ENGINE
10
3
overall diameter while
th
e hot
cy
linder head
is
s
li
ghtly larger due to heat expansion. This will
make valve guide insta
ll
a
ti
on much easier.
5.
Turn the
cy
linder head upside down on wood
block
s.
Make sure the cyl
in
der
is properly
supported on the wood blocks.
6.
From
th
e combu s
ti
on chamber side
of
the
cy
linder head, drive
OU
I the old vah'e guide
wi
lh
a hammer and valve guide remover.
Use Suzuki
specinl t
oo1.
Valve Guide Remover
lln
staller.
pa
rt
N
o.
099
16-4
4511.
Rem
ove
the special tool.
7.
Remove and discard the
va
lve guide
an
d ring.
Never reinstall a
va
l
ve
guide
or
circlip
Ih
al
ha
s been
rem
ove
d
as
il is no longer true nor within
tolerances.
8.
Insert the valve guide reamer into the valve
guide ho
le
in the
cy
linder head. Usc Suz
uki
special
tools,
Val
ve
Guide Hole 12.3 mm Ream
er
(A.
Fig
ur
e
141
). part
No.
09916-34
531
and Reamer
Handle
(B. Figure
141
).
part
No.
09916-34541.
ROlat
e the reamer clockwise. Continue 10 rotate the
ream
er
and work
il
down through the entire length
of the valve guide hole
in
the cylinder head .
9.
Wh
i
le
rOlaling the reamer clockwise. withdraw
th
e reamer from
the
valve guide
ho
le
in
the
cyli
nder
head. Rem
ove
the reamer and handle.
1
0.
I
nS
lall a new ring O
ni
O the
va
l
ve
guide.
CAUTION
Failure to applyfresh engine oil
10
bOlh
the
va/~
'e
guide lind Ihe mh'e
guide
h
ole
in the cylinder
head
will result in
damage to the cylinder
head
and/or
the
new vah'e g
uid
e.
II.
Apply fresh engine oil to the new valve guide
and the
va
l
ve
guide hole in
th
e
cy
lind
er
head.
12
. From the top side (valve side)
of
the cylinder
head.
dr
ive
in Ihe new valve guide. Use Suzuki
s
pe
cial
to
ols.
Valve
Guide
In
staller Handle (A,
Figure
142
).
pan
No
.
09916
-57320 and Attachment
(
B.
Figure
142
), parI
No.
099
16
-57311.
13
. After insta
ll
ation, ream t
he
new
va
lv
e guide
as follows:
a.
Use Suzuki special lools. Valve Guide 7 mm
Ream
er
(A. Figure
14
3
).
part No,
09916-
34520 and Ream
er
Handle (B. Fig
ur
e
143
),
part N
o.
09916-34541.
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