Note. Before assembly, lubricate all rotating and sliding parts with engine oil.
Crankcase bearings
Install the bearings into the crankcase using the special tool.
![](https://motoinstruction.ru/img/suzuki/4/112592.jpg)
09913-70210: Bearing installation tool
Bearing | Device |
(1) | 22 mm |
(2) | 40 mm |
(3) | 42 mm |
(4) | 52 mm |
(5) | 55 mm |
(6) | 68 mm |
Install bearing retainers (1).
Note. Apply a small amount of THREAD LOCK SUPER "1322" or THREAD LOCK "1342" threadlocker to the bearing retainer screws.
99000-32050: THREAD LOCK "1342" (For USA) 99000-32110: THREAD LOCK SUPER "1322" (For other countries)
![](https://motoinstruction.ru/img/suzuki/4/112593.jpg)
Install the balancer shaft bearing retainer.
![](https://motoinstruction.ru/img/suzuki/4/112594.jpg)
Note. Apply a small amount of THREAD LOCK SUPER "1322" or THREAD LOCK "1342" to the threads of the bearing retainer screws.
99000-32050: THREAD LOCK "1342" (For USA)
99000-32110: THREAD LOCK
SUPER "1322" (For other countries)
Oil seals
Install oil seals into the crankcase holes.
Apply lubricant to the seal lips.
![](https://motoinstruction.ru/img/suzuki/4/112595.jpg)
99000-25030: SUZUKI SUPER GREASE "A" (For USA)
99000-25010: SUZUKI SUPER GREASE "A" (For other countries)
Install the oil jet (1).
Attention! Replace the rubber sealing ring with a new one.
![](https://motoinstruction.ru/img/suzuki/4/112596.jpg)
Crankshaft and balancer shaft
![](https://motoinstruction.ru/img/suzuki/4/112597.jpg)
1. Knees, shaft (Left); 2. Neck of knees, shaft; 3. Connecting rod; 4. Knees, shaft (Right); 5. Balancer shaft drive drive gear; 6. Timing drive drive star; 7. Front drive drive gear; 8. Balancer shaft; 9. Balancer shaft driven gear
Detail | H-m | Kgs-m |
A | 70 | 7,0 |
B | 50 | 5,0 |
Crankshaft
When installing the crankshaft into the crankcase, it is necessary to press its left side into the left half of the crankcase using a special tool.
![](https://motoinstruction.ru/img/suzuki/4/112598.jpg)
09910-32812: Tool for installing the crankshaft.
09911-11310: Nozzle
09910-20116: Connecting rod holder
Precaution! When installing the crankshaft into the crankcase, never tap it with a plastic hammer. Always use a special device, otherwise the alignment accuracy of the mating parts may be impaired.
Balancer shaft and gears
When installing the drive gear (1) balancer shaft drive, align the hole in the crankshaft cheek with the pin
![](https://motoinstruction.ru/img/suzuki/4/112599.jpg)
When installing the driven gear (2) align the marks (A) And (B).
Install washers (3) And (4).
![](https://motoinstruction.ru/img/suzuki/4/112600.jpg)
Selector and gear shift forks
![](https://motoinstruction.ru/img/suzuki/4/112601.jpg)
1. Stopper; 2. Return spring; 3. Gear shift shaft; 4. Gear shift foot; 5. Fork No. 16) Fork No. 2; 7. Lock cam; 8. Gear selector; 9. Selector lock; 10. Fork No. 3
DETAIL | Nm | Kgs-m |
(A) | 19 | 1,9 |
(B) | 10 | 1,0 |
(C) | 10 | 1,0 |
Transmission
Install slave (1) and presenter (2) shaft assemblies into the left side of the crankcase.
![](https://motoinstruction.ru/img/suzuki/4/112602.jpg)
Gear shift mechanism
Install the plugs (3), (4),And (5) into the corresponding grooves (6).
![](https://motoinstruction.ru/img/suzuki/4/112603.jpg)
Note:
- Forks used - (3), (4) And (5) very similar.
- Look carefully at the photo to ensure they are in the correct position.
![](https://motoinstruction.ru/img/suzuki/4/112604.jpg)
3. Fork No. 1; 4. Fork No. 2; 5. Fork No. 3
Install fork shafts (7) And (8).
![](https://motoinstruction.ru/img/suzuki/4/112605.jpg)
Carter
Remove the sealant from the mating surfaces of the left and right halves of the crankcase and carefully wipe off any oil stains.
Install the locating pins into the left half as shown.
Lubricate the lower end of the connecting rod and gear with oil.
Apply "SUZUKI BOND 1207B" to the mating surfaces of the left and right crankcase halves and assemble the crankcase within a few minutes.
![](https://motoinstruction.ru/img/suzuki/4/112606.jpg)
99104-31140: SUZUKI BOND 1207V (for USA)
99000-31110: SUZUKI BOND 1215 (for other countries)
![](https://motoinstruction.ru/img/suzuki/4/112607.jpg)
Secure the wiring clamps in the desired position.
Tighten the crankcase fasteners to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112608.jpg)
Crankcase fasteners
Bolts A | 17 Nm (1.7 kgf-m) |
Other fasteners | 11 Nm (1.1 kgf-m) |
After tightening the fasteners, check the shafts for ease of rotation.
If you notice increased resistance to rotation, try to free the shafts by lightly tapping them with a plastic hammer.
Generator installation
Install the starter drive gear (1) to the starter clutch.
![](https://motoinstruction.ru/img/suzuki/4/112609.jpg)
Degrease the conical part of the generator rotor and crankshaft.
Install the key.
![](https://motoinstruction.ru/img/suzuki/4/112610.jpg)
Install the generator rotor assembly.
Apply THREAD LOCK SUPER «1303» onto the thread of the generator rotor nut and tighten it with the specified torque.
![](https://motoinstruction.ru/img/suzuki/4/112611.jpg)
99000-32030: THREAD LOCK SUPER «1303»
Tightening torque of the generator rotor nut: 100 Nm (10 kgf-m, 72.5 lb-ft)
Drive gear
Install the timing chain sprocket (1).
Insert the key (2) into the slot on the crankshaft.
![](https://motoinstruction.ru/img/suzuki/4/112612.jpg)
Install the drive gear (3), aligning the slot and the key.
Install the wave washer (4) and drive gear nut (5), as shown in the illustration.
Note. screw (5) has a left-hand thread.
![](https://motoinstruction.ru/img/suzuki/4/112613.jpg)
Tighten the drive gear nut to the specified torque while holding the generator rotor with a 27mm wrench.
![](https://motoinstruction.ru/img/suzuki/4/112614.jpg)
Tightening torque of drive gear nut: 70 Nm (7.0 kgf-m, 50.5 lb-ft).
Install timing chain (6) to an asterisk.
![](https://motoinstruction.ru/img/suzuki/4/112615.jpg)
Install the strain gauge (7) and a puck (8).
![](https://motoinstruction.ru/img/suzuki/4/112616.jpg)
Balancer nut
Apply THREAD LOCK SUPER "1322" or THREAD LOCK "1342" to the shaft threads.
![](https://motoinstruction.ru/img/suzuki/4/112617.jpg)
99000-32050: THREAD LOCK 1342 (For USA)
99000-32110: THREAD LOCK SUPER 1322 (For other countries)
Install the washer (1)
Tighten the balancer nut to the appropriate torque, holding the generator rotor with a 27mm wrench.
Lock the nut (2) balancer by punching.
Broadcast
Align the hole in the gear detent cam with the pin on the selector drum
Apply a small amount of THREAD LOCK SUPER "1322" or THREAD LOCK "1342" threadlocker to the threads of the gear lock cam bolt and tighten to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112618.jpg)
99000-32050: THREAD LOCK 1342" (For USA)
99000-32110: THREAD LOCK SUPER 1322" (For other countries)
Gear lock cam bolt: 10 Nm (1.0 kgf-m)
Install the selector drum stopper and its spring
![](https://motoinstruction.ru/img/suzuki/4/112619.jpg)
Tighten the stopper bolt to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112620.jpg)
Install snap rings (3), (8), washers (4), (9), springs (5), (7), and lever (6) gear shift to the gear shift rod.
![](https://motoinstruction.ru/img/suzuki/4/112621.jpg)
Install the shift rod.
![](https://motoinstruction.ru/img/suzuki/4/112622.jpg)
Note. Stopper (10) place between the ends of the return spring.
Install the washer and spring ring onto the transmission shaft.
![](https://motoinstruction.ru/img/suzuki/4/112623.jpg)
Apply a small amount of THREAD LOCK SUPER 1322 or THREAD LOCK 1342 to the fastener threads.
![](https://motoinstruction.ru/img/suzuki/4/112624.jpg)
99000-32050: THREAD LOCK "1342" (For USA)
99000-32110: THREAD LOCK SUPER "1322" (For other countries)
Install a partition (3).
Install the kick starter idler gear (4).
Install the latch (5).
Oil pump
Before installing the oil pump (6) Apply oil to the internal friction surfaces of the housing and shaft.
Apply a small amount of THREAD LOCK SUPER "1322" or THREAD LOCK "1342" thread locker to the oil pump mounting threads.
![](https://motoinstruction.ru/img/suzuki/4/112625.jpg)
99000-32050: THREAD LOCK "1342" (For USA)
99000-32110: THREAD LOCK SUPER "1322" (For other countries)
Tighten the oil pump fasteners.
Install the washer (7) and cotter pin (8).
Install the pump drive gear (9) and retaining ring (10).
![](https://motoinstruction.ru/img/suzuki/4/112626.jpg)
09900-06107: Pliers for removing and installing expansion rings
![](https://motoinstruction.ru/img/suzuki/4/112627.jpg)
1. Clutch release drive shaft; 2. Bolt; 3. Spring; 4. Pressure disk; 5. Clutch release rod; 6. Master disk (6 pcs); 7. Driven disk (6 pcs); 8. Master disk (1 PC); 9. Spring washer; 10. Spring washer seat; 11. Washer; 12. Inner clutch drum; 13. Washer; 14. Clutch basket; 15. Spacer sleeve; A. Clutch inner drum lock nut
Install the spacer (1) to the secondary shaft.
![](https://motoinstruction.ru/img/suzuki/4/112628.jpg)
Install the clutch basket (1) and thrust washer (2).
![](https://motoinstruction.ru/img/suzuki/4/112629.jpg)
Install the inner clutch drum (3), lock washer (4) and nut (5).
![](https://motoinstruction.ru/img/suzuki/4/112630.jpg)
Note. Washer (4) The concave side should be facing the inner clutch drum.
![](https://motoinstruction.ru/img/suzuki/4/112631.jpg)
Tighten the nut (4) at the appropriate moment.
![](https://motoinstruction.ru/img/suzuki/4/112632.jpg)
09920-53740: Drum holder
Clutch inner drum nut: 50 Nm (5 kgf-m)
Lock the nut (4) punching in place (A).
![](https://motoinstruction.ru/img/suzuki/4/112633.jpg)
9. Driven disk; 10. Drive disk No. 2
Install the wave washer (7) her nest (6) inner drum (8) as it shown on the picture.
![](https://motoinstruction.ru/img/suzuki/4/112634.jpg)
Install the drive and driven discs one by one in the prescribed order, driving disc first
![](https://motoinstruction.ru/img/suzuki/4/112635.jpg)
Insert the clutch release rod into the pressure plate and install it on the clutch basket.
Install the springs and their bolts on the pressure plate.
Tighten the spring bolts diagonally to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112636.jpg)
Clutch spring bolts: 10 Nm (1.0 kgf-m)
Kickstarter
![](https://motoinstruction.ru/img/suzuki/4/112637.jpg)
1. Oil seal; 2. Guide; 3. Spring; 4. Kickstarter shaft; 5. Kickstarter drive gear; 6. Washer; 7. Spring ring; 8. Kickstarter; 9. Spring; 10. Washer; 11. Spring split ring; 12. Washer; 13. Bolt; 14. Kickstarter guide; 15. Kickstarter stopper
When installing the kickstarter drive gear onto the shaft, align the mark (A) on kickstarter with groove (B) on the kickstarter shaft.
![](https://motoinstruction.ru/img/suzuki/4/112638.jpg)
Install the kickstarter shaft assembly, then hook the end of the spring onto the crankcase boss.
![](https://motoinstruction.ru/img/suzuki/4/112639.jpg)
Install new oil seals on the clutch cover (1) and clamps (2)
![](https://motoinstruction.ru/img/suzuki/4/112640.jpg)
Retainer bolt: 8 Nm (0.8 kgf-m)
Tighten the clamp bolt to the appropriate torque.
Install the clutch release shaft (3), bearings (4) (5) and oil seal (6).
![](https://motoinstruction.ru/img/suzuki/4/112641.jpg)
Install the pins, new gasket and clutch cover onto the housing.
![](https://motoinstruction.ru/img/suzuki/4/112642.jpg)
Attention! To avoid leaks, use a new gasket.
Tighten the clutch bolts to the specified torque.
![](https://motoinstruction.ru/img/suzuki/4/112643.jpg)
Clutch spring bolts: 10 Nm (1.0 kgf-m)
Note. The teeth of the clutch release rod should face forward.
Attention! To avoid leaks, use a new gasket.
Apply THREAD LOCK SUPER "1322" or THREAD LOCK "1342" to the kickstarter mounting bolt.
![](https://motoinstruction.ru/img/suzuki/4/112644.jpg)
99000-32050: THREAD LOCK "1342" (for USA)
99000-32110: THREAD LOCK SUPER "1322" (for other countries)
Tighten the kickstarter installation bolt to the appropriate torque.
Kickstarter installation bolt: 23 Nm (2.3 kgf-m)
Oil filter
Install a new oil filter.
![](https://motoinstruction.ru/img/suzuki/4/112645.jpg)
Note. Make sure the spring (1) and new rubber o-rings (2), (3) installed correctly.
Install the filter cover.
![](https://motoinstruction.ru/img/suzuki/4/112646.jpg)
Pan filter
Install a new oil filter.
![]() | ![]() |
Starter idler gear
Install the idler gear as shown in the figure.
![](https://motoinstruction.ru/img/suzuki/4/112649.jpg)
1. Intermediate gear No. 2 starter; 2. Idler gear axis; 3. Washer; 4. Washer; 5. Spring ring
Note. Lubricate the clutch and gears with engine oil.
Generator cover
Apply SUZUKI BOND "1207B" or "1215" to the surface of the cable seal groove.
![](https://motoinstruction.ru/img/suzuki/4/112650.jpg)
99000-31140: SUZUKI BOND "1207B" (for USA)
99000-31110: SUZUKI BOND "1215" (for other countries)
Install the pin and new gasket.
Attention! To avoid leaks, use a new gasket.
Install the generator cover (1).
Install the oil seal retainer (2).
Install the cover (3).
![](https://motoinstruction.ru/img/suzuki/4/112651.jpg)
Attention! To avoid leaks, use a new O-ring.
Note.
- Carefully align the gasket with the bolts (A)
- On a bolt (B) install the wire clamp.
Install starter idler gear No. 1 and axle (5).
Install the transmission cover.
![](https://motoinstruction.ru/img/suzuki/4/112652.jpg)
Note. Apply lubricant to the rubber O-ring.
99000-25030: SUZUKI SUPER GREASE "A" (for USA)
99000-25010: SUZUKI SUPER GREASE "A" (for other countries)
Starter motor
Install the starter motor.
![](https://motoinstruction.ru/img/suzuki/4/112653.jpg)
Note. Apply lubricant to the rubber O-ring.
99000-25030: SUZUKI SUPER GREASE "A" (for USA)
99000-25010: SUZUKI SUPER GREASE "A" (for other countries)
![]() | ![]() |
Oil scraper ring
First install the axial expander into the groove (1). Then install the upper and lower disks (2) on both sides of the expander. The new discs and expander do not have a top or bottom side. When reinstalling previously used parts, install them in the original position and direction.
![]() | ![]() |
Top ring and second ring
The top and second rings differ in the shape of the inner side. Both rings have the letter "R" on them. When installing the rings on the piston, make sure the "R" is on top.
![](https://motoinstruction.ru/img/suzuki/4/112658.jpg)
Position the ring locks as shown in the figure. Before installing the piston into the cylinder, check that the locks are in the correct position.
![](https://motoinstruction.ru/img/suzuki/4/112659.jpg)
Place a clean rag under the cylinder base to prevent the spring rings from falling into the crankcase.
Apply molybdenum grease to the piston pin.
Apply molybdenum grease to the upper end of the connecting rod.
When installing the piston, orient the side with the arrow toward the exhaust.
![](https://motoinstruction.ru/img/suzuki/4/112660.jpg)
Install the spring rings (1).
![](https://motoinstruction.ru/img/suzuki/4/112661.jpg)
Attention! Use new spring rings to avoid breakage that can occur with bent rings.
Insert the dowel pins and install the new gasket.
![](https://motoinstruction.ru/img/suzuki/4/112662.jpg)
Attention! To avoid leaks, use a new gasket.
Holding the rings in the required positions, insert the piston into the cylinder (2).
![](https://motoinstruction.ru/img/suzuki/4/112663.jpg)
Note. When installing the cylinder, keep the chain tensioned so that it does not jam between the sprockets when turning the crankshaft.
Install the timing chain guide (3).
![](https://motoinstruction.ru/img/suzuki/4/112664.jpg)
Note. A special holder for the timing chain guide is cast in the crankcase. Make sure the guide (3) installed correctly.
Cylinder head
Install the pins (4) and a new gasket (5).
![](https://motoinstruction.ru/img/suzuki/4/112665.jpg)
Attention! To avoid gas breakthrough, use a new gasket.
Install the head onto the cylinder.
The bolts and washers must be installed correctly as shown in the illustration.
![](https://motoinstruction.ru/img/suzuki/4/112666.jpg)
(A) copper washers
Tighten the head bolts diagonally to the appropriate torque.
Head bolts:
- (A) (M10): (Pre-tightening) 25 Nm (2.5 kgf-m), (Final tightening) 42 Nm (4.2 kgf-m)
- (IN) (M6): 10 Nm (1.0 kgf-m)
Tighten the fasteners at the base of the cylinder to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112667.jpg)
Nuts at the base of the cylinder (WITH) 10 Nm (1.0 kgf-m)
Tighten the cylinder bolt to the appropriate torque.
Cylinder bolt (0) 10 Nm (1.0 kgf-m)
Fit a new gasket and tighten the cylinder side bolt (1).
![](https://motoinstruction.ru/img/suzuki/4/112668.jpg)
Cylinder side bolt 14 Nm (1.4 kgf-m)
Attention! To avoid gas breakthrough, use a new gasket.
Camshaft
To check the position of the valves, remove the plug (2) and a plug in the generator cover (3).
![](https://motoinstruction.ru/img/suzuki/4/112669.jpg)
Turn the generator rotor counterclockwise with a wrench until the "T" sign " (A) on the generator rotor will not coincide with the center of the inspection hole when the timing chain is tensioned.
![](https://motoinstruction.ru/img/suzuki/4/112670.jpg)
Place each camshaft in the correct position.
![](https://motoinstruction.ru/img/suzuki/4/112671.jpg)
Note. The exhaust camshaft can be distinguished from the intake camshaft by the presence of an automatic decompressor (IN).
With the "T" aligned with the center of the inspection hole, hold the camshaft and tension the chain to remove slack between the crankshaft and exhaust camshaft sprockets.
The exhaust camshaft sprocket has an arrow with the number "1" (A) . Rotate the exhaust camshaft to align the end of the arrow with the cylinder head connector. Place the timing chain on the exhaust camshaft sprocket.
Another arrow with the number "2" (IN) should point straight up. Recount the axes of the chain links towards the intake camshaft, starting with the link axis located directly above arrow "2" and ending with the seventeenth link axis.
Install the timing chain onto the intake camshaft sprocket, placing the seventeenth axis of the link above the arrow with the number "3" (WITH) on a star.
Note. Tie the chain to each sprocket with wire clamps to prevent disengagement when stowing the camshaft bearing caps. Do not turn the crankshaft until the shaft caps and chain tensioner are securely fastened.
![](https://motoinstruction.ru/img/suzuki/4/112672.jpg)
Insert the bearing cap locating pins.
![](https://motoinstruction.ru/img/suzuki/4/112673.jpg)
Tighten the covers and chain guide.
![](https://motoinstruction.ru/img/suzuki/4/112674.jpg)
Attention! The position of each bearing cap is determined by the letters cast on them. Install covers correctly.
Note. Uneven tightening of bearing cap bolts can cause damage to the cylinder head or camshafts.
Tighten the cover bolts to the appropriate torque.
Bearing cap bolts: 10 Nm (1.0 kgf-m)
Chain tensioner
Secure the extension spring with a slotted screwdriver.
Install the chain tensioner onto the cylinder and tighten it to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112675.jpg)
Chain tensioner bolts: 10 Nm (1.0 kgf-m)
Note. After installing the chain tensioner, turn the screwdriver counterclockwise.
Attention! After installing the chain tension adjuster, ensure its operation by checking the chain tension.
Install the rubber cap (2).
Install the clutch cable clamp (3).
![](https://motoinstruction.ru/img/suzuki/4/112676.jpg)
Cylinder head cover
Turn the generator rotor 2 turns counterclockwise and align the "T" mark on the generator rotor with the center of the inspection hole,
Recheck the position of the camshafts.
Adjust the valve clearance. (section 2-5).
![](https://motoinstruction.ru/img/suzuki/4/112677.jpg)
Carefully wipe off oil from the mating surfaces of the cylinder head and cover.
Apply SUZUKI BOND "1207B" to the sprocket side of the head gasket as shown in the illustration.
![](https://motoinstruction.ru/img/suzuki/4/112678.jpg)
99104-31140: SUZUKI BOND "1207B" (for USA)
99000-31140: SUZUKI BOND "1207" (for other countries)
Install the cylinder head cover and tighten the fasteners to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112679.jpg)
Cylinder head cover bolts:
- Pre-tightening: 10 Nm (1.0 kgf-m)
- Final tightening: 14 Nm (1.4 kgf-m)
Install the radiator hose (1) and tighten it to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112680.jpg)
Radiator hose bolts: 20 Nm (2.0 kgf-m)
Install the plug (2) and a traffic jam (3) generator covers, then tighten them to the appropriate torque.
![](https://motoinstruction.ru/img/suzuki/4/112681.jpg)
Plug for checking valve clearance: 23 Nm (2.3 kgf-m)
Generator cover plug: 11 Nm (1.1 kgf-m)