Caution! Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "No.1", "No.2", "Exhaust", "Intake", so that each will be restored to the original location during assembly.
Camshaft
All camshafts should be checked for runout and also for wear of cams and journals if the engine has been noted as giving abnormal noise, vibration or lack power output. Any of these conditions may be caused by camshafts worn down or distorted to the service limit.
The camshafts can be identified by the embossed letters (1) and cords (2) stamped on the camshaft ends.
![](https://motoinstruction.ru/img/suzuki/14/119940.jpg)
Letter (1) | Cord (2) | |
No.1 (Front) intake camshaft | INF | K |
No.1 (Front) exhaust camshaft | EXF | B |
No.2 (Rear) intake camshaft | INR | M |
No.2 (Rear) exhaust camshaft | EXR | D |
Cam wear
Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output.
The limit of cam wear is specified for both intake and exhaust cams in terms of cam height (H), which is to be measured with a micrometer. Replace camshaft if it wears worn down to the limit.
Cam height (H):
- Service Limit:
- (Intake): 35.18 mm (1.385 in)
- (Exhaust): 33.18 mm (1.306 in)
- 09900-20202: Micrometer (25-50 mm)
![](https://motoinstruction.ru/img/suzuki/14/119941.jpg)
Camshaft journal wear
Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.
Use the plastigauge to read the clearance at the widest portion, which is specified as follows:
Camshaft journal oil clearance:
- Service Limit (IN & EX): 0.150 mm (0.0059 in)
- 09900-22301: Plastigauge
- 09900-22302: Plastigauge
![](https://motoinstruction.ru/img/suzuki/14/119942.jpg)
Notes:
- Install camshaft journal holder to their original positions. (3-99, 3-102)
- Do not rotate the camshaft with the plastigauge in place.
![](https://motoinstruction.ru/img/suzuki/14/119943.jpg)
Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque.
- Camshaft journal holder bolt: 10 N·m (1.0 kgf·m, 7.0 lb·ft)
Remove the camshaft holders, and read the width of the compressed plastigauge with envelope scale. This measurement should be taken at the widest part.
![](https://motoinstruction.ru/img/suzuki/14/119944.jpg)
If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification.
Journal holder I.D.
- Standard (IN & EX): 22.012-22.025 mm (0.8666-0.8671 in)
![](https://motoinstruction.ru/img/suzuki/14/119945.jpg)
- 09900-20602: Dial gauge (1/1000,1 mm)
- 09900-22403: Small bore gauge (18-35 mm)
Camshaft journal O.D.
- Standard (IN & EX): 21.959-21.980 mm (0.8645-0.8654 in)
![](https://motoinstruction.ru/img/suzuki/14/119946.jpg)
- 09900-20205: Micrometer (0-25 mm)
Camshaft runout
Measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit.
Camshaft runout:
- Service Limit (IN & EX): 0.1 mm (0.004 in)
- 09900-20607: Dial gauge (1/100 mm)
- 09900-20701: Magnetic stand
- 09900-21304: V-block set (100 mm)
![](https://motoinstruction.ru/img/suzuki/14/119947.jpg)
Cam chain tension adjuster
Check that the push rod (1) can slide smoothly with the lock (2) of the ratchet mechanism released. If it does not slide smoothly or the ratchet mechanism is worn or damaged, replace the cam chain tension adjuster with a new one.
![](https://motoinstruction.ru/img/suzuki/14/119948.jpg)
Cam chain tensioner
Check the contacting surface of the cam chain tensioner.
If it is worn or damaged, replace it with a new one.
![](https://motoinstruction.ru/img/suzuki/14/119949.jpg)
Cam chain guide
Check the contacting surface of the cam chain guide. If it is worn or damaged, replace it with a new one.
![](https://motoinstruction.ru/img/suzuki/14/119950.jpg)