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Engine reassembly







 

 
Checking groove width

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

 
® Washer

@ 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.

 

 

 
Install the gearshift forks to the crankcase in the correct positions and directions.

CD For 5th driven gear (No. 1)

® For 3rd/4th drive gear (No. 3)

® For Top driven gear (No. 2)

© Gearshift cam stopper


 

 

 
Install the roller CD to the No. 1 gearshift fork.

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.

 
Check the oil jets CD fitted on the upper crankcase for clogging.

 

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

 
Install the countershaft assembly and driveshaft assembly 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.


 

 

 
NOTE:

Before fitting the crankshaft journal bearings, check the nozzles

CD fitted on the upper crankcase for clogging.

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

 

 

 
When fitting the crankshaft journal bearings to the upper and lower crankcases, be sure to fix the stopper part ® first and press the other end.

(Refer to page 3-38.)

 

CAUTION:

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

 

 
Install the cam chain guide ® and two dampers @ properly.

• Fit the 0-ring ®·

CAUTION:

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

 

 

 
Before installing the crankshaft, apply SUZUK I MOLY PASTE to each journal bearing lightly.

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.)

 

 
Clean the mating surfaces of the crankcases before matching the upper and lower ones.

• Install the dowel pins to the upper crankcase.


 

 

 
Apply SUZUKI BOND NO. 12078 to the mating surface of the lower crankcase in the following procedure.

(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.

*

 
Spread on surfaces thinly to form an even layer, and assem­

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 copper washers to the No. 9 and No. 11 bolts.

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

• Locate the two alien bolts at position ®.

 
Tighten the crankshaft tightening 8-mm bolts in the ascend­ ing order of numbers assigned to these bolts, tightening each bolt a little at a time to equalize the pressure. Tighten the lower and upper crankcase securing bolts to the speci­ fied torque values.

 

Tightening torque Initial tightening Final tightening
N-m kg-m lb-ft N-m kg-m lb-ft
6 mm bolt   0.6 4.5   1.3 9.5
8 mm bolt   1.3 9.5   3.2 23.0

 

• 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.

 

 

 
Install the countershaft bearing retainer with two screws.

 

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"


 

 

 
Install each gear shifting pawl into the cam driven gear. The large shoulder ® must face to the outside as shown.

• 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

 

 

 
Fit a new 0-ring @ and shim ®· CAUTION:

Use a new 0-ring to prevent oil leakage.

 

 

 
Fit a new 0-ring, then install the oil sump filter guide and oil sump filter.

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.

 

 
Seat the washer and install the oil pressure regulator CD to the oil pan.

• 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.


 

 

 
Apply grease lightly to the 0-ring CD.

• 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)

 
Install the return spring CD, spacer ® and washer ® onto the gearshift shaft.

 

 
Instal I the gearshift shaft with the center of the gear on shaft aligned the center of gearshift cam driven gear.

 

 
Install the washer CD and fix the gearshift shaft with the circlip ® ·

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

09900-06107: Snap ring pliers CAUTION:

Replace the oil seal with a new one.


 

 

 
Install the oil pump CD and oil separator inner case ® with the bolts.

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.

 

 

 
Install the washer ® and pin ® ·

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

 






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