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
|
Rear brake light switch inspection
Inspect the rear brake light switch in the following
procedures:
lift and support the fuel tank. Refer to “fuel tank
removal and installation” in section 1g (page 1g-
9).
Disconnect the rear brake light switch lead wire
coupler (1).
Inspect the rear brake light swi ...
Tightening torque list
Engine
Fi system + intake air system
Cooling system
Chassis
Tightening torque chart
For other bolts and nuts not listed in the preceding page, refer to this
chart:
Conventional bolt
“4” Marked bolt
“7” Marked bolt
...
Precautions
Precautions for wheel and tire
Proper tire pressure and proper tire loading are important
factors. Over loading tire can lead to tire
failure and loss of motorcycle control.
Under-inflated tires make smooth cornering difficult, and
can result in rapid tire wear.
...