99011-94471-03A Suzuki MANUAL, OWNER'S

Engine Valve Lash
Check/Adjust
All valve lash adjustments after the Initial 92 Day FRA Inspection Interval are to be performed at Every 184 Day Inspection Interval.The crankshaft/camshaft timing must be checked and a bridge adjustment made before making a valve clearance adjustment.Use the following sequence to perform this maintenance.
Thoroughly clean the area around the valve mechanism covers to prevent the entry of foreign material into the top of cylinder head, unit injector and valve mechanism. After the covers are removed, place a clean cloth over the unit injector and install protective covers in the openings whenever fuel lines are disconnected to prevent entry of airborne dirt, debris and abrasive particles, which may cause unit injector seizures.Failure to observe these precautions can result in unit injector seizures.
Cam, bridge, valve and unit injector checks/adjustments can be made with only two turns of the crankshaft. The first turn is to obtain Top Center (TC) of No. 1 piston on the compression stroke. The cam timing as well as one-half of all bridges, valves, and unit injectors can be checked at this setting.The second turn of the crankshaft is to obtain TC of no. 1 piston on the exhaust stroke. All remaining bridges, valves and unit injectors can then be checked.3508 Engine Timing
3512 Engine Timing
3516 Engine Timing
1. Set No. 1 piston to TC Compression stroke and check timing between the camshaft and crankshaft. At No. 1 piston TC Compression, both rocker arms should be loose and the unit injector should be partially depressed.2. Perform valve clearance check. If valve clearance is within specifications, no adjustment is necessary.3. If adjustment is necessary, first adjust the bridge assembly. Refer to topic Bridge Adjustment in this section. Lubrication is not necessary for correct operation if bridge adjustment is required.4. Check unit injector timing, make adjustments as necessary. Refer to the Service Manual for this procedure.5. Rotate the crankshaft one revolution to set No. 1 piston to TC Exhaust stroke, then repeat steps 1 through 3.6. Conclude by installing all valve mechanism covers.Check Crankshaft/Camshaft Timing
Be sure the engine cannot be started while this maintenance procedure is being performed. To prevent possible injury, do not use the starting motors to turn flywheel and crankshaft. Disconnect battery to starting motor connection.
To perform this and the following maintenance procedures, refer to the Service Manual for this engine.1. Disable the starting system so the engine cannot accidentally start.2. Clean around all valve mechanism covers and remove covers.
The crankshaft and camshaft must be synchronized. If the camshaft timing pin cannot be installed, refer to Camshaft Gear Removal in the Service Manual. Do Not attempt to adjust the valves if the crankshaft and camshaft are not synchronized. Disregard for this notice can result in bent valves.
Bridge Adjustment
Be sure to adjust the valve bridges before adjusting valves.
To perform this and the following maintenance procedures, refer to the Service Manual for this engine.1. Apply clean SAE 40 engine oil in the lubrication passage of the bridge (hole in top surface of cast web). Be sure the rocker arm is loose to verify there is valve lash.2. Back off the adjusting screw and press down on the rocker arm directly above the bridge. Apply a force of 5 to 40 N (1 to 10 lb).3. Turn the adjusting screw clockwise until the screw touches the valve stem.4. Turn the screw an additional 15 to 25 degrees (1/3turn of a hex nut) to equalize clearance with the dowel.5. Hold the adjusting screw in this position and torque the locknut to 30 4 N m (22 3 lb ft).6. Perform this procedure for both bridges at each cylinder. Apply clean engine oil on the contact point of each bridge and unit injector.After completing the bridge adjustment for each cylinder as indicated in the Engine Timing Chart, proceed with the Valve Lash (Clearance) adjustment.Valve Lash Clearance Adjustment
Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the crankshaft and flywheel.
With the engine stopped and cold, measure the valve clearance. Always turn the flywheel in the direction of normal rotation when barring the engine.Before checking or adjusting the valve lash, move the valve rocker arm up and down several times to push the oil out of the push rod socket. This is necessary to get accurate valve lash measurements.Check
When the valve lash (clearance) is checked, an adjustment is NOT necessary if the measurement is within 0.08 mm ( 0.003 in) of the value given in the chart below. Valve Clearance is measured between the rocker arm and the bridge for the valves. Adjust the valve clearance to the value specified in the chart. Be sure to adjust the valve bridges before adjusting the valve.Refer to the Engine Timing chart for your engine.1. Press the oil out of the push rod socket. Use a feeler gauge and measure the valve clearance for the intake and exhaust valves in the sequence found in the Engine Timing chart for your engine. The clearance dimension is listed in the chart above.2. If the valve clearance check is found to be within 0.08 mm ( 0.003 in), the valve clearance setting is correct. Proceed with the topic "Unit Injector Timing and Injector Synchronization".3. If the clearance dimension is not within this tolerance, proceed to the topic "Bridge Adjustment," before making a valve clearance adjustment.Valve lash dimensions are to be made to specific values. Adjust the intake valve and exhaust valves in the sequence found in the Engine Timing Chart for your engine.4. Adjust the intake valves to get 0.38 mm (0.015 in) clearance between the rocker arm button and the bridge wear seat. Turn the adjusting screw clockwise (CW) to achieve this dimension. After this clearance is obtained, tighten the locknut to a torque of 70 15 N m (50 11 lb ft). Recheck each adjustment and put a mark on the rocker arm to indicate that the adjustment has been made.