11115-93J10-001 Suzuki GUIDE, VALVE (OS)

1. Remove all access covers (1) from the sides of the engine. 2. Push valve lifters (2) up away from the camshaft into the cylinder head assemblies, and hold the lifters in position. An O-ring seal can be used to hold the valve lifters up. 3. Remove the bolts and cover (3) from both sides of the front drive housing.
Use the 8B7561 Step Plate of tooling (A) to prevent damage to the end of the camshaft during removal of drive gear (4).
6. Use tooling (A) to remove drive gear (4) from the end of the camshaft on each side of the engine. It may be necessary to hit the end of the screw, part of 8B7548 Push-Puller in tooling (A), to loosen drive gear (4) from the taper on the camshaft. Remove the drive gears from the flywheel housing. 7. Remove bolts (6) and washer (5) from the end of the camshaft on each side of the engine.
Typical Example8. Install tooling (B) on each end of rear camshaft (8). Tooling (C) can be installed on the flywheel housing to remove the camshafts from the rear of the engine, or it can be installed on the front drive housing to remove the camshafts from the front of the engine.9. Install tooling (C) on the flywheel housing.10. Install tooling (D) on one end of tooling (B).11. Pull the camshafts out while rotating them with tooling (D). Pull the camshafts out of the engine until a hoist can be fastened to them. Remove front camshaft (7) and rear camshaft (8) as a unit from the engine. The weight of the 3512 Engine camshaft unit is approximately 63 kg (139 lb). The weight of the 3516 Engine camshaft unit is approximately 82 kg (181 lb). 12. Remove bolts (9). Separate the camshafts, and remove spacer (10).13. If necessary, remove the dowel from the end of the front camshaft.Install Camshafts
Typical Example1. Position tooling (C) on the flywheel housing. Install the bolts that hold it. Do not tighten the bolts at this time.2. Install tool (B) on the end of front camshaft (7).3. Install front camshaft (7) in the engine until tool (B) is located in the first camshaft bearing.4. Rotate the camshaft and tighten the bolts that hold tooling (C) to the flywheel housing.5. Rotate the camshaft and install it until the end of the camshaft is just out of tooling (C).
Typical Example
Typical Example6. If dowel (11) was removed from the front camshaft, install the dowel in the front camshaft. Install the dowel until the end of the dowel is 22.0 0.5 mm (.87 .02 in) from the end surface of the camshaft. Make sure the camshafts are installed respective to the marks (rear L.H., rear R.H.) on the ends of the camshafts.7. Fasten a hoist to rear camshaft (8). Install spacer (10) and rear camshaft (8) on front camshaft (7). Install bolts (9) and tighten by hand to a torque of 55 7 N m (41 5 lb ft).8. Install tooling (B) and (D) on the end of rear camshaft (8).9. Rotate and install the camshafts the remainder of the way.10. Remove tooling (B), (C) and (D) from the flywheel housing and camshafts. 11. Install washers (5) and bolts (6). 12. Remove timing pin (12) from the storage position on the side of the engine. 13. Turn the camshaft until timing pin (12) can be installed through the cylinder block and into the groove (13) in the camshaft. 14. Remove cover (14) and plug (15). 15. Install timing bolt (16) in the flywheel housing. Use tool (A) and a ratchet to turn the flywheel until the timing pin can be installed in the hole in the flywheel. The No. 1 cylinder is not at top dead center. 16. Install drive gears (4) on the end of the camshaft on each side.17. Install service meter. See the topic, Install Service Meter.18. Install magneto drive. See the topic, Install Magneto Drive.19. Remove the timing pins for the camshafts and return them to their storage positions.20. Remove the timing bolt from the flywheel. Install the plug in the timing hole. Remove tool (A) and install the cover on the flywheel housing. 21. Install the gasket and cover (3) on both sides of the front drive housing. 22. Remove the O-ring seals from valve lifters (2). Push the valve lifters down against the camshaft. 23. Make sure the seals in place in access covers (1). Install the access covers on each side of the engine.End By:a. install governorb. install rocker shaft assemblies and push rodsc. install magnetod. install service meter and rear cover