Note the crankcase must be separated to service the crankshaft and conrod. |
Crankcase breather (pcv) cover
Remove the crankcase breather (pcv) cover (1).
Starter motor
Remove the starter motor (1).
Clutch
Remove the clutch component parts (1). Refer to “clutch removal” in section 5c .
Gearshift system
Remove the gearshift shaft (1) and gearshift cam plate (2). Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b .
Starter torque limiter / starter clutch
Remove the starter torque limiter (1) and starter clutch (2) component parts. Refer to “starter torque limiter removal and installation” in section 1i and “starter clutch removal and installation” in section 1i .
Cam chain / cam chain tensioner / cam chain guide no. 1
Generator
Remove the generator cover (1) and rotor. Refer to “generator removal and installation” in section 1j .
Water pump
Gear position switch
Remove the gear position switch (1).
Oil pressure switch
Remove the oil pressure switch lead wire (1) and switch (2).
Oil filter
Remove the oil filter (1) with the special tool.
Special tool
(a): 09915–40610 (oil filter wrench)
Oil pan
Oil pressure regulator / oil strainer
Oil pump
Crankcase
Note loosen the crankcase bolts diagonally and smaller size ones first. |
Balancer shaft
Remove the balancer shaft assembly (1) and plug (2).
Transmission
Remove the transmission component. Refer to “transmission removal” in section 5b .
Crankshaft
Piston cooling oil jet
Remove the piston cooling oil jet (1) from the upper crankcase.
Piston / conrod
Caution be careful not to damage the cylinder wall by the conrod. |
Note scribe the cylinder number on the piston head. |
Crankshaft journal bearing
Remove the crankshaft journal bearings, upper and lower.
Caution
|
Note
|
Oil jet
Remove the oil jet (1) (for transmission) from the lower crankcase.
Oil gallery plug
Water jacket plug
Remove the water jacket plugs (1) from the upper crankcase.
Oil seal / bearing
Remove the oil seal and bearings if necessary. Refer to “transmission removal” in section 5b .
Breather oil return plate
Remove the breather oil return plate (1) from the upper crankcase.
Rear shock absorber adjustment
After installing the rear suspension, adjust the spring
pre-load and damping force as follows:
Spring pre-load adjustment
The set length 179.3 Mm (7.06 In) provides the
maximum spring pre-load.
The set length 189.3 Mm (7.45 In) provides the
minimum spring pre-load.
Std position
184.3 ...
Fuel injector inspection and cleaning
Inspect the fuel injector in the following procedures:
remove the fuel injector. Refer to “throttle body disassembly and
assembly” in section 1d .
Check the fuel injector for evidence of dirt and
contamination. If present, clean and check for
presence of dirt in the fuel lin ...
Engine oil
Oil quality is a major contributor to
your engine's performance and
life. Always select good quality
engine oil. Suzuki recommends
the use of suzuki performance
4 motor oil or equivalent
engine oil. Use sf/sg or sh/
sj with jaso ma in api (american
petroleum institute) classification.
A ...