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.
![](https://motoinstruction.ru/img/suzuki/14/119829.jpg)
ITEM | N·m | kgf·m | lb·ft |
A F | 45 | 4.5 | 32.5 |
B G | 12 | 1.2 | 8.5 |
C | 93 | 9.3 | 67.5 |
D | 25 | 2.5 | 18.0 |
E H | 55 | 5.5 | 40.0 |
I | 35 | 3.5 | 25.5 |
Before installing the engine assembly, install the spacer (A), collar (B) and engine thrust adjuster (C).
![](https://motoinstruction.ru/img/suzuki/14/119830.jpg)
Install the collar (1) onto the crankcase properly as shown.
![](https://motoinstruction.ru/img/suzuki/14/119831.jpg)
Install the left engine mounting bracket (2).
![](https://motoinstruction.ru/img/suzuki/14/119832.jpg)
Apply THREAD LOCK to the engine mounting bracket bolts.
Tighten the engine mounting bracket bolts to the specified torque.
- Engine mounting bracket bolt: 35 N·m (3.5 kgf·m, 25.5 lb·ft)
- 9900°-32050: THREAD LOCK "1342"
Put the drive chain on the driveshaft.
![](https://motoinstruction.ru/img/suzuki/14/119833.jpg)
Gradually raise the engine assembly and align all the bolt holes.
Install the engine mounting bolts and tighten them temporarily.
Tighten the engine mounting thrust adjusters to the specified torque.
- Engine mounting thrust adjuster: 12 N·m (1.2 kgf·m, 8.5 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/119834.jpg)
Tighten the engine mounting thrust adjuster lock-nuts to the specified torque with the special tool.
- 09940-14990: Engine mounting thrust adjuster socket wrench
- Engine mounting thrust adjuster lock-nut: 45 N·m (4.5 kgf·m, 32.5 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/119835.jpg)
After tightening the engine mounting bolt, tighten the pinch bolt (A).
- Engine mounting bolt: 55 N·m (5.5 kgf·m, 40.0 lb·ft)
- Engine mounting pinch bolt (A): 25 N·m (2.5 kgf·m, 18.0 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/119836.jpg)
Tighten the engine mounting nuts to the specified torque.
- Engine mounting nut (A): 93 N·m (9.3 kgf·m, 67.5 lb·ft)
- Engine mounting nut: 55 N·m (5.5 kgf·m, 40.0 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/119837.jpg)
Install the washers and tighten the union bolt to the specified torque.
- Oil cooler union bolt: 23 N·m (2.3 kgf·m, 16.5 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/119838.jpg)
Install the new gaskets.
![](https://motoinstruction.ru/img/suzuki/14/119839.jpg)
Apply THREAD LOCK to the muffler mounting bolt.
- 99000-32050: THREAD LOCK "1342"
![](https://motoinstruction.ru/img/suzuki/14/119840.jpg)
![](https://motoinstruction.ru/img/suzuki/14/119841.jpg)
ITEM | N·m | kgf·m | lb·ft |
A B C D | 23 | 2.3 | 16.5 |
Adjust the brake pedal height.
- Brake pedal height (A): Standard: 20-30 mm (0.79-1.18 in)
![](https://motoinstruction.ru/img/suzuki/14/119842.jpg)
Install the gearshift arm as shown.
- Gearshift arm angle (A): Approx. 63.6°
![](https://motoinstruction.ru/img/suzuki/14/119843.jpg)
Adjust the gearshift lever as shown.
- Gearshift lever height (A): Standard: 20-30 mm (0.79-1.18 in)
![](https://motoinstruction.ru/img/suzuki/14/119844.jpg)
Install the engine sprocket.
![](https://motoinstruction.ru/img/suzuki/14/119845.jpg)
Install the engine sprocket and the washer.
Apply a small quantity of THREAD LOCK to the drive shaft thread portion.
- 99000-32050: THREAD LOCK "1342"
Tighten the engine sprocket nut (1) to the specified torque.
- Engine sprocket nut: 145 N·m (14.5 kgf·m, 105 lb·ft)
Bend the lock washer.
![](https://motoinstruction.ru/img/suzuki/14/119846.jpg)
Adjust the drive chain slack. (2-21)
Tighten the rear axle nut (2) to the specified torque.
- Rear axle nut: 100 N·m (10.0 kgf·m, 72.5 lb·ft)
Install the cotter pin. (For E-03, 28, 33)
![](https://motoinstruction.ru/img/suzuki/14/119847.jpg)
Apply SUZUKI SUPER GREASE to the clutch push rod and install it.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
![](https://motoinstruction.ru/img/suzuki/14/119848.jpg)
Install the clutch cable to the generator cover temporarily.
![](https://motoinstruction.ru/img/suzuki/14/119849.jpg)
Apply SUZUKI MOLY PASTE to the clutch release.
- 99000-25140: SUZUKI MOLY PASTE
![](https://motoinstruction.ru/img/suzuki/14/119850.jpg)
Assemble the clutch release so that the lever arm (A) will be angle of 80 degree with axle (B).
Adjust the clutch cable play. (2-17)
![](https://motoinstruction.ru/img/suzuki/14/119851.jpg)
Note: After installing the clutch release, make sure that there is clearance between the clutch cable end and the driveshaft end.
![](https://motoinstruction.ru/img/suzuki/14/119852.jpg)
After installing the engine, route the wire harness, cables and hoses properly. (9-16)
Adjust the following items.