Suzuki LT-R450K6 User manual

GENERAL INFORMATION 1-1
CONTENTS
.........................................................................
WARNING/CAUTION/NOTE 1- 2
GENERAL PRECAUTIONS ......................................................................... 1- 2
SUZUKl LT-R450K6 ('06-MODEL) ............................................................. 1- 4
.....................................................................
SERIAL NUMBER LOCATION 1- 4
.......................
1 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION 1- 5
..........................................................
FUEL (FOR USA AND CANADA)
1- 5
........................................................
FUEL (FOR OTHER COUNTRIES)
1- 5
ENGINE OIL (FOR USA)
........................................................................ 1- 5
ENGINE OIL (FOR OTHER COUNTRIES) ............................................. 1- 5
........................................................................................
BRAKE FLUID 1- 5
ENGINE COOLANT ................................................................................ 1- 6
BREAK-IN PROCEDURES ........................................................................... 1- 6
..............................................................................
INFORMATION LABELS 1- 7
SPECIFICATIONS ......................................................................................... 1- 8
.............................................................
DIMENSIONSAND DRY MASS
1- 8
ENGINE .................................................................................................. 1- 8
DRIVE TRAIN ......................................................................................... 1- 8
CHASSIS ................................................................................................ 1- 9
......................................................................................... ELECTRICAL 1- 9
CAPACITIES .......................................................................................... 1- 9
COUNTRY AND AREA CODES
The following codes stand forthe applicable country(-ies)and area(-s)
CODE
E-19
E-28
E-33
COUNTRY or AREA
E.U.
Canada
California
(U.S.A.)
EFFECTIVE FRAME NO .
JSAAL41A 62100001 -
JSAAL41A 62100001 -
JSAAL41A 62100001 -

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructionscarefully.To emphasize special information,the symbol
and the words WARNING. CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlightedby these signal words.
Indicates a potentialhazardthat could result indeath or injury.
I CAUTION I
lndicates a potential hazard that could resultinvehicledamage.
NOTE:
Indicatessoecialinformationto make maintenanceeasier orinstructionsclearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potentialhazards relating to the sewicing, or lack of servicing,
of the vehicle. In additionto the WARNINGS
and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to performa particular service operation, ask a more experiencedmechanic for advice.
GENERAL PRECAUTIONS
Proper service and repair procedures are Important for thesafety of the service mechanic and
the safety and reliability of the vehicle.
When 2 or more personswork together, pay attention tothe safety of each other.
When it is necessary to run the englne indoors, make sure that exhaust gas isforced out-
doors.
When working with toxic or flammable materials, make sure that the area you work iniswell-
ventilated andthat you follow ail of the material manufacturer's instructions.
Never use gasoline asa cleaning solvent.
'To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
untilthey have cooled.
After servicing thefuel, oil, water, exhaust or brake systems, check all lines andfittings related
tothesystem for leaks.

+ If parts replacement isnecessary, replace the partswith Suzuki Genulne Parts or their equiva-
lent.
When removlng parts that are to be reused, keep them arranged inan orderly manner sothat
they may bereinstalled inthe proper order and orientatlon.
* Besureto use special toolswhen instructed.
Make surethat all parts used in reassembly areclean. Lubricatethem when specifled.
Usethespecified lubricant. bond, or sealant.
* When removingthe battery, dlsconnect the negative cablefirst andthenthe positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover onthe positiveterminal.
When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negativecablefrom the battery.
When tightening the cylinder head or case bolts and nuts, tlghten the larger sizes first.
Always tighten the boltsand nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
Never reuse a circlip. When installinga newcircllp, takecare nottoexpand theendgap larger
than requiredto slip theclrclip over the shaft. After Installinga circlip, always ensurethat itis
completely seated
in itsgrooveand securely fltted.
' Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread issmeared with them.
1 After reassembling, check partsfor tightness and proper operation.
' Toprotecttheenvironment, do notunlawful\ydispose of used motor oil, engine coolant and
other fluids: batteries and tlres.
' To protect Earth's natural resources, properly disposeof usedvehicle and parts.

1-4 GENERAL INFORMATION
SUZUKI LT-R450K6 ('06-MODEL)
a
Differencebetween photograph andactual vehicle may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) (1) is stamped on the right side of the
steering head pipe. The engine serial number
la is located on the rear side of the crankcase. These num-
bers are required especially for registeringthe machine and orderingspare parts.

GENERAL INFORMATION 1-5
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleadedgasoline of at least 90 pump octane (Rl2 + Ml2).
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol
with appropriate cosolvents and corrosion inhibitor is permissible.
FUEL (FOR OTHER COUNTRIES)
Gasoline used should be graded 95 octane (Research Method) or higher. Unleaded gasoline is recom-
mended.
ENGINE OIL (FOR USA)
Oil quality is a major contributorto your engine's performance and life.Always select good quality engine oil.
Suzuki recommends the use of SUZUKl PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of
SFISG or SHISJ in API with MA inJASO.
Suzuki recommends the use of SAE 10W-40engine oil. if SAE 10W-40engine oil is not available,select an
alternativeaccording to the following chart.
ENGINE OIL (FOR OTHER COUNTRIES)
Oil quality is a major contributor to your engine's performance
and life. Always select good quality engine oil. Use of SF/SG or
SHISJ inAPI with MA in JASO.
Suzuki recommends the use of SAE 10W-40 engine oil.
If SAE
10W-40engine oil is not available, select an alternative accord-
ing to the right chart.
BRAKE FLUID
Specificationand classification: DOT 4
Since the brake system of this vehicle isfilled with a glycol-based brakefluid by the manufac-
turer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluidtor refillingthe system, otherwiseserious damage will result.
Donotuseany brake fluid taken from old or usedorunsealedcontainers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

1-6 GENERAL INFORMATION
ENGINE COOLANT
Use an anti-freezelenginecoolant compatible with an aluminum radiator, mixedwith distilledwater only.
WATER FOR MIXING
Use distilledwater only. Water other than distilled water can corrode and clog the aluminum radiator.
ANTI-FREEZUENGINE COOLANT
The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze.Therefore, the engine
coolantshould be usedat all times eventhough the atmospheric temperatureinyour area does not go down
to freezing point.
Suzuki recommends the use of SUZUKl COOLANT anti-freezelengine coolant.
If this is not available, use
an equivalent which is compatiblewith an aluminum radiator.
LIQUID AMOUNT OF WATERlENGlNE COOLANT
Solutioncapacity (total): Approx. 1 400 ml(1.511.2 USllmpqt)
For engine coolant mixtureinformation, refer to cooling system section in page
6-2.
CAUTION
Mixing of anti-freezelengine coolant should be limited to 60%. Mixing beyond it would reduce
itsefficiency. Ifthe anti-freezelengine coolant mixing ratio is below
50% rust inhabiting perfor-
mance isgreatly reduced. Besure to mix it above
50% even though the atmospheric tempera-
ture does notgo downtothefreezing polnt.
BREAK-IN PROCEDURES
Duringmanufacture only the best possible materialsare used and all machinedparts are finished to a very
highstandard but it is still necessary to allow the moving parts to "BREAK-IN"before subjecting the engine
to maximumstresses. The future performanceand reliabilityofthe engine depends on the care and restraint
exercisedduring its early life. The general rules are as follows.
Keep to these break-in engine speed limits:
Break-In englne speeds
Initial
10 hours: Lessthan % throttle
After the engine has been operatedfor 10 hours the engine to full throttle operation, for short periods of
time.

GENERAL INFORMATION 1-7
INFORMATION LABELS
NO
(11
(2' Informationlabel ,EN
(3' Tireair pressurelabel (Warningno-passenger) :E,
(41 Tire air pressurelabel (Warning no-passenger) lr'
(51 Generalwarning and Age,l6 label 'E:
'61 Generalwarning label F'
~~~
-
'I1 Warning no-passengermark (El
-.
LABELor PLATE NAME
Certlf~callonpalo IE'
Swingarm
(81 Wamin
-
0
-
0
-
0
g no-passengermark 8 1Fi
Umersutlace
APPLIED SPECIFICATION
-
-
-
-
-
9'
'I0
(11'
oZ
'13
t14
-
4
'$6
\
@l Rghlside of frame
E-19
-
0
0
0
0
-
Age, 16 label iFI
Manualnolice label 'B
ICESCanada label !E 'F;
Comoliancelabel 'D
-
0
0
-
-
Chain adjuslmenl label {Fi
~ .-
Chain adjuslment label 'El
EC approval mark
Fuelinformation label
:E' !F
Fuel information label E',
eH side offrame
0
0
-
0
-
0
0
0
-
0
n
oiiue~tank cover
E-28
-
-
0
-
-
.,
0
0
-
0
-
E-33
0
-
-
0
-
-
n
-
0

1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ......................................................
Overall width ........................................................
Overall height ............. ...... .............................
Wheelbase ...........................................................
Fronttrack ............................................................
Reartrack .........................................................
Ground clearance .................... ... ...................
Seat height ...................... ... .............................
Dry mass ..............................................................
ENGINE
Type .................... .... .......................................
Number of cylinders .............................................
Bore .....................................................................
Stroke ...................................................................
Displacement .......................................................
Compression ratio .............................................
Fuel system ........................................................
Air cleaner ............................................................
Startersystem ......................................................
Lubricationsystem ...............................................
Idle speed ..................................................
DRIVE TRAIN
Clutch ...................................................................
. .
Transm~ss~on ....... ....... .................................
Gearshiftpattern ..................................................
Primary reduction ratio .........................................
............................................... Gear ratios, Low
2nd..
................... ... ....................
3rd ..................................................
4th ...................................................
Top ..............................................
Finalreduction ratio .............................................
Drivechain ...........................................................
1845 mm (72.6 in)
1245 mm (49.0 in)
1085 mm (42.7 in)
1 285 mm (50.6 in)
1045 mm (41.1 in)
985 mm (38.8in)
240 mm (9.4in)
780 mm (30.7in)
167 kg (368Ibs)
Four stroke, liquid-cooled,DOHC
1
95.5 mm (3.760in)
62.8 mm (2.472in)
450 cm3(27.5 cu. in)
11.7: 1
Fuel injection
Polyurethane foam element
Electric
Dry sump
1800 100 rlmin
Wet multi-platetype
5-forward
1down 4 up, foot operated
2.851 (77127)
2.076 (2711
3)
1.647 (28117)
1.333 (28121)
1.095 (23121)
0.913 (21123)
2.571 (36114)
RK 520SMOZlOS. 96 Links

GENERAL INFORMATION 1-9
CHASSIS
Front suspension .................................................
Rear suspension ................... .. .........................
Frontwheel travel ................................................
.................. Rear wheel travel ................... ....
Caster ..................................................................
Trail .................... ....... ..................................
Toe-in ..................................................................
.................................... .................... Camber ..
Steeringangle ................................... .... ..............
Turning radius ..................... .... .....................
Front brake ..........................................................
Rear brake ................... ... ............................
Front tire size ....................................................
. .
Rear ttre slze .......................................................
ELECTRICAL
Spark plug ...........................................................
Battery .................................................................
Generator ............................................................
Mainfuse ............... ... .......................................
Fan fuse
Ignitionfuse
.........................................................
Headlight .............................................................
Brake lightrraillight ..............................................
Neutralindicator light ......................................
Fuel indicator light ...............................................
Coolant tempereturel
Fuelinjectionwarning light
................ ...........
CAPACITIES
Fueltank, includingreserve ................................
Engineoil, oil change .........................................
with filter change ...............................
......................................... overhaul
Coolant
................................................................
Independent, double wishbone, coilspring, oil damped
Swingarrntype, coil spring, oil damped
254 rnm (10.0
in)
277 mm (10.9 in)
8.0"
30 mm (1.18 in)
0 mm
-3.0"
41"
3.5 m (11.5
fl)
Disc brake,twin
Disc brake
AT20
x 7 RlO.>{f<fy, tubeless
AT18
x 10 R868j>, tubeless
Electronicignition (Transistorized)
8" B.T.D.C. at 1800 rlmin
NGK CR8EB
12 V 21.6 kc(6Ah)/lO HR
Three-phaseA.C. generator
20
A
10 A
10 A
12 V 40140
W
LED
12v3.4 W
12v3.4 W
10.0 L (2.612.2 USIlmpgal)
Oil tank 1200 ml (1.311.1 USIlrnpqt)
Engine 400 ml (0.410.4 USIlmpqt)
Oil tank 1300 ml (1.411.1 USIlmp qt)
Engine 400 ml (0.410.4 USllmp qt)
Oil tank 1400 ml (1.511.2 USllmp qt)
Engine 400 ml (0.410.4 USllmp qt)
1.4 L (1.511.2 USllmpqt)
These specifications are subject to change without notice.

SYMBOL
Listed in the table below are the symbols indicatinginstructionsand other informationnecessaryfor servic-
ing. The meaningof each symbol is also includedin the table.
rque control required.
pply oil. Use engine oil unless
ixture of engine oil and SUZUKl Apply or use brake fluid.
easure in voltage range.
Apply SUZUKI SILICONE GREASE. Measure in resistance range.
a
a
a
Apply SUZUKI BOND "1215"
or equivalent bond.
99000-31
110
Apply SUZUKI BOND"1216B".
99000-31230
APPBTHREAD LOCK SUPER '1303''.
99000-32030
Apply THREAD LOCK SUPER "1322"
or equivalent thread lock.
99000-321
10
Measure in diode test range.
Measure in continuity test range.
special tool,
Indicatessewice data

ABBREVIATIONS USED INTHIS
MANUAL
A
ABDC
: After Bottom Dead Center
AC
: Alternating Current
ACL
: Air Cleaner. Air Cleaner Box
API
: American Petroleum Institute
ATDC
: After Top Dead Center
AIF
: Air Fuel Mixture
B
BBDC
: Before Bottom Dead Center
BTDC
: Before Top Dead Center
B+ : Battery Positive Voltage
C
CKP Sensor : CrankshaftPosition Sensor
(CKPS)
CKT : Circuit
CLP Switch
: Clutch Lever Position Switch
(Clutch Switch)
CO : Carbon Monoxide
CPU
: Central Processing Unit
D
DC : Direct Current
DMC
: Dealer Mode Coupler
DOHC
: Double Over HeadCamshaft
DRL
: Daytime Running Light
DTC
: Diagnostic Trouble Code
E
ECM : Engine Control Module
EngineControl Unit (ECU)
(FIControl Unit)
ECT Sensor
: Engine Coolant Temperature
Sensor (ECTS),Water Temp
Sensor (WTS)
F
F1
: Fuel Injection. Fuel Injector
FP
: Fuel Pump
FPR
: Fuel Pressure Regulator
FP Relay
: Fuel Pump Relay
I
IAP Sensor
IAT Sensor
IG
IAS
Max
MIL
Min
N
NOX
0
OHC
P
PCV
R
RH
ROM
S
SAE
SDS
T
TO Sensor
TP Sensor
: Hydrocarbons
: Intake Air PressureSensor (IAPS)
(MAP Sensor)
: Intake Air Temperature Sensor
(IATS)
: Ignition
: Idle air screw
: Left Hand
: Malfunction Code
(Diagnostic Code)
: Maximum
: Malfunction Indicator Lamp
: Minimum
: Nitrogen Oxides
: Over HeadCamshaft
: Positive Crankcase
Ventilation (Crankcase Breather)
: Right Hand
: Read Only Memory
: Society of Automotive Engineers
: Suzuki Diagnosis System
: Tip-Over Sensor (TOS)
: Throttle Position Sensor (TPS)
G
GEN : Generator
GND
: Ground
GP Switch
: Gear Posilion Switch

PERIODIC MAINTENANCE 2-1
CONTENTS
...........................................
PERIODIC MAINTENANCESCHEDULE 2-2
PERIODICMAINTENANCE CHART
.......................................... 2-2
MAINTENANCE AND TUNE-UPPROCEDURES
.............................. 2-3
............................................................................
AIR CLEANER 2-3
.......................
EXHAUST PIPE NUTS AND MUFFLER BOLTS 2-4
VALVECLEARANCE
.............................................................. 2-5
SPARK PLUG ............................................................................. 2-10
FUEL LINE
................................................................................. 2-11
FUEL FILTER
.............................................................................. 2-11
THROTTLECABLEPLAY
.......................................................... 2-11
ENGINE IDLE SPEED
................................................................ 2-12
THROTTLEBODY
...................................................................... 2-12
................................................... ENGINE OILAND OIL FILTER 2-12
ENGINE OILHOSE
.................................................................... 2-14
ENGINE COOLANT
................................................................... 2-15
RADIATOR
.................................................................................. 2-16
RADIATOR HOSE
...................................................................... 2-16
SPARKARRESTER
................................................................... 2-17
CLUTCH CABLEPLAY
.............................................................. 2-18
BRAKES
...................................................................................... 2-78
............................................................................
BRAKE FLUID 2-21
............................................................................. BRAKE HOSE 2-23
TIRES
........................................................................................ 2-23
STEERING
.................................................................................. 2-24
DRIVE CHAIN
............................................................................. 2-25
...........................................................................
SUSPENSIONS 2-28
FRONT AND REAR WHEEL SET NUTS
.................................... 2-28
REAR AXLE NUT AND LOCK-NUT
........................................... 2-29
....................................................
CHASSIS BOLTSAND NUTS 2-30
GENERAL LUBRICATION
......................................................... 2-33
COMPRESSIONPRESSURE CHECK
................................................ 2-34
COMPRESSION TESTPROCEDURE
........................................ 2-34
OIL PRESSURE CHECK
..................................................................... 2-35
OIL PRESSURE TESTPROCEDURE
........................................ 2-35
........................................................................................
SDS CHECK 2-36

2.2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCESCHEDULE
The chart below lists the recommended intervalsfor all the requiredperiodicservice work necessaryto keep
the vehicle operatingat peak performance and economy. Maintenance intervals are expressed in terms of
months
NOTE:
More frequent servicingmaybe performedon vehicles that are use undersevere conditions
PERIODIC MAINTENANCE CHART
Interval
Item
Air cleaner element
Exhaustoioe nuts and muffler bolts
Valve clearance
Spark plug
Spark arrester
Idle speed
Throttle cable play
Throttle body
Initial
1 month
-
T
Fuelline
Enaine coolant Reolaceevew
2 vears.
I
-
-
-
I
I
-
Fuelfilter
Every
3 months
C
T
-
Replaceevery 4 years.
Every
6 months
C
T
I
Radiator
Radiator hose
Drive chain
Drive chainbuffer
Brakes
-
Replaceevery 4 years.
I
Brakesfluid
I
I
-
Engineoil and oil filter
-
t
R
-
-
Tires
Suspensions
Front and rearwheel set nuts
Rear axle nut and lock-nut
NOTE:
I = lnspect andadjust, clean, lubricate, or replace asnecessary.
R = Replace C = Clean
T = Tighten L =Lubricate
Replaceevery
18 months.
I
-
I
I
I
I
-
Replaceevery 2 years.
I
Brake hose I
Replaceevery
4 years.
I
I
T
L
L
C
I
I
I
I
~ -
I
Steering
Chassis bolts and nuts
General lubrications
Clean, lubricateand inspect eachtime the vehicle is ridden.
Inspecteach time the vehicle
is ridden.
I I I I I
-
I
I
T
L
I
-
I
T
L
Tighten eachtime the vehicle is ridden.
T
I T I T
-

PERIODIC MAINTENANCE 2.3
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item
mentioned in the Periodic Maintenance chart.
AIR CLEANER
Clean every 3 months. c
If the air cleaner is clogged with dust, intake resistance will be
increased, with a resultant decrease in power output and an
increase in fuel consumption, Check and clean the air cleaner
element in the following manner.
Removethe seat. (p7-6)
Removethe air cleaner case cover (7:).
Remove the air cleaner element m.
Separate the polyurethane foam element 3, element frame
m and element holder. 0
@
I
Fill a wash pan of a proper size with a non-flammable clean-
ing solvent. Immerse the air cleaner element in the cleaning
solvent andwash it.
Press the air cleaner element between the palms of both
handsto removethe excess solvent: do not twist or wring the
element or
it will tear.
lmmerse the element in motor oil, and then squeeze out the
excess oil leaving the element slightly wet.
Non-flammable cleaning solvenl
[Bi MOTUL AIR FILTER OIL or equivalent filter oil

2-4 PERIODIC MAINTENANCE
PAUTIONA
" Inspect the air cleaner element for tears. A torn ele-
ment must bereplaced.
* If driving under dusty conditions, clean the air
cleaner element more frequently. The surest way to
accelerate enginewear isto operate the engine with-
out the element or with torn element. Make sure that
the air cleaner element is in good condition at all
times. Life of the engine depends largely on this
component!
Remove the drain cap m of the air cleaner box to allow any
water to drain out.
,d ,..
, ., ,2,..-
"4
$ ,,
,', ,
7
EXHAUST PIPE NUTS AND MUFFLER
F -9'
BOLTS \
Tighten initially at 1 month and every 3 months there-
after.
Tighten the exhaust pipe nuts (71, muffler connection bolt (2,
and mufflermountingbolt d to the specifiedtorque.
[Z1 Exhaustpipenut:
23 N.m (2.3 kgf-m, 16.5 lb-ft)
Muffler connection bolt:
23 N.m (2.3 kgf-m, 16.5 lb-ft)
Muffler mounting bolt:
23 N.m (2.3 kgf-m, 16.5 lb-ft)

PERIODIC MAINTENANCE 2-5
VALVE CLEARANCE
Inspect initially at 1 month and every 6 monthsthere-
after.
Excessivevalve clearance results in valve noise and insufficient
valve clearance results in valve damage and reducedpower.
Check the intake and exhaust valve clearancesat the distances
indicatedabove andadjust the valveclearancesto specification.
if necessary.
Removethe seat. (U7-6)
Removethe side covers, fuel tank cover and front fender.
(-7-6) I
Removethe fueltank and fueltank lower cover. (W5-4)
.L--
,''< , ./ ' -;
\,
* Removethe spark plugcap and spark plug. (D2-10)
* Disconnectthe breatherhose rtl andoil tank over-flowhose (3,
Removethe cylinder headcover 0).
The valve clearance specification is different for intake and
exhaustvalves.
Valve clearance must be checked and adjusted,
I) at the time of . , .,
periodic inspection. 2) when the valve mechanism is serviced,
,
and 3) when the camshaftsare removedforservicing.
Remove the valve timing inspection plug (41 and generator
cover cap
(3.
NOTE:
The pistonmust be at top deadcenter (TDC) on the cornpres-
sionstroke in order to check oradjust the tappet clearance.
* The tappetclearanceshouldonly becheckedwhen the engine
is cold.

2-6 PERlOOiC MAINTENANCE
- Rotate the crankshaft with a box wrench to set the piston at
TDC on the compression stroke. (Rotate the crankshaft until
the "T line on the generator rotor is aligned with the triangle
mark on the generator cover.)
Insert a thickness gauge between the tappet and the cam. If
the clearance is out of specification,adjust it to the specifica-
tion as follows.
09900-20803: Thickness gauge
Valve clearance (whencold)
IN: 0.10
- 0.20 mm (0.0039 - 0.0079 in)
EX: 0.20 - 0.30 mm (0.0079- 0.0118in)
NOTE:
The cam must be at position [A), when checking and adjusting
the valve clearance. Clearance readings should not be taken
with the caminany otherposition than this position.
ADJUSTMENT
The clearance is adjusted by replacingthe existing tappet shim
with athicker or thinner shim.
Removethe intakeor exhaust camshafts. (-3-13)
Remove the tappet and shim by hand or with a magnet.
(W3-25)

PERIODIC MAINTENANCE 2-7
Check the numbers printed on the tappet shim. These num-
bers indicatethe thickness of the tappet shim, as illustrated.
Select a replacement tappet shim that will provide the proper
clearance. Tappet shims are available in 25 sizes, ranging
from 2.30 to 3.50mm (0.09 to
0.14 in) in increments of 0.05
mrn (0.002in). lnstall the selected shim a,l! at the valve stem
end, with the numbers facing towards the tappet. Be sure to
measurethe shim with a micrometer to ensure that it is of the
proper size.
Refer to the tappet shim selectiontable for details.
NOTE:
"Besure to apply molybdenum oil solution to the top and bot-
tom faces of the tappet shim.
* When installing the tappet shim, make sure that the side with
the numbers face towards the tappet.
I Install the camshaftsas specified. (-3-76) I
- After replacing the tappet shim and camshafts, rotate the
crankshaft so that the tappet is depressed fully (this will
squeeze out any oil trapped between the tappet shim and the
tappet that could cause an incorrect measurement). After
rotating the crankshaft, check the valve clearance again to
make sure that it is within specification.
When installingthe cylinder headcover, apply SUZUKI BOND
"12168" to the cam end caps of the cylinder head cover gas-
ket.
a 99000-31230: SUZUKI BOND "1216B"
Tighten the generator cover cap and valve inspectionplug.
(W3-76)
Apply engine oil to both sides of the washers.
Tightenthe cylinder head cover boltsto the specifiedtorque.
(W3-79)
Cylinder headcover bolt:
Initial 10 N.m (1.0 kgf-m, 7.0 lb-ft)
Final
14 N.m (1.4 kgf-rn, 10.0 lb-ft)

2-8 PERIODIC MAINTENANCE
INTAKE