Engine Mechanical: 1D-13
Engine Top Side Assembly
B827H11406016
Assemble the engine top side in the reverse order of
disassembly. Pay attention to the following points:
CAUTION
!
When turning the crankshaft, pull the cam
chain upward, or the chain will be caught
between the crankcase and the cam drive
sprocket.
Piston
• Apply a light coat of molybdenum oil solution to the
piston pin.
M/O: Molybdenum oil (MOLYBDENUM OIL
SOLUTION)
• Install the piston and piston pin.
NOTE
When installing the piston, the indent “A” on
the piston head must be face to the exhaust
side.
• Place a cloth beneath the piston, install the circlip (1).
CAUTION
!
Use new piston pin circlips (1) to prevent
circlip failure which will occur when it is bent.
NOTE
End gap of the circlip (1) should not be
aligned with the cutaway in the piston pin
bore.
• Position the gaps of the three rings and side rails as
shown in the figure. Before inserting piston into the
cylinder, check that the gaps are properly positioned.
Cylinder
• Apply bond lightly to the crankcase mating points.
: Sealant 99000–31140 (SUZUKI BOND
No.1207B or equivalent)
• Fit the dowel pins and the new gasket (1).
CAUTION
!
Use the new gasket to prevent gas leakage.
A
I827H1140017-01
“B”: 2nd ring and lower side rail
“C”: Upper side rail
“D”: 1st ring and spacer
1
I827H1140018-01
EX
IN
“C”
“B”
“D”
I718H1140051-01
1
I827H1140019-01
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