Engine Mechanical: 1D-63
• Before installing the crankshaft assembly, apply
engine oil to each crankshaft journal bearing.
• Install the crankshaft assembly along with the cam
chain into the upper crankcase.
• Insert the right and left-thrust bearings with the oil
grooves “A” facing towards the crankshaft web.
NOTE
• Right-thrust bearing has green painting.
• Inspect and select the crankshaft thrust
clearance if necessary. Refer to
“Crankshaft Thrust Clearance Inspection
and Selection (Page 1D-80)”.
Crankcase
• Install the dowel pins and O-rings in the upper
crankcase.
CAUTION
!
Replace the O-rings with new ones.
• Apply SUZUKI BOND to the mating surface of the
lower crankcase as follows.
NOTE
• Make surfaces free from moisture, oil, dust
and other foreign materials.
• Spread the sealant on surfaces thinly to
form an even layer, and assemble the
crankcases within a few minutes.
• Take extreme care not to apply any bond to
the oil hole, oil groove and bearing.
• Apply to distorted surfaces as it forms a
comparatively thick film.
: Sealant 99000–31110 (SUZUKI BOND
No.1215 or equivalent)
• Tighten the crankshaft journal bolts (M9) in ascending
order of numbers assigned to these bolts. Tighten
each bolt a little at a time to equalize the pressure in
the following two steps.
CAUTION
!
Fit new gasket washers to the bolts (“9”,
“10”, “11” and “12”) to prevent oil leakage.
Tightening torque
Crankcase journal bolt (M9) (Initial): 18 N·m (1.8
kgf-m, 13.0 lb-ft)
Crankcase journal bolt (M9) (Final): 32 N·m (3.2
kgf-m, 23.0 lb-ft)
I718H1140209-01
“A”
“A”
I718H1140399-01
I718H1140183-01
I718H1140213-01
12
3
5
6
7
8
911
1012 4
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