Suzuki SV1000 2003-2005 Service Manual 3 Engine

ENGINE

CONTENTS

ENGINE

3-1

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL
ENGINE INSTALLATION

ENGINE DISASSEMBLY

ENGINE TOP SIDE
ENGINE BOTTOM SIDE

ENGINE COMPONENTS INSPECTION AND SERVICING

CYLINDER HEAD COVER
CAMSHAFT/CYLINDER HEAD
CYLINDER/PISTON INSPECTION
CONRODICRANKSHAFT
CLUTCH
TRANSMISSION
GEARSHIFT FORK
PRIMARY DRIVE GEAR
STARTER TORQUE LIMITER
STARTER CLUTCH
GEARSHIFT
CRANKCASE
CRANKCASE-CRANKSHAFT BEARING
GENERATOR COVER
CLUTCH COVER
GEARSHIFT COVER

ENGINE REASSEMBLY

ENGINE BOTTOM SIDE
ENGINE TOP SIDE

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3- 2
3- 3
3- 3
3-10
3-17
3-17
3-24

3-34
3-34
3-35
3-48

3-50
3-54

3-56
3-62
3-63

3-64

3-65

3-66

3-66

3-73

3-77

3-77

3-77

3-78

3-78

3-93

40

3- 2

ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame
the page listed in this section for removal and reinstallation instructions

ENGINE LEFT SIDE

.

. Refer to

4

PARTS
Generator rotor
Gearshift

ENGINE RIGHT SIDE

PARTS
Clutch cover

Clutch
Oil pump driven gear

Primary drive gear
Cam drive idle gear/sprocket
Gear position switch
Oil sump filter
Oil pressure switch
Oil jet

ENGINE CENTER

PARTS

Cylinder head cover

Camshaft
Cylinder head (Front)
Cylinder (Front)
Piston (Front)
Cam chain tension adjuster 3-18 and -22
Oil filter
Starter motor

REMOVAL

3-30
3-31

REMOVAL

3-25
3-25
3-28 3-86

3-29 3-83
3-28

3-27

3-28
3-67 3-67

3-68

REMOVAL
3-17 and -20
3-18 and -21

3-19 3-96
3-20 3-95
3-20 3-93

3-24
3-19

INSTALLATION

3-82
3-80

INSTALLATION

3-91
3-86

3-84
3-85
3-85

3-68 and -95

INSTALLATION

3-112
3-106

3-102 and -105

3-93

3-113

4

It

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ENGINE 3-3

ENGINE REMOVAL AND INSTALLATION

010

1

ENGINE REMOVAL

Before taking the engine out of the frame, wash the engine
using a steam cleaner
in the following steps
removal procedure

•

Remove the under cowling.(C-,-6-5)

•

Drain engine oil

•

Drain engine coolant

•

Remove the seat

. Engine removal is sequentially explained

. Reinstall the engine by reversing the

.

. (=2-14)

. (172-17)

. (=6-7)

6-7)

r

•

Disconnect theObattery lead wire

•

Remove the radiator

•

Lift and support the fuel tank

•

Remove the air cleaner

. (C75-5)

.

(r-

. (174-75)

74-65)

.

r

40

•

Remove the throttle body

.(C-

74-76)

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3-4 ENGINE

•

Disconnect the engine coolant temperature sensor lead wire
coupler0

•

Disconnect the gear position switch 02
H02 sensor ® and camshaft position sensor lead wire cou­plers ($

•

Remove the rubber heat shield

.

,

side-stand switch

OO

,

1

.

OO

.

•

Remove the spark plug caps

•

Disconnect the generator lead wire coupler
erator lead wire coupler 07 after removing the screws

•

Remove the gearshift lever

.

0

and signal gen-

.

OO

.

l

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Bind the clutch lever with a rubber band to prevent the clutch

•

release cylinder piston from coming out

Remove the clutch release cylinder ®

•

.

.

ENGINE 3-

5

•

Remove the push rod 09

•

Remove the engine sprocket cover 10

•

Remove the speed sensor 11

Remove the engine sprocket nut while depressing the brake

•

pedal

.

.

.

.

40

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3-6 ENGINE

•

Loosen the rear axle nut 1©

•

Loosen the chain adjusters 13 by loosening the lock nuts

.

(W

.

4

•

Remove the engine sprocket 15 and washer i

.

•

Disconnect the engine ground lead wire i

•

Remove the mufflers

•

Loosen the front exhaust pipe mounting bolts

. (L & R)

.

.

l

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•

Remove the front exhaust pipe

ENGINE 3-7

.

J

•

Remove the rear exhaust pipe

•

Remove the oil cooler

•

Disconnect the starter motor lead wire 79 and oil pressure

switch lead wire 20

(I

.

.

(f"

.

r5-20)

~

~

~

3-8

ENGINE

•

After removing the pinch bolt (3,
bolt

(2

.

Remove the engine mounting bolt 23

•

remove the engine mounting

, (3

.

•

Remove the engine mounting nut

(S,

26

.

I

11

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~

ENGINE3-9

•

Loosen the engine mounting thrust adjuster lock nut

.

40

09940-14990

•

Loosen the engine mounting thrust adjuster v

: Engine mounting thrust adjuster socket

wrench

.

I'

•

Loosen the pinch bolt 28

•

Gradually lower the engine assembly by removing the bolts

(a

.

CAUTION

Be careful not to damage the frame and engine when
removing the engine from the frame

.

.

~

3-10

ENGINE

ENGINE INSTALLATION

Remount the engine in the reverse order of engine removal
Pay attention to the following points

NOTE

:
* The engine mounting nuts are self-locking
"

Once the nut has been removed, it is no longer of any use
to the specified torque

.

:

.

.

. Be sure to use new nuts, and then tighten them

r

c

i

A=

' '

ITEM

~©©
OE©

T WK

DJ ©

E

®

N

.m

kgf-m

55 5

®

93 9

12

45

23

1 .2

4

2

.5

.3

.5

.3

lb-ft

40

.0

67

.5

8

.5

32

.5

16

.5

l

~

~

•

Before installing the engine assembly, install the spacer

collar © and engine thrust adjuster

©, O,

OO

.

OO

,

ENGINE 3-

1 1

to

•

Install the collar © onto the crankcase properly as shown

.

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3

-12 ENGINE

•

Put the drive chain on the driveshaft

Gradually raise the engine assembly and align all the bolt

•

holes

.

Install the engine mounting bolts and tighten them tempo-

•

rarily

.

Tighten the engine mounting thrust adjuster lock nut to the

•

specified torque with the special tool

.

.

Engine mounting thrust adjuster

•

Engine mounting thrust adjuster lock nut

09940-14990

: Engine mounting thrust adjuster socket

wrench

: 12 N

.m (1

45 N

.m (4 .5 kgf-m, 32

.2 kgf-m, 8

:

.5 Ib-ft)

.5 Ib-ft)

•

After tightening the engine mounting bolt

bolt ©

.

Engine mounting bolt

•

Engine mounting pinch bolt

OA

:

55 N

.m (5 .5 kgf-m, 40

©

:

23 N

.m (2

tighten the pinch

A),

.3 kgf-m, 6

.0 Ib-ft)

.5 Ib-ft)

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ENGINE 3-13

•

Tighten the engine mounting bolt to the specified torque

.

Engine mounting bolt

•

•

Tighten the engine mounting nuts
specified torque

Engine mounting nut(: 93 N-m (9

•

Engine mounting bolt
Engine mounting nut

•

After tightening the bolts ©, tighten the pinch bolt
specified torque

•

Engine mounting bolt
Engine mounting pinch bolt (L

.

.

OO

(F

©

©

:

55 N

:

55 N

:

55 N

:

55 N

23 N

.m (5

.5 kgf-m, 40

OO ,

OO

.3 kgf-m, 67

.m (5

.5 kgf-m, 40

.m (5

.5 kgf-m, 40

.m (5

.5 kgf-m, 40

.m (2

.0 lb-ft)

and bolt (

.6 lb-ft)

.0 lb-ft)

.0 lb-ft)

.0 lb-ft)

.3 kgf-m, 16

.5 lb-ft)

to the

to the

4

•

Install the new washers and tighten the union bolt to the spec­ified torque

Oil cooler hose union bolt

•

•

Install the new gaskets

.

: 23 N

.m (2

.3 kgf-m, 16

. (Front & Rear)

.5 lb-ft)

~

3

-14 ENGINE

•

Install the exhaust pipes and mufflers

NOTE

:

Apply THREAD LOCK to the bolt

. (L & R)

.

99000-32050

: THREAD LOCK "1342"

I

ITEM

OO©©OO®

N

.m

kgf-m

23
25

lb-ft

2

.3

16

.5

2

.5

18

.0

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ENGINE 3-15

•

40

Adjust the brake pedal height

•

Brake pedal height

Standard

•

Install the gearshift arm as shown

•

Gearshift arm angle

: 55 -

65 mm (2

OA

©

.

.17

Approx

:

- 2

.

.56 in)

. 17

.5°

•

Install the engine sprocket and washer

•

Apply THREAD LOCK SUPER to the engine sprocket nut and
tighten it to the specified torque while depressing the brake

pedal

.

Engine sprocket nut

0

99000-32030

•

Tighten the speed sensor rotor bolt

: 115 N

: THREAD LOCK SUPPER "1303"

.m (11

.

.5 kgf-m, 83

.

.0 lb-ft)

40

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3

-16 ENGINE

•

Apply SUZUKI SUPER
install it

•

Install the clutch release cylinder

.

GREASE to the push rod 10 and

.

99000-25030
99000-25010

•

Adjust the gearshift lever as shown

•

Gearshift lever height

Standard

•

After installing the engine, route the wire harness, cables and

hoses properly

•

Adjust the following items

•

Engine oil =2-14

•

Engine coolant L7'2-19

•

Engine idle speed C12-16

•

Throttle cable play

•

Engine oil capacity

Oil change
Oil and filter change

Engine overhaul

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

.

: 60-70 mm (2.4-

. (Cr8-14)

:

r

-

72-16

: 2

.7 L (2

.9/2

.4 US/Imp qt)

: 2

.9 L (3

: 3

.3 L (3

.8 in)

2

.6 US/Imp qt)

.1/2

.5/2

.9 US/Imp qt)

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ENGINE 3-17

ENGINE DISASSEMBLY

ENGINE TOP SIDE

•

Remove the spark plugs.(

r -

7-2-6)

40

•

Remove the thermostat

.

•

Remove the valve timing inspection plugOand generator

cover plug 02

FRONT CYLINDER HEAD COVER

•

Remove the front cylinder head cover J

.

.

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3-18 ENGINE

•

Turn the crankshaft to bring the "F I T" line on generator rotor
to the index mark of the valve inspection hole and also to

bring the cams to the position as shown

NOTE

:

At the above condition, the No

compression stroke and also the engraved lines
shafts are parallel with the mating surface of the cylinder head

cover

.

. 1 (Front) cylinder is at TDC of

.

(

on the cam-

FRONT CYLINDER CAMSHAFT

•

Remove the camshaft journal holders

CAUTION

Be sure to loosen the camshaft journal holder bolts
evenly by shifting the wrench diagonally

•

Remove the camshafts

NOTE

:

Do not drop the dowel pins into the crankcase

FRONT CAM CHAIN TENSION ADJUSTER

•

After loosing the spring holder bolt
tension adjuster

.

.

.

.

.

remove the cam chain

O,

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~

ENGINE 3-19

FRONT CYLINDER HEAD

•

Remove the cam drive idle gear/sprocket 90 by removing its

shaft, copper washer and thrust washer

NOTE

:

Do not the drop the thrust washer

OO

OO

.

into the crankcase

.

400

•

Remove the cylinder head bolts and cam chain tensioner
mounting bolt

•

Remove the cam chain tensioner

.

.

STARTER MOTOR

(Z

.

D

.

.

(T

•

Remove the starter motor

•

Remove the cylinder head nut

•

Loosen the cylinder nuts

•

Remove the oil cooler mounting bracket

.

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3-20 ENGINE

•

Remove the cylinder head bolts

•

Remove the cylinder head

NOTE

:

.

.

* When loosening the cylinder head bolts, loosen each bolt little

by little diagonally

.

* To identify each cylinder head, mark the cylinder as the front

and

rear,

cylinder head uses the same part

.

FRONT CYLINDER

•

Remove the cylinder head gasketO,dowel pinsOOand cam

chain guide (3

•

Remove the cylinder

NOTE

:

Firmly grip

cylinder does not come off, lightly

.

.

the cylinder at both ends, and lift it

tap

on the finless portions of

straight up

.

If the

the cylinder with a plastic mallet to make the gasketed joint

loose

.

•

Remove the cylinder base gasket ® and dowel pins

.

FRONT PISTON

•

Place a clean rag over the cylinder base so as not to drop the

piston pin circlip into the crankcase

•

Remove the piston pin circlip

•

Remove the piston by driving out the piston pin

NOTE

:

Scribe the

cylinder number on the head of the piston

.

.

.

.

REAR CYLINDER HEAD COVER

•

Remove the rear cylinder head cover 90

.

~

~

•

Turn the crankshaft to bring the "F I T" line mark on generator

rotor to the index mark of the valve inspection hole and also to
bring the cams to the position as shown

NOTE

:
At the above condition, the rear cylinder is at ATDC 90° on
expansion stroke and also the engraved lines
shafts are parallel with the mating surface of the cylinder head
cover

.

.

on the cam-

OA

ENGINE

3-21

CAUTION

Pull the front cam chain upward, or the chain will be
caught between the crankcase and cam drive idle
gear/sprocket when turning the crankshaft

REAR CYLINDER CAMSHAFT

•

Remove the camshaft journal holders

CAUTION

Be sure to loosen the camshaft journal holder bolts

evenly by shifting the wrench diagonally

•

Remove the camshafts

.

.

.

.

NOTE

:

Do not drop the dowel pins into the crankcase

.

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~

3-22 ENGINE

REAR CAM CHAIN TENSION ADJUSTER

After loosing the spring holder bolt t, remove the cam chain

•

tension adjuster

REAR CYLINDER HEAD

•

Remove the cam drive idle gear/sprocket 1O by removing its

shaft, copper washer and thrust washer 02

NOTE

:

Do not drop the thrust washer

•

Remove the cylinder head bolts and cam chain tensioner
mounting bolt

•

Remove the cam chain tensioner

.

.

2

into the crankcase

.

.

.

c

k-

I

•

Remove the cylinder head nuts (O

•

Remove the cylinder head nut ®

•

Loosen the cylinder nuts 05

)-

.

.

~L

4

~

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~

~

~

~

~

~

•

Remove the cylinder head bolts

•

Remove the cylinder head

NOTE

:

* When loosening the cylinder head bolts, loosen each bolt little

by little diagonally

* To identify each cylinder head, mark the cylinder as the Front

and Rear

REAR CYLINDER

•

Remove the cylinder head gasket 90, dowel pins 02 and cam

chain guide

•

Remove the cylinder

NOTE

Firmly grip the cylinder at both ends, and lift it straight up
cylinder does not come off, lightly tap on the finless portions of
the cylinder with a plastic mallet to make the gasketed joint
loose

.

:

.

(1

.

.

.

.

.

. If the

ENGINE

3-23

40

•

Remove the cylinder base gasket ® and dowel pins

REAR PISTON

•

Place a clean rag over the cylinder base so as not to drop the
piston pin circlip into the crankcase

•

Remove the piston pin circlip

•

Remove the piston by driving out the piston pin

NOTE

:

Scribe the cylinder number on the head of the piston

.

.

.

.

.

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~

3-24 ENGINE

ENGINE BOTTOM SIDE

OIL FILTER

•

Remove the oil filter with the special tool

.

:

09915-40610

•

Remove the generator cover

: Oil filter wrench

.

.

•

Remove the gasket 90 and dowel pin

•

Remove the starter torque limiter

•

Remove the bushings ® from the crankcase and generator

cover

.

.

and starter idle gear 03

O

.

~

~

~

~

~

~

ENGINE 3-25

•

Remove the water pump case

.

40

40

WATER PUMP DISASSEMBLY

CLUTCH

•

Remove the clutch cover

•

Remove the gasketDand dowel pins

(r

r5-14)

.

.

S

490

40

•

Hold the generator rotor with the special tool

09930-44541

•

While holding the generator rotor, remove the clutch spring
set bolts and springs diagonally

•

Remove the pressure plate 02

: Rotor holder

.

.

.

40

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~

~

~

~

~

3

-26 ENGINE

•

Remove the thrust washer ©, bearing ® and clutch push

piece ©

.

I

I

•

Remove the clutch push rod ©
Remove the clutch drive and driven plates

•

.

.

k-

Remove the wave washer (7 and wave washer seat ©

•

•

Unlock the clutch sleeve hub nut

While holding the clutch sleeve hub with the special tool,

•

remove the clutch sleeve hub nut

:

.

09920-53740

: Clutch sleeve hub holder

.

.

.

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~

~

~

~

~

~

ENGINE 3-27

•

40

Remove the washer ©9

•

Remove the clutch drive cam

clutch sleeve hub

NOTE

:

The clutch drive and driven cams should be replaced as a set

•

Remove the thrust washer

•

Remove the primary driven gear assembly 14

(2

.

(2,

clutch driven cam 11 and

.

.

(D

.

.

4-

•

Remove the needle roller bearing 15

washer 17

GEAR POSITION SWITCH

•

Remove the gear position switch

•

Remove the gear position switch contacts ® and springs

.

,

spacer(* and thrust

.

OO

.

~

~

~

~

~

3-

2 8

ENGINE

OIL SUMP FILTER

•

Remove the oil sump filter

OIL PUMP

•

Remove the oil pump driven gear 90 by removing the snap
ring

.

. .

09900-06107

: Spring ring pliers

.

•

Remove the pinOOand washer 03

NOTE

:

Do not drop the snap ring, pin and washer into the crankcase

Hold the generator rotor with the special tool

•

09930-44541

CAM DRIVE IDLE GEAR/SPROCKET

•

While holding the generator rotor, remove the cam drive idle

gear/sprocket nut

: Rotor holder

.

.

.

.

~

~

~

~

~

~

~

ENGINE 3-29

•

Insert a suitable bar into the holes of primary drive gears to

410

align the teeth of scissors gears

•

Remove the cam drive idle gear/sprocket and cam chain

•

Remove the key

O

.

.

.

PRIMARY DRIVE GEAR

•

Hold the generator rotor with the special tool

09930-44541

•

While holding the generator rotor, remove the primary drive
gear nut

CAUTION

This bolt has left-hand thread
clockwise may cause damage

•

Remove the washer ®

•

Remove the primary drive gear assembly

.

: Rotor holder

. Turning it counter-

.

.

0

.

.

9

~

~

~

~

~

~

3-30

ENGINE

•

Remove the key ® and thrust washer ®

.

GENENRATOR ROTOR

While holding the generator rotor with the special tool, remove

•

its bolt

. .

•

•

.

09930-44541

Install the special tool to the boss
Remove the generator rotor by turning the special tool while

holding the generator rotor with the special tool

09930-30450

: Rotor holder

.

.

: Generator rotor remover bolt

k.

I

Remove the key 1O and starter driven gear E

•

Remove the cam drive idle gear shaft ® and cam chain ®

•

.

.

~

~

~

~

~

~

GEARSHIFT

•

Remove the gearshift cover

Remove the gasket 1O and dowel pins

•

•

Draw out the gearshift shaft

.

.

OO

.

ENGINE

3-31

•

Remove the gearshift cam plate ®

•

Remove the gearshift cam stopper ®

Remove the engine sprocket spacer O5

•

.

.

.

~

~

~

~

~

~

3-32 ENGINE

•

Remove the crankcase bolts

.

Separator the crankcase into 2 parts, right and left with the

•

crankcase separating tool

09920-13120

NOTE

:

•

Fit the crankcase separating tool, so that the tool arms are in
parallel with the side of crankcase

•

The crankshaft and transmission components should remain

in the left crankcase half

When separating the crankcase, tap the end of the counter-

•

shaft with a plastic hammer

•

Remove the dowel pins

: Crankcase separating tool

.

.

.

.

.

~

~

~

ENGINE 3-33

•

Remove

gearshift cam ©

•

Remove the countershaft and driveshaft

•

Remove the crankshaft

the

gearshift

fork

shafts

.

.

©,

gearshift

.

forks

(7)

and

40

~

~

~

~

~

~

3-34 ENGINE

ENGINE COMPONENTS INSPECTION AND SERVICING

CYLINDER HEAD COVER

DISASSEMBLY

CAUTION

Be sure to identify each removed part as to its loca-

tion, and lay the parts out in groups designated as

"No

. 1", "No

be restored to the original location during assembly

Remove the camshaft position sensor 10

•

Remove the PAIR reed valve cover

•

. 2" "Exhaust", "Intake", so that each will

.

.

OO

.

INSPECTION

Inspect the PAIR reed valve for the carbon deposit

•

If the carbon deposit is found in the reed valve, replace it with

•

a new one

REASSEMBLY

Apply SUZUKI SUPER GREASE to the O-ring and install it

•

99000-25030

99000-25010

•

Apply THREAD LOCK to the thread and install the PAIR reed
valve cover

.

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

.

.

.

99000-32050

: THREAD LOCK "1342"

~

ENGINE3-35

CAMSHAFT/CYLINDER HEAD

CAUTION

Be sure to identify each removed part as to its loca-

tion, and lay the parts out in groups designated as

"No

go

. 1", "No

be restored to the original location during assembly

. 2", "Exhaust", "Intake", so that each will

.

CAMSHAFT
All camshafts should be checked for runout and also for wear of

cams and journals if the engine has been noted as giving abnor-

mal noise, vibration or lack power output

. Any of these condi-

tions may be caused by camshafts worn down or distorted to the
service limit
The camshafts can be identified by the engraved letter

1O No

No

OO

No

(3

® No

.

.

. 1 (Front) intake camshaft ("INF" and "I"
. 1 (Front) exhaust camshaft ("EXF" and "E"
. 2 (Rear) intake camshaft ("INR" and "I"
. 2 (Rear) exhaust camshaft ("EXR" and "E"

: Intake)

: Exhaust)

: Intake)

: Exhaust)

CAM WEAR

Worn-down cams are often the cause of mistimed valve opera-

tion resulting in reduced power output

.

The limit of cam wear is specified for both intake and exhaust

cams in terms of cam height

S

micrometer

. Replace camshaft if it wears worn down to the limit

which is to be measured with a

(R,

.

Cam height

Service Limit (IN)

09900-20202

: Micrometer (25 - 50 mm)

(EX)

: 37

.48 mm (1

: 36

.08 mm (1

.476 in)
.420 in)

~

~

~

3-36 ENGINE

CAMSHAFT JOURNAL WEAR
Determine whether or not each journal is worn down to the limit

by measuring the oil clearance with the camshaft installed in
place

. Use the plastigaugeOto read the clearance at the widest

portion, which is specified as follows

•

Camshaft journal oil clearance

Service Limit (IN&EX)

:

: 0

.150 mm (0

.0059 in)

09900-22301
09900-22302

NOTE

:

Install camshaft journal holder to their original positions
Tighten the camshaft journal holder bolts evenly and diagonally

to the specified torque

Camshaft journal holder bolt

NOTE

:

Do not rotate the camshaft with the plastigauge in place

Remove the camshaft holders, and read the width of the com­pressed plastigauge with envelope scale
should be taken at the widest part

: Plastigauge

: Plastigauge

.

: 10 N-m (1

.

.0 kgf-m, 7

. This measurement

.

.0 lb-ft)

.

If the camshaft journal oil clearance measured exceeds the limit,

measure the inside diameter of the camshaft journal holder and
outside diameter of the camshaft journal
or the cylinder head depending upon which one exceeds the

specification

Camshaft journal holder I.D.

•

09900-20602
09900-22403

•

Camshaft journal O.D.

09900-20205

.

Standard (IN&EX)

22

.012 - 22
: Dial gauge (1/1 000 mm, 1 mm)
: Small bore gauge (18 -

Standard (IN&EX)

21

.972 -21.993 mm (0
: Micrometer (0

:

.025 mm (0

:

. Replace the camshaft

.8666 - 0

35 mm)

.8650-0

- 25 mm)

.8671 in)

.8659 in)

~

CAMSHAFT RUNOUT

Measure the runout with a dial gauge

the runout exceeds the limit
=

Camshaft runout

Service Limit (IN

09900-20607
09900-20701
09900-21304

: Dial gauge (1/100 mm, 10 mm)
: Magnetic stand

-block (100 mm)

: V

.

&

EX)

: 0

CAM GEAR AND AUTOMATIC-DECOMP

Inspect the cam gear teeth for wear and damage
Inspect the automatic-decomp

tion

.

. for damage and smooth opera-

. Replace the camshaft if

.10 mm (0

.004 in)

.

.

If there are unusual, replace the camshaft assembly and cam

chain as a set

.

CAUTION

ENGINE3.

3 7

Do not attempt to disassemble the cam gears and
automatic-decomp

. assembly

. They are unserviceable

.

CAM CHAIN TENSION ADJUSTER

The cam chain tension adjusters are maintained at the proper

cam chain tension automatically
Unlock the ratchet
if it slides smoothly

(k,

and move the push rod © in place to see

. If any stickiness is noted or ratchet mecha-

.

nism is faulty, replace the cam chain tension adjuster assembly
with a new one

.

90 Front cam chain tension adjuster

(2 Rear cam chain tension adjuster

CAM CHAIN GUIDE AND CAM CHAIN TENSIONER
Check the cam chain guide and tensioner for wear and damage

.

If they are found to be damaged, replace them with the new

ones

4

.

O

Front cam chain tensioner
Rear cam chain tensioner

OO

(3 Front and Rear cam chain guide

~

~

~

~

~

3-38 ENGINE

CYLINDER HEAD

Remove the pin 10 and O-ring

•

•

Remove the tappets
hand

.

Using special tools, compress the valve spring and remove

•

two cotter halvesOOfrom the valve stem

.

.

09916-14510
09916-14910
09916-84511

O

: Valve lifter
: Valve lifter attachment

: Tweezers

2

.

and shims ® by fingers or magnetic

.

i

•

Remove the valve spring retainer © and valve spring 07

•

Pull out the valve from the other side

.

.

t

. '

~

~

•

Remove the oil seals ® and spring seats

CAUTION

O

.

ENGINE3-39

aI

Do not reuse the removed oil seals

CYLINDER HEAD DISTORTION
Decarbonize the combustion chambers

Check the gasketed surface of the cylinder head for distortion

with a straightedge and thickness gauge, taking a clearance

reading at several places indicated
position of the straightedge exceeds the limit, replace the cylin-

der head

VALVE STEM RUNOUT

Support the valve with "V" blocks, as shown, and check its runty
with a dial gauge
The valve must be replaced if the runout exceeds the limit

.

Cylinder head distortion

Service Limit

09900-20803

: 0

.05 mm (0

: Thickness gauge

.

.

.

. If the largest reading at any

.002 in)

.

40

d

Valve stem runout

Service Limit

09900-20607
09900-20701
09900-21304

VALVE HEAD RADIAL RUNOUT

Place the dial gauge at right angles to the valve head face, and

measure the valve head radial runout

If it measures more than the limit, replace the valve

'~Valve head radial runout

Service Limit

09900-20607
09900-20701
09900-21304

: 0

.05 mm (0

: Dial gauge (1/100 mm)

: Magnetic stand

: V-block (100 mm)

: 0

.03 mm (0

: Dial gauge (1/100 mm)
: Magnetic stand
: V

-block (100 mm)

.002 in)

.

.

.001 in)

3-40

ENGINE

VALVE FACE WEAR
Visually inspect each valve for wear of its seating face

any valve with an abnormally worn face
decreases as the wear of the face advances

. The thickness

.

. Replace

OT

Measure the thickness and, if the thickness is found to have
been reduced to the limit, replace it

.

Valve head thickness

Service Limit

09900-20101

: 0

: Vernier calipers

OT

.5 mm (0

.02 in)

VALVE STEM DEFLECTION
Lift the valve about 10 mm (0

.39 in) from the valve seat

.
Measure the valve stem deflection in two directions, "X" and "Y",
perpendicular to each other, by positioning the dial gauge as

shown

. If the deflection measured exceeds the limit, (see below)

then determine whether the valve or the guide should be

replaced with a new one

.

Valve stem deflection (IN&EX)

Service Limit

09900-20607
09900-20701

: 0

.35 mm (0

.014 in)

: Dial gauge (1/100 mm)
: Magnetic stand

VALVE STEM WEAR

If the valve stem is worn down to the limit, as measured with a

micrometer, where the clearance is found to be in excess of the
limit indicated, replace the valve
then replace the guide
recheck the clearance

. After replacing valve or guide, be sure to

.

; if the stem is within the limit,

Valve stem O.D.

Standard (IN):5

09900-20205

NOTE

:

If

valve

(EX):5
: Micrometer (0 - 25 mm)

guides havetobe

.475

- 5

.455

.490 mm (0

- 5

.470 mm (0

.2156-0
.2148-0

.2161 in)
.2154 in)

removed for replacement after
inspecting related parts, carry out the steps shown in valve
guide servicing

.

~

~

~

~

~

VALVE GUIDE SERVICING

Using the valve guide remover, drive the valve guide out

•

toward the intake or exhaust camshaft side

.

.

09916-44910

NOTE

:

•

Discard the removed valve guide subassemblies
Only oversized valve guides are available as replacement

•

. (Part No

parts

•

Re-finish the valve guide holes in cylinder head with the
reamer and handle

09916-34580
09916-34542

: Valve guide remover/installer

. 111 15-32E70)

.

: Valve guide reamer
: Reamer handle

.

.

ENGINE3-4

1

S

S

•

Oil the stem hole, too, of each valve guide and drive the guide
into the guide hole with the valve guide installer and attach­ment

.

09916-44910
09916-53340

CAUTION

Failure to oil the valve guide hole before driving the
new guide into place may result in a damaged guide or

head

.

•

After fitting the valve guides, re-finish their guiding bores with
the reamer

09916-34550
09916-34542

NOTE

:

Insert the reamer from the combustion chamber and always turn
the reamer handle clockwise

VALVE SEAT WIDTH

•

Coat the valve seat uniformly with Prussian blue
and tap the coated seat with the valve face in a rotating man-

ner, in order to obtain a clear impression of the seating con-

tact

. In this operation, use the valve lapper to hold the valve

head

.

: Valve guide remover/installer
: Attachment

. Be sure to clean and oil the guides after reaming

: Valve guide reamer
: Reamer handle

.

. Fit the valve

.

im

~

~

3-42 ENGINE

•

The ring-like dye impression left on the valve face must be

continuous without any break
ring, which is the visualized seat "width", must be within the

following specification

L 1

Valve seat width

Standard

. .

09916-10911

If either requirement is not met, correct the seat by servicing is
as follows

VALVE SEAT SERVICING
The valve seats for both intake and exhaust valves are

machined to four different angles
cut 45°

:

.)

: 0

:

.9 -1.1 mm (0

: Valve lapper set

. In addition, the width of the dye

.035-0

. (The seat contact surface is

.043 in)

INTAKE

45

0

60°
15°

30°

NOTE

:

The valve seat contact area must be inspected after each cut

09916-21111
09916-24210
09916-24480
09916-24810
09916-27710

•

Insert the solid pilot with a slight rotation

snugly

•

Using the 45° cutter, descale and clean up the seat with one

or two turns

•

Inspect the seat by the previously described seat width mea­surement procedure
seat conditioning with the 45° cutter is required

NOTE

:

Cut only the minimum amount necessary from the seat to pre­vent the possibility of the tappet shim replacement

N-615 or N-626 N-615 or N-626

N-211 N-211

_

N-626

: Valve seat cutter set
: Valve seat cutter (N-615)
: Solid pilot (N-140-5

: Valve seat cutter (N-626)
: Valve seat cutter (N-211)

. Install the 45° cutter, attachment and T-handle

.

. If the seat is pitted or burned, additional

EXHAUST

_

N-615

.

.5)

. Seat the pilot

.

.

.

If the contact area is too high on the valve, or if it is too wide, use

the 150/600cutters (for exhaust side) and 30°/60° cutters (for

intake side) to lower and narrow the contact area

.

ENGINE 3-43

1

40

If the contact area is too low or too narrow, use the 45° cutter to
raise and widen the contact area

•

After the desired seat position and width is achieved, use the

.

Contact area too low and too
narrow on face of valve

45° cutter very lightly to clean up any burrs caused by the pre­vious cutting operations

.

CAUTION

DO NOT use lapping compound after the final cut is
made

. The finished valve seat should have a velvety

smooth finish and not a highly polished or shiny fin-

ish

.
This will provide a soft surface for the final seating of
the valve which will occur during the first few seconds
of engine operation

.

40

40

•

Clean and assemble the head and valve components
intake and exhaust ports with gasoline to check for leaks

. Fill the

. If
any leaks occur, inspect the valve seat and face for burrs or
other things that could prevent the valve from sealing

.

A WARNING

Always use extreme caution when handling gasoline

NOTE

:

.

After servicing the valve seats, be sure to check the tappet

.

(r7

clearance after the cylinder head has been reinstalled

2-8)

~

3-44 ENGINE

VALVE SPRING
The force of the coil spring keeps the valve seat tight

ened spring results in reduced engine power output, and often
account for the chattering noise coming from the valve mecha­nism
Check the valve springs for proper strength by measuring their
free length and also by the force required to compress them
the spring length is less than the service limit, or if the force
required to compress the spring does not fall within the range
specified, replace it

(

Valve spring free length (IN&EX)

Service Limit

Valve spring tension (IN & EX)

Standard

.

: 41

.2 mm (1

: 197 - 227 N/35

(20

.1 -23.1 kgf/35

.62 in)

.6 mm

.6 mm, 44.3-51.0 lbs/1

. Weak-

. If

L

.40 in)

09900-20102

CAM DRIVE IDLE GEAR/SPROCKET THRUST CLEARANCE

Install the cam drive idle gear/sprocket
washer (3 and thrust washer ® to each cylinder head
the shaft02to the specified torque
measure the thrust clearance between the cylinder head and the
thrust washer

90

Cam drive idle gear/sprocket thrust clearance

Standard

: Vernier calipers

®

.

: 0

.15 -

.29 mm (0

0

(1),

its shaft

. Use a thickness gauge to

.006

.011 in)

- 0

02,

copper

. Tighten

Cam drive idle gear/sprocket shaft

0

40 N

09900-20803

: Thickness gauge

:

.m (4 .0 kgf-m, 29

.0 lb-ft)

Re

~

~

~

~

~

If the thrust clearance exceeds the standard range, adjust the

thrust clearance by the following procedures

•

Remove the thrust washer, and measure its thickness with a
micrometer

•

Change the thrust washer with the other washer if the thrust
clearance is incorrect

•

Perform the thrust clearance measurement described above

once again checking to make sure it is within standard

09900-20205

.

: Micrometer (0

Color/Mark

(Part No

(09181-15182)

Yellow

(09181-15181)

Light blue

(09181-15176)

Light green

(09181-15172)

Brown

(09181-15166)

"J" mark

(09181-15164)

.)

Blue

.

- 25 mm)

Thrust washer thickness E

:

1

.38-1

(0

.054-0.056)
1

.28-1

(0

.050

-0

1

.18-1

(0

.046-0
1

.08-1

(0

.043-0

0

.98-1

(0

.039-0
0

.88-0

(0

.035

- 0

Unit

.42

.32
.052)
.22
.048)

.12

.044)
.02

.040)
.92

.036)

.

: mm (in)

ENGINE

3-45

40

CYLINDER HEAD REASSEMBLY

•

Install the valve spring seats

•

Apply oil to each oil seal, and press-fit them into position with

the valve guide installer

09916-44910

CAUTION

Do not reuse the removed oil seals

•

Insert the valves, with their stems coated with molybdenum oil

solution all around and along the full stem length without any

break

.

CAUTION

When inserting each valve, take care not to damage
the lip of the oil seal

MOLYBDENUM OIL SOLUTION

-a

: Valve guide remover/installer

.

.

.

.

~

~

~

~

~

3- 46ENGINE

•

Install the valve spring with the small-pitch portion
cylinder head

Large-pitch portion

©

:

•

Put on the valve spring retainer, and using the valve lifter,
press down the spring, fit the cotter halves to the stem end,
and release the lifter to allow the cotter 1~ to wedge in
between retainer and stem
the cotter fits snugly into the groove © in the stem end

~ •

09916-14510
09916-14910
09916-84511

.

. Be sure that the rounded lip © of

: Valve lifter
: Valve lifter attachment
: Tweezers

OO

.

facing

I

(D C

~

CAUTION

Be sure to restore each spring and valve to their origi­nal positions

•

Install the tappet shim and tappet to their original position

NOTE

:

•

Apply engine oil to the shim and tappet before fitting them

•

When seating the tappet shim, be sure the figure printed sur-

face faces the tappet

•

Apply engine oil to the 0-ring and install it

.

.

.

.

.

I

~

~

~

~

~

•

Install the pin (

INTAKE PIPE/WATER UNION

•

Remove the intake pipe

.

.

ENGINE

3-47

.0

•

Remove the water union

•

When installing the intake pipe, apply grease to the 0-ring

NOTE

:

"UP" mark faces upward

99000-25030
99000-25010

CAUTION

Use the new 0-ring to prevent air from sucking

through the joint

•

Apply engine coolant to the new 0-ring and install the water

union

.

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

.

.

.

.

~

~

~

~

3-48

ENGINE

CYLINDER/PISTON INSPECTION

CYLINDER DISTORTION
Check the gasketed surface of the cylinder for distortion with a

straightedge and thickness gauge, taking a clearance reading at
several places as indicated
of the straightedge exceeds the limit, replace the cylinder

•

Cylinder distortion

Service Limit

.

•

09900-20803

CYLINDER BORE

Inspect the cylinder wall for any scratches, nicks or other dam-

. Measure the cylinder bore diameter at six places

age

•

Cylinder bore

Standard

: Thickness gauge

: 98

. If the largest reading at any position

.

.05 mm (0

: 0

.000 - 98

.002 in)

.015 mm (3

.8583 - 3

.8589 in)

.

k.

PISTON DIAMETER
Using a micrometer, measure the piston outside diameter at

10 mm (0
less than the limit, replace the piston

•

.

.

PISTON-TO-CYLINDER CLEARANCE
As a result of the previous measurement, if the piston to cylinder

clearance exceeds the following limit, replace both cylinder and
piston

•

.4 in) from the piston skirt end

Piston diameter

Service Limit

09900-20204

.

Piston to cylinder clearance

Service Limit

: 97

.880 mm (3

: Micrometer (75 - 100 mm)

: 0

.12 mm (0

. If the measurement is

.

.8535 in)

.0047 in)

~

~

~

~

~

PISTON RING TO GROOVE CLEARANCE
Using a thickness gauge, measure the side clearances of the
1st and 2nd rings

replace both piston and piston rings
(

Piston ring to groove clearance

Service Limit (1st)

. If any of the clearances exceeds the limit,

.

:

0

(2nd)

.18 mm (0

:0.15 mm (0

.0071 in)
.0059 in)

O

ENGINE 3-

4 9

•

Piston ring groove width

Standard (1st):0

(2nd)

(Oil)

•

Piston ring thickness

Standard (1st):0

(2nd):0

09900-20803
09900-20205

PISTON RING FREE END GAP AND PISTON RING END GAP
Before installing piston rings, measure the free end gap of each

ring using vernier calipers
measure each ring end gap using a thickness gauge

If any ring has an excess end gap, replace the ring

•

Piston ring free end gap

Service Limit (1st):7

: Thickness gauge
: Micrometer (0

.93 - 0

1

.55-1

: 1

.01 - 1

: 2

.51 -2.53 mm

.86

1

.38
.97-0

. Next, fit the ring in the cylinder, and

(2nd):8

.95 mm

(0

.0366-0

.57

mm

(0

.0610

.03 mm

(0

.0398-0

(0

.0988-0

.91 mm (0

- 0
1

.40 mm (0

-

.99 mm (0

- 25 mm)

.0 mm (0

.1 mm (0

.0374 in)

- 0 .0618 in)

.0406 in)

.0996 in)

.034 -0.036 in)
.054-0
.038-0

.

.

.28 in)
.32 in)

O

O3

.055 in)
.039 in)

10

i

H

l

O

li®

1

09900-20101

: Vernier caliper

3-50 ENGINE

Piston ring end gap

Service Limit (1st):0

(2nd)

09900-20803

PISTON PIN AND PIN BORE
Using a small bore gauge, measure the piston pin bore inside

diameter, and using a micrometer, measure the piston pin out­side diameter . If the difference between these two measure-

ments is more than the limits, replace both piston and piston pin

Piston pin bore I.D.

Service limit

09900-20602
09900-22403

: Thickness gauge

: 22

.030 mm (0

: Dial gauge (1/1 000 mm, 1 mm)
: Small bore gauge (18-35 mm)

.7 mm (0
.7 mm (0

:

0

.03 in)
.03 in)

.

.8673 in)

L

Using a micrometer, measure the piston pin outside diameter at

three positions

Piston pin O.D.

Service Limit

09900-20205

.

: 21

.980 mm (0

: Micrometer (0 -

.8654 in)

25 mm)

CON ROD/CRANKSHAFT

CONROD SMALL END I
Using a small bore gauge, measure the inside diameter of the

conrod small end

Conrod small end I.D.

Service Limit

09900-20602
09900-22403

If the inside diameter of the conrod small end exceeds the limit,
replace the conrod

.

: Dial gauge (1/1 000 mm, 1 mm)
: Small bore gauge (18 -

.

.D

.

: 22

.040 mm (0

.8677 in)

35 mm)

~

~

~

~

~

~

~

CONROD BIG END SIDE CLEARANCE
Check the conrod side clearance by using a thickness gauge

the clearance exceeds the limit, replace conrod or crankshaft

•

Conrod big end side clearance

Service Limit

09900-20803

Conrod big end width

[

Standard

•

Crank pin width

Standard

09900-20205

: 0

.50 mm (0

: Thickness gauge

: 21

.95 - 22

.17 -

44

: 44

: Micrometer (0

.020 in)

.00 mm (0

.22 mm (1

- 25 mm)

.864 -0.866 in)

.739-1

.741 in)

. If

.

OWN

ENGINE3-5

1

S

CONROD-CRANK PIN BEARING INSPECTION

•

Loosen the bearing cap bolts, and tap the bearing cap bolt
lightly with plastic hammer to remove the bearing cap

CAUTION

Never reuse the bearing cap bolt

Remove the conrods, and mark them to identify the cylinder

•

position
Inspect the bearing surfaces for any sign of fusion, pitting,

•

burn, or flaws
bearings

CONROD-CRANK PIN BEARING SELECTION

Place plastigauge axially on the crank pin avoiding the oil

•

hole, at TDC or BDC side as shown in the illustration

•

Tighten the bearing cap bolts as the specified manner

.

. If any, replace them with a specified set of

.

.

.

.

.

09900-22301
09900-22302

NOTE

:

Never rotate the crankshaft or conrod when a piece of plasti­gauge is in the clearance

: Plastigauge
: Plastigauge

.

~

~

~

~

3-52 ENGINE

Remove the caps and measure the width of compressed plas-

•

tigauge

taken at the widest part

•

If oil clearance exceeds the service limit, select the specified

bearings from the bearing selection table

•

Check the corresponding conrod I
«2„

•

Check the corresponding crank pin O
"2" or "3" stamped on the left crank web

Bearing selection table

with envelope

Con rod big end oil clearance

Service Limit

scale

.

: 0

.080 mm (0

. This measurement should be

.0031 in)

.D

. code number

.D

.

"1" or

OO,

. code number ©,
.

"1",

Crank pin O.D.

Code

Con rod I

code

[

Conrod big end I.D. specification

. D

.

C

Conrod big end oil clearance

Standard

Code

1

2 Black

: 0

.040 -0.064 mm (0

OO

1

2

1

Green

48

(1

48

(1

I

.D

2 3

Black

Brown

.0016

- 0

. specification

.000-48

.8898

.008 -48.016 mm

.8900 -1.8904 in)

.008 mm

- 1

.8900 in)

Brown

Yellow

.0025 in)

FRONT

Crank pin O.D. specification

Code

©

1

2

3

09900-20202

: Micrometer (25 -

O.D. specification

44

(1

44

(1

44

(1

- 45

.992

.7713

.984

.7710 - 1

.976

.7707

50 mm)

.7717 in)

- 1

- 44
.7713 in)

- 44

- 1

.7710 in)

.000 mm

.992 mm

.984 mm

~

~

ENGINE 3-53

Bearing thickness

Color (Part No

Green

(12164-16G00-OAO)

Black

(12164-16G00-OBO)

Brown

(12164-16G00-OCO)

Yellow

(12164-16G00-ODO)

CAUTION

Bearing must be replaced as a set

BEARING ASSEMBLY

When fitting the bearings to the bearing cap and conrod, be

•

sure to fix the stopper part

.)

Thickness

1

.476

- 1

.480 mm

(0

.0581-0

1

.480 -1.484 mm

(0

.0583-0

1

.484-1

(0

.0584-0

1

.488 -1.492 mm

(0

.0586

.

first, and press in the other end

OO

.0583 in)

.0584 in)

.488 mm

.0586 in)

- 0

.0587 in)

0

.

•

Apply molybdenum oil solution to the crank pin and bearing
surface

-9

.

MOLYBDENUM OIL SOLUTION

~

~

3-54 ENGINE

•

When fitting the conrods on the crankshaft, make sure that

I.D. codes © of the conrods face each cylinder intake valve

sides

.

NOTE

:

The shape of the conrod is not symmetrially right and left

CAUTION

.

Never reuse the bearing cap bolt

Apply engine oil to the bearing cap bolts

•

Tighten the bearing cap bolts as following two steps

Conrod bearing cap bolt

(Initial):35 N
(Final)

•

Check the conrod movement for smooth turning

.m (3

.5 kgf-m, 25

: After tightening the bolts to the above torque,

tighten them 1/4 of a turn (90

.

.

.5 Ib-ft)

0 )

.

.

.

CLUTCH

CLUTCH DRIVE PLATES

NOTE

:

Wipe off engine oil from the clutch drive plates with a clean rag

Measure the thickness of drive plates with a vernier calipers
each drive plate is not within the standard range, replace it with
a new one

:

.

.

Drive plate thickness

Standard (No

(No

. 2&No

09900-20102

. 1):2

.92 - 3

. 3):3

.72-3

: Vernier calipers

.08 mm (0

.88 mm (0

.115

- 0

.146-0

.121 in)

.153 in)

.

. If

~

~

~

ENGINE 3-55

Measure the claw width of drive plates with a vernier calipers

Replace the drive plates found to have worn down to the limit

•

Drive plate claw width (No

Standard (No

(No

. 2&No

09900-20102

CLUTCH DRIVEN PLATES
NOTE

:

Wipe off engine oil from the clutch driven plates with a clean rag

Measure each driven plate for distortion with a thickness gauge

and surface plate

Replace driven plates which exceed the limit

•

Driven plate distortion

Service Limit

09900-20803

CLUTCH SPRING FREE LENGTH

Measure the free length of each coil spring with a vernier cali­pers, and compare the length with the specified limit
the springs if any spring is not within the limit

•

Clutch spring free length

Service Limit

. 1):13
. 3):13

: Vernier calipers

.

: 0

.10 mm (0

: Thickness gauge

: 26

.7 mm (1

. 1 and No

.85

-13

.90-14

.004 in)

.05 in)

. 2)

.96 mm (0
.00 mm (0

.

.

.545

- 0

.550 in)

.547-0

.551 in)

. Replace all

.

.

.

09900-20102

CLUTCH BEARING
Inspect the clutch release bearing for any abnormality, particu-

larly cracks, to decide whether it can be reused or should be
replaced
Smooth engagement and disengagement of the clutch depends

on the condition of this bearing
NOTE

Thrust washer is located between the pressure plate and the
bearing

j

.

:

.

: Vernier calipers

.

~

~

~

~

~

ENGINE

3-56

TRANSMISSION

CONSTRUCTION

1® 1st driven gear

02 5th driven gear

(3

4th driven gear
3rd driven gear

•

•

6th driven gear

•

2nd driven gear

(7 Driveshaft

•

Countershaft

(9 5th drive gear

10 3rd & 4th drive gear
11 6th drive gear

2nd drive gear

•

~

~

~

~

ENGINE 3-57

DISASSEMBLY

CAUTION

Be sure to identify each removed part as to its loca-

tion, and lay the parts out in groups designated as

"Drive" and "Driven", so that each will be restored to

40

the original location during assembly

Countershaft

•

Remove the 0-ring 1, 2nd drive gear ( and top drive gear

.

(

CAUTION

.

The removed 0-ring must be replaced with a new one

•

Remove the top drive gear bushing ®, washer ($ and 3rd/4th
drive gears ©

•

Remove the snap ring with the special tool

09900-06107

.

.

: Spring ring pliers

.

•

Remove the 5th drive gear (7 and its bushing ©

.

~

~

~

~

~

3-58 ENGINE

Driveshaft

•

Remove the washer 1O and 1 st driven gear

Remove the 1st driven gear bushing 03,washer ® and 5th

•

driven gear O5

.

OO

.

Remove the snap ring with the special tool

•

09900-06107

Remove the washer ®, 4th driven gear 07 and its bushing ®

•

Remove the washer ®, 3rd driven gear 1o and its busing

•

: Spring ring pliers

.

.

(b)

.

~

~

~

~

~

~

~

~

~

•

Remove the washer 1©

•

Remove the top driven gear 13 by removing the snap ring

. .

09900-06107

•

Remove the snap ring with the special tool

09900-06107

: Spring ring pliers

: Spring ring pliers

.

(W

.

.

ENGINE 3

.59

•

Remove the 2nd driven gear

REASSEMBLY
Assemble the transfer in the reverse order of disassembly

attention to the following points
NOTE

:

•

Always use new snap rings

•

4

Before installing the gears, coat lightly engine oil to the shafts
and gears

CAUTION

•

Never reuse a snap ring
removed from a shaft, it should be discarded and a
new snap ring must be installed

•

When installing a new snap ring, care must be taken
not to expand the end gap larger than required to slip
the snap ring over the shaft

•

After installing a snap ring, always ensure that it is
completely seated in its groove and securely fitted

.

15 ,

its bushing16and washer

:

.

. After a snap ring has been

.

.

(T

. Pay

.

.

3-60

ENGINE

•

When installing a new snap ring, pay attention to the direction
of the snap ring
in the figure

CAUTION

When installing the 3rd and 4th driven gear bushings
on to the driveshaft, align the shaft oil holesOOwith
the bushing oil hole

. Fit it to the side where the thrust is as shown

.

©

.

M
w

z
z

w

~

~

~

3

-62 ENGINE

GEARSHIFT FORK

GEARSHIFT FORK TO GROOVE CLEARANCE
Using a thickness gauge, check the gearshift fork clearance in

the groove of its gear
The clearance for each gearshift fork plays an important role in

the smoothness and positiveness of the shifting action

•

Shift fork to groove clearance

Service Limit

.

: 0

.50 mm (0

.

.020 in)

09900-20803
09900-20102

If the clearance checked is noted to exceed the limit specified,
replace the fork or its gear, or both

•

Shift fork groove width

Standard

: Thickness gauge
: Vernier calipers

.

: 5

.0 -5.1 mm (0

.197

- 0

.201 in)

•

Shift fork thickness

Standard

: 4.8- 4

.9 mm (0

.189 -0.193 in)

~

~

~

~

~

~

~

PRIMARY DRIVE GEAR

PRIMARY DRIVE GEAR INSPECTION

Visually inspect the gear teeth for wear and damage
worn, replace the gear with a new one

PRIMARY DRIVE GEAR DISASSEMBLY

•

Disassemble the primary drive gear by removing the snap
ring

D

.

09900-06107

Snap ring

•

Spring washer

•

03 Scissors gear

Spring

•

~5 Primary drive gear

: Spring ring pliers

.

. If they are

ENGINE 3-

6 3

S

PRIMARY DRIVE GEAR REASSEMBLY

•

Set the springs 1O into the grooves

•

Install the scissors gear

NOTE

:
Align the hole of the primary drive gear with the hole of the scis­sors gear

•

Install the spring washerOOnot to cover the holes of the
gears

NOTE
The convex side of the washer faces upward

.

.

:

(Z

.

.

.

T

~

~

~

~

~

~

3-64 ENGINE

•

Install the snap ring ® completely with the special tool

. .

09900-06107

CAUTION

•

Never reuse a snap ring

•

When installing a new snap ring, care must be taken

not to expand the end gap larger than required to slip

a snap ring over the gear

•

After installing a snap ring, always insure that it is

completely seated in its groove and securely fitted

: Spring ring pliers

.

.

.

.

STARTER TORQUE LIMITER

STARTER TORQUE LIMITER INSPECTION

CAUTION

Do not attempt to disassemble the starter torque lim-

iter

.
The starter torque limiter is available only as an
assembly

•

Check the slip torque with the special tools

Slip torque

09930-73110
09930-73120

•

Set the starter torque limiter to the special tools and vise as
shown in the illustration

•

If the slip torque is not within the specification, replace the
starter torque limiter with a new one

.

Standard

.

: 22

- 45 N-m (2.2-4.5 kgf-m, 16.0-32.5 Ib-ft)

: Starter torque limiter holder
: Starter torque limiter socket

.

.

O

O2

~

~

~

~

~

~

~

~

ENGINE 3-65

STARTER CLUTCH

DISASSEMBLY

•

Remove the starter clutch securing bolts by holding the rotor

with the special tool

.

+/

09930-44541

REASSEMBLY

•

Install the starter clutch in the proper direction

NOTE

:

* When installing the starter clutch onto the rotor, face the

flange sideOOof the one way clutch to the rotor

* The arrow mark © must face to the engine side

•

Apply engine oil to the starter clutch

•

Apply THREAD LOCK SUPER to the bolts, and then tighten
them to the specified torque with the special tool

Starter clutch bolt

0

99000-32030

.M

09930-44541

: Rotor holder

.

.

: 25 N

.m (2 .5 kgf-m, 18

: THREAD LOCK SUPER "1303"

: Rotor holder

.0 Ib-ft)

.

.

.

+/

d#

410

INSPECTION

•

Install the starter driven gear to the starter clutch

•

Check that the starter driven gear turns in the opposite direc­tion of the arrow mark © on the rotor while holding the gener­ator rotor

•

If there is anything unusual, replace the one way clutch

Inspect the starter driven gear bushing for any damage

. The gear never turns in the direction of the arrow

.

.

.

.

~

~

~

~

~

~

~

~

~

3-66 ENGINE

GEARSHIFT

GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY

•

Remove the following parts from the gearshift shaft/gearshift

arm 90

•

03 Snap ring

•

O5

.

Washer

Gearshift shaft return spring

© Plate return spring

Washer

07

© Snap ring

Gearshift cam drive plate~© Washer

09900-06107

: Snap ring pliers

GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION
Check the gearshift shaft/gearshift arm 1~ for wear or bend

.

RETURN SPRINGS INSPECTION
Check the return springs, ® and ©, for damage or fatigue

.

GEARSHIFT SHAFT/GEARSHIFT ARM REASSEMBLY

•

Install the following parts to the gearshift shaft/gearshift arm

1O as shown in the right illustration

(2 Washer

Snap ring

•

Gearshift shaft return spring

•

Gearshift cam drive plate~© Washer

05

. .

09900-06107

NOTE

:

When installing the gearshift shaft return spring ®, position the
stopperOAof the gearshift arm between the shaft return spring
ends

©

.

CRANKCASE

: Snap ring pliers

.

© Plate return spring

Washer

07

© Snap ring

OIL PUMP

•

Remove the oil pump

.

~

~

~

~

~

~

~

ENGINE 3-67

oil

•

Rotate the
smoothly

If it does not move smoothly, replace the oil pump assembly

•

CAUTION

.

pump

by

hand

and

check thatitmoves

.

.I`

Do not attempt to disassemble the oil pump assembly

The oil pump is available only as an assembly

•

Install the oil pump

OIL PRESSURE REGULATOR

•

Remove the oil pressure regulator 1~

•

When installing the oil pressure regulator, apply engine oil to
the new O-ring

.

.

.

.

.

if

Check the operation of the oil pressure regulator by pushing on

the piston with a proper bar

replace the oil pressure regulator with a new one

OIL PRESSURE SWITCH

•

Remove the oil pressure switch 10

•

When installing the oil pressure switch, apply SUZUKI BOND
to the thread

©

Oil pressure switch

1207B

99104-31140

.

: SUZUKI BOND "1207B"

. If the piston does not operate,

.

.

: 14 N

.m (1

.4 kgf-m, 10

.0 Ib-ft)

~

~

~

~

~

~

3-

6 8

ENGINE

OIL JET

•

Remove the oil gallery plug

•

Remove the oil jet with a suitable bar

.

.

•

Remove the oil jet

•

Check the oil jets for clogging
oil passage with a proper wire or compressed air

•

Fit the new 0-ring to the oil jet

CAUTION

.

. If they are clogged, clean their

.

.

Use the new O-ring to prevent oil leakage

NOTE

:

Apply engine oil to the O-ring when installing the oil jet

•

Install the oil jet with a suitable bar

.

.

.

~

~

~

~

~

~

~

ENGINE 3-69

•

Tighten the oil gallery plug to the specified torque

.

Oil gallery plug (M8)

•

•

Apply engine oil to the new O-ring and install it

•

Apply THREAD LOCK to the screw and tighten it to the speci-

fied torque

•

Piston cooling oil nozzle screw

99000-32050

.

:18 N

.m (1

.8 kgf-m, 13

: 8 N

.m (0

: THREAD LOCK "1342"

.0 Ib-ft)

.

.8 kgf-m, 6

.0 lb-ft)

When replacing the gearshift arm stopper bolt, apply

•

THREAD LOCK SUPER to it

Gearshift arm stopper bolt

•

99000-32030

BEARING/OIL SEAL
Rotate the bearing inner race by finger to inspect for abnormal

play, noise and smooth rotation while the bearings are in the

crankcase

Replace the bearing in the following procedure if there is any-

4

thing unusual

.

: THREAD LOCK SUPER "1303"

.

.

: 23 N

.m (2

.3 kgf-m, 16

.5 lb-ft)

~

~

~

~

3-70

ENGINE

•

Remove the oil seal retainer

•

Remove the oil seal

CAUTION

.

.

The removed oil seal must be replaced with a new one

•

Remove the oil seal with the special tool

09913-50121

CAUTION

The removed oil seal must be replaced with a new one

•

Remove the bearing retainers

: Oil seal remover

.

.

.

.

~

ENGINE 3-71

•

Remove the bearings with the special tool

.

09921-20240

NOTE

:

: Bearing remover set

If there is no abnormal noise, the bearing removal is not neces­sary

.

•

Install the bearings with the special tool

09913-70210

: Bearing installer set

.

NOTE

:

The sealed side of the driveshaft bearing

must face outside

OO

.

~

~

~

~

3-72 ENGINE

•

Install the bearing retainers

NOTE

:

.

When installing the bearing retainers, apply THREAD LOCK to
the screws

Install the oil seals with the special tool

•

Apply SUZUKI SUPER GREASE to the oil seal lip

•

,!j6H

.

09900-32050

09913-70210

99000-25030
99000-25010

: THREAD LOCK "1342"

.

Bearing installer set

:

: SUZUKI SUPER GREASE
: SUZUKI SUPER GREASE

"A"

"A"

.

(USA)

(Others)

•

Install the oil seal retainer

.

~

~

~

S

v/r'

CRANKCASE-CRANKSHAFT BEARING
CRANKCASE-CRANKSHAFT BEARING INSPECTION

•

Inspect the crankshaft journal bearings for any damage

any, replace them with a specified set of bearings

•

Inspect the crankshaft journal for any damage

•

Measure the crankshaft journal O

Crankshaft journal O.D.

Standard

: 47

.985 -48.000 mm (1

.D

. with the special tool

.8892

.

.

- 1

.8898 in)

. If

.

ENGINE 3-73

40

09900-20202

CRANKCASE-CRANKSHAFT BEARING SELECTION
Select the specified bearings from the crankcase bore I

The crankcase bore I.D. code
the inside of each crankcase half

Bearing selection table

I

.D

. code O

A

B

C

Bearing thickness

Color (Part No

(12229-06G00-OAO)

(12229-06G00-OBO)

(12229-06G00-0C0)

: Micrometer (25 -

I.D. specification

52

.000-52

(2

.0472-2

52

.006-52

(2

.0475 - 2

52

.012 -52.018 m m

(2

.0477 - 2

.)

Green

Black

Brown

50 mm)

O "A",

"B" or

.

.006 m m

.0475 in)

.012 mm

.0477 in)

.0479 in)

1

(0

1

(0

2

(0

.D . code

"C", is stamped on

Bearing

Green

Black

Brown

Thickness

.996 -1.999 mm

.0786 -0.0787 in)

2

.999
.0787 -0.0788 in)
.002 -2.005 mm

.0788 -0.0789 in)

.002 mm

-

.

Color code

to

CAUTION

Bearing must be replaced as a set

.

~

~

3-74

ENGINE

CRANKSHAFT JOURNAL BEARING REPLACEMENT
Use the special tool to replace the crankshaft journal bearings

The replacement procedure is as follows

.

.

09913-60230

Set the special tool as shown to remove the crankshaft journal

•

bearings

NOTE
Remove the crankshaft journal bearings in only one direction,

from inside to outside of each crankcase half

.

:

: Journal bearing remover/installer

:

.

.

Gradually press out the bearing with the special tool by using

•

the hand-press

CAUTION

The removed bearings must be replaced with new
ones

.

NOTE

:

Using the hand-press is recommended to remove the crankshaft

journal bearings

be removed by using with the following special tools

09924-84510
09924-74570

.

. However, the crankshaft journal bearings can

.

: Bearing installer set

: Final drive gear bearing remover/installer

Bearing

~

~

~

ENGINE 3-75

• Set the specified crankshaft journal bearings to the special
tool

.

CAUTION

•

Before setting the bearing, apply enough engine oil

to the special tool and bearings

•

When setting the bearing, align the bearing side with
the engraved lineOAand also the bearing edge with
the mating surface of the special tool

.

.

09913-60210
09913-60240

NOTE

:

Journal bearing remover/installer (09913-60240) is included in

Journal bearing remover/installer set (09913-60210)

•

Tighten the special tool bolt to the specified torque

Special tool bolt

0

CAUTION

: Journal bearing remover/installer set or
: Journal bearing remover/installer

.

.

: 23 N

.m (2

.3 kgf-m, 16

.5 lb-ft)

Before installing the bearings, lightly shave off the
sharp edge part of the crankcase chamfer by using an
oilstone and wash the crankcase bore with enough
engine oil

.

~

~

~

~

~

3-

7 6

ENGINE

Set the bearings installed in the special tool to the crankcase

•

half as shown

.

CAUTION

Be sure the bearing protruded side©faces the

•

crankcase bore
Align the special tool mating surface with the line

•

on the crankcase

©

NOTE

mark

:

The upper and lower bearings are same

.

.

.

•

Apply enough engine oil to the special tool and the bearings

and then set the special tool carefully

•

Gradually press in the bearing into the main journal bore by

.

using the hand-press until the special tool 10 stops the special

tool

OO

.

. .

09913-60230

NOTE

:

: Journal bearing remover/installer

Using the hand-press is recommended to install the crankshaft

journal bearings

be installed by using the following special tools

. However, the crankshaft journal bearings can

.

.

.

09924-84510
09924-74570

: Bearing installer set

: Final drive gear bearing remover/installer

~

~

~

~

~

ENGINE 3-77

•

After installing the bearings, check the bearing surface for any
scratch or damage

.

GENERATOR COVER

40

DISASSEMBLY AND REASSEMBLY

•

Remove the generator stator

•

When installing the generator stator or crankshaft position
sensor, apply THREAD LOCK to the generator stator set
bolts

.

.

40

40

99000-32050

: THREAD LOCK "1342"

CLUTCH COVER

OIL SEPARATER

•

Remove the oil separator 19

.

GEARSHIFT COVER

OIL SEAL INSPECTION
Inspect the gearshift shaft oil seal for damage or wear on the lip

If any defects are found, replace the oil seal with a new one
OIL SEAL REPLACEMENT

•

Remove the gearshift shaft oil seal

CAUTION

.

.

.

40

The removed oil seal must be replaced with a new one

•

Install the new oil seal with the special tool

. .

09913-70210

NOTE

:

Apply grease to the oil seal lip to prevent damage when install-

ing the gearshift cover

99000-25030
99000-25010

: Bearing installer set

.

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

.

.

~

~

~

3- 78ENGINE

ENGINE REASSEMBLY

Reassemble the engine in the reverse order of disassembly
NOTE

:

.

Apply engine oil to each running and sliding part before reas-

sembling

ENGINE BOTTOM SIDE

.

CRANKSHAFT

•

Install the crankshaft into the left crankcase half

NOTE

:

.

Coat lightly molybdenum oil solution to the crankshaft journal
bearings

-2

.

MOLYBDENUM OIL SOLUTION

CAUTION

Never strike the crankshaft with a plastic hammer

when inserting it into the crankcase

•

Install the countershaft assembly and driveshaft assembly

•

Install the gearshift forks and gearshift cam

NOTE

:

Identify the gearshift forks as follows

90 For 3rd/4th drive gear [width

For 5th driven gear [width

OO

03 For 6th driven gear [width

OA

40 mm (1

OO

:

40 mm (1

OO

:

:

.

:

36 mm (1

.6 in)]
.6 in), Painted]

.

.

.4 in)]

~

~

~

~

~

~

~

~

ENGINE 3-79

•

Fit the dowel pins

r

.

•

Apply grease to the O-ring and install it

99000-25030
99000-25010

CAUTION

Use the new O-ring to prevent oil leakage

Clean the mating surfaces of the left and right crankcase

•

halves
Apply SUZUKI BOND to the mating surface of the left crank-

•

case

1207B

NOTE
Use of SUZUKI BOND is as follows

•

Make surfaces free from moisture, oil, dust and other foreign materials
Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes

•

•

Take extreme care not to apply any bond to the oil hole, oil groove and bearing

•

Apply to distorted surfaces as it forms a comparatively thick film

.

.

99104-31140

:

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

: SUZUKI BOND "1207B"

.

.

:

.

.

.

.

40

~

~

3.8 0

ENGINE

When securing the right and left crankcase halves, tighten

•

each bolt a little at a time to equalize the pressure

the securing bolts to the specified torque values

. Tighten all

.

Crankcase bolt

0

CAUTION

Do not drop the 0-ring into the crankcase when
assembling the right and left crankcase halves

NOTE

:

After the crankcase bolts have been tightened, check if the
crankshaft, the driveshaft and the countershaft rotate smoothly

Install the engine sprocket spacer 1O onto the driveshaft

•

CAUTION

Use the new 0-ring to prevent oil leakage

:

NOTE

The grooved

crankcase side

* Apply grease to the oil seal lip and O-ring

99000-25030
99000-25010

: (M6) 11 N

(M8) 26 N

side of the engine sprocket spacer faces

OO

.

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A" (Others)

.m (1

.1 kgf-m, 8

.m (2 .6 kgf-m, 19

.0 lb-ft)

.0 lb-ft)

.

.

.

.

.

GEARSHIFT

Install the gearshift cam stopper 10, its bolt

•

return spring ®

NOTE

:

Apply a small quantity of THREAD LOCK to the gearshift cam

stopper bolt

99000-32050

Gearshift cam stopper bolt

0

.

and tighten it to the specified torque

OO

: THREAD LOCK "1342"

: 10 N

.m (1

washer

OO

,

.

.0 kgf-m, 7

and

OO

.0 lb-ft)

~

~

~

~

~

~

~

S

•

Check the gearshift cam stopper movement

•

Make sure that the gear position is neutral

•

Install the gearshift cam stopper plate after aligning the gear­shift cam pinOAwith the gearshift cam stopper plate hole ©

•

Apply a small quantity of THREAD LOCK to the gearshift cam

stopper plate boltOand tighten it to the specified torque

99000-32050

Gearshift cam stopper plate bolt

0

: THREAD LOCK "1342"

:

10 N

.

.

.m (1

.0 kgf-m, 7

.

.

.0 lb-ft)

ENGINE

3-81

•

Assembly the geafshift shaft/gearshift arm

Install the gearshift shaft as shown

•

Install the dowel pins and gasket ©

•

.

.

.

40

CAUTION

Use new gasket to prevent oil leakage

.

~

~

~

~

~

~

~

3-82ENGINE

•

Install the gearshift cover

NOTE

:

Fit the clamp to the bolt ©

•

•

Apply grease to the oil seal lip before installing the gearshift
cover

.

99000-25030
99000-25010

GENERATOR ROTOR

•

Install the cam drive idle gear shaft

•

Degrease the tapered portion of the generator rotor assembly
and also the crankshaft
to wipe off oily or greasy matter and make these surfaces
completely dry

: SUZUKI SUPER GREASE "A" (USA)
: SUZUKI SUPER GREASE "A"

.

.

.

(Others)

iD

and cam chain

. Use nonflammable cleaning solvent

OO

.

•

Install the key

•

Install the generator rotor together with the starter drive gear

®

.

•

Install the generator rotor bolt

CAUTION

Make sure that the one way clutch on the crankshaft is
fitted into the generator rotor properly

(T

.

.

.

~

~

~

~

~

~

ENGINE 3-83

•

While holding the generator rotor with the special tool, tighten
the bolt to the specified torque

.

Generator rotor bolt

0

09930-44541

PRIMARY DRIVE GEAR

Install the thrust washer onto the crankshaft

•

NOTE

:

The chamfer side

side

.

•

Install the key

: Rotor holder

O

: 140 N

of the thrust washer faces the crankcase

(O

.m (14

.0 kgf-m, 101

.0 Ib-ft)

.

.

•

Install the primary drive gear assembly

NOTE

:
The convex side of the washer
faces outside

•

Install the primary drive gear nut

NOTE

:

•

This nut has left-hand thread

•

The "L" mark on the nut faces outside

.

.

.

and washer

OO

.

C3C

.

~

~

~

~

~

~

3-

8 4

ENGINE

•

Hold the generator rotor with the special tool

.

.

09930-44541

•

While holding the generator rotor, tighten the primary drive
gear nut to the specified torque

: Rotor holder

.

.

Primary drive gear nut

0

•

Install the cam chain and key ®

CAM DRIVE IDLE GEAR/SPROCKET

•

Insert a suitable bar to the holes of the primary drive gears

and align the two gears

•

Install the cam drive idle gear/sprocket 90

NOTE

:
Align the punched marks
and primary drive gear

: 115 N

.

OO

on the cam drive idle gear/sprocket

.

.m (11

.

.5 kgf-m, 83

.

.0 Ib-ft)

•

Install the washer (2 and nut

O

.

~

~

~

~

~

~

ENGINE 3-85

•

Hold the generator rotor with the special tool

.

09930-44541

• While holding the generator rotor, tighten the cam drive idle

I

gear/sprocket nut to the specified torque

Cam drive idle gear/sprocket nut

CAUTION

Before tightening the cam drive idle gear/sprocket nut,
be sure to engage the front and rear cam chains to

each sprocket

OIL SUMP FILTER

•

Clean the oil sump filter using compressed air

: Rotor holder

.

.

:

70 N-m (7

.0 kgf-m, 50

.

.5 lb-ft)

40

,/

•

Install the oil sump filter

NOTE

:

The projection (& of the oil sump filter faces to the bottom

GEAR POSITION SWITCH

•

Install the springs )

.

.

and gear position switch contacts O2

.

~

~

~

~

~

~

3-86

ENGINE

•

Install the gear position switch and cable guide

OIL PUMP DRIVEN GEAR

•

Install the washer 1O and pin

•

Install the oil pump driven gear
®

.
09900-06107

: Spring ring pliers

OO

.

by installing the snap ring

OO

.

NOTE

:

The bossOAof the oil pump driven gear faces crankcase side

CLUTCH

Install the thrust washer onto the countershaft

•

NOTE

:

The chamfer side

of thrust washer faces crankcase side

OO

.

.

.

•

Install the needle bearingt0and spacerOOonto the counter-

shaft

.

•

Apply engine oil to them

.

~

~

~

~

~

~

ENGINE 3-87

vo

•

Install the primary driven gear assembly O3 onto the counter­shaft

.

NOTE

:

* When installing the primary driven gear assembly, align the

teeth of the primary drive gears by inserting a suitable bar to

the holes of them

* Be sure to engage the oil pump drive and driven gears, pri-

mary drive and driven gears

•

Install the thrust washer ®

•

Install the clutch spring support bolts to the specified torque

.

.

.

.

•

-%

+/

qm/

Clutch spring support bolt

J

•

Install the clutch drive cam ©, driven cam © onto the clutch
sleeve hub

NOTE

:

* Align the punched markOOon the clutch drive cam © with

punched mark © on the clutch driven cam ©

* Apply molybdenum oil solution to shaft of clutch drive cam O5

before installing to the clutch sleeve hub

•

Install the clutch sleeve hub
and driven cam ©

•

Install the washer ® and clutch sleeve hub nut

07

.

.

: 23 N

.m (2

.3 kgf-m, 16

.

07

.

(

P -

73-90)

with the clutch drive cam

07

.

.5 lb-ft)

OO

~

~

~

3-88 ENGINE

NOTE

:

The convex side of the washer faces outside

•

Tighten the clutch sleeve hub nut to the specified torque with
the special tool

.

.

Clutch sleeve hub nut

0

09920-53740

•

Lock the clutch sleeve hub nut with a center punch

•

Install the spring washer seat (O and spring washer* onto

the clutch sleeve hub correctly

: Clutch sleeve hub holder

: 95 N

.m (9 .5 kgf-m, 68

.

.5 lb-ft)

.

•

Insert the clutch drive plates and driven plates one by one into
the clutch sleeve hub in the prescribed order, No
being inserted first

NOTE

:
Insert the outermost No
clutch housing as shown

. (Refer to page 3-90

. 2 drive plate claws to the other slits of

.

.)

. 3 drive plate

~

~

~

ENGINE 3-89

S

•

Install the clutch push rod 11 into the countershaft

2,

•

Install the clutch push piece

(W

.

•

Tighten the clutch spring set bolts diagonally to the specified
torque while holding the generator rotor with the special tool

©

Clutch spring set bolts

.

.

09930-44541

: Rotor holder

: 10 N

bearing 13 and thrust washer

.m (1

.0 kgf-m, 7

.

.

.0 lb-ft)

~

~

~

~

~

~

ENGINE

3-90

NOTE

:

*The No

position from the clutch sleeve hub

. 2 driven plate should be installed between 4th to 7th

.

*Set the numbers of driven plate to the standard specifications

when replacing the driven plates with the new ones

.

DRIVEN PLATE

•

No

. 1 driven plate~Standard

•

No

. 2 driven plate~Standard

DRIVE PLATE

No

. 1 drive plate~8 pcs

•

© No

. 2 drive plate

© No

. 3 drive plate

:

:

~
~

00

1 pc
1 pc

2

.8 mm

(0

.11 in)

.
.

.

: 7 pcs
: 2 pcs

.
.

® No

12 mm
(0

Factory setting

5 - 8 pcs

1 -

. 1 driven

.47 in)

N

a

l

4 pcs

.
.

3
(0

2

.0 mm

(0

.08 in)

.8 mm

.15 in)

® No

.0 mm

8

(0

.31 in)

k

driven

. 2

plateplate

2

.3 mm

(0

.08 in)

3

.8 mm

.15 in)

(0

No

. 1 drive plate

OA

NOTE

:

Apply molybdenum oil solution to shaft of clutch drive cam

installing
Clean the excess oil firmly

.

.

© No

. 2 drive plate

OD

before

© No

. 3 drive plate

~

~

~

~

~

ENGINE 3-91

CLUTCH COVER

•

Install the gasket 1O and dowel pins

.

CAUTION

Use the new gasket to prevent oil leakage

•

Install the clutch cover

NOTE

:

Set the impeller shaft end

NOTE

:

Fit the clamp to the bolts ©

.

to the cam drive idle shaft ©

OO

.

.

.

•

Fit the dowel pin
Apply engine coolant to the 0-ring

•

•

Install the water pump case

.

.

.

~

~

~

~

~

3

-92

ENGINE

•

Install the starter idle gear

NOTE

:
Apply engine oil to the shaft

•

Install the bushingsOinto the crankcase and generator

cover

.

NOTE

:
Apply molybdenum oil solution to the inside of the bushings

MOLYBDENUM OIL SOLUTION

-2

spacer © and shaft ®

O,

.

.

.

•

Fit the washers onto the starter torque limiter ©

•

Install the starter torque limiter © with the washers

•

Install the dowel pin and gasket ©

CAUTION

.

.

.

Use the new gasket to prevent oil leakage

.

~

~

~

• Install the generator cover

.

OIL FILTER

•

Apply engine oil lightly to the 0-ring

•

Install the oil filter turning it by hand until feeling that the

0-ring contacts the mounting surface
with the special tool

. .

09915-40610

.

: Oil filter wrench

.

. Then tighten it 2 turns

ENGINE 3-

9 3

ENGINE TOP SIDE

PISTON

•

Install the piston rings in the order of oil ring, 2nd ring and 1st

ring

.

NOTE

:

1st ring and 2nd ring differ in the shape

•

Be sure to bring the concave side of 1st ring to top when fit-

ting it to the piston

•

2nd (middle) ring has letters "RN" marked on the side

.

.

. Be
sure to bring the marked side of the 2nd ring to top when fit­ting it to the piston

•

The first member to go into the ring groove is spacer
placing the spacer, fit the two side rails

top and bottom, are not applied to the spacer and side rails
you can position each either way

.

After

D

.

Side designations,

OO

.

:

.

~

~

~

~

3-94

ENGINE

•

Position the gaps of the three rings as shown
each piston into the cylinder, check that the gaps are so
located

•

Apply a light coat of molybdenum oil solution to the piston pin

-ff

NOTE

When installing the pistons, front and rear, the indentsOAon the

piston heads must be located to each exhaust side

•

Place a clean rag over the cylinder base so as not to drop the
piston pin circlips into the crankcase

•

Install the pistons, front and rear

•

Install the piston pin circlips

.

MOLYBDENUM OIL SOLUTION

:

.

.

.

. Before inserting

.

.

CAUTION

Use new piston pin circlips to prevent circlip failure

which will occur with a bend one

CAUTION

When turning the crankshaft, pull the cam chains
upward, or the chains will be caught between the
crankcase and the cam drive sprocket

NOTE

:
End gap of the circlip should not be aligned with the cutaway in
the piston pin bore

.

.

.

~

~

~

~

~

OIL JET

•

Apply engine oil to the new O-rings

•

Install each of the oil jets front and rear

.

.

CAUTION

Use the new O-rings to prevent oil leakage

.

ENGINE 3-

9 5

40

CYLINDER

•

Coat SUZUKI BOND lightly to the mating surfaces at the part­ing line between the right and left crankcases as shown

NOTE

:

When replacing the stud bolt

thread of the crankcase side

1207B

99104-31140

•

Fit the dowel pins and new gaskets
and rear

.

: SUZUKI BOND "1207B"

apply SUZUKI BOND to the

OO

,

.

to the crankcase front

D

.

CAUTION

Use the new gaskets to prevent oil leakage

•

Apply engine oil to the sliding surface of the pistons and cylin-

ders

.

.

NOTE

:

The cylinders can be distinguished by the embossed-letters, "F"

and

"R"

.

"F"

: Front (No

"R":Rear (No

. 1) cylinder

. 2) cylinder

~

~

~

~

~

~

3-96 ENGINE

•

Hold the piston rings in proper position, and insert each of the
pistons into the respective cylinders

NOTE

:

When installing the cylinders, keep the cam chains taut

cam chain must not be caught between cam drive sprocket and
crankcase when turning the crankshaft

•

Tighten the cylinder nuts (M6) temporarily

NOTE

:

Fit the clamp to the front cylinder nut ©

.

. The

.

.

.

CYLINDER HEAD

•

Pull the cam chains out of the cylinders and install the cam

chain guides

NOTE

:

There are the guide holders for the bottom ends of each cam

chain guide cast in the crankcase
guides are inserted properly

•

Fit the dowel pins and new cylinder head gaskets 02 to the

cylinders, front and rear

CAUTION

Use the new gaskets to prevent gas leakage

•

Place the rear cylinder head on the cylinder

NOTE

:

When installing the cylinder head, keep the cam chain taut

•

Tighten the cylinder head bolts (Ml 0) to the specified two step
torque with a torque wrench sequentially and diagonally

Cylinder head bolt (M10)

Initial 25 N
Final 47 N

O

.

.

.

:

.m (2 .5 kgf-m, 18
.m (4 .7 kgf-m, 34

. Be sure that the cam chain

.

.

.

.

.0 lb-ft)
.0 lb-ft)

No

~

ENGINE 3-97

NOTE

:

moo

* Install the washers to the cylinder head bolts (M10) as shown
* Apply engine oil to the washers and thread portion of the bolts

before installing the cylinder head bolts

,

•

After firmly tightening the cylinder head bolts (M10), tighten

the cylinder head nuts, bolts and cylinder nuts

Cylinder head nut (M8)

0

Cylinder head nut (M6) ©
Cylinder head bolt (M6)

Cylinder nut (M6)

OO

:

OO

©:10 N

10 N

25 N

:
: 10 N

.m (1

.

.

.m (2

.5 kgf-m, 18

.m (1

.0 kgf-m, 7

.m (1

.0 kgf-m, 7

.0 kgf-m, 7

.0 lb-ft)

.0 lb-ft)

.0 lb-ft)

.0 lb-ft)

.

~

~

~

~

~

3-98 ENGINE

•

Place the front cylinder head on the cylinder

NOTE

:

When installing the cylinder head, keep the cam chain taut

•

Tighten the cylinder head bolts (M10) to the specified
two-step torque with a torque wrench sequentially and diago-

nally

.

.

.

Cylinder head bolt (M10)

•

NOTE

:

•

Install the washers to the cylinder head bolts (M10) as shown

•

Apply engine oil to the washers and thread portion of the bolts

before installing the cylinder head bolts

•

After firmly tightening the cylinder head bolts (M10), install the
cylinder head nuts, bolts and oil cooler mounting bracket 10

•

Tighten the cylinder head nuts, bolts and the cylinder nuts

Cylinder head nut (M8)OE:

•

Cylinder head nut (M6)®F:
Cylinder head bolt (M6) ©
Cylinder nut (M6)

©:10 N

: Initial 25 N

Final 47 N .m

25 N

.m (2 .5 kgf-m, 18

10 N

.m (1

: 10 N

.m (1

.0 kgf-m, 7

.m

(2

.5 kgf-m, 18

(4

.7 kgf-m, 34

.

.0 kgf-m, 7

.m (1

.0 kgf-m, 7

.0 lb-ft)

.0 lb-ft)

.

.

.

.0 Ib-ft)

.0 lb-ft)

.0 lb-ft)

.0 lb-ft)

v%

.

4

~

~

ENGINE 3-99

•

Pull the cam chains upward and install the cam chain tension-

ers into each cylinder head

O

For No
For No

. 1 (Front) cylinder head
. 2 (Rear) cylinder head

.

.we

NOTE

:

* When installing the cam chain tensioners, insert the their

holder ends

* When installing the No

it rear side of the rib Q)

into each guide cast on the cylinder

O

. 1 (Front) cam chain tensioner, through

.

.

•

Tighten the cam chain tensioner mounting bolts to the speci­fied torque

Cam chain tensioner mounting bolt

0

.

:

10 N

.m (1

.0 kgf-m, 7

.0 lb-ft)

~

~

~

~

~

3-100 ENGINE

FRONT CAM DRIVE IDLE GEAR/SPROCKET

•

Turn the crankshaft counterclockwise with the box wrench
and align "F I T" lineOAon the generator rotor with the index

mark © of the valve timing inspection hole while keeping the

camshaft drive chain pulled upward

CAUTION

Pull the cam chains upward, or the chain will be

caught between crankcase and cam drive sprocket

CAUTION

To adjust the camshaft timing correctly, be sure to
align "F I T" lineOwith the index mark © and hold

this position when installing the cam drive idle gears/
sprockets, front and rear

.

.

.

•

Apply molybdenum oil solution to the cam drive idle gear/
sprocket bearing, its shaft 10, and thrust washer

MOLYBDENUM OIL SOLUTION

-a

NOTE

:

* The thickness of thrust washerOmust be selected for each

cylinder head

* Paint the engraved line © on the cam drive idle gear/sprocket

•

Install the cam drive idle gear/sprocket onto the front cylinder
head and engage the cam chain on it

•

Align the engraved line © on the cam drive idle gear/sprocket

with the embossed line

•

Install the cam drive idle gear/sprocket shaft 90, copper

washer © and thrust washer

. (THRUST WASHER SELECTION= 3-44)

.

on the cylinder head

OD

(Z

.

(Z

.

.

.