Engine bottom side reassembly (Suzuki V-Strom DL-650, 1 generation, 2004-2011) [Engine and systems: Engine repair]

Reassemble the engine in the reverse order of disassembly.

The following steps require special attention or precautionary measures should be taken.

Note: Apply engine oil to each running and sliding part before reassembling.

Transmission

Install the countershaft assembly (1) and the driveshaft assembly (2) to the left crankcase half.

Install the washer (3) onto the driveshaft assembly (2).

Gearshift

Install the gearshift forks (1)/(2)/(3), gearshift cam (4) and gearshift fork shafts (5).

Note: Identify the gearshift forks as follows.

(1) For 5th driven gear; (2) For 6th driven gear; (3) For 3rd/4th drive gear

Crankshaft

Coat lightly MOLYBDENUM OIL SOLUTION to the crankshaft journal bearings.

Molybdenum oil solution

Install the crankshaft into the left crankcase half.

Caution! Never strike the crankshaft with a plastic hammer when inserting it into the crankcase. It will be easy to install the crankshaft to left crankcase.

Crankcase

Clean the mating surfaces of the left and right crankcase halves.

Install the O-rings (1), (2) and dowel pins (3).

Apply SUZUKI SUPER GREASE to the O-rings (1), (2).

99000-25030: SUZUKI SUPER GREASE "A" (USA)
99000-25010: SUZUKI SUPER GREASE "A" (Others)

Apply SUZUKI BOND to the mating surface of the left crankcase.

99104-31140: SUZUKI BOND "1207B" (USA)
99000-31110: SUZUKI BOND "1215" (Others)

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 SUZUKI BOND to the oil hole, oil groove and bearing.

Apply to distorted surfaces as it forms a comparatively thick film.

When securing the right and left crankcase halves, tighten each bolt a little at a time to equalize the pressure. Tighten all the securing bolts to the specified torque values.

Crankcase bolt:

(M8) 26 N·m (2.6 kgf·m, 19.0 lb·ft)
(M6) 11 N·m (1.1 kgf·m, 8.0 lb·ft)

Caution! Do not drop the O-ring into the crankcase when assembling the right and left crankcase halves.

Notes:

After the crankcase bolts have been tightened, check if the crankshaft, the driveshaft and the countershaft rotate smoothly.

Fit the clamp to the bolt (C) as shown.

Oil plate

Install the oil plate (1) and the oil plate bolts tighten to the specified torque.

Oil plate bolt: 10 N·m (1.0 kgf·m, 7.0 lb·ft)

Engine sprocket spacer

Install the new O-ring (1) into the engine sprocket spacer (2).

Caution! Use the new O-ring to prevent oil leakage.

Install the engine sprocket spacer (2).

Notes:

The grooved (A) side of the engine sprocket spacer (1) must face crankcase side.

Apply SUZUKI SUPER GREASE to the oil seal lip and O-ring.

99000-25030: SUZUKI SUPER GREASE "A" (USA)
99000-25010: SUZUKI SUPER GREASE "A" (Others)

Gear position switch

Install the gear position switch contacts (1) and springs.

Apply SUZUKI SUPER GREASE to the O-ring (2) and then install it onto the gear position switch.

99000-25030: SUZUKI SUPER GREASE "A" (USA)
99000-25010: SUZUKI SUPER GREASE "A" (Others)

Install the gear position switch (3) as shown.

Tighten the gear position switch bolt to the specified torque.

Gear position switch bolt: 6.5 N·m (0.65 kgf·m, 4.7 lb·ft)

Install the drive shaft oil seal retainer (4).

Note: Pass through the gear position switch lead wire under the driveshaft oil seal retainer.

Front cam chain

Install the front cam chain (1).

Install the cam chain tensioner (2), washer (3) and cam chain tensioner bolt (4).

Tighten the cam chain tensioner bolt (4) to the specified torque.

Cam chain tensioner bolt: 10 N·m (1.0 kgf·m, 7.0 Ib-f)

Note: The front and rear cam chain tensioners are the same.

Generator rotor

Install the starter driven gear (1).

Apply engine oil to the bushing of the starter driven gear.

Degrease the tapered portions (A) of the generator rotor assembly and the crankshaft. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry.

Fit the key (2) in the key slot on the crankshaft completely.

Install the generator rotor assembly onto the crankshaft.

While holding the generator rotor with the special tool, tighten its bolt to the specified torque.

09930-44530: Rotor holder
Generator rotor bolt: 120 N·m (12.0 kgf·m, 87 lb·ft)

Cam chain drive sprocket

Install the cam chain drive sprocket (1) onto the crankshaft.

Notes:

Align the punched mark (A) on the cam chain drive sprocket with the punched mark (B) on the crankshaft.

Apply MOLYBDENUM OIL SOLUTION to the cam chain drive sprocket.

Molybdenum oil solution

Rear cam chain

Install the rear cam chain (1).

Install the cam chain tensioner (2), washer (3) and cam chain tensioner bolt (4).

Tighten the cam chain tensioner bolt (4) to the specified torque.

Cam chain tensioner bolt: 10 N·m (1.0 kgf·m, 7.0 lb·ft)

Note: The front and rear cam chain tensioners are the same.

Primary drive gear

Install the primary drive gear (1) and water pump drive gear (2).

Hold the generator rotor (crankshaft) with the special tool.

09930-44530: Rotor holder

Tighten the primary drive gear bolt to the specified torque.

Primary drive gear bolt: 70 N·m (7.0 kgf·m, 50.5 lb·ft)

Note: This bolt has left-hand thread.

Oil pipe

Install the oil pipe (1).

Tighten the oil pipe stopper screw (2) to the specified torque.

Oil pipe stopper screw: 8 N·m (0.8 kgf·m, 6.0 lb·ft)

Note: Align the projection (A) of the oil pipe with the groove (B) of its stopper.

Gearshift system

Install the gearshift cam stopper (1), its bolt (2), washer (3) and return spring (4).

Gearshift cam stopper bolt: 10 N·m (1.0 kgf·m, 7.0 lb·ft)

Confirm the gearshift cam stopper movement.

Check the neutral position.

Note: Hook the return spring end (5) to the stopper.

Install the gearshift cam stopper plate (6) with the gearshift cam pins (A) inserted into the gearshift cam stopper plate holes (B).

Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque.

99000-32050: THREAD LOCK "1342"
Gearshift cam stopper plate bolt: 13 N·m (1.3 kgf·m, 9.5 lb·ft)

Install the gearshift shaft/gearshift arm (7) with the washer (8) as shown.

Locate the gearshift arm stopper (9) between return spring ends (C).

Install the washer (10) and snap ring (11).

Oil pump

Install the oil pump with the three screws.

Install the washer (1) and pin (2).

Install the oil pump driven gear (3).

Install the snap ring (4).

Clutch

Install the spacer (1) and apply ENGINE OIL to it.

Install the primary driven gear assembly (2) onto the countershaft.

Note: Be sure to engage the oil pump drive and driven gears, primary drive and driven gears.

Install the thrust washer (3).

Install the clutch sleeve hub (4) and lock washer (5).

Caution! Replace the lock washer (5) with a new one.

Install the clutch sleeve hub nut (6).

Note: The chamfer side (A) of the clutch sleeve hub nut faces outward.

Hold the clutch sleeve hub with the special tool.

09920-53740: Clutch sleeve hub holder

Tighten the clutch sleeve hub nut to the specified torque.

Clutch sleeve hub nut: 50 N·m (5.0 kgf·m, 36.0 lb·ft)

Bend the lock washer to lock the nut securely.

Install the spring washer seat (7) and spring washer (8) onto the clutch sleeve hub correctly.

Insert the clutch drive plates (9), (10) and driven plates (11) one by one into the clutch sleeve hub in the prescribed order, No.2 drive plate (9) being inserted first.