- Install the countershaft assembly on the upper crankcase.
Note: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.
- Install the driveshaft assembly on the upper crankcase.
Note: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.
- Turn the bearings to install the bearing dowel pins f in the respective positions.
- Install the O-rings 1.
- Apply SUZUKI SUPER GREASE "A" to the O-rings.
- 99000-25010: SUZUKI SUPER GREASE "A" or equivalent
Caution: Use a new O-ring to prevent oil leakage.
- Install the dowel pins 2.
- Apply SUZUKI BOND to the mating surface of the lower crankcase.
- 99000-31110: SUZUKI BOND "1215" or equivalent
Note: Use of SUZUKI BOND is as follows:
- Make surfaces free from moisture, oil, dust and other foreign materials.
- Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.
- Take extreme care not to apply any BOND to the oil hole, oil groove and bearing.
- Apply to distorted surfaces as it forms a comparatively thick film.
- Match the upper and lower crankcases.
Note: Align the gearshift forks 3 with their grooves 4.
- Tighten the crankcase bolts a little at a time to equalize the pressure.
Note:
- Fit the new copper washers to the crankcase bolts В.
- Fit the new gasket washers to the crankcase bolts С.
Crankcase bolt:
- (M6): 11 Nm (1.1 kgf·m, 8.0 lb·ft)
- (M8): 26 Nm (2.6 kgf·m, 19.0 lb·ft)
- (M10) Initial: 30 Nm (3.0 kgf·m, 21.5 lb·ft)
- Final: 50 N·m (5.0 kgf·m, 36.0 lb·ft)
Caution: Use the new copper washers and new gasket washers to prevent oil leakage.
- Apply SUZUKI BOND to the mating surface of the breather cover.
- 99000-31140: SUZUKI BOND "1207B" or equivalent
Note: Use of SUZUKI BOND is as follows:
- Make surfaces free from moisture, oil, dust and other foreign materials.
- Spread on surfaces thinly to form an even layer, and assemble the breater cover within few minutes.
- Apply to distorted surfaces as it forms a comparatively thick film.
- Tighten the breather cover bolts.
- Check that the driveshaft and countershaft rotate smoothly.
