Becareful!nottodamagethecylinderwallbytheconrod.

_•

•CheckthatIDcode~·ontheeachconrodsfacestowardintake

^side._@

_ACAUTIONI

^{IBesuretocleantheconrodbigend.}

•Applymolybdenumoilsolutiontothecrankpinbearingssur•

_face.

^{mtMOLYBDENUMOILSOLUTION}

CRANKSHAFT

•PositiontheNo.2andNo.3conrodbigendstowardsameside

andtheNo.1andNo.4conrodbigendstowardoppositesideof

No.2andNo.3.

•Setthecrankshafttotheconrodsanduppercrankcase.

•Applymolybdenumoilsolutiontothecrankpinandbearingsurface.

1L1molybdenumoilsolution

Iacautioni

Besuretocleantheconrodbigend.

•Whenfittingtheconrodcap,makesurethatl.D.code'§)oneachconrodfacestowardintakevalveside.

•Applyengineoiltothebearingcapbolts.

•Tightenthebearingcapboltbyusinga10mm,12pointsocketwrenchasfollowingtwosteps.

(!JConrodbearingcapbolt:

Initial:15n·m(1.5kgf·m,11.0lb-ft)Final:90°(1/.Iturn)

•Applyengineoiltotheconrodbigendsidesurfaces.

•Checktheconrodmovementforsmoothturning.

CRANKSHAFT

•Applymolybdenumoilsolutiontoeachcrankshaftjournalbear•

Inglightly.

^{filMOLYBDENUMOILSOLUTION}

•Inserttherightandleft-thrustbearingswithoilgroove'§:ifacingthecrankweb..

NOTE:

Right-thrustbearinghasgreenpainting.

CRANKCASE

•Cleanthematingsurfacesofthecrankcases.

•Installthedowelpins·1)and0-ring~totheuppercrankcase.

•ApplySUZUKIBONDtothematingsurfaceofthemiddlecrank-case.

~99104-31140:SUZUKIBOND"12078"(ForUSA)

(ifilJ99000-31110:SUZUKIBOND"1215"(Fortheothers)

NOTE:

UseofSUZUKIBONDisasfollows:

*Makesurfacesfreefrommoisture,oil,dustandotherf9reignmaterials.

"Spreadonsurfacesthinlytoformanevenlayer,andassemble

thecrankcaseswithinfewminutes.

"TakeextremecarenottoapplyanyBONDtotheoilhole,oilgrooveandbearing.

*Applytodistortedsurfacesasitformsacomparativelythick

_film.

_-

^{Alignthegearshiftforkswiththeeachgear.}

•Tightenthecrankcasebolt(9mm)inascendingorderofnum•bersassignedtothesebolts.Tighteneachboltalittleatatimetoequalizethepressure.

(!JCrankcasebolt:(M9)

Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)

•Tightentheothercrankcaseboltsalittleatatimetoequalizethepressure.

_{(!)Crankcasebolt:}

(M6)	initial:6N·m(0.6kgf·m,	4.5lb-ft)
	Final:11N·m(1.1kgf·m,	8.0lb-ft)

^NOTE:

Fittheclamptothecrankcasebolt®.

^NOTE:

Fitthegaskettothecrankcasebolt'ID.

NOTE:

Afterthecrankcaseboltshavebeentightened,checkifthecrank•

shaftrotatessmoothly.

\

@

_..^-

^.•/~,

TRANSMISSION

•InstallthebearingpinsG)andtheC-ring(2)ontheuppercrank·

case.

•Installthecountershaftassemblyontheuppercrankcase.

NOTE:

AligntheC-ringwiththegrooveonthebearingandthebearingpinwiththeindentonthebearing.

•Installthedriveshaftassemblyontheuppercrankcase.

NOTE:

Alignthebearingringwiththegrooveonthecrankcaseandthebearingpinwiththeindentonthebearing.

•InstalltheoilsealG).

•Turnthebearingstoinstallthebearingdowelpins®inthe

respectivepositions.-

•Installthe0-rings.

•Installthedowelpins(t.

•ApplySUZUKIBONDtothematingsurfaceofthelowercrank-case.

..1201~99104-31140:SUZUKIBOND"1207B"(ForUSA)

~99000-31110:SUZUKIBOND"1215"(Fortheothers)

NOTE:

UseofSUZUKIBONDisasfollows:

*Makesurfacesfreefrommoisture,oil,dustandotherforeignmaterials.

*Spreadonsurfacesthinlytoformanevenlayer,andassemblethecrankcaseswithinfewminutes.

~TakeextremecarenottoapplyanyBONDtotheoilhole,oilgrooveandbearing.

*Applytodistortedsurfacesasitformsacomparativelythick

_film.

_....

•Matchthemiddleandlowercrankcases.

NOTE:

Alignthegearshiftforkswiththeirgrooves.

•Tightenthecrankcaseboltsalittleatatimetoequalizethepressure.

(!)Crankcasebolt:(M6}initia:l6N·m(0.6kgf·m,4.5lb-ft}Final:11N·m(1.1kgf·m,8.0lb-ft}

(MS}initial:15N·m(1.5kgf·m,10.8lb-ft}Final:26N·m(2.6kgf.m,19.0lb-ft)

NOTE:

•Fitthecopperwashertothecrankcasebolts®·

•Fitthegasketwashertothecrankcasebolts@.

•Checkthedriveshaftandcountershafttorotatesmoothly.

OILSTRAINER

•Installthe0-ring.

NOTE:

Applygreasetothe0-ring.

,@99000-25010:SUZUKISUPERGREASE"A"

:ACAUTIONI

Usethenew0-ringtopreventoilleakage.

•Installtheoilstrainerasshown.

(!)Oilstrainerbolt:10N·m(1.0kgf·m,7.0lb-ft)

OILPRESSUREREGULATOR

•Applygreasetothe0-ringandpressintheoilpressureregula•

tortothecrankcase.

,..@99000-25010:SUZUKISUPERGREASE"A"

IACAUTIONI

Usethenew0-ringtopreventoilleakage.

OILPAN

•InstallthegasketCD.

IACAUTIONI

Usethenewgaskettopreventoilleakage.

•Installtheoilpan.

NOTE:

Fitthegasketwashertotheoilpanbolt®·

•Tightentheoilpanboltsdiagonallytothespecifiedtorque.

(!)Oilpanbolt:1ON·m(1.0kgf·m,7.0lb-ft)

•InstallthecowlingbracketsG)and~-

OILPRESSURESWITCH

•ApplySUZUKIBOND"12078"tothethreadpartoftheoilpres-sureswitchG)andtightenittothespecifiedtorque.

~99000-31140:SUZUKIBOND"12078"

_{~Oilpressureswitch:14N·m(1.4kgf·m,10.0lb-ft)}

NOTE:

_-

BecarefulnottoapplySUZUKIBOND"12078"totheholeofthethreadend.

OILCOOLER

•Applythegreasetothe0-ring.

~99000-25010:SUZUKISUPERGREASE"A"

IACAUTIONI

Usethenew0-ringtopreventoilleakage.

•Installtheoilcoolerasshown.

~Oilcoolerbolt:10N·m(1.0kgf·m,7.0lb-ft)

OILFILTER

•Installtheoilfilterusingthespecialtool.(L?2-14)

iT'OOli09915-4061O:Oilfilterwrench

_ENGINEvn

•Installthegasket.

•Installthebreathercover.

_{(!JBreathercoverbolt:1ON·m(1.0kgf·m,7.0lb-ft)}

_.....

GEARPOSITIONSWITCH

•InstallthegearpositionswitchcontactsG)andthesprings(?).

•Applythegreasetothe0-ring.

,099000-25010:SUZUKISUPERGREASE"A"

•Installthegearpositionswitchasshown.

WATERPUMP

•Applygreasetothe0-ring.

IACAUTIONI

-

Usethenew0-ringtopreventoilleakage.

~99000-25010:SUZUKISUPERGREASE"A"

•Tightenthewaterpumpmountingboltstothespecifiedtorque.(!)Waterpumpmountingbolt:10N·m(1.0kgf·m,7.0lb-ft)

NOTE:

Passthroughthegearpositionswitchleadwireunderthewarterpumplib®·

•Applytheenginecoolanttothe0-ring.

•Installthewaterinletcover.

(!)Waterinletcoverbolt:10N·m(1.0kgf·m,7.0lb-ft)

•Installtheradiatorhoses.(c::::TB-24)

-

GENERATORROTOR

•Degreasethetaperedportionofthegeneratorrotorandalsothecrankshaft.Usenonflammablecleaningsolventtowipeoffoilyorgreasymatterandmakethesesurfacescompletelydry.

•Installthegeneratorrotorontothecrankshaft.

•Installtherotorboltwiththewasher.

•Holdingthegeneratorrotorwiththespecialtoolandtightenitsbolttothespecifiedtorque.

!TM!09930-44520:Rotorholder

_{(!)Generatorrotorbolt:120N·m(12.0kgf·m,88.5lb-ft)}

_.....

GENERATORCOVER

-

•ApplySUZUKIBOND"12078"lightlytothematingsurfacesatthepartinglinebetweentheupperandlowercrankcasesasshown.

~99000-31140:SUZUKIBOND"1207B"

•InstallthedowelpinsandnewgasketG).

IACAUTIONI

Usethenewgasketstopreventoilleakage.

•Installthegeneratorcoverandtightenthegeneratorcoverboltstothespecifiedtorque.

(!JGeneratorcoverbolt:10N·m(1.0kgf·m,7.0lb-ft)

A.WARNING

Becarefulnottopinchthefingerbetweenthegeneratorcoverandthecrankcase.

NOTE:

Fitthegasketwashertotheboltsf;;.

•InstalltheCKPsensor.

•ApplySUZUKIBOND"12078"lighttothegrooveofthesignalgeneratorleadwiregromet.

_{..1201sJ99000-31140:SUZUKIBOND"12078"}

CAMCHAINDRIVESPROCKET

•Installthecamchaindrivesprocketontothecrankshaft.

NOTE:

_-

Alignthepunchedmark®onthecamchaindrivesprocketwiththepunchedmark@onthecrankshaft.

CAMCHAINTENSIONERANDCAMCHAINGUIDE

•Installthecamchain.

•ApplyasmallquantityofTHREADLOCK"1342"tothecamchaintensionerboltandcamchainguidebolt..

^{•InstallthecamchaintensionerCD,washer(2)andcamchain}

guide®·

teJ99000-32050:THREADLOCK"1342"

~ Camchaintensionerbolt:10N·m(1.0kgf·m,7.0lb-ft)Camchainguidebolt:10N·m(1.0kgf·m,7.0lb-ft)

STARTERCLUTCH

•InstallthewasherCD.

•Installthestarterclutchassemblyontothecrankshaft.

NOTE:

Aligntheengravedline®onthestarterclutchwiththepunchedmark'§)onthecrankshaft.

_....

•Installthestarterclutchboltwiththewasher.

•Holdthestarterclutchwithspecialtoolandtightenitsbolttothespecifiedtorque.

1ffiih09920-34830:Starterclutch

(!JStarterclutchbolt:55N·m(5.5kgf·m,40.0lb-ft)

STARTERIDLEGEAR

•InstallthestarteridlegearNo.2CDitsshaft(biandthewavewasherQ).

•ApplySUZUKIBOND"12078"lightlytothematingsurfaces®atthepartinglinebetweentheupperandlowercrankcasesandsurface@asshown.

..l20n999000-31140:SUZUKIBOND"12078"

•InstallthenewgasketG)andthedowelpins.

,ACAUTIONI

_{Useanewgaskettopreventoilleakage.}

•Installthestarterclutchcoverandtightenitsboltasshown.

-

NOTE:

"Fitthewireclamptothestarterclutchcoverbolt®asshown.

•Fitthenewgasketwashertothestarterclutchcoverboltcg.asshown.

-

IACAUTIONI

Usethenewgasketwashertopreventoilleakage.

(!JStarteridlegearcover:10N·m(1.0kgf·m,7.0lb-ft)

_{•InstallthestarteridlegearNo.1shaftCDandthethrustwasher}

~thebearing®andthestarteridlegearNo.1®thewasher

'IDandthewavewasher®·

•Installthedowelpinsandthenewgasket(!).

_IACAUTIONI

^{IUseanewgaskettopreventoilleakage.}

•Installthestarteridlegearcoverandtightenitsboltstothespecifiedtorque.

(!JStarteridlegearcover:1ON·m(1.0kgf·m,7.0lb-ft}

NOTE:

Fitthegasketwashertothebolt®·

GEARSHIFTSYSTEM

•InstallthegearshiftcamstopperG),itsbolt(%),thewasher'~

andthereturnspring@.

NOTE:

ApplyasmallquantityofTHREADLOCK"1342"tothegearshiftcamstopperbolt®andtiqntenittothespecifiedtorque.

ttm99000-32050:THREADLOCK"1342"

(!JGearshiftcamstopperbolt:10N·m(1.0kgf·m,7.0lb-ft)

NOTE:

HookthereturnspringendtothestopperG).

•Confirmthegearshiftcamstoppermovement.

•Checktheneutralposition.

•Installthegearshiftcamstopperplateafteraligningthegear•

shiftcampin®withthegearshiftcamstopperplatehole@.

•ApplyasmallquantityofTHREADLOCK"1342"tothegear•

shiftcamstopperplateboltandtightenittothespecifiedtorque.

'tJE99000-32050:THREADLOCK"1342"

(!JGearshiftcamstopperplatebolt:10N·m

(1.0kgf·m,7.0lb-ft)

•Installthegearshiftshaft/gearshiftarmJ)withthewashersasshown.

NOTE:

Pinchthegearshiftarmstopper<2)withreturnspringends®·

_{•Installthewasher@andcirclip@.}

_-

OILPUMP

•Installthe0-ringtotheoilpumpandapplygreasetoit.

IACAUTIONI

Usethenew0-ringtopreventoilleakage.

,099000-25010:SUZUKISUPERGREASE"A"

NOTE:

Settheoilpumpshaftendtothewaterpumpshaft.

•Installtheoilpumpwiththethreeboltsandthentightenthemtothespecifiedtorque.

(!)Oilpumpmountingbolts:10N·m(1.0kgf·m,7.0lb-ft)

•InstallthewasherG)andthepin(2).

NOTE:

BecarefulnottodropthewasherG)andthepin(2)intothecrank•

case.

•Installtheoilpumpdrivengear@.

•Installthecirclip~-

lrMu09900-06107:Snapringpliers

CLUTCH

•Installthethrustwasherontothecountershaft.

NOTE:

Thechamferside®ofthethrustwasherfacescrankcaseside.

•InstalltheoilpumpdrivegearG)totheprimarydrivengearassembly.

•.

NOTE:^~

Becarefulnottocontacttheprimarydrivengearwiththecrankwebwheninstallingtheclutchhousing.

•InstallthebearingG)andspacer~andapplyengineoiltothem.

•Installtheprimarydrivengearassembly.

3·86ENGINE_-

_{•InstallthethrustwasherCD.}

•Installtheclutchsleevehub(2)ontothecountershaft.

•Installthewasher®andspringwasher@.

NOTE:

Theconvexsideofthewasher@facesoutside.

-

_-

^{•InstalltheclutchsleevehubnutCD.}

•Holdtheclutchsleevehubusingthespecialtool.

fTOOtt09920-53740:Clutchsleevehubholder

•Tightentheclutchsleevehubnuttothespecifiedtorque.

(!)Clutchsleevehubnut:150N·m(15.0kgf·m,108lb-ft)

•Locktheclutchsleevehubnutwithacenterpunch.

_CLUTCH

•InsertthewasherCDandspringwasher~.

•Inserttheclutchdriveplatesanddrivenplatesonebyoneintotheclutchsleevehubintheprescribedorder.

NOTE:

Inserttheoutermostdriveplateclaws®totheotherslits@of

_{clutchhousingasshown.}

~DRIVEPLATENo.1(40frictionpcs):7pcs

])DRIVEPLATENo.2(48frictionpcs):1pc

@DRIVEPLATENo.3(Withdamper):1pc

:Q)DRIVENPLATENo.1)(Thickness:2.6mm):6-8pcsT.

_{~DRIVENPLATENo.2iota}¹⁸_pcs

(Thickness:2.3mm):o-2pcs

©^@

Directionofoutside---

^@@@@@

_.....

_®

_{•InstalltheclutchpushrodCDintothecountershaft.}

•Installtheclutchpushpiece(2),thebearingQ)andthethrustwasher©tothecountershaft.

NOTE:

Thrustwasher©islocatedbetweenthepressureplateandthebearing®·

•Installtheclutchpressureplate.

•Installtheclutchsprings.

_-

•Holdtheclutchhousingusingthespecialtool.

IACAUTIONI

Becarefulnottodamagetheclutchhousingorclutchplates.

n'OOh09920-53740:Clutchsleevehubholder

•Tightentheclutchspringsetboltstothespecifiedtorque.

~Clutchspringsetbolt:1ON·m(1.0kgf·m,7.0lb-ft)

NOTE:

Tightentheclutchspringsetboltsdiagonally.

CLUTCHCOVER

•ApplySUZUKIBOND"12078''lightlytothematingsurfacesatthepartinglinebetweentheupper,middleandlowercrank•casesasshown.

@i99000-31140:SUZUKIBOND"12078"

-

•Installthegasket(j)andthedowelpins.

:ACAUTIONI