Caution! Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions.
Remove the spark plugs. (2-6)
Disconnect the crankcase breather hoses (1).
Disconnect the PAIR hoses (2).
![](https://motoinstruction.ru/img/suzuki/14/119853.jpg)
Remove the thermostat case (3) along with the hoses (4).
Note: Refer to the section 6 for their servicing.
![](https://motoinstruction.ru/img/suzuki/14/119854.jpg)
Remove the water unions (5) and intake pipes (6).
![](https://motoinstruction.ru/img/suzuki/14/119855.jpg)
Remove the oil cooler bracket (7).
![](https://motoinstruction.ru/img/suzuki/14/119856.jpg)
Remove the rear exhaust pipe (8) and gasket.
![](https://motoinstruction.ru/img/suzuki/14/119857.jpg)
Remove the valve timing inspection plug (9) and generator cover plug (10).
![](https://motoinstruction.ru/img/suzuki/14/119858.jpg)
Cylinder head cover
Remove the front cylinder head cover (1).
![](https://motoinstruction.ru/img/suzuki/14/119859.jpg)
Remove the dowel pin (2) and O-ring (3).
![](https://motoinstruction.ru/img/suzuki/14/119860.jpg)
Remove the rear cylinder head cover (4).
![](https://motoinstruction.ru/img/suzuki/14/119861.jpg)
Remove the dowel pin (5) and O-ring (6).
![](https://motoinstruction.ru/img/suzuki/14/119862.jpg)
Front camshafts
Turn the crankshaft to bring the "| F" line (A) on generator rotor to the index mark (B) of the valve inspection hole and also to bring the cams to the position as shown in illustration.
![](https://motoinstruction.ru/img/suzuki/14/119863.jpg)
Notes:
- At the above condition, the front cylinder is at TDC of compression stroke.
- Before removing the camshafts, inspect the valve clearance. (2-8)
![](https://motoinstruction.ru/img/suzuki/14/119864.jpg)
Remove the cam chain guide (1).
![](https://motoinstruction.ru/img/suzuki/14/119865.jpg)
Remove the spring holder bolt (2), spring and gasket.
Remove the cam chain tension adjuster (3).
![](https://motoinstruction.ru/img/suzuki/14/119866.jpg)
Remove the intake camshaft journal holder (4).
Remove the exhaust camshaft journal holder (5).
Note: Mark the cylinder location as "F" to the camshaft journal holders.
![](https://motoinstruction.ru/img/suzuki/14/119867.jpg)
Remove the dowel pins (6).
Remove the intake camshaft (7).
Remove the exhaust camshaft (8).
Note: Do not drop the dowel pins into the crankcase.
![](https://motoinstruction.ru/img/suzuki/14/119868.jpg)
Front cylinder head
Remove the cylinder head bolt (M6) (1).
![](https://motoinstruction.ru/img/suzuki/14/119869.jpg)
Remove the cylinder head bolts (M6) (2).
Remove the cylinder head bolts (3) and washers.
Note: When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
Remove the cylinder head (4).
![](https://motoinstruction.ru/img/suzuki/14/119870.jpg)
Remove the cylinder head gasket (5), dowel pins (6) and cam chain guide (7).
![](https://motoinstruction.ru/img/suzuki/14/119871.jpg)
Front cylinder
Remove the cylinder nuts (1).
Remove the cylinder (2).
![](https://motoinstruction.ru/img/suzuki/14/119872.jpg)
Remove the cylinder base gasket (3) and dowel pins (4).
Note: Make sure that the oil jet is inserted in the crankcase.
![](https://motoinstruction.ru/img/suzuki/14/119873.jpg)
Front piston
Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.
Remove the piston pin circlip (1).
Remove the piston (2) by driving out the piston pin.
Note: Scribe the cylinder number on the head of the piston.
![](https://motoinstruction.ru/img/suzuki/14/119874.jpg)
Rear camshafts
Rotate the generator 360 degrees (1 turn) counterclockwise and align the "| F" line (A) on the generator rotor with the index mark (B) of the valve timing inspection hole.
![](https://motoinstruction.ru/img/suzuki/14/119875.jpg)
Notes:
- At the above condition, the rear cylinder is at ATDC 90° on expansion stroke.
- Before removing the camshafts, inspect the valve clearance. (2-8)
![](https://motoinstruction.ru/img/suzuki/14/119876.jpg)
Remove the cam chain guide (1).
![](https://motoinstruction.ru/img/suzuki/14/119877.jpg)
Remove the cam chain tension adjuster cap bolt (2), spring and gasket.
Remove the cam chain tension adjuster (3).
![](https://motoinstruction.ru/img/suzuki/14/119878.jpg)
Remove the intake camshaft journal holder (4).
Remove the exhaust camshaft journal holder (5).
Note: Mark the cylinder location as "R" to the camshaft journal holders.
![](https://motoinstruction.ru/img/suzuki/14/119879.jpg)
Remove the dowel pins (6).
Remove the intake camshaft (7).
Remove the exhaust camshaft (8).
![](https://motoinstruction.ru/img/suzuki/14/119880.jpg)
Rear cylinder head
Remove the cylinder head bolt (M6) (1).
![](https://motoinstruction.ru/img/suzuki/14/119881.jpg)
Remove the cylinder bolts (M6) (2).
Remove the cylinder head bolts (3) and washers.
Note: When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
Remove the cylinder head (4).
![](https://motoinstruction.ru/img/suzuki/14/119882.jpg)
Remove the cylinder head gasket (5), dowel pins (6) and cam chain guide (7).
![](https://motoinstruction.ru/img/suzuki/14/119883.jpg)
Rear cylinder
Remove the cylinder nuts (1) and clamp.
Remove the cylinder (2).
![](https://motoinstruction.ru/img/suzuki/14/119884.jpg)
Remove the cylinder base gasket (3) and dowel pins (4).
Note: Make sure that the oil jet (5) is inserted in the crankcase.
![](https://motoinstruction.ru/img/suzuki/14/119885.jpg)
Rear piston
Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.
Remove the piston pin circlip (1).
Remove the piston (2) by driving out the piston pin.
Note: Scribe the cylinder number on the head of the piston.
![](https://motoinstruction.ru/img/suzuki/14/119886.jpg)
Starter motor
Remove the starter motor mounting bolts and the clamp (1).
Remove the starter motor (2).
![](https://motoinstruction.ru/img/suzuki/14/119887.jpg)