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
|
Inspecting the drive chain
When inspecting the chain, look
for the following:
loose pins
damaged rollers
dry or rusted links
kinked or binding links
excessive wear
improper chain adjustment
If you find anything wrong with the
drive chain condition or adjustment,
correct the pr ...
Carrying a passenger
Carrying a passenger, when done
correctly, is a great way to share
the joy of motorcycling. You will
have to alter your riding style
somewhat since the extra weight
of a passenger will affect handling
and braking. You may also need
to adjust tire pressures and suspension;
please refer to the ...
Chassis bolt and nut inspection
Tighten chassis bolt and nut
initially at 1 000 km (600 miles, 2 months) and every
6 000 km (4 000 miles, 12 months) thereafter
Check that all chassis bolts and nuts are tightened to
their specified torque.
Steering stem
lock-nut 80 n·m (8.0 Kgf-m, 58.0 Lbf-ft)
Stee ...