Engine Top Side Assembly - Suzuki SFV650 Service Manual

1D-31 Engine Mechanical:

Engine Top Side Assembly

Assemble the engine top side in the reverse order of
disassembly. Pay attention to the following points:
Piston
• When installing the piston pins, apply molybdenum oil
solution onto each piston pins.
M/O: Molybdenum oil (MOLYBDENUM OIL
SOLUTION)
NOTE
When installing the pistons, the indent "A"
on the piston head must be faced to each
exhaust side.
• Place a clean rag over the cylinder base so as not to
drop the piston pin circlips (1) into the crankcase.
• Install the piston pin circlips (1).
CAUTION
!
Replace the piston pin circlips (1) with new
ones.
NOTE
End gap of the circlip (1) should not be
aligned with the cutaway "A" in the piston pin
bore.
"A"
• Apply molybdenum oil solution to the position rings.
M/O: Molybdenum oil (MOLYBDENUM OIL
SOLUTION)
B944H11406007
"A"
I944H1140163-01
1
I944H1140164-02
• Position the piston ring gaps as shown in the figure.
Before inserting each piston into the cylinder, check
that the gaps are properly positioned.
"B"
"B": 2nd ring and lower side rail
"C": Upper side rail
"D": 1st ring and spacer
Cylinder
• Thoroughly wipe off oil from the fitting surface of the
crankcase.
• Coat bond lightly to the mating surfaces at the parting
line between the right and left crankcases as shown.
: Sealant 99000–31110 (SUZUKI BOND
No.1215 or equivalent)
• Install the dowel pins (1) and new gaskets (2), front
and rear.
CAUTION
!
Use a new gaskets (1) to prevent oil leakage.
2
1
EX
"C"
IN
"D"
I718H1140051-01
I944H1140165-01
2
1
I944H1140166-01