Ventitsshortoropencircuit.

•Removethereservertank.

ENGINESPROCKETANOGEARSHIFTLEVER

•Removethespeedsensor.

•Removethegearshiftlever.

•Removetheenginesprocketcover.

•RemovetheclutchpushrodG).

NOTE:

Jackupthemotorcycleandfixitforsafety.

•RemovethespeedsensorrotorCD.

•Removetheenginesprocketnut(?.)andthewasher.

•Removethecotterpin.(ForE-03,28,33)

•LoosentherearaxlenutQ)andthereartorquelinknut@.

•Loosentheleftandrightchainadjusters@.

•Pushtherearwheelforwardandmakesurethatthedrivechainhasenoughslack.

•Disengagethedrivechainfromtherearsprocket.

•Removetheenginesprocket@.

ENGINE

•Supporttheengineusinganenginejack.

•Removetheenginemountingbolts<D.~.

•LoosentheenginemountingpinchboltsQ).

•Removetheenginemountingbolts@.

•Removetheenginemountingnut@.

•Removetheenginemountingthrustadjusterlocknut(§)withthespecialtool.

•Loosentheenginemountingthrustadjuster(!)fullywiththe

specialtool.

!Mi09940-14990:Enginemountingthrustadjustersocketwrench

•RemovetheenginemountingnutCD.

•Loosentheenginemountingthrustadjusterlocknut~-

•Loosentheenginemountingthrustadjuster@.

NOTE:

_{Donotremovetheenginemountingboltsatthisstage.}

_-

•Removetheenginemountingboltsandgraduallylowerthefrontsideoftheengine.Then,takeoffthedrivechainfromthedriveshaft.

_{•Removetheengineassembly.}

-

ENGINEREINSTALLATION

Reinstalltheengineinthereverseorderofengineremoval.Payattentiontothefollowingpoints:

NOTE:

Becarefulnottodamagetheframeandenginewheninstallingtheengine.

•Beforeinstallingtheengine,installthespacerG).

•Beforeinstallingtheengine,installtheenginemountingthrustadjusters~andQ).

•Installallenginemountingbolts,spacersandtightenthemtem•

porarily.(c:::::T3-12)

!ACAUTIONI

Becarefulnottocatchthewiringharnessbetweentheframeandtheengine.

•Tightentheenginemountingthrustadjusterstothespecifiedtorquewiththespecialtool.

!Mbtt09940-14990:Enginemountingthrustadjustersocketwrench

~Enginemountingthrustadjuster:23N·m

(2.3kgf·m,16.5lb-ft)

•Tightentheenginemountingthrustadjusterlocknutstothespecifiedtorquewiththespecialtool.

!Mott09940-14990:Enginemountingthrustadjustersocketwrench

~Enginemountingthrustadjusterlocknut:

45N·m(4.5kgf·m,32.5lb-ft)

•Tightenallenginemountingboltsandnutstothespecifiedtorque.(c::::r3-12)

NOTE:

Theenginemountingnutsareself-locking.Oncethenutshavebeenremoved,theyarenolongerofanyuse.

•Tightentheenginemountingpinchbolttothespecifiedtorque.(L::l'3-12)

_{<;:::JLettRight¢}

_®

_@

©

_@

^@@

_LENGTH

ITEM	N·m	kgf·m	lb-ft
®'~)©	55	5.5	39.8
@@	75	7.5	54.0
(1)!{)	23	2.3	16.5

@

101.07.3				ITEM	~©	mm 45	in 1.77
			Bolt		®	55	2.17
					©®	215	8.46
			Spacer		~	30.5	1.20
45	4.5	32.5	Adjuster		:4)(V	40	1.57

t~@

•Installtheenginesprocketandthewasher.

•ApplyasmallquantityofTHREADLOCK"1342"tothedriveshaftthreadportion.

^{-tfE99000-32050:THREADLOCK"1342"}

•Tightentheenginesprocketnuttothespecifiedtorque.

(!JEnginesprocketnut:115N·m(11.5kgf·m,83.2lb-ft)

•Installthespeedsensorrotor.

•Tightenthespeedsensorrotorbolttothespecifiedtorque.

(!JSpeedsensorrotorbolt:20N·m(2.0kgf·m,14.4lb-ft)

•Applygreasetotheclutchpushrodandinstallit.

.,099000-25010:SUZUKISUPERGREASE"A"

•Aligntheholeoftheclutchreleasecylinderwiththeendoftheclutchpushrodwheninstallingtheenginesprocketcover.

•TightenthespeedsensorboltG)tothespecifiedtorque.

(!JSpeedsensorbolt:4.5N·m(0.45kgf·m,3.0lb-ft)

•Installtheenginesprocketcoverandthegearshiftlever.

52-62mm

(2.05-2.44in)

•InstalltheradiatormountingbracketG).

•Installtheexhaustpipe/muffler.