ENGINE 341 —— conrenrs | ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ENGINE LEFT SIDE ENGINE RIGHT SIDE i} ENGINE CENTER ' ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL .. ENGINE INSTALLATION. | ENGINE DISASSEMBLY .. ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD AUTOMATIC DECOMP. .. CAMSHAFT. CAM CHAIN TENSION ADJUSTER AND TENSIONER 3-36 CYLINDER PISTON AND PISTON RING CONROD CRANKSHAFT BALANCER SHAFT AND BALANCER DRIVEN AND DRIVE GEAR. STARTER CLUTCH .. GENERATOR : STARTER TORQUE LIMITER OIL PUMP. CLUTCH GEARSHIFT FORK AND GEAR TRANSMISSION .. OIL STRAINER .. CRANKCASE .. : RIGHT CRANKCASE COVER .. GEARSHIFT SHAFT ENGINE REASSEMBLY22 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE “The part listed below can be removed and installed without removing the engine fom the frame. Refer to ‘the page listed in each section for removal and installation instructions. ENGINE LEFT SIDE PARTS REMOVAL | INSTALLATION Engine sprocket 36 Ec Starter divtcrven gear 514,15 371 [Generator rotor 321 363 Starter clutch 321 362 {Gear postion switch 31 379 Joi pump No.2 3.21 362 Balancer crank 322 S [Cam chain tensioner 3.21 02 ENGINE RIGHT SIDE PARTS REMOVAL | INSTALLATION Exhaust pipermatior a4 310 it titer 315 370 [Cutch pressure plat, drive plates, and riven plates 316,17 3-63,-69 [Clutch sleeve hub 317 367 Primary drven gear assembly a7 ser Primary drive gear 3.20 363 Oi pump idle gear and arven gear 318 363,47 Jou pump No.1 38 368 IGearshit shaft a8 365 |Gearshitt cam don gear 39) 365 JGoarshit cam stopper pate 319 364 JGearshit cam stopper 349) 364 Balancer drvelariven gear 320 363,64 ENGINE CENTER PARTS REMOVAL | INSTALLATION HThvote boay 514 518 Starter motor an 379 [Cam chain tension aduster 312 378 cylinder head cover at 379 |Camshatvautomatic decompression assembly 313 378 [Cylinder head 313 375 Icyinaer 313 274 Piston 34 373 [cam chain 321 262 [Cam chain guide 3.13 374ENGINE 3.3 ttn ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, wash the engine Using a steam cleaner. Engine removals sequentially explained in the folowing steps. * Drain engine coolant. (72-18) + Drain engine ol (72-13) + Rlomove the fuel tank and fuel tank lower cover. (75-4) + Remove th ol rtum tank. (76-28) + Remave the ol tank. (6-22) + Remove the sparkplug cap ©. + Disconnect the aver-fow hose and breather hose + Disconnect the engine coolant inlot hose @ brather hose and engine coolant outet hose + Flemove the throttle body assembly. (5-14)ENGINE + Disconnect the ECT sensor coupler + Loosen ther mute clamp bot, + Remove the exhaust pipe + Remove the gasket 8. + Remove the mutter @ + Disconnect the motor lead wire,ENGINE 38 + Rlomove the starter motor lead wie 2 and wiring hamess 6 from the clamp. + Disconnect the ground lead wire coupler‘ + Remove the parking brake cable from the bracket. * Disconnect the generator stator coupler i, CKP sensor and goar poston switch couplar + Remove the generator lead wire and gear poston switch lead ite tom the clamp, + Remove the rear brake switch‘ and brake pedal (r67 + Remove the rear brake switch wie 1 from the clamp.36 ENGINE + Remove the engine sproket cover + remove the gearshit lev + Remove the clutch cable bracket @. + Remave the clutch olease arm i along withthe clutch cable + Remove the engine sprocket with crive chain + Remove the engine mounting lower brackets + Remave the engine mounting upper brackes. + Remove teh engine mounting bolts and nuts.eione 27 ‘+ Flemove the swingarm pivot shaft nut and washer. + Extract three quarters of the swingarm pivot shalt so as to keep the swingarm is position, NOTE: Tho swingarm will come off when the swingarm pivot shalt is completely removed. + Remove the engine trom the right sideane ENGINE INSTALLATION Install the engine in the rverse ocder of engine removal Pay attotion tothe following points: * Tighten the swingarm pivot shaft nut tothe spectiod torque. Nore: “The engine mounting nuts are settlocking, * Once the nut has been removed, its ne longer of any use. Be sure 10 use new nuts, and then tghten them to the specified torque. Ten] tem | kgtm | ft ® [ss [55 | 00 @ | 2 | 26 | 190 @ | 26 [26 | 100 o | 55 | 55 | 400 © [ss [55 | #00evone 19 + Install the engine sprocket with crve chain, Nore: The fetter ® on the engine sprocket should face to the outside. + Anply THREAD LOCK SUPER 1205" tothe sprocket bots ‘99000-32030: THREAD Lock SUPER “1309” + Tighten the engine sprocket bolts tothe specified torue, (Engine sprocket bolt: 10 N-m (1.0 kgf-m, 7.0 bt) * Install he clutch release arm @D as shown inthe istration, + Install the gearshit lever @ inthe correct poston Gearshift ever height &: 5 ~ 10 mm (02-0. (© Gearshit lever bolt: 10 Nem (1.0 kgf-m, 7.0 loft) Install he brake pedal and rear brake switch. (7-67) in)s40_ENGINE + Install the muller ® and exhaust pipe @ (CAUTION. Use now gaskets to pr haust gas leakage. {mutter mounting bolt: 25 N-m 3 kgm, 16.5 bt) Exhaust pipe Bolt 23 Nm (23 kgm, 16.51) Mutlor connecting bolt: 23 Nem (2.3 kgm, 16.5 Ib) + Install the throtte body assembly. ([7'5-18) + Install the oll tank. (76-23) + Install the ol return tank. (C=7'6-23) + Install the fuel tank, (C758) “Alter instaling the engine, route the wing hamess, cables and hoses property. (79-15) + Adjust the following items. Engine ol 72-13 * Engine coolant 72.45 * Throtle cable play (72-11 Engine idle speed 7 2-12 * Clutch cable play 7-218 * Drive chain slack = 226 * Brake pedal height (72-19 * Rear brake switch 2-19eNowe_o1 ENGINE DISASSEMBLY STARTER MOTOR + Remove the starter motor. GEAR PosiTIOn switch * Remove the gear postion switch @. + Remove the O-ring 2, switch contacts @ and springs + Flemove the sparkplug 09930-10121: Spark plug wrench set CYLINDER HEAD coven * Remove the cynder head cover bots, and then remove the ao cinder hoas cover. a22 ENGINE CAMSHAFT “Remove the vale timing inspection plug @ and generator ‘cover cap 2. “+ Tum the generator rotor unti the “Tlie on the generator rotor ie aligned wih the center of the hole in the generator NOTE: Before removing the camshaft joumal holders, the piston must bbe at TOC of the compression stroke ‘+ Flemove the spring holder bolt @ of the can chain tension adjuster with spring @. + Flemove the cam chain tension acjuster ‘5 and gasket. + Flemove camshatt journal holders ©. NOTE: ‘Loosen the camshaft journal holder bolts dlagonaly.evGine 33 + Remove the dowel pins, imake camshatt ®, exhaust cam- shaft @ and O-rings [CAUTION| Do not drop the dowel pins, cam chain and C-rings | into the crankease. CYLINDER HEAD + Remove the cylinder head bolts. + Loosen the cylinder hase bot 2, + remove the four eylinder head bots in diagonal stages, and then remove the cylinder head, NOTE: te cyunger head does not come ot easy, ght tap it using a plastic mate. CYLINDER * Remove the cylinder head gasket (D and dowel pins. + Remove the cam chain guide 2) + Remove the cylinder base bot, and then remove the cylinder. Note: I" the eyinder does not come off easily, oh tap using a plas- tie mallet,au ane. + Flemove the cylinder gasket ©) and dowel pins. PISTON * Place a clean rag over the cylinder base to prevent the piston pin exelp trom dropping ito the crankcase. + Flemove the piston pin clip, + Draw out the piston pin © and remove te piston 2) GENERATOR ROTOR COVER * Remave the starr torque imiter assembly cover. + Remove the colars 2, washers @® and starter torque limiter assembly @.ENGINE 3.15 + Rlomove the generator rotor cover + Remove the shalt @, statr ido gear 5), gasket 8 and dowel pins. OWL FILTER, + Remove the olfiter cap + Remove the ol fter 2 and O-ring @. CLUTCH cover * Remove the clutch cover ®.216 ENGINE + Remove the gasket 2. RIGHT CRANKCASE COVER ‘Remove the right crankcase cover . + Romave the gasket 2, dowel pins and ol seal. NoTE: 1 there is no wear or damage at oll sea! ip, the o seal > removal s not necessary. cLuTcH * Hold the generator rotor using the special tool + Loosen the clutch spring set bolts working in diagonal stages. + Femave the bolts and springs. (09030-44520: Rotor holderevGne 317 + Remove the drive plates ® and deven plates @) + Remove the spring washer and spring washer seat, + Remove the push piece @ and push rod 6. + Fation the lock washer @. “Hold the clutch sleeve hub using the special tool, and then remove the cutch sleeve hub nut (02020-58740: Clutch sleeve hub holder + Flemove the lock washer ® and clutch sleeve hub ©)210_evene + Remove the spacer i. OL PUMP (No.1) * Remove tho ol pump idle gear © and il pump dtiven gear @ (2 00000.08107; snap ing pars + Remove the pia ®, washer @) and ol pump assembly. + Remove the folowing pats trom the oll pump assembly Outer rotor 6 Inner rotor 2 Pin ® Oil pump body ® i pump shat GEARSHIFT SHAFT ‘+ Remove the gearshift shalt) by removing the snap ring . (2) 09900-06107: Snap ring pliersevGINE 219 + Remove the gearshit paw! liter ®) and gearshit cam driven gear @ Nore: {Be careful not to drop the pins and springs when removing the gearshift cam driven gear + Remove the gearshitt pawis ©, pins @) and springs @. + Remove the gearshitt cam driven gear pin @ and gearshit cam stopper plate + Flomove the spring. ‘+ Remove the gearshit cam stopper bolt @, gearshift cam ‘stopper ® and washer. GENERATOR ROTOR ‘Hold the generator rotor using the special tool, and then Femove the balancer driven gear nut. (09820-44520: Rotor holder+ Remove the washer (D, balancer driven gear 2 + Remave the pin. ‘Hold the generator rotor using the special tool, and then remove the primary tive gear nut (CAUTION! ‘The primary drive gear nut has, threads. eee (09830-44520: Rotor holder + Remove the washer @ and primary drive gear . + Remove the key and balancer drive gear @. ‘Hold the generator rotor using the special tool, and then remove the generator rotor nu (6) 09930-44520: Rotor holderevgine 221 + Remove the generator roto using the special tool (02090-81821: Rotor remover Note: Temporariy install the generator rotor nut othe crankshaft. and then remove the generator oto using the special took. [CAUTION] Do not hit the generator rotor with a hammer, otherwise the rotor may be damaged. + Remove the generator rotor key. + Remove the starter driven gear ®. ‘CAM CHAIN * Remove the cam chain tensioner @, washer @ and cam chain 3. lL PUMP (No.2) * Flemove the oll pump assembly + Remove the pin 2, inner rotor) and ovter rotor322_evane BALANCER CRANK * Remove the balancorerank ©, CRANKCASE. + Remove the retainar ©. + Remove the spacer 2. + Remove the gearshift fork shat retainer [cauTion) Do not pull out tho goarsift fork shaft @ at this point because the gearshift fork comes of in the crankcase. + Remave the let crankcase bolts and engin ol drain plugs + Remove the right crankcase bots. parate the crankcase using the special too, 09920-13120: Crankease separating too! NOTE: Fit the crankcase separating tool to the right crankcase, s0 hat the to! plate is paralleled with the end face ofthe crankcase.ENGINE 323 + Flomove the dowel pins + Flomove the ail strainers + Remove the gearshit fork shafts, gearshit forks (and ‘gearshitt cam ©. + Remove the countorshatt assembly (and crveshatt assem- by @. “+ Flemove the crankshalt from the crankcase using the special too) (© 09020-13120: Crankease separating toot2 Bane ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD DISASSEMBLY ‘CAUTION + Remove the ETC sensor trom the cylinder head. + Remove the thermostat cover @ and thermostat .ENGINE 225 + Flemove the tappots @ and shime ® by fingers or magnetic hana. [cauTion) ‘entity the position of each removed par =| * Using the special tools, compress the valve spring and Femove the two cotter halves & trom the valve stem, (09016-14510: vaive titer (09916-14521: Valve lifter attachment (Exhaust side) (09916-14910: Va 09016-0451 ;CAUTION) Be careful not to damage the tappet sliding surtace with the special toot. ‘+ Remove the valve spring retainer and valve spring + Pullout the valve ® from the combustin chamber side,225 _ eG + Flomove the ol seal and spring seat i. [CAUTION, Do not reuse the removed oil seal + Remove the other valvas in the same manner as described previously, CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. (Check the gasket surtace of the cyinder head for distortion with ‘a straightedge and thickness gauge, taking a clearance reading several places indicated. the largest reading a any postion ‘ofthe straightedge exceeds the limi, replace the cylindr head. FE oytinder head distortion: Service Limit: 0.05 mm (0.002 in) (2 02900.20803: Thickness gauge VALVE STEM RUNOUT ‘Support the valve using V-bocks and checks runout using the dial gauge a shown. If the runout exceeds the service tm Valve stem runout: ‘Service Limit: 0.05 mm (0.002 in) 09000-20607: Dial gauge (1/100 mm) 9900-20701: Magnetic stand (09900-21204: V.bloek set (100 mm) (CAUTION] Be caraful not to damage the vaive and valve stem when handling it VALVE HEAD RADIAL RUNOUT Place the dal gauge ata right angle tothe valve head face and ‘measure the valve head racial runout, I measures mare than the sorvico limit roplace the valve, Valve head radial runout: ‘Service Limit: 0.03 mm (0.001 in) 09900-20607: Dial gauge (1/100 mm) (09900-20701: Magnetic stand (09900-21308: V-block set (100 mm) (CAUTION) Be caroful not to damage the valve when handling ItENGINE 3.27 VALVE STEM AND VALVE FACE WEAR CONDITION ‘Visually inspect each valve stom and valve face for wear and pit ting. 1 tis worn or damaged, replace the valve witha new one, VALVE STEM DEFLECTION Lift the valve about 10 mim (0:39 in) from the valve seat “Measure the valve stem deflection in wo dtections, perpendicu- lar to each other, by positioning the al gauge as shown, HY te detection measured exceeds the limit, then dtermine ‘whether the valve or the guide should be replaced with a new ‘Valve stem deflection (IN & EX): ‘Service Limit: 0.25 mm (0.010 in) (09900-20607: Dial gauge (1/100 mm) (08900-20701: Magnetic stand VALVE STEM WEAR Ifthe valve stom ie worn dovn to the limit, as measured with a ‘micrometer, replace the valve. he stem is within the imi, then roplace the guide, Ate eplacing valve or guide, be sur to recheck the detection, EX Vaive stem 0.0 ‘Standard (IN) : 475 ~ 5.490 mm (0.2156 ~0.2161 in) (©): 5.455 ~5.470 mm (0.2148 — 0.2154 in) (02200-20205: micrometer (0~ 25 mm) NOTE: 1 valve guides have 10 be removed for replacement afer Inspecting related parts, carry out the stops shown in vaive uide servicing. (F328)28 ec VALVE GUIDE SERVICING * Using the valve guide remover, dive the valve guide out toward the intake or exhaust camshat sie. (09916-44910: Valve guide removerinstalier Nore: * Discard the removed valve guido subassemblies. * Only oversized vaive guides are available as replacement parts. (PartNo. 11115-48670) + Recnish the valve guide holes in cylinder head with the samer and handle (09916-34580: Valve guide roamer (10.8 mm) (09916-34542: Reamer handle [CAUTION ‘When refinishing or removing the reamer from the valve guide hole, always tur it clockwise + Coo! down the new valve guides in freezer for about one hour and heat the cylinder head to 100 ~ 150 °C (12 - 302 °F) witha hot pat. iON) Do not use a burner to heat the valve guide hole to prevent cylinder head distortion. + Apply engine ol tothe valve guide hole + Drive the valve guide into the hole using the valve guide instar and attachment 2) (09916-44310: Valve guide removerrinsalier (09916-53360: Attachment NoTE: Insta the valve guide unti the attachment contacts with the cy indor bead. (CAUTION Failure to oll the valve guide hole before driving the ‘new guide into place may result in a damaged guide or head.ENGINE $29 * After instaling the valve guides, re-inigh ther guiing bores using the reamer. + Clean and engine ol the guides ater reaming (09016-34550: Valve guide reamer (5.5 mm) (09916-34542: Reamer handle Nore: * Be sure to coo! down the cylinder head to ambient air temper. ature * Insert the reamer from tho combustion chamber and always tun the reamer handle clockwise. VALVE SEAT WIDTH INSPECTION + Visually check for valve seat width on each valve face + Hf the valve face has worn abnormally, place the valve + Coat the valve seat with @ red lead (Prussian Ble) and set ‘he valve in place. Rotate the valve with light pressure. + Check that the transferred red lead (blue) an the valve face is uniform all around and in center ofthe valve face. (09916-10911: Vaive lapper sat * Ifthe seat wiath{) measured exceeds the standard value or ‘seat width isnot uniform, refuse the seat using the seat cuter. EID Vaive seat widths: ‘Standard: 0,3 ~ 1.1 mm (0.095 ~ 0,043 in) tthe valve seatis out of specification, corec the seat by servic: Ing tas fotows:20_evGine VALVE SEAT SERVICING * The valve seals () for both the intake valve @ and exhaust valve are machined to three ferent angles. The seat con- taot surface is cut at 45° INTAKE EXHAUST | seat angle 307, 45°, 6" 15°, 45", 60" ae 09-t1mm | 09-1. mm (0.035 -0.043n)_| (0.095 ~0.043 im) valve diameter | 36mm/(1.¢2 in) | 29 mm(t.t4 in) 5500-5.512mm | 5500-5.512mm valve guide LD. (9.2165 - 0.2170 in) | (0.2165 ~ 0.2170 in) (CAUTION ‘The valve seat contact area must be inspected after each cut, (CAUTION) Do not use lapping compound ater the final cut is ‘made, The finished valve seat should have a velvety ‘smooth finish but not a highly polished or shiny fin- ish, This will provide a soft surtace forthe final seat- Ing of the valve which will accur during the frst fow seconds of engine operation (CAUTION) “The titanium valves are costed wih an oxiaized mem- brane treatment to resist woar but the membrane tend. to.be removed if lapped after valve seat servicing. Nore: ‘Alter servicing the valve seats, be sure fo check the valve clear ‘ance after the cylinder head has been reinstalled. (—F 2-5) + Clean and assemble the head and valve components Fil he Intake and exhaust ports with gasoline to check for leaks. any leaks occur inspect the valve seat and face for burs or ‘other things that could prevent the valve from sealing,eNonie_231 VALVE SPRING ‘Tho force ofthe coll spring Keeps the valve seat tight. Weak: lened spring results in reduced engine power output, and often ‘accounts forthe chattering noise coming from the valve mecha- Check the vaive spring for proper strength by measuring its fee length and also bythe force requted to compress i It the spring length is less than the service limi, oF I the force Fequired to compress the spring does not fal within the range spoctiod replace the spring, Valve spring free length: Service limit: (IN.) 34.0 mm (1.34 in) (EX) 33.3 mm (1.31 in) (09900-20102: Vernier calipers ‘Valve spring tension: Standard: (UN) Approx. 119-137 N,11.9- 19.7 kgt/30.9 mm (28.2 30.21bs/1.22In) (EX, Approx. 78.5 N, 7.85 kal! 20.9 mm (17.3 tba! 1.22in) REASSEMBLY inal he valve sprig ooat + Apply MOLYBDENUM OL SOLUTION tothe ol seal, and preset tint positon. “Bl wowveoenuw on sovurion (CAUTION) Do not use the removed oll seal + Insert the vave, with its stom coated with MOLYBDENUM (OL SOLUTION all around and along the ful stam length with ‘ut any break (CAUTION) When inserting the valve, take care not to damage the lip of the oll sea “Bl wouraoenuw on sovution IN Aero 19157 (118-187 et Rope SSN (Feb) | o 1.3090 (1.20%) © 209m (122)352 eva + Install the valve spring withthe smaltpitch portion facing cylinder head. |B Large-ptch portion (© UPWARD, (D Paint + Put onthe value sping retainer 2, and using the valve iter ress dw the spring tthe valve cote halves to the stem fend, and tlease the ier to allow the valve eater 3) to wedge In between retainer an stem (09016-14510: Vaive titer (09916-14521: Valve liter attachment (Exhaust side) (09916-14910: Valve titer attachment (intake side) (09916-84511: Twoozers + Bo sure that the rounded ip ofthe cotter fits snugly into the groove ® in the stom ena. + Install the other valves and springs in the same manner as scribed previously ‘CAUTION Be sure to restore each spring and valve to their ‘original positions. “Be careful not to damage the valve and valve stem when handling I @ Valve spring retainer Valve cotter + Inatall he tappet shims and the tappets to thelr eiginal pos tons, Nore: * Apply engine ol fo the stem end, shim and tappet before fing thom, * When soating tho tappet shim, be sure tho igure printed sur face faces the tappetENGINE 309 + Install the ETC sensor. (76-11) + Aoply SUZUKI SUPER GREASE to the O-ring AGS 99000-25010: SUZUKI SUPER GREASE “A” (or equivatent grease) ‘The removed O-ring must be replaced with a new one. (CAUTION + Apply THREAD LOCK SUPER “1203" to the intake pipe bolts. + Install the intake pipe Nore: Make sure thatthe "yp mark"(®) comes tothe upperside WB 99000-22090: THREAD Lock SUPER “1203" AUTOMATIC DECOMP, (Check the decomp. cam moves smoothly and shaft @ rotates together. any abnormal condition are found, replace the cam- ‘hatt assembly, CAMSHAFT (CAUTION) Do not attempt to disassemble the camshaftiauto- matic decomp. assembly. itis not serviceable. AM SPROCKET Inspect the sprocket toth for wear. If they are wor, replace the ‘camshatts, crankshaft and cam chain as a set > 7 i e04_evone CAMSHAFT BEARING Inspect the bearings fr play, discoloration, wear and soizure. Move the outer race by finger and inspect for smooth move: ‘ment, I there i anything unusual, replace the camshaft assom: by. cam wean ® Check the camshaft for wear or damage, + Measure the cam height wih a micrometer Cam height ‘Service Limit (N.) 32.264 mm (1.2702 in) (©) 23.151 mm (1.2052 In) (GB 09900-20202: Micrometer (25 - 50 mm) CAMSHAFT JOURNAL WEAR * Determine whatero: not each jouma is worn down fo the limit by measuing the oll clearance wih the camsnat inated in place. « Use te plasignuge to ead te clearance at he widest por ton, wichis speci as folows (5 00000-22201: Piastigauge (09000-22302; Pastigauge Nore: Install the camshaft jour holders to ther orginal positions. + Tighten the camshaft journal holdor bots evenly and diago- aly tothe specified torque [camshaft journal holder bolt: 10 Num (1.0 kgf-m, 7.0 Ib) NoTE: Do not rotate the camshaft withthe plastigauge in place. ‘+ Remove the camshatt journal holders, and road the with of the compressed plastigauge with envelope scale. Tis mea- surement shouldbe taken athe widest pat ‘Camshaft journal oll clearance: ‘Service Limit (IN. & EX.): 0.150 mm (0,006 in)ENGINE 335 + If the camshaft journal ol clearance measured exceeds the limit, measure the inside diameter of the camshat journal holder and outside diameter ofthe camshatt journal. ‘+ Replace the camshat or the cylinder head depending upon hich one exceeds the specication EI camshatt journal holder 1.0. ‘Standard: (IN & EX): 22.012 ~22.025 mm (0.9667 - 0.8671 in) (09900-20602: dial gauge (1/1000, 1 mm) (09900-22403: Small bore gauge (18 - 35 mm) ‘Camshatt journal 0.0: ‘Standard (IN & EX): 21.959 - 21.980 mm (0.8645 — 0.8653 in) (02900-20205: micrometer (0 25 mm)236_ENGINE CAM CHAIN TENSION ADJUSTER AND TENSIONER ‘Check that the push rad slides smoothly when unlocking the ratchet mechanism (. It push rod does not slide smoothy, replace the cam chain te- sion adjuster witha now one. + Fomave the cam chain guide @ trom cylinder head cover. Check the contacting surface of the cam chain tensioner and cam chain guides. Hf any detects are found, replace it with a new one. CYLINDER CYLINDER DISTORTION Check the gasket surface of tho cylinder for distortion with a Staightedge and thickness gauge, taking a clearance reading at ‘Several places indicated. I the largest reading at any positon of the straightedge exceeds tho limi, replace the cylinder head, [EW cylinder distortion: Service Limit: 0.08 mm (0.002 in) (09900-20803: Thickness gaugeENGNE_337 CYLINDER BORE Inspect the eyinder wal for any scratches, nicks or other dam- ‘age. Measure the cylinder bore diameter at sx places, Hany one ofthe measurements exceed the limi, eplace the oy Inder. Cylinder bore EE i ‘Standard: 95.500 ~ 95.515 mm (3.7598 - 9.7604 in) 08900-20530: Cylinder gauge ss (08900-20513: Rod (94 mm) SS PISTON AND PISTON RING PISTON DIAMETER Using a micrometer, measure the piston outside diameter at 10 rm (0.4 in) 9 om the piston shit ea the measurement is less than the limit, replace te piston Piston dlameter: 95.380 mm (3.7551 in) at 15 mm (08 in) trom the skirt end (02900-20204: micrometer (75 - 100 mm) PISTON-TO-CYLINDER CLEARANCE ‘Subtract the piston dameter trom the cylinder bore diameter. (TFavove) It the piston-o-cyinder clearance exceeds the service limi, replace the cylinder or the piston, or both. Ei] Piston-to-cytinder clearance: ‘Service Limit: 0.120 mm (0.0047 in)200_evGINe PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore ‘gauge. It the measurement is out of specifications ropiace the Piston, Piston pin bore LO. ‘Service Limit: 1.030 mm (0.7482 in) 02200-20602: Dial gauge (1/1000 mm) (09900-22403: Small bore gauge (18-35 mm) Measure the piston pin outside diameter at three postions using the micrometer. any ofthe measurements are out at spectca tion, roplace te piston pin. [BD Piston pin 0.0. ‘Service Limit: 18,980 mm (0.7472 in) (2 09900-20205: ticrometer (0-25 mm) PISTON-RING-TO-GROOVE CLEARANCE Measure the side clearances ofthe tst and 2nd piston rings using he thickness gauge. if any of he clearances excoods the limit, replace both the piston and piston rings ss (© 09000-20803: Mickness gauge - ew (09900-20205: Micrometer (0~ 25 mm) Piston-ring-to-groove clearance Service Limit: eo 4st: 0.180 mm (0.007 in) 2nd: 0.150 mm (0.006 in) Piston ring groove wieth ‘Standard: 1st: 0.78 ~ 0,80 mm (0.0307 ~ 0.0815 in) i 1.30 ~ 1.32 mm (0.0512 ~ 0.0520 in) ae 2nd: 0.81 0.89 mm (0.0319 0.0327 in) T Ea T Oil: 2.01 2.03 mm (0.0791 ~ 0.0799 in)ENGINE_3.39 EZ] Piston ring thickness ‘Stand: 1st: 0.71 ~0.76 mm (0.0280 - 0.0299 in) 1.08 ~ 1.10 mm (0.0825 ~ 0.0833 in) ‘and: 0.77 -0.79 mm (0.0203 0.0911 in) PISTON RING END GAP Fit the piston ring squarely into the cylinder and measure the Pision ring end gap using the thickness gauge, Hany of the measurements exceads the service limi, replace the piston rng with a new one. EEX Piston ring end gap: Service Limit: peas 41st: 0.50 mm (0.020 In) 2nd: 0.50 mm (0.020 in) (02900-20808: Thickness gauge i ) ‘CONROD i CONROD SMALL END 10. Using a small bore gauge, measure the inside diameter of the onrod small end, he inside diameter of he conrod small end lexcoeds the limit, replace the convod CConrod small end 1.0. ‘Service Limit: 19.040 mm (0.7496 in) (© 02900-20602: Dial gauge (1/1 000 mm, 1 mm) (08900-22403: Small bore gauge (18-35 mm) oa40_ ENGINE CONROD DEFLECTION AND BIG END SIDE CLEARANCE ‘Wear on the big end of the conrod can be estimated by checking the movement of the small end of te rod. This method can also be used to check the extent of wear on the pars ofthe conrod big end Conrod deflection ‘Service Limit: 3.0 mm (0.12 in) (09900-20701: Magnetic stand (08900-20807: Dial gauge (1/100 mm) (09900-21304: V-block set (100 mm) Push the big end of the conrod to one side and measure the side clearance using a thickness gauge. If the clearance ‘exceeds the service limit, replace the crankshat assembly with ‘anew one or bring the deflection and the side clearance within the service limit by replacing the wom parts (contod, big end ‘bearing, crank pin, etc) with new ones. FED conrod big end side clearance ‘Service Limit: 1.0 mm (0.08 in) (©) 02000-20805: Thickness gauge CRANKSHAFT (CRANKSHAFT RUNOUT ‘Suppor the crankshaft using V-blocks and measure the crank shaft runout using the dial gauge, as shown. if the runout ‘exceeds the sence limit, replace the crankshalt witha new one. Note: * Place the crankshaft onto the V-blocks so that becomes hor zontal * Measure the runout ram the tps of tho crankshaft Crankshaft runout ‘Service Limit: 0.080 mm (0.008 in) (2 09200-20607: Dial gauge 1/100 mm) (09900-20701: Magnetic stand (09910-21308: Vblock set (100 mm)ENGNE_ 341 BALANCER SHAFT AND BALANCER DRIVEN AND DRIVE GEAR 2 STARTER CLUTCH INSPECTION Install the starter driven gear ont the starter clutch and tum the Starter driven gear by hand to Ingpeet the stater clutch for a ‘smooth movement. The gear turns one diction only. Ha large resistance is felt o rotation, inspect the starter clutcn for da ‘age or inspect the starter clutch contacting surlace ofthe starter ‘hiven gear for woar of damage. I hey are found to be damaged, replace them with new ones. DISASSEMBLY * Hold te rotor using the spacial tool and remove the bolts (02930-44520: Rotor holder eAssenoty * Install the starter clutch in the proper direction as shown. g a a. Ii tg De srt cs eas acc _ thearow man @ he burg hoe bob + Apply engine ol tthe starter chute alt! 9 y * Apply @ small quantity of THREAD LOCK SUPER "1922" to the stator clutch bot. ‘YB 99000-32110; THREAD LOCK SUPER "1322" =p,2_evaINe + Tighton tho ots while holding he rotor using the special ool starter ciuteh bot: 10 Nem (1.0 kghm, 7.01) (3 02030-44520: Rotor holder ‘STARTER DRIVEN GEAR BEARING INSPECTION Inspect the start diven gear bearing for any damages. ‘STARTER DRIVEN GEAR BEARING REPLACEMENT + Remove the Bearing using the special too, (2) 00013-70210: Bearing installer set + Install he bearing using the special 00 09913-70210: Bearing instalor sot [CAUTION] ‘The removed bearing must be replaced with a new NOTE: The stamped mark on the bearing must face crankcase side,ENGINE 349 GENERATOR INSPECTION (7-8-9, -21) ‘Remove the generator stator (D, CKP sensor 2, bracket and gromm * When replacing the gonealor stator or CKP sensor, route the FN q wite propery + Anply a small quantity of THREAD LOCK SUPER 1903" to the generator stalor mounting bolls, and tighten them securely. WB 22000-32030: THREAD LUCK SUPER “1309” STARTER TORQUE LIMITER ‘CAUTION Do not attempt to disassemble the starter torque lim- iter. tis unserviceable, [iach Lehn Check the sip torque of he starter torque limiter using the spe- ial fools and vise as shown, ithe sip torque is not within the speciied torque, replace the starter torque limiter with a new ; (02030-73170: Startor torque limiter holder (09930-73120: Starter torque limiter socket stip torque: 20.5 ~ 26.0 Nom (2.05 ~3.6 kgm, 14.8 -26.0 Ib)4 evn lL PUMP INSPECTION Inspect the outer rotor D and inner rotor 2 for any soratches oF other damage. any damages are found, replace them with new Rotate the oll pump by hand and check that it moves smoothly. Wit does not move smoothly, replace the ol pump assembly,ENGINE 245 CLUTCH CLUTCH DRIVE PLATE Note: Wipe of engine ol rom the clutch eve plates with a clean rag, Measure the thickness of rive plates using the verier capes, I the drive plate thickness is found to have reached the limi, replace i with a new one Drive plate thickness (No.1 & No.2}: ‘Service Limit: 2.77 mm (0.109 in) Measure the ciaw width of ative plates using the vornier cal pers. Replace the drive plates found to have wom down to the lit Drive plate claw width (No.1 & No.2): ‘Service Limit: 13.35 mm (0.528 in) (09900-20101: Vernier calipers CLUTCH DRIVEN PLATE Nore: Wipe of engine ol trom the clutch crven plates with a clean rag Measure each driven plate for distortion with a thickness gauge land surface plate, Replace driven plates which exceed the iil Driven plate distortion: ‘Service Limit: 0.10 mm (0.008 in) (02000-20803: Thickness gauge CLUTCH SPRING Measure tho foe longth of each cal spring with a verier cal ers, and compare the length with the specie init Feplace al he springs if any sping isnot within the limi (Clutch spring free length: ‘Service Limit: 50.4 mm (1.98 In) 09900-20101: Vernier calipers246 eve PUSH ROD Inspect the push rod for wear and damage. any detects are found, replace the push rod with anew one. RELEASE BEARING Inspect the release bearing for pay, wear and damage. Move the inner race by finger and inspect for smooth movement. It any detects are found, replace the release bearing with a new RELEASE BEARING REPLACEMENT + Remove the release bearing using the special 100. (09013-70210: Boarng instalor sot + Press the bearings using the special too. (09913-70210: Bearing installer set CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY Inspect the slat ofthe clutch sleave hub and primary devon geat assembly for damage or wear caused by the clutch plates. It necessary, replace it with anew one.ONE 347 GEARSHIFT FORK AND GEAR GEARSHIFT FORK-TO-GROOVE CLEARANCE Using a thickness gauge, check the gearshift fork clearance in the groove ofits gear. ‘The clearance foreach gearshift fork plays an important role in the smoothness and positveness ofthe shiting action Shift forkto-groove clearance: ‘Service Limit: 0.5 mm (0020 in) (09900-20101: Vernier calipers (09900-20803: Thickness gauge I the clearance checked is noted to exceed the mit specie, roplace the fork ots gear, or both, GEARSHIFT FORK GROOVE WIOTH Measure the gearshift fork groove width using the verner cal pers. ‘Shift fork groove width: ‘Standard: 4.8 ~ 4.9 mm (0.189 -0.193 in) (02000-20101; Vernier calipers GEARSHIFT FORK THICKNESS Measure the gearshift frk thickness using the verniar calipers, Shift fork thickness: ‘Standard: 4.6 ~ 4.7 mm (0.181 ~ 0.185 in) (02900-20101: Vernier calipers GEARSHIFT CAM Inspect the gearshit cam groove for abnormal wear and dam ‘ge. I any defects are found, replace the gearshtt cam with aevans TRANSMISSION DISASSEMBLY Disassemtl Co, ( ©.REASSEMBLY FReassemble the countershatt and driveshaft inthe reverse order of cisassembiy, Pay attention tothe flowing points: Note: * Bovore insaling the gears, apply engine of tothe inner surtace ‘of each gear and bushing * Apply molybdenum ail solution to the surface of countershaft and inner surtace of Sth eve gear @ Pr wovveoenum on souuTion CAUTION “Never reuse a snap ring, After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed, * When installing a new snap ring, do not expand the ‘end gap larger than required to slip the snap ring ‘over the shat “After instaling a new snap ring, make sure that itis completely seated in its groove and securely fitted. NOTE: Wren reassembing the transmission, attention must be given to the locations and postions of the washers and snap rings. The crass sectional view shows the correc positon of the gears, bushings, washers, and snap tings. (7 3-50) + When instaling @ new snap rng, pay attention to the arection. Fititto the side wnere the thrust is as shown inthe iustation, Thrust B Sharp edgo + When instaling the 3rd diven gear bushing @, align the itso hole withthe drvoshat i hole,350_eNGiNe a] Ne Koen E I - = | Sie i I ie t ih oe 0000 0000 0 8 Oo.ENGINE 351 OIL STRAINER * Clean the ol strainers using the compressed ai. CRANKCASE GEARSHIFT ARM STOPPER * Remove the gearshtt am stopper @) and washer 2, + Apply a small quantiy of THREAD LOCK SUPER “1303 to the gearshift arm stopper. + Install the washer 2 and tightening the gearshit arm stopper Do the spected torque. ‘Yl 99000-32030: THREAD LOCK SUPER "1303" [) Gearsnitt arm stopper: 32 Nom (8.2 kgt-m, 25.0 Ib) OIL SEAL INSPECTION Inspect the ol seal lips for weat or damage. f any detects are found, replace the oll seal with new ones, OWL SEAL REMOVAL ‘+ Flemove the erankcase plate). + Remove the ol seals 2.152_ENGINE OIL SEAL INSTALLATION + Install the ol seals D using the special tool [CAUTION] ‘The removed ol seals must be replaced with new (00019-7020; Bearing instar et + Apply SUZUKI SUPER GREASE "Ato te lip ofthe ol seals Gx 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) + instal the crankcase plate BEARING INSPECTION FRotat the bearing inner race by finger to inspect for abnormal Poy play, noise and smooth rotation while the bearings are in the = ae crankcase id Fepiace the bearing in the folowing procedure there is any- thing unusual 7 : BEARING REMOVAL, * Remove the of seals. (3.51) + Remove the bearing retainers.(GE _ 359 smove the bearings using the special tol (09913-70210: Bearing installer set Bearing @) 22 Attachment Bearing 3: / 25 Attachment Bearing ©, (30 Attachment Bearing 3 Attachment Bearing 2: 42 Attachment + Flemove the bearings using the special oo (0021-20240: Bearing remover set {Bs Remover 17 mm + Remove the bearing (3 09021-20210: Bearing remover 09930-30108: Siising shatt354_eNGINE INSTALLATION + Press the bearings using the special too. Beating 20 Attachment Beating ®, 0: 32 Attachment Beating: ¢ 40 Attachment Bearing ®), #42 Attachment Bearing ©: 6 52 Attachment Bearing D: 62 Attachment Boaring 2, 3) 72 Attachment The stamped mark side of the bearing faces ® outside. * The stamped mark side ofthe Bearing faces (2, ®, @, ©, ®, ©, @, £9) inside. * The sealed side of the bearing faces (, ®) outside + Apply a small quanity of THREAD LOCK SUPER “130° to ‘he Bearing retainer screws, and ghten tem securely il} 90000-22020: THREAD LOCK SUPER "1303"ENGINE 355 CLUTCH RELEASE CAMSHAFT INSPECTION Folate the clutch release camshaft by finger to inspect for abnormal noige ar smooth movement If any defects are found, replace the clutch release camshalt or bearings with new ones, CLUTCH RELEASE CAMSHAFT AND BEARING REPLACEMENT ‘+ Remove the ol seal retainer, + Flemove the following pats DON seal Washer | Upper bearing @ Cluteh release camshatt + Remove the lower bearing S.56_eae + Apply engine oto the bearings. + Apply grease tthe ol seal ip ‘5x 99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) + instal the cuch release camshaft conecy ‘CAUTION Nore: The stamped mark side ofthe bearing faces upside. RIGHT CRANKCASE COVER WATER PUMP res OL SEAL INSPECTION Inspect the ol seal ip for wear or damage, any detects are found, replace the ol seal with a new one. OIL SEAL REPLACEMENT ‘Remove the retaner @) + Remove th ol seal using the special tool (09913-50121: Oil seal remover + Install he ol seal using the special tol (09919-70210: Bearing instator set [CAUTION] ‘The removed oll geal must be replaced with a new one + Apply grease othe ol seal ip Aix: 99000-25010: SUZUKI SUPER GREASE “A” fed ° (or equivalent grease) Ne_alGEARSHIFT SHAFT DISASSEMBLY + Remove the folowing parts from the goarsit shatt Shim @ Snap ring @ Return sping (02900-06107: Snap ring piers Inspection Inspect tho gearshift shaft for bend or damage. Inspect the retum spring for damage of fatigue Roplace the detective parts wth a new one i necessary REASSEMBLY FReassemble the goarshit shat in the reverse order of disas- ‘sembly. Pay attention tothe folowing points When instaling the gearshift shatt return spring, position the stopper ® of gearshift arm between the shat retum spring ends 8.358 ENGINE ENGINE REASSEMBLY Feassemble the engine inthe reverse order of aisassombly. The folowing steps require special attention or precautionary measures should be taken Nore: ‘Apply engine ol fo each running and siding part before reassembiing, CranKsnaet al ( (CN ¢ yn foes” @ % ® . ~~ oe LS ao HO) o @ a (( [ ]eeanng Beare ] 2 Ganesha 5 |Crank ia Con 5 [orn + Determine the wiath between the wobs refering tothe figure wen rebuiding the erankshatt | Crank-web-to-web-wiath ‘Standard: 62.0 + 0.1 mm (2.441 = 0.004 in) “When maunting the crankshaft in the crankcase, it is neces: ‘sary to pull its let end into the crankcase by using the special tools. (09910-32612: Crankshatt installer i) (09911-11310: Attachment 2 (08913-70210: Bearing installer set (inner driver attachment » 35)eNGNE 359 'Nevor ft the crankshaft into the erankcase by striking ‘with a plastic hammer. Always use the special tool, otherwise the accuracy of the crankshaft alignment will be affected, COUNTERSHAFTIDRIVESHAFT * Install the countorshaft assembly and drveshatt assembly. GEARSHIFT CAM, FORK AND SHAFT * Install the gearshift forks into the goarshiting grooves in the correc positon and direction. Gosraht fork No.t 2 Gearshit fork No.2 (® Goarshit fork No.3 + Install the goarshtt cam @ + Install the gearshit fork shat, Note: “Attor the gearshift ork shatt and goarshit forks have been ft ed, make sure thatthe goars engage normally, * Sot ho transmission gears to the neutral poston. ‘CRANKCASE * Thoroughly remove the sealant material and ol stains onthe ‘mating surface of he right and lat erankcases, tal he dowat pins tothe left erankcase + Install the ol strainers ©. + Apply engine ol tothe conrod big end and tothe ansmission gears. © [‘H40_ ENGINE + Apply SUZUKI BOND “1215 to the mating surface ofthe right crankcase as shown. CE) 99000-31110; SUZUKI BOND "1215" (or equivatent bond) Nore: Use of SUZUKI BOND “1215"is as follows: * Make surfaces tre trom moisture, ol, dust and other foreign ‘materials + Spreact on surfaces thinly fo frm an even layer, and assomble the crankcases within few minutes. * Take extreme care not to apply any BOND "1215" tothe oil hole, oi groove and bearing. “Apply to distorted surfaces as i forms a comparatively tickENGINE 361 + Tighten the crankcase bolls and engine oildrain plug @ to the spectied torque, (crankcase bolt: 11 Nem (1.1 kgf-m, 8.0 tot) Engine oll drain plug: 18 Nem (1.8 kgt-m, 13.0 1b-t) + Alter the crankcase bolts have been tightened, check i the Crankshaft, countershatt, and dvoshalt rotate smoothly. + Apply a small quantiy of THREAD LOCK SUPER "1203" to the gearshift fork shat retainer screw, and tighten it securely, ‘i 92000-32030: THREAD LOCK SUPER "1303" + Install the spacer @ and retainer @. + Install the balancer erank. lL PUMP No.2 * Install the pin 2 to oll pump No.2 shat. + ntall he nner rotor D to ol pump No.2 shat. Nore: Fit tho slot ofthe inner rotor on the pin 262_ENGNE + Apply engine oilto the outer otr. + Install the outer rotor @ to the let crankcase. + Apply engine cilto the oll pump shaft and inner rotor. CAUTION] “The punch mark B on the outer rotor must face to the crankcase side. + Install the oll pump No.2 &. ‘Tighten the oll pump No.2 mounting bots 10 the specified torque. Toit pump No.2 mounting bolt: 10Nm (1.0 kgf-m, 7.016) CAM CHAIN + Install the cam chain ® onto the sprocket. + Install the cam chain tensioner @ and washer @. + Tighten the cam chain tensioner mounting bolt @ tothe spec- [cam chain tensioner mounting bott: 10 Nem (1.0 kgm, 7.0 b-A) STARTER CLUTCH AND GENERATOR ROTOR * Aaply engine ol to he starter driven gear bearing and crank- shat. + Install tho stator driven goar + Degrease the tapered portion of generator ror and also the crankshaft. Use nonflammable cleaning solvent to wipe off ‘ly oF greasy matter and make these surfaces completely dry. + Install the key @.ENGINE 363 tin. + Install he generator rotor. + Tighten the generator rotor nut to the specified torque using the special too (Generator rotor mut: 120 Num (12.0 kgf-m, 87.0 Ib-t) (09520-24520: Rotor holder PRIMARY DRIVE GEAR AND BALANCER GEAR * Install the balancer stve gear ®, + Install the key 2) + Install the primary chive gear @) and washer @, Nore: ae Install the washer @) as shown inthe istration « Primary are + Apply engine oto the thread and inside surface ofthe nuts64_evGNe + Hold the generator ror using the special too, and then tighlon the primary dive gear nut othe specie torque. (Primary drive gear nut: 140 Nim (14.0 kgm, 1015 Ios) NOTE: This ut has letsnand three. (22) 09990-44520: Rotor holder + Install the pin Install the balancer driven gear ® by aligning the matching marks @) + Install the washer @. ‘Hold the generator rotor using the special tool, and then tighten the balancer driven gear nut tothe spected torque. {9 Balancer driven gear nut: 50 Nem (5.0 kgh-m, 36.0 1b) GEARSHIFT CAM DRIVEN GEAR Install the washer (and gearshit'cam stopper @ to the ‘goarshit cam stopper bolt. + Apply a small quanity of THREAD LOCK SUPER "1303" to the gearshift cam stopper bolt + Tighten the gearshift cam stopper bot. + Install the spring @. J 99000-32030: THREAD LOCK SUPER “1303 + Aign the pin groove wth the pin when isang the Sw ‘stopper plate ®ENE 345, + Apply @ small quantity of THREAD LOCK SUPER "1203" to the gearshift cam driven gear bot. * Tighten the gearshit cam driven gear bol to the species torque. (©) Goarshitt cam driven gear bott 31 Nem (3:1 kale, 225 tb) ‘¥ 99000-2030: THREAD LOCK SUPER “120: + Install each paw! titer into the gearshitt cam driven gear. The large shoulder © must face tothe outside, + With the pawis held in pushed postin, Install the paw! liter 6. the paw! liter screw, and then tighten the screw and nut securely iD 92000-3203 + Apply a small quantiy of THREAD LOCK SUPER “1903" to Re We oe 4 = IREAD LOCK SUPER “1303" + Install he gearshitt shat Note: ‘Align the center tooth on the gearshift shaft with the center teeth (on the gearshift cam driven gear.‘M66 ENGINE + Insal the washer and new snap rng " eo (09900-06107: Snap ring piers r O1L PUMP No.1 * Install the of pump body @ inner rotor @ and pin to oil pump shaft, NoTE: Fitthe slot ofthe ner rotron the pin @) [CAUTION] ‘The alt must face tothe erankease side. + Apply engine ol tothe outer rotor. + Install the outer rotor to the right erankease. + Apply engine ito the oll pump shaft and inner rotor. [CAUTION ‘The punch mark (on the outer rotor must face to the cll pump body. + Install the oil pump No.t ®. + Install the washer 7 and pin 8: + When instaling the of pump driven gear ® align the pin withthe groove ©. (2) 09900-08107: Snap ring pliersENGINE 367 + Insta he ot pump ie gear. (2 09900-06107: Snap ring piers cLutcH * Apaly engine ol othe spacer + Install he spacer ©. the clutch sleeve hub @), new lock washer ® and clutch steove hub nut) Note: The concave side of clutch sleeve hub nut faces inside, + Hold the clutch seove hub using te special tool, and hon tohien tho th steve hub nut to the spectiod toa ctutehsteove hub nut: 90 Nem (9.0 kam, 65.0 bt)62_evaINe + Bend the tongue ofthe washer securely + Install the push rod @ and push piece + Install the spring washer seat @ and spring washer (9 onto the clutch sleeve hub correctly + Apply engine otto the dive plates i) and driven patos 2. ‘Install the clutch drive plates and driven plates one by one Into the clutch sleeve hub in the prescribed order as show in istration.eNGINE_360 @ Pomtenstousce gy ae Draenor pate | Back Diver Ns 2 isle | Bue + Apply engine ito the release bearing . + Install he clutch pressure plate 8: the generator rotor using the special to. n the clutch sping set bos securely in diagonal / (2 02000-44520; Rotor holder + Apply engine oto the lip ofthe of sel. + Install the ol seal 19 dowel pins and gasket . [CAUTION] Use anew and gasket to p370_evGiNe + Tighten the right crankcase cover bolts securely + Install tho gasket ‘CAUTION Use a new gasket to prevent oll leakage. + Tight the clutch cover bots securely (©: Bott win clamp OWL FILTER * Apply engine oilto the O-ring ring @ and oil iter. + Install the CAUTION) Use a new O-ring to prevent ol leakage. + Apply engine ol tothe Oxing + Install he O-xing @ and spring @. [CAUTION} Use a now O-ring to prevent oil leakageENGINE 971 + Replace the ol iter cap and tighten the bots securely, Note: 4 Face the tiangle mark ® on the cap rearward GENERATOR ROTOR COVER * Boforeinstaling the starter isle gear, apply molybdenum oil solution tothe hole of starter ale goar shat “Pl mowvaoenum on socurion + Install the startor idle gear ©, shaft 2, dowel pins and gasket o. CAUTION) Use a now gasket to prevent oil leakage. + Tighten the generator rotor cover boli securoy | Bott with clamp |B: Bott with lead wire (©: Bott with bracket + Before instaling the startr torque limiter assombiy, apply ‘molybdenum ol solution to the colars @ of starter torque im hor ascembly shat, * Install tie collars @, washers and starter torque limiter assembly ©. FPP wovraoenum on souuTiona_evane + Apply engine oto the O-ring + Install the starter torque limiter assembly cover PISTON RING ‘Install he piston rings in the order of ol ring, 2nd ring and 1st ring. + The first member to go ito the il ing groove isa spacer. After placing the spacer, the two side ais 2) ‘NOTE! ‘Side designations, top and bottom, are not applied to the spacer ‘and side rails: you can postion each either way. @ INCORRECT \® CORRECT + Install he 2nd rng @® and the 1st ing @ tothe piston, Nore: It ing and nd ring citer n shape. + Be sure to bring the concave sid of 1st ring tothe top when fiting itt te piston, + 2nd ring has letter “R* marked on the side. Be eure to bring the marked sie rng othe top when iting itt te piston,+ Position the gaps ofthe three ing as shown. Before inserting ‘each piston into the cylinder, check that the gaps are so locates, I Exhaust sie 1 ako sso 5 2d ng and wer ss al 1 Upper side ral sang an pacar PISTON AND CYLINDER ‘Apply molybdenum oll solution onto the piston pin and small ond ofthe conrod. Note: Insta he piston wih the punch mark ® on the piston head fac ing toward the exhaust sae. “Bi movvavenum oi. sovurion + Place a clean rag over the cylinder base to prevent the piston in cicip trom dropping into the erankcase, and then fit the Piston pin exclp wth fong-nase pliers, (CAUTION) Use a new piston pin circlip to prevent clclip failure | with a bent o NOTE: End gap of the crip should not be aligned with the cutaway in the piston pin bore + Thoroughly wipe off el tom the fiting surface of the crank + Apply SUZUKI BOND "1215" to the crankcase (as shown, Ci) 90000-31110: suZUKI BOND “1215" {or equivalent bone)Pa + Apply molybdenum ol solution to the siding surface of the piston and piston rings. + Install the dowel pins and gasket (Dont the crankcase. “Bi wotvedenum on. soLurion + Hold each piston ring with the piston ring sections positioned Correctly and pu into the cylinder, Make sue that the piston Fings are caught by the cylinder skit Note: “When mounting the cylinder, afte attaching the camshaft drive ‘chain, keep the camshaft dive chain taut. The camshatt drive ‘chain must not be caught Between the cam drive chain “sprocket and crankcase when the crankshaft i rotated. + Install ho cam chain guido @. Nore: ‘Make sure that the guide is inserted property or bing ofthe ‘cam chain and guide may result + Install the dowel pins and gasket @ [CAUTION] Ui ew gasket to prevent gas leakage.ENGINE 275 CYLINDER HEAD * With the head snugly seated on the eylinder, secure it by tightening the bots in diagonal stages. Tighten the cylinder head bots diagonally to the spectied torque. Moytinder head bort Initial: 25 Nim (2.5 kgt-m, 18.0 Final: 47 Nam (4.7 kgt-m, 34.0 bt) Nore: “Apply engine oll fo the treaded parts of the cylinder head bolts and both sides ofthe ts washers * Be sure to instal the washer with rounded side facing up. [CAUTION] [se now pe vashers to prevent oil leakage, + Altar tightening the cyndor neac bolts to specication, tighten the cylinder head bolts (D and cylinder Boks to the speci tied torque [cylinder head bott: 10 Nm (1.0 kgt-m, 7.0 tb) Cylinder bolt: 10 Nm (1.0 kgE-m, 7.0 bt) CAMSHAFT/AUTOMATIC DECOMP. ASSEMBLY * Tum the gonerator rotor unt the "T” ine on the generator Fotor is aligned wih the center of the hole in the generator (CAUTION) the crankshaft Is turned without drawing the eam chain upward, the cam chain will eatch between erank- cease and cam chain drive sprocket.ENGINE + Just betore insaling the camshaft into the cylinder head, BE ‘app¥y engine oll to the camshalt journals, cam faces, cam- a aj ‘shaft joumal holders and camshaft bearings. 4) + With the “T" tne aligned withthe center ofthe hole, hold the camshaft steady and light pullup the cam chain 1 remove any slack botwaen the eam chain deve eprocket and exhaust camshatt sprocket. + The exhaust camshatt sprocket has an punch marked @. Tum the exhaust camshat so thatthe punch is algned wih the gasket surlace ofthe cylinder head. Engage the cam chain withthe exhaust camshalt sprocket + The other punch marked B should now be pointing straight up. Stating from the roller pin thats directly above the punch marked ®, count out 15 rller pins (rom the exhaust camshatt side going towards the intake camshaft sido, Engage the 15th oll pin onthe cam chain withthe punch markod © on the intake sprocket. Refer to the following itustrations, NOTE: * The cam chain should now be on all three sprockets. Be careful not 1o move the crankshaft unt the cam: shaft joumal holders and cam chain tensioner are secured. + Make sure thatthe punch mark 0. i aligned withthe gasket surtace ofthe cylinder head.ENGNE 377 + Install the dowel pine and C-rng + Place each camshatt journal holers into the correct poston Note: CCamshaitjoural holders marked “EX” are fo the exhaust side {nd those marked "IN" are forth intake side, + Tighien the camshat journal holder bots tothe speciiod toraue ( camshatt journal notder bot: 10 Nm (1.0 kgm, 7.0 +8) Nore: “When tightening the camshat journal holder bots, the piston positon must bo at TDC onthe compression srke. “Tighten the camshaft joumal holder bots agonal ‘CAM CHAIN TENSION ADJUSTER * Unik the ratchet mechanism () and push the push rod 2 all the way. + Install the gasket @ and cam chain tension adjuster tothe cy indo. (CAUTION) Us ow gasket to prevent oil leakage, + Tighten the cam chain tension adjuster mounting bots to the -spectiod torque, [7] cam chain tension adjuster mounting bolt: 10 Nem (1.0 kgf-m, 7.0 1b) Nore: Make sure thatthe ‘yp mark") comes fo the upperside.a_evGne Insta he spring @) + Tighten the spring holder bolt othe speciied torque. [cam chain tension spring holder bott: 30 Nem (8.0 kgt-m, 21.5 lb-ft) {Aler installing the cam chain tension adjuster, check to be sure that the adjuster works properly by check: |_ ing the slack of am chain, + Atlr insaling the cam chain tension adjuster, rotate the Crankshaft (wo tums), and rechock the positions ofthe cam- ‘halts. (73-76) + Agply grease tothe O-ring + Tighten the gonerator cover cap (and valve timing inspec: tion pug. (Generator cover cap: 15 Nim (1.5 kgf-m, 11 Ib) Valve timing inspection plug 28 Num (2.3 kgfem, 16.5 lb-ft) CYLINDER HEAD covER “= Thoroughly wipe off il rom the fiting surfaces of he cylinder head and cover + Apply SUZUKI BOND "12168" tothe end caps ofthe cylinder head cover gasket as shown, C3 99000-31230: SUZUKI BOND "12168"ENGINE 9.78 + Apply engine oil o both sides ofthe washers + Lightly tighten the cylinder head cover bolts and then tighten them tothe specied torque cylinder head cover bott Initial: 10 Nem (1.0 kgtem, 7.0) Final: 14 Nem (14 kgl-m, 10.0 tb) (CAUTION, Use new washers to prevent oll leakage. + Tighten the sparkplug. (72-10) GEAR POSITION swiTcH * Apply grease tothe O-ring + Install the Oring ®, springs @ and contacts @) [CAUTION Use a new O-ring to prevent oll leah Ax 99000-25010: SUZUKI SUPER GREASE “A” {or equivalent grease) + Install the gear postion switch @ and tighten the bolts tothe spected torque, [Gear position switch bott: 6.5 Nim (065 katem, 4.7 Ih) STARTER MOTOR * Apply grease tothe O-ring + Install the starter motor AGH 99000-25010; SUZUKI SUPER GREASE * (or equivalent grease)