Piston
Install the piston rings in the order of oil ring, 2nd ring and 1st ring.
The first member to go into the oil ring groove is a spacer (1). After placing the spacer, fit the two side rails (2).
![](https://motoinstruction.ru/img/suzuki/14/120170.jpg)
Note: Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way.
Caution! When installing the spacer, be careful not to allow its two ends to overlap in the groove.
![](https://motoinstruction.ru/img/suzuki/14/120171.jpg)
(A) Incorrect; (B) Correct
Install the 2nd ring (3) and 1st ring (4).
Note: 1st ring and 2nd ring differ in shape.
![](https://motoinstruction.ru/img/suzuki/14/120172.jpg)
1st ring (5) and 2nd ring (6) have letters "T" marked on the side. Be sure to bring the marked side to the top when fitting them to the piston.
![](https://motoinstruction.ru/img/suzuki/14/120173.jpg)
Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
![](https://motoinstruction.ru/img/suzuki/14/120174.jpg)
(A) 2nd ring and Lower side rail; (B) Upper side rail; (C) 1st ring and spacer
Apply a small quantity of MOLYBDENUM OIL SOLUTION onto each piston pin.
- Molybdenum oil solution
Note: When installing the pistons, front and rear, the indents (D) on the piston heads must be located to each exhaust side.
![](https://motoinstruction.ru/img/suzuki/14/120175.jpg)
Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase.
Install the pistons (7), front and rear.
Install the piston pin circlips (8).
Caution! Use new piston pin circlips to prevent circlip failure which will occur with a bend one.
![](https://motoinstruction.ru/img/suzuki/14/120176.jpg)
Note: End gap of the circlip should not be aligned with the cutaway in the piston pin bore.
Caution! When turning the crankshaft, pull the cam chains upward, or the chains will be caught between the crankcase and the cam drive sprocket.
Oil jet
Apply SUZUKI SUPER GREASE to the new O-rings.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
Apply engine oil to the oil jet holes on the crankcase.
![](https://motoinstruction.ru/img/suzuki/14/120177.jpg)
Install each of the oil jet (#14) to the left and right crankcase, as shown in the illustration.
Caution! Use the new O-rings to prevent oil leakage.
![](https://motoinstruction.ru/img/suzuki/14/120178.jpg)
Cylinder
Coat SUZUKI BOND lightly to the mating surfaces at the parting line between the right and left crankcases as shown.
- 99104-31140: SUZUKI BOND "1207B" (USA)
- 99000-31110: SUZUKI BOND "1215" (Others)
![](https://motoinstruction.ru/img/suzuki/14/120179.jpg)
Apply engine oil to the sliding surface of the pistons.
Fit the dowel pins (1), (2) and new gaskets (3), (4) to the crankcase.
Caution! Use the new gaskets to prevent oil leakage.
![](https://motoinstruction.ru/img/suzuki/14/120180.jpg)
![](https://motoinstruction.ru/img/suzuki/14/120181.jpg)
Apply engine oil to the sliding surface of the cylinders.
Notes:
- The front and rear cylinders can be distinguished by the embossed-letters (A).
- "FRONT': Front cylinder
- "REAR" : Rear cylinder
![](https://motoinstruction.ru/img/suzuki/14/120182.jpg)
Hold the piston rings in proper position, and insert each of the piston into the respective cylinders.
Note: When installing the cylinders, keep the cam chains taut. The cam chain must not be caught between cam drive sprocket and crankcase when turning the crankshaft.
![](https://motoinstruction.ru/img/suzuki/14/120183.jpg)
Tighten the cylinder nuts (M6) temporarily.
![](https://motoinstruction.ru/img/suzuki/14/120184.jpg)
Cylinder head
The cylinder heads can be distinguished by the embossed-letters (A).
- "F": Front cylinder head
- "R": Rear cylinder head
![](https://motoinstruction.ru/img/suzuki/14/120185.jpg)
Pull the cam chain out of the cylinder and install the cam chain guide (1).
Caution! There is the guide holder for the bottom end of the cam chain guide (1) cast in the crankcase. Be sure that the cam chain guide (1) is inserted properly.
Note: The front and rear cam chain guides are the same.
![](https://motoinstruction.ru/img/suzuki/14/120186.jpg)
Fit the dowel pins (2) and new cylinder head gasket (3) to the cylinder.
Caution! Use the new gasket to prevent gas leakage.
![](https://motoinstruction.ru/img/suzuki/14/120187.jpg)
Install the washers (4) to the cylinder head bolts (M10) (5) as shown.
Apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts.
![](https://motoinstruction.ru/img/suzuki/14/120188.jpg)
Place the rear cylinder head on the cylinder.
Note: When installing the cylinder head, keep the cam chain taut.
Tighten the cylinder head bolts (M10) to the specified two-step torque with a torque wrench sequentially and diagonally.
Cylinder head bolt (M10):
- Initial 25 N·m (2.5 kgf·m, 18.0 lb·ft)
- Final 42 N·m (4.2 kgf·m, 30.5 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/120189.jpg)
After firmly tightening the cylinder head bolts (M10), install the cylinder head bolts (M6) (6), (7).
Tighten the cylinder head bolts (6), (7), and cylinder nuts (8).
![](https://motoinstruction.ru/img/suzuki/14/120190.jpg)
Install the front cylinder head in same manner as the rear cylinder head installation.
![](https://motoinstruction.ru/img/suzuki/14/120191.jpg)
Cam shaft
The cam shafts are identified by the embossed letters.
- INF: No.1 (Front) intake camshaft (1)
- EXF: No.1 (Front) exhaust camshaft (2)
- INR: No.2 (Rear) intake camshaft (3)
- EXR: No.2 (Rear) exhaust camshaft (4)
![](https://motoinstruction.ru/img/suzuki/14/120192.jpg)
Before installing the camshafts to the cylinder head, apply MOLYBDENUM OIL SOLUTION to their journals.
- Molybdenum oil solution
No.1 (Front) Camshafts
Turn the crankshaft counterclockwise with the box wrench and align "|F" line (A) on the generator rotor with the index mark (B) of the valve timing inspection hole while keeping the cam chains pulled upward.
![](https://motoinstruction.ru/img/suzuki/14/120193.jpg)
Caution!
- Pull the cam chains upward, or the chain will be caught between crankcase and cam drive sprocket.
- To adjust the camshaft timing correctly, be sure to align "|F" line (A) with the index mark (B) and hold this position when installing the camshafts.
![](https://motoinstruction.ru/img/suzuki/14/120194.jpg)
Pull the cam chain lightly.
The No.1 exhaust camshaft sprocket has an arrow mark "|F" (C). Install the exhaust camshaft so that the arrow (C) is aligned with the mating surface of the cylinder head.
Engage the cam chain with the exhaust camshaft sprocket.
Note: Before installing the camshaft, check that the tappets are installed correctly.
![](https://motoinstruction.ru/img/suzuki/14/120195.jpg)
The other arrow mark "2" on the exhaust camshaft sprocket should now be pointing straight up. Starting from the roller pin that is directly above the arrow mark "2" count out 16 roller pins (from the exhaust camshaft side going towards the intake camshaft side). Engage the 16 roller pin (D) on the cam chain with the arrow mark "3" on the intake sprocket.
![](https://motoinstruction.ru/img/suzuki/14/120196.jpg)
Note: The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster is secured.
No.1 (Front) Cylinder head
![](https://motoinstruction.ru/img/suzuki/14/120197.jpg)
Install the dowel pins (1).
![](https://motoinstruction.ru/img/suzuki/14/120198.jpg)
Apply engine oil to the camshaft journal holders.
Install the camshaft journal holders, intake and exhaust.
Fasten the camshaft journal holders evenly by tightening the crankshaft journal holder bolts sequentially and diagonally.
Notes:
- Align the flange (E) of the camshafts with the groove (F) of the camshaft journal holders.
- Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.
- Each camshaft journal holder is identified with a cast-on letters (G).
![](https://motoinstruction.ru/img/suzuki/14/120199.jpg)
Tighten the camshaft journal holder bolts to the specified torque.
- Camshaft journal holder bolt: 10 N·m (1.0 kgf·m, 7.0 lb·ft)
Caution!
- The camshaft journal holder bolts are made of a special material and much superior in strength, compared with other types of high strength bolts.
- Take special care not to use other types of bolts instead of these special bolts. To identify these bolts, each of them has a figure "9" on its head.
Recheck the front camshaft positions, intake and exhaust.
![](https://motoinstruction.ru/img/suzuki/14/120210.jpg)
Cam chain tension adjuster
With the spring holder bolt and spring removed from the cam chain tension adjuster, release locking of the ratchet mechanism (1) and push the push rod (2) all the way in.
![](https://motoinstruction.ru/img/suzuki/14/120200.jpg)
Install the gasket and oil jet.
Install the cam chain tension adjuster (3) with "UP" mark faced to the top of cylinder head.
Tighten the cam chain tension adjuster mounting bolts to the specified torque.
![](https://motoinstruction.ru/img/suzuki/14/120201.jpg)
Caution! Use the new gasket to prevent oil leakage.
- Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf·m 7.0 lb·ft)
Install the spring (4), gasket (5) and spring holder bolt (6).
Caution! Use the new gasket to prevent oil leakage.
Tighten the cam chain tension adjuster cap bolt to the specified torque.
- Cam chain tension adjuster cap bolt: 23 N·m (2.3 kgf·m, 16.5 lb·ft)
Caution! After installing the cam chain tension adjuster, check to be sure that the adjuster work properly by checking the slack of cam chain.
![](https://motoinstruction.ru/img/suzuki/14/120202.jpg)
Install the cam chain guide (7).
![](https://motoinstruction.ru/img/suzuki/14/120203.jpg)
No.2 (Rear) camshafts
From the position where the front camshafts have now been installed, rotate the generator rotor 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/14/120204.jpg)
Caution! Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.
Caution! To adjust the camshaft timing correctly, be sure to align "|F" line (A) with the index mark (B) and hold this position when installing the camshafts.
![](https://motoinstruction.ru/img/suzuki/14/120205.jpg)
Pull the cam chain lightly.
The No.2 intake camshaft sprocket has an arrow mark "1R" (C). Install the intake camshaft so that the arrow (C) is aligned with the mating surface of the cylinder head.
Engage the cam chain with the intake camshaft sprocket.
Note: Before installing the camshaft, check that the tappets are installed correctly.
![](https://motoinstruction.ru/img/suzuki/14/120206.jpg)
The other arrow mark "2" on the intake camshaft sprocket should now be pointing straight up. Starting from the roller pin that is directly above the arrow mark "2" count out 16 roller pins (from the intake camshaft side going towards the exhaust camshaft side). Engage the 16th roller pin (D) on the cam chain with the arrow mark "3" on the exhaust sprocket.
![](https://motoinstruction.ru/img/suzuki/14/120207.jpg)
Note: The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster is secured.
No.2 (Rear) cylinder head
![](https://motoinstruction.ru/img/suzuki/14/120208.jpg)
Install the dowel pins (1).
![](https://motoinstruction.ru/img/suzuki/14/120209.jpg)
Apply engine oil to the camshaft journal holders.
Install the camshaft journal holders, intake and exhaust.
Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally.
Notes:
- Align the flange (E) of the camshafts with the groove (F) of the camshaft journal holders.
- Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.
- Each camshaft journal holder is identified with a cast-on letter (G).
![](https://motoinstruction.ru/img/suzuki/14/120211.jpg)
Tighten the camshaft journal holder bolts to the specified torque.
- Camshaft journal holder bolt: 10 N·m (1.0 kgf·m, 7.0 lb·ft)
Caution!
- The camshaft journal holder bolts are made of a special material and much superior in strength, compared with other types of high strength bolts.
- Take special care not to use other types of bolts instead of these special bolts. To identify these bolts, each of them has a figure "9" on its head.
![](https://motoinstruction.ru/img/suzuki/14/120212.jpg)
Recheck the rear camshaft positions, intake and exhaust.
Cam chain tension adjuster
Install the cam chain tension adjuster.
Install the cam chain guide (1).
After installing the rear camshafts, rotate the generator rotor (same turns), and recheck the positions of the camshafts.
![](https://motoinstruction.ru/img/suzuki/14/120213.jpg)
No.1 (Front) Cylinder TDC of compression stroke
![](https://motoinstruction.ru/img/suzuki/14/120214.jpg)
(1) Cam chain guide; (2) Cam chain guide; (A) Forward
Cylinder head cover
Pour engine oil in each oil pocket in the front and rear cylinder heads.
Note: Be sure to check the valve clearance. (2-8)
Install the dowel pins (1) and O-rings (2).
![](https://motoinstruction.ru/img/suzuki/14/120215.jpg)
Install the new gaskets to each cylinder head cover.
Apply SUZUKI BOND to the cam end caps of the gaskets.
- 99104-31140: SUZUKI BOND "1207B" (USA)
- 99000-31110: SUZUKI BOND "1215" (Others)
![](https://motoinstruction.ru/img/suzuki/14/120216.jpg)
Caution! Use the new gaskets to prevent oil leakage.
The cylinder head covers can be distinguished by the embossed letters (A).
- "F": Front cylinder head cover
- "R": Rear cylinder head cover
![](https://motoinstruction.ru/img/suzuki/14/120217.jpg)
Install the cylinder head covers on each cylinder head.
Fit the gaskets (3), (4) to each head cover bolt.
Caution! Use the new gaskets to prevent oil leakage.
Note: The metal side of the gasket (3) must face to the bolt flange.
![](https://motoinstruction.ru/img/suzuki/14/120218.jpg)
After applying engine oil to the gaskets tighten the head cover bolts to the specified torque.
- Head cover bolt: 14 N·m (1.4 kgf·m, 10.0 lb·ft)
![](https://motoinstruction.ru/img/suzuki/14/120219.jpg)
Exhaust pipe
Tighten the exhaust pipe bolts (1) to the specified torque.
- Exhaust pipe bolt: 23 N·m (2.3 kgf·m, 16.5 lb·ft)
Caution! Use the new gasket to prevent exhaust gas leakage.
![](https://motoinstruction.ru/img/suzuki/14/120220.jpg)
Water union
Install the O-ring to the water union.
Caution! Replace the O-ring with a new one.
When installing the water union, apply engine coolant to the O-ring.
- Engine coolant
![](https://motoinstruction.ru/img/suzuki/14/120221.jpg)
Intake pipe
Apply SUZUKI SUPER GREASE to the O-ring.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
Caution! Use the new O-ring to prevent air from sucking through the joint.
![](https://motoinstruction.ru/img/suzuki/14/120222.jpg)
Make sure that the "UP" mark (A).
Install the intake pipes.
Notes:
- The intake pipe can be identified by the mark (B).
- F: Front cylinder head intake pipe
- R: Rear cylinder head intake pipe
![](https://motoinstruction.ru/img/suzuki/14/120223.jpg)
Generator cover plug
Apply engine oil to the O-ring of the generator cover plug.
Tighten the valve timing inspection plug (1) and generator cover plug (2) to the specified torque.
- Valve timing inspection plug: 23 N·m (2.3 kgf·m, 16.3 lb·ft)
- Generator cover plug: 11 N·m (1.1 kgf·m, 8.0 lb·ft)
Caution! Use the new O-ring to prevent oil leakage.
![](https://motoinstruction.ru/img/suzuki/14/120224.jpg)
Thermostat case and water hose
Install the thermostat case (1) along with the water hoses (2) and tighten the clamp screws securely. (9-24)
![](https://motoinstruction.ru/img/suzuki/14/120225.jpg)
Spark plug and hoses
Connect the PAIR hoses (1).
Connect the crankcase breather hoses (2).
Install the spark plugs. (2-6)
![](https://motoinstruction.ru/img/suzuki/14/120226.jpg)