Valve Guide Replacement - Suzuki AN400 Service Manual

1D-32 Engine Mechanical:

Valve Guide Replacement

1) Remove the cylinder head. Refer to "Engine Top
Side Disassembly (Page1D-16)".
2) Remove the valves. Refer to "Cylinder Head
Disassembly and Reassembly (Page1D-25)".
3) Using the valve guide remover, drive the valve guide
out toward the intake or exhaust camshaft side.
Special tool
(A): 09916–43210 (Valve guide remover/
installer)
NOTE
• Discard the removed valve guide sub
assemblies.
• Only oversized valve guides are available
as replacement parts. (Part No. 11115-
32C71)
(A)
4) Refinish the valve guide holes in the cylinder head
using the reamer and handle.
CAUTION
!
When refinishing or removing the reamer
from the valve guide hole, always turn it
clockwise.
Special tool
(B): 09916–34561 (Valve guide reamer (11.3
mm))
(C): 09916–34542 (Reamer handle)
5) Cool down the new valve guides in a freezer for
B705H11406051
6) Apply engine oil to each valve guide (1) and valve
7) Drive the guide into the guide hole using the valve
I705H1140060-02
(C)
8) After installing the valve guides, refinish their guiding
(B)
I705H1140061-03
about one hour and heat the cylinder head to 100 –
150 °C (212 – 302 °F) with a hot plate.
CAUTION
!
Do not use a burner to heat the valve guide
hole to prevent cylinder head distortion.
guide hole.
guide installer.
CAUTION
!
Failure to oil the valve guide hole before
driving the new guide into place may result in
a damaged guide or head.
Special tool
(A): 09916–43210 (Valve guide remover/
installer)
(D): 09916–53330 (Attachment)
"a"
"A"
"A": Cylinder head "a": 13.3 mm (0.52 in)
bores using the reamer. Be sure to clean and oil the
guides after reaming.
Special tool
(C): 09916–34542 (Reamer handle)
(E): 09916–33210 (Valve guide reamer (4.5
mm))
(A)
(D)
I705H1140023-04
(A)
I705H1140062-02