09205-04019 Suzuki PIN

1. Remove bolts (1) and lift shaft (2) and the rocker arms off the valve cover base and the push rods. 2. Remove push rods (3) from the valve lifters and valve cover base. Put identification marks on the push rods as to their location in the engine. 3. Remove bridge assemblies (4) from the dowels.Install Rocker Shaft Assemblies And Push Rods
1. Loosen the adjustment nuts and screws (5) on valve bridges (4).2. Put clean engine oil on the bridge dowels, the inside diameter of valve bridges (4) and on the top pad of the valve bridge. Install valve bridges (4) on the bridge dowels as shown.3. While bridges (4) are pushed straight down with a force of 5 to 45 N (1 to 10 lb) on the top contact surface, turn adjustment screw (5) until it makes contact with the valve stem. Turn screw (5) another 20° to 30° (1/3 to 1/2 hex on nut). This will straighten the dowel in the guide and compensate for clearance (slack) in the threads.4. Hold adjustment screw (5) in position, and tighten the nut around screw (5) to a torque of 30 4 N m (22 3 lb ft).
Install the push rods in their original location in the engine.
5. Put clean engine oil on the push rods and in the lifter cups for the push rods. Put push rods (3) in position in the valve lifters.
Make sure the crankshaft and camshafts are in time with each other and that adjustment screws (6) are turned all the way out before the rocker shaft bolts are tightened or damage to the valves or pistons can be the result. See the topic, Install Camshafts, for the procedure to time the engine.
6. Put the rocker arms and shaft (2) in position on the valve cover. Make sure the rocker shafts and push rods are in alignment, and install the bolts to hold shaft (2). Tighten the bolts to a torque of 109 14 N m (80 10 lb ft).7. Make an adjustment to the Bridges. See the topic, Bridge Adjustment, in the Testing And Adjusting manual for the correct procedures.8. Adjust the valve lash for the intake and exhaust valves and set the injection pump timing. See instructions for Valve Lash Adjustment and Injection Pump Timing in Testing And Adjusting.9. Tighten the adjusting screw locknuts on the rocker arms to a torque of 70 15 N m (52 11 lb ft).End By:a. install valve coversDisassemble And Assemble Rocker Shaft Assemblies
Start By:a. remove rocker shaft assemblies and push rods 1. Slide shaft assembly (1) out of rocker arms (2). If necessary, remove the dowel from shaft assembly (1). 2. Remove adjustment screw (4) and the nut from rocker arm (2).3. Use a hammer and punch to push socket (3) out of rocker arm (2). 4. Remove the ring that holds button (5) in socket (3), and remove the button from the socket. 5. Use tool group (A) to remove bearing (6) from rocker arm (2).6. Do Steps 2 through 5 for the other two rocker arms. The following steps are for installation of the rocker shaft assemblies.7. Align the oil hole (slot) in the bearing with the oil passage in rocker arm (2). Use tool group (A) to install the bearing in rocker arm (2) with the joint in the bearing toward the top of the rocker arm. The bore in the bearing must be 37.140 0.015 mm (1.4622 .0006 in) after assembly. To obtain the above dimension on bearing (6), it will be necessary to machine prior to assembly. It is also necessary that bearing (6) have a machined surface to allow for proper lubrication and evenness of wear. 8. Align the scribe mark on socket (3) with the mark on rocker arm (2), and install the socket in the rocker arm.9. Put button (5) in socket (3), and install ring (7) to hold the unit together.10. Install adjustment screw (4) and the nut on rocker arm (2).11. Do Steps 1 through 4 for the other two rocker arms.12. If the dowel was removed from shaft assembly (1), install the new dowel in the shaft until it is 6.00 mm (.236 in) above the surface of the shaft.13. Put clean engine oil on the rocker arm bearings and shaft assembly (1). Install rocker arms (2) on shaft assembly (1).End By:a. install rocker shaft assemblies and push rods