment of Governor (In-line Fuel Injection Pump Specification)
Inspection and adjustment of minimum no-load speed (low idle speed) and maximum no-load speed
(a) Each engine has the minimum no-load speed (low idle speed) and maximum no-load speed checked on the test bench at the factory and has the setting bolts sealed. These settings can be inspected and adjusted at our designated service shop only.(b) After the governor parts are adjusted, seal all external stoppers as done at the time of factory shipment.(c) Whether the seals are intact or not has important bearing on the validity of claims under warranty. Be sure to seal all the specified sections.(d) When inspecting and adjusting the governor, be prepared to operate the engine stop lever manually in anticipation of the engine overrunning (running at an extremely high speed).
Inspect and adjust the governor after engine warm-up operation long enough for the water and oil temperatures to rise to 70 °C [158 °F].(1) Starting engine(a) Pull the speed control lever to the high-speed side, and operate the starter switch.(b) The engine fires at a speed of about 150 min-1, and then increases in speed. Operate the speed control lever to maintain the engine speed at 800 to 1000 min-1.(c) When the engine speed has stabilized, return the speed control lever to the low idle speed position.
Starting