09492-80005 Suzuki JET, PILOT (80)

1. Remove four bolts (1) and the washers from the rocker shaft.2. Remove rocker shaft (2) from the cylinder head.3. Remove push rods (3) from the engine.Install Rocker Shaft Assembly And Push Rods
1. Loosen adjusting screws (4) on the rocker arms for valve clearance. This will prevent a bent valve or push rod at installation.2. Install push rods (3) as shown.3. Put rocker shaft (2) in position on the cylinder head.4. Put 5P3931 Anti-Seize Compound on the threads of the bolts (except the rear bolt flywheel end) that holds the rocker shaft in position. Install the four bolts and washers. Make sure the rocker arms are on all of the push rods.
The dowels on each end of the rocker shaft assembly must make an alignment with the holes in the cylinder head assembly. If the dowels and holes are not in alignment when the rocker shaft assembly is tightened, damage to the rocker shaft assembly will be the result.
5. Tighten the bolts for the rocker shaft as follows:a. Tighten bolts in number sequence to a torque of 155 N m (115 lb.ft.).b. Tighten bolts again in number sequence to a torque of 250 17 N m (185 13 lb.ft.).c. Tighten bolts again and for the last time in number sequence (hand tighten only) to a torque of 250 17 N m (185 13 lb.ft.). 6. The assembled length of springs (5) at both ends of the rocker shaft must be 1.50 0.25 mm (.059 .010 in.). Remove or install the washers behind springs to change the assembled length of the springs.7. Make adjustments until the intake valve clearance is 0.38 mm (.015 in.) and the exhaust valve clearance is 0.64 mm (.025 in.). See the Topic, Engine Valve Lash as shown in the Maintenance Guide. Tighten the locknuts for the adjusting screws to a torque of 29 7 N m (21 5 lb.ft.).end By:a. install valve coverRocker Shaft Assembly, Disassemble And Assemble
Start By:a. remove rocker shaft assembly and push rods 1. Remove O-ring seal (1) from the rear support bracket. A replacement of the O-ring seal must be made each time the head bolt is removed from the rear support bracket. 2. Remove retainer ring (6), washer (5), spring (4) and washers (3) from each end of the rocker shaft. Make a note of the number of washers (3) used at each end of the shaft. Remove rocker arms (2) from each end of the rocker shaft. All the rocker arms, springs, washers and brackets, except the rear support bracket, can be removed from the shaft. 3. Remove the pin from the rear support bracket with a hammer and punch. Remove rear support bracket (7) from the shaft.4. Remove remainder of the rocker arms, springs, washers and brackets from the shaft.5. Remove the plugs from each end of the shaft if necessary. The following steps are for the assembly of the rocker shaft assembly. 6. Install rocker arms (12), brackets (8), washers (11) and springs (9) on the rocker shaft.7. Install rear support bracket (7) on the rocker shaft. Make sure the hole in the rear support bracket is in alignment with the hole in the rocker shaft.8. Put pin (10) in position in the bracket. 9. Install pin (10) through the bracket and shaft with a hammer.10. Pin (10) must extend 9.60 mm (.378 in.) above the bracket. 11. Install O-ring seal (1) in the rear support bracket. Install rocker arm (2) the original number of washers, the spring, the washer and the retainer ring on the rocker shaft.12. Install the front support, rocker arm, original number of washers, the spring, the washer and the retainer ring on the rocker shaft.13. Install the plugs in each end of the rocker shaft, if they were removed.End By:a. install rocker shaft assembly and push rods