Use only new gasket to prevent oil leakage.

•

• F it the key in the key slot on the crankshaft, then install the starter clutch/signal generator rotor.

NOTE:

* Apply a small quantity of TH READ LOC K SUPE R " 1303" / " 1305" to the starter clutch bolt.

(For U.S.A. model)

99000-32030: THR EAD LOCK SUPER " 1303"

(For the other models)

99000-32100: THR EAD LOCK SUPER " 1305"

•

Tightening torque: 85 - 95 N-m

(8.5 - 9.5 kg-m, 61.5 - 68.5 lb-ft)

• I nsta ll the sta rter id le gea r a nd its shaf t.

• I nsta ll the sta rter motor.

* Appl y SUZU K I SUPER GREAS E " A" to the starter motor 0-ring.

* Fit the engine ground wire CD and lead wire clamp ® to the

starter motor mounting bolt.

(For U.S.A. model)

99000-25030: SUZUKI SUPER GR EASE " A"

(For the other models)

99000-25010: SUZUKI SUPER GR EASE " A"

•

• I nsert the cl utch push rod i nto the cou ntershaft.

•

NOTE:

When installing the neutral position indicator switch, be sure to locate the spring, CD switch contact ® and 0-ring ®·

•

NOTE:

* Apply SUZUKI SUPER GREASE J'A " to the water pump 0-ring.

* Set the water pump shaft lug CD to the oil pump shaft slit @.

(For U.S.A. model)

99000-25030: SUZUKI SUPER GREASE " A"

(For the other models)

• Install the piston rings in the order of oil ring, 2nd ring and top ring.

NOTE:

Top ring and 2nd ring differ in the shape of ring face.

• Top and 2nd rings have letter " R " and " R N" marked on the side. Be sure to bring the marked side to top when fitting them to the piston.

• The first member to go into the oil ring groove is spacer CD. After placing spacer, fit the two side rails @. Side designa­ tions, top and bottom, are not applied to the spacer and side rails: you can position each either way.

=- Top

=-2nd

Top c; ng

/; y 2nd ri ng

®

CD

®

CAUTION:

When installing the spacer, be careful not to allow its two ends to overlap in the groove.

• Position the gaps of the three rings as shown. Before insert­ ing each piston into the cylinder, check that the gaps are so

located.

EX

· Lower side

rail ·Upper side

rail

·Top ring IN ·Spacer

NOTE:

Tightening torque: 13 - 16 N-m

(1.3 - 1.6 kg-m, 9.5 - 11.5 lb-ft)

•

• Be sure to install the pistons in the cylinder from which they

were taken out in disassembly, refer to the letter mark, " l"

through " 4", scribed on the piston.

• Have each piston pin moly paste oiled lightly before install- ing it.

• Place a cloth beneath the piston, and install the circlips.

CAUT10N:

Be sure to use new circlips.

•

NOTE:

Be sure to identify the top surface by nup" mark CD on the cylinder gasket as shown in the Fig.

CAUTION:

Use a new gasket to prevent oil leakage.

• Install the piston ring holders to each piston.

09916-74521: Holder body

09916-74530: Band

•

NOTE:

Be sure to identify the top surface by uUP" mark CD on the cylinder head gasket as shown in the Fig.

CAUTION:

Use a new gasket to prevent gas leakage.

•

Tighteni ng torque: 25 - 29 N-m

(2.5 - 2.9 kg-m, 18.0 - 21.0 lb-ft)

•

Tightening torque: 8 - 12 N-m

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

•

• Apply engine oil to the 0-rings CD.

• Tighten the oil pipe bolts to the specified torque.

Tightening torque: 8 - 12 N-m

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

• Place the right and left oil hoses and tighten the union bolts to the specified torque.

NOTE:

Install the gaskets to both sides of union.

Tightening torque:

® Upper side: 18 -22 N-m (1.8 -2.2 kg-m, 13.0 - 16.0 lb-ft)

® Lower side: 20 -24 N.m (2.0 -2.4 kg-m, 14.5 -17.5 lb-ft)

CAUTION:

Replace the gaskets (© and ©) with new ones to prevent oil leakage.

• P lace t he ca m cha i n gu id e CD properl y.

• W h i le hold i ng down t he ca m chai n, rotate t he cra nkshaf t i n norma l d i recti on to b ri ng the a rrow " CD " ma rk on the signa l generator rotor to the a rrow " CD /1 ma rk on t he cra n k­ case.

NOTE:

Just before placing the camshaft on the cylinder head, apply SUZUKI MOL Y PASTE to its journals, fully coating each

journal ® with the paste taking care not to leave any dry spot.

Apply engine oil to the camshaft journal holders.