Engine reassembly

Checking thickness

The engine is reassembled by carrying out the steps of disassembly in the reversed order, but there are a number of steps which demand special descriptions or precautionary measures.

NOTE:

Apply engine oil to each running and sliding part before reassembling.

• Install the gearshift cam related parts.

CD Gearshift cam

@ Pin

© Gearshift cam stopper plate

@ Spacer

NOTE:

When installing the cam stopper plate ©, align the pin groove

® with the pin ® as shown in the Fig.

•

CD For 5th driven gear (No. 1)

® For 3rd/4th drive gear (No. 3)

® For Top driven gear (No. 2)

© Gearshift cam stopper

•

NOTE:

Position the gearshift cam to the neutral so that gearshift forks and transmission can be installed easily.

• Hook the gearshift cam stopper spring to the crankcase.

•

• Fit the bearing pins ® and C-rings @ on the upper crankcase.

•

NOTE:

* Be sure to install the bearing dowel pins ® in the respective positions.

* Install the countershaft end cap to the position @.

* Make sure that the countershaft turns freely while holding the driveshaft. If not, shift the gear which is engaged to the neutral position.

Before fitting the crankshaft journal bearings, check the nozzles

CD fitted on the upper crankcase for clogging.

CD Nozzle (4 pcs)............. For upper case

•

(Refer to page 3-38.)

CAUTION:

Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.

•

• Fit the 0-ring ®·

CAUTION:

Replace the 0-ring with a new one to prevent oil leakage.

•

99000-25140: SUZUKI MOLY PASTE

• Instal I the crankshaft with the cam chain to the upper crankcase.

• Insert the right and left-thrust bearings with oil grooved facing the crank web. (R efer to page 3-38.)

•

• Install the dowel pins to the upper crankcase.

•

(For U.S.A. model)

99104-31140: SUZUKI BOND NO. 1207B

(For the other models)

99000-31140: SUZUKI BOND NO. 12078

NOTE:

Use of SUZUKI BOND NO. 1207B is as follows:

* Make surfaces free from moisture, oil, dust and other foreign materials.

*

ble the cases within few minutes.

* Take extreme care not to apply and BOND NO. 1207B to the bearing surfaces.

* Apply to cornered surface as it forms a comparatively thick

film.

•

• Fit the lead wire clamp to the No. 6 bolt.

• Locate the two alien bolts at position ®.

•

• Fit the lead wire clamps @ to the correct position as shown.

• Fit the gaskets © to the correct positions as shown.

CAUTION:

Use a new gasket to prevent oil leakage.

•

NOTE:

* Apply a small quantity of THREAK LOCK " 1342" to the two screws.

* When replacing the oil gallery plug retainer (Q), apply a

small quantity of THREAD LOCK " 1342" to its screw.

99000-32050: THREAD LOCK " 1342"

•

• When installing the cam guide CD and pawl lifter ®, apply a small quantity of THR EAD LOCK " 1342" to the screws ®·

99000-32050: THREAD LOCK " 1342"

09900-09003: Impact driver set

•

Use a new 0-ring to prevent oil leakage.

•

NOTE:

Be sure to face the arrow mark on the oil sump filter guide and oil sump filter to the front side.

CAUTION:

Use a new 0-ring to prevent oil leakage.

•

• Tighten the oil pressure regulator to the specified torque.

Tightening torque: 25 - 30 N·m

(2.5 - 3.0 kg-m, 18.0 - 21.5 lb-ft)

• Fit a new gasket and install the oil pan with bolts. Tighten the oil pan bolts to the specified torque.

Tightening torque: 6 - 10 N-m

(0.6 - 1.0 kg-m, 4.5 - 7.0 lb-ft)

NOTE:

Fit the lead wire clamps ® and air cleaner water drain hose guide ® to the correct positions as shown.

CAUTION:

Use a new gasket to prevent oil leakage.

•

• Install the oil filter and its cap.

NOTE:

Be sure that the 0-ring CD and spring ®are installed correctly.

CAUTION:

Replace the 0-ring CD with a new. one. Tightening torque

Oil filter cap nut: 12 - 16 N-m

(1.2 - 1.6 kg-m, 8.5 - 11.5 lb-ft)

NOTE:

When replacing the oil pressure switch ®, apply SUZU K I BON D NO. 1201B to its thread lightly.

(For U.S.A. model)

99104-31140: SUZUKI BOND NO. 1207B

(For the other models)

99000-31140: SUZUKI BOND NO. 1207B

Tightening torque: 12 - 15 N·m

(1.2 - 1.5 kg-m, 8.5 -11.0 lb-ft)

•

•

•

• Press-fit the oil seal ® into the crankcase.

09900-06107: Snap ring pliers CAUTION:

Replace the oil seal with a new one.

•

Tightening torque: 8 - 12 N- m

(0.8 - 1.2 kg-m, 6.0 - 8.5 lb-ft)

NOTE:

Before mounting the oil pump, apply engine oil to the sliding surfaces of the case, outer rotor, inner rotor and shaft.

•

• Fix the oil pump driven gear ® with the circlip.