21111-93100-01J Suzuki Lever, Clutch

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-6195 Valve Spring Compressor 1
416-0292 Adapter 1
416-0288 Head 1 Start By:
Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clean the bottom mating surface of the cylinder head. Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to Specifications, "Cylinder Head Valves" for the correct dimensions.
Place a temporary identification mark on the heads of the valves to identify the correct position.Note: Inlet valves have a recess in the center of the head.
Use a suitable lifting device to position the cylinder head with the valve springs upward. The weight of the cylinder head is approximately 65 kg (143 lb).Note: Ensure that the cylinder head is kept on a clean, soft surface to prevent damage to the machined face.
Personal injury can result from being struck by parts propelled by a released spring force.Make sure to wear all necessary protective equipment.Follow the recommended procedure and use all recommended tooling to release the spring force.
Illustration 1 g01335985
Typical example
Install Tooling (A) in position on the cylinder head to compress appropriate valve spring (3).
Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
Apply sufficient pressure to Tooling (A) to remove valve keepers (1).Note: Do not compress the spring so that valve spring retainer (2) touches valve stem seal (4).
Slowly release pressure on Tooling (A).
Illustration 2 g01335986
Remove valve spring retainer (2). Remove valve spring (3).
Repeat steps 4 to 7 for the remaining valves.
Remove Tooling (A).
Remove valve stem seals (4).
Use a suitable lifting device to carefully turn over the cylinder head.
Remove valves (5).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 9U-6195 Valve Spring Compressor 1
416-0292 Adapter 1
416-0288 Head 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clean all components of the cylinder head assembly. Ensure that all ports, all coolant passages, and all lubrication passages in the cylinder head are free from debris. Follow Steps 1.a through 1.d to inspect the components of the cylinder head assembly. Replace any components that are worn or damaged.
Inspect the cylinder head for wear and for damage. Refer to System Operation, Testing and Adjusting, "Cylinder Head Inspect".
Inspect the valve seats for wear and for damage. Refer to Specifications, "Cylinder Head Valves" for further information.
Inspect the valve guides for wear and for damage. Refer to Specifications, "Cylinder Head Valves" and System Operation, Testing and Adjusting, "Valve Guide - Inspect" for further information.
Inspect the valves for wear and for damage. Refer to Specifications, "Cylinder Head Valves" for the correct procedure.
Inspect valve springs (3) for damage and for the correct length. Refer to Specifications, "Cylinder Head Valves" for the correct procedure.
Illustration 3 g01335986
Lubricate the stems of valves (5) with clean engine oil. Install valves (5) in the appropriate positions in the cylinder head. Check the depth of the valves below the face of the cylinder head. Refer to System Operation, Testing and Adjusting, "Valve Depth - Inspect" for more information.
Use a suitable lifting device to carefully turn over the cylinder head. The weight of the cylinder head is approximately 65 kg (143 lb).Note: Ensure that all the valves remain in place.
Install new valve stem seals (4) onto each of the valve guides.Note: The outer face of the valve guides must be clean and dry before installing valve stem seals (4).
Install valve spring (3) onto the cylinder head. Position valve spring retainer (2) on valve spring (3).
Personal injury can result from being struck by parts propelled by a released spring force.Make sure to wear all necessary protective equipment.Follow the recommended procedure and use all recommended tooling