Front Upper Valve Body Disassembly and Assembly: Assembly

Assemble each component by reversing disassembly procedure and noting the following points.

• Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size.
  COIL OUTER DIAMETER AND VALVE SPRING FREE LENGTH SPECIFICATION
  
  

  Name of Spring	Outer Diameter	Free Length
  Secondary regulator valve spring	17.43 mm (0.681 in.)	71.27 mm (2.806 in.)
  Cut back valve spring	6.85 mm (0.259 in.)	23.00 mm (0.906 in.)
  Throttle valve secondary spring	8.56 mm (0.337 in.)	18.86 mm (0.743 in.)
  Throttle valve primary spring	10.90 mm (0.429 in.)	39.55 mm (1.557 in.)

  Fig 1: Checking Coil Outer Diameter

  Courtesy of SUZUKI OF AMERICA CORP.
• Install as many throttle valve compensating rings as written down when disassembled.
• Tighten throttle cam bolt (1) to specified torque.

  Tightening torque 

  Throttle cam bolt (a): 7.5 N.m (0.75 kg-m, 5.5 lb-ft) 

  Fig 2: Tightening Throttle Cam Bolt

  Courtesy of SUZUKI OF AMERICA CORP.
• Tighten pressure relief valve bolts (1) to specified torque.

  Tightening torque 

  Pressure relief valve bolt (b): 5.5 N.m (0.55 kg-m, 4.0 lb-ft) 

Fig 3: Tightening Pressure Relief Valve Bolt

Courtesy of SUZUKI OF AMERICA CORP.