Pay attention to the following points:
Note:
- The engine mounting nuts are self-locking.
- Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque.
ITEM | Nm | kgf·m | lb·ft |
(A)(B)(D)(E) | 55 | 5.5 | 40.0 |
(J)(K)(L) | 23 | 2.3 | 16.5 |
(F)(H) | 12 | 1.2 | 8.5 |
(G)(I) | 45 | 4.5 | 32.5 |
(C) | 75 | 7.5 | 54.0 |
- Before installing the engine assembly, install the spacer (A), collar (B) and engine thrust adjuster (C), (D).
- Install the collar (B) onto the crankcase properly as shown.
- Apply THREAD LOCK "1342" to the engine mounting bracket bolts.
- Tighten the bolts to the specified torque.
- Engine mounting bracket bolt: 23 Nm (2.3 kgf·m, 16.5 lb·ft)
- 99000-32050: THREAD LOCK "1342"
- Put the drive chain on the driveshaft.
- Gradually raise the engine assembly and align all the bolt holes.
- Install the engine mounting bolts and bracket bolts, and tighten them temporarily.
- Tighten the engine mounting thrust adjuster and its lock nut to the specified torque with the special tool.
- Engine mounting thrust adjuster: 12 Nm (1.2 kgf·m, 8.5 lb·ft)
- Engine mounting thrust adjuster lock nut: 45 Nm (4.5 kgf·m, 32.5 lb·ft)
- 09940-14990: Engine mounting thrust adjuster socket wrench
- After tightening the engine mounting bolt (A), tighten the pinch bolt (B).
- Engine mounting bolt (A): 55 N·m (5.5 kgf·m, 40.0 lb·ft)
- Engine mounting pinch bolt (B): 23 N·m (2.3 kgf·m, 6.5 lb·ft)
- Tighten the engine mounting bolt to the specified torque.
- Engine mounting bolt (C): 55 Nm (5.5 kgf·m, 40.0 lb·ft)
- Tighten the engine mounting nut (A), (B) to the specified torque.
- Engine mounting nut (A): 75 Nm (7.5 kgf·m, 54.0 lb·ft)
- Engine mounting nut (B): 55 Nm (5.5 kgf·m, 40.0 lb·ft)
- After tightening the bolt (C), tighten the pinch bolt (D) to the specified torque.
- Engine mounting bolt (C): 55 Nm (5.5 kgf·m, 40.0 lb·ft)
- Engine mounting pinch bolt (D): 23 Nm (2.3 kgf·m, 16.5 lb·ft)
- Install the washers and tighten the union bolt to the specified torque.
- Oil hose union bolt: 23 N·m (2.3 kgf·m, 16.5 lb·ft)
- Install the new gaskets.
- Install the exhaust pipes and mufflers.
NOTE: Apply THREAD LOCK "1342" to the bolt (E).
- 99000-32050: THREAD LOCK "1342"
- Adjust the brake pedal height.
Brake pedal height (A):
Standard: 20 - 30 mm (0.8 -1.2 in)
- Install the gearshift arm as shown.
Gearshift arm angle (A): Approx. 60°
- Adjust the gearshift lever as shown.
Gearshift lever height (A):
Standard: 20 - 30 mm (0.8 - 1.2 in)
- Install the engine sprocket.
- Apply THREAD LOCK SUPER "1303" to the engine sprocket nut and tighten it to the specified torque while depressing the brake pedal.
- Engine sprocket nut: 115 Nm (11.5 kgf·m, 83.0 lb·ft)
- 99000-32030: THREAD LOCK SUPER "1303"
- Tighten the speed sensor rotor bolt to the specified torque.
- Speed sensor rotor bolt: 23 Nm (2.3 kgf·m, 16.5 lb·ft)
- Apply SUZUKI SUPER GREASE "A" to the push rod (1) and install it.
- Install the clutch release cylinder.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
- After installing the engine, route the wire harness, cables and hoses properly. (8-14)
- Adjust the following items.
- Engine oil (2-13)
- Engine coolant (2-18)
- Engine idle speed (2-15)
- Throttle cable play (2-15)
Engine oil capacity:
- Oil change: 2.7 L (2.9/2.4 US/Imp qt)
- Oil and filter change: 2.9 L (3.1/2.6 US/Imp qt)
- Engine overhaul: 3.3 L (3.5/2.9 US/Imp qt)