Suzuki GSF650S - Engine Service and Overhaul

3
6
ENGINE 3-1
CONTENTS
ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..............3- 2
ENGINE REMOVAL AND INSTALLATION ....................................................3- 3
REMOVAL ..............................................................................................3- 3
INSTALLATION ......................................................................................3- 7
ENGINE DISASSEMBLY ................................................................................3-12
ENGINE COMPONENTS INSPECTION AND SERVICE ................................3-26
CAMSHAFT/CYLINDER HEAD INSPECTION AND SERVICE .............3-26
CYLINDER BLOCK/PISTON INSPECTION ..........................................3-39
CLUTCH/CLUTCH RELEASE ASSEMBLY INSPECTION ...................3-43
STARTER CLUTCH INSPECTION ........................................................3-45
GEARSHIFT LINKAGE INSPECTION ...................................................3-45
TRANSMISSION INSPECTION AND SERVICE ....................................3-47
CONROD/CRANKSHAFT INSPECTION ...............................................3-55
CONROD-CRANK PIN BEARING INSPECTION AND SERVICE .........3-55
CRANKCASE-CRANKSHAFT BEARING INSPECTION
AND SERVICE ......................................................................................3-58
CRANKSHAFT THRUST CLEARANCE ADJUSTMENT ......................3-60
ENGINE REASSEMBLY .................................................................................3-63
ENGINE LUBRICATION SYSTEM ..................................................................3-86
OIL PUMP ...............................................................................................3-86
OIL SUMP FILTER/OIL PRESSURE REGULATOR .............................3-86
OIL PRESSURE SWITCH ......................................................................3-89
OIL COOLER ..........................................................................................3-90
OIL FILTER ............................................................................................3-90
OIL PRESSURE .....................................................................................3-90
OIL JET ..................................................................................................3-91
ENGINE LUBRICATION SYSTEM CHART ...........................................3-93
ENGINE LUBRICATION SYSTEM .........................................................3-94
CYLINDER HEAD COOLING SYSTEM CHART ...................................3-95
CYLINDER HEAD COOLING SYSTEM .................................................3-96
PAIR (AIR SUPPLY) SYSTEM ........................................................................3-97
REMOVAL ..............................................................................................3-97
INSPECTION ..........................................................................................3-97
INSTALLATION ......................................................................................3-98