Refer to “engine top side disassembly” .
Refer to “engine top side assembly” .
Caution identify the position of each removed part. Organize the parts in their respective groups (i.E., Intake, exhaust, no. 1 Or no. 2) So that they can be installed in their original locations. |
Disassembly
Caution be careful not to damage the tappet sliding surface with the special tool. |
Special tool
(a): 09919–28620 (sleeve protector)
(b): 09916–14522 (valve lifter
attachment)
(c): 09916–14510 (valve lifter)
: 09916–84511 (tweezer)
Assembly
Assembly is in the reverse order of disassembly. Pay attention to the following points:
Caution replace the gaskets with new ones. |
Tightening torque cam chain tension adjuster service cap (a): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft) oil gallery plug (cylinder head) (b): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)
Caution replace the o-rings with new ones. |
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
Tightening torque intake pipe bolt (c): 8.5 N·m (0.85 Kgf-m, 6.5 Lbf-ft)
Caution use new o-ring to prevent oil pressure leakage |
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
Tightening torque bypass hose union (d): 12 n·m (1.2 Kgf-m, 8.5 Lbfft)
Note the air bleeder hole “b” of the thermostat faces upside. |
Tightening torque thermostat cover bolt (e): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)
Tightening torque ect sensor (f): 18 n·m (1.8 Kgf-m, 13.0 Lbf-ft)
Caution
|
Caution do not reuse the removed oil seal. |
M/o: molybdenum oil (molybdenum oil solution)
Caution when inserting the valve, take care not to damage the lip of the oil seal. |
M/o: molybdenum oil (molybdenum oil solution)
|
Caution
|
Special tool
(a): 09916–14510 (valve lifter)
(b): 09916–14522 (valve lifter
attachment)
(c): 09919–28620 (sleeve protector)
: 09916–84511 (tweezer)
|
Note
|
Engine oil and filter change
Change the engine oil and oil filter
at the scheduled times. The
engine should always be warm
when the oil is changed so the oil
will drain easily. The procedure is
as follows:
Place the motorcycle on the
side stand.
Remove the three screws of
the right fairing 1.
...
Exterior parts construction
Upper cowling bracket
: set the punch mark to the front and upper side.
Rear view mirror cushion
: set the dent side to inside.
To frame
To headlight assembly
To sprocket cove
To side-stand bracket
...
Piston and piston ring inspection
Refer to “piston ring removal and installation” .
Piston diameter
Measure the piston diameter using the micrometer at 15
mm (0.6 In) “a” from the skirt end. If the piston diameter
is less than the service limit, replace the piston.
Special tool
(a): 09900–20203 (micrometer (50 –
75 mm))
Pis ...