- Remove the frame side covers. (9-5)
- Remove the fuel tank. (6-3)
- Remove the frame head covers and radiator covers. (9-6)
- Remove the air cleaner chamber. (6-13)
- Remove the all spark plugs. (2-13)
- Remove the right and left cylinder head cover brackets. (3-14)
![](https://motoinstruction.ru/img/suzuki/24/129332.jpg)
- Disconnect the PAIR hoses 1.
- Disconnect the lead wire 2 from to frame.
- Remove the front and rear PAIR reed valve covers 3.
- Remove the cylinder head covers.
Note: Remove the front cylinder head cover to left side and rear cylinder head cover to right side.
![](https://motoinstruction.ru/img/suzuki/24/129333.jpg)
The valve clearance specification is different for intake and exhaust valves. Valve clearance must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing.
Valve clearance (when cold):
Standard:
- IN. : 0.09 - 0.16 mm (0.004 - 0.006 in)
- EX.: 0.20 - 0.30 mm (0.008 - 0.012 in)
Note:
- The tappet clearance should be taken when each cylinder is at Top Dead Center (TDC) of compression stroke.
- The cams (IN & EX) on the front cylinder at position А show the front cylinder at TDC of compression stroke.
- The cams (IN & EX) on the rear cylinder at position В show the rear cylinder at TDC of compression stroke.
- The clearance specification is for COLD state.
- To turn the crankshaft for clearance checking, be sure to use a wrench, and rotate in the normal running direction. All spark plugs should be removed.
![](https://motoinstruction.ru/img/suzuki/24/129334.jpg)
- Remove the secondary gear case cover. (3-6)
- Remove the generator cover cap 4, valve timing inspection plug 5 and generator cover plug 6.
![](https://motoinstruction.ru/img/suzuki/24/129335.jpg)
- Turn the crankshaft to set the #1 (Rear) cylinder at TDC of compression stroke. (Align the "R | T" line on the generator rotor to the center of valve timing inspection hole and also bring the camshafts to the position as shown in page 2-8.)
![](https://motoinstruction.ru/img/suzuki/24/129336.jpg)
- To inspect the #1 (Rear) cylinder tappet clearance, use a thickness gauge between the tappet and the cam. If the clearance is out of specification, adjust it into the specified range.
09900-20803: Thickness gauge
![](https://motoinstruction.ru/img/suzuki/24/129337.jpg)
- Turn the crankshaft 486 degrees (1-1/3 turns) to set the #2 (Front) cylinder at TDC of compression stroke. (Align the "F | T" line on the generator rotor to the center of valve timing inspection hole and also bring the camshafts to the position as shown in page 2-8.)
![](https://motoinstruction.ru/img/suzuki/24/129338.jpg)
- Inspect the #2 (Front) cylinder tappet clearance as the same manner of #1 (Rear) cylinder and adjust the clearance if necessary.
09900-20803: Thickness gauge
![](https://motoinstruction.ru/img/suzuki/24/129339.jpg)
Valve clearance adjustment
The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim.
- Remove the intake or exhaust camshafts. (3-14 to 3-15 and 3-17 to 3-18)
- Remove the tappet and shim by fingers or magnetic hand.
- Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated.
- Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 25 sizes of tappet shim are available ranging from 2.30 to 3.50 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure its size. Refer to the tappet shim selection table (2-11 and 2-12) for details.
![](https://motoinstruction.ru/img/suzuki/24/129340.jpg)
![](https://motoinstruction.ru/img/suzuki/24/129341.jpg)
Note:
- Be sure to apply engine oil to tappet shim top and bottom faces.
- When seating the tappet shim, be sure the figure printed surface faces the tappet.
Note: Reinstall the camshafts in the specified manner. (3-102 to 3-109)
- After replacing the tappet shim and camshafts, rotate the L engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement. Then check the clearance again to confirm that it is within the specified range.
- After finishing the valve clearance adjustment, reinstall the following items.
- Cylinder head cover (3-109)
- PAIR control solenoid valve (12-7)
- Spark plug and plug cap (2-16)
- Valve timing inspection plug and generator cover plug (3-111)
![](https://motoinstruction.ru/img/suzuki/24/129342.jpg)
Intake side
Tappet shim selection table [intake] tappet shim no. (12892-41c00-xxx)
![](https://motoinstruction.ru/img/suzuki/24/129344.jpg)
How to use this chart:
I. Measure tappet clearance. "ENGINE IS COLD"
II. Measure present shim size.
III. Match clearance in vertical column with present shim size in horizontal
Example
- Tappet clearance is — 0.23 mm
- Present shim size — 2.70 mm
- Shim size to be used — 2.80 mm
Exhaust side
Tappet shim selection table [exhaust] tappet shim no. (12892-41c00-xxx)
![](https://motoinstruction.ru/img/suzuki/24/129345.jpg)
How to use this chart:
I. Measure tappet clearance. "ENGINE IS COLD"
II. Measure present shim size.
III. Match clearance in vertical column with present shim size in horizontal
Example
- Tappet clearance is — 0.38 mm
- Present shim size — 2.90 mm
- Shim size to be used — 3.05 mm