Engine Removal And Installation Engine Removal

Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps.

• Remove the seat and side frame covers. (CFS-S and -6)

• Remove the fuel tank mounting bracket bolts ©.

• Remove the air cleaner box mounting bolts (2).

First disconnect the battery © lead wire, then disconnect the battery © lead wire.

Remove the oil drain plug @ and drain the engine oil. (CT2-9)

• Disconnect all of the spark plug caps

Engine Timing Bandit 250

• Disconnect the PAIR valve hoses ©, (D and (D. CD Air cleaner hose @ Vacuum hose ® PAIR hoses

Removing Starter Motor Suzuki Gs850g

• Loosen the respective carburetor clamp screws (4).

Vmax Carb Sync Fitting

• Disconnect the throttle position sensor lead wire coupler (D.

• Slightly move the air cleaner box backward.

Fzs 600 Throttle Position SensorCarburetor Assy 1100

• Remove the carburetor assembly by disconnecting the starter cable © and throttle cables

• Disconnect the various lead wires. ® Gear position switch

(D Signal generator ® Oil pressure switch © Speed sensor © Side-stand switch

Oil Sensor 1100 Yamaha ViragoOil Pressure Switch Bandit Gsf 600

Remove the two wire clamps.

Disconnect the starter motor lead wire ©.

Disconnect the generator lead wire (D and coupler

Remove the gearshift lever by removing its mounting bolt. Remove the engine sprocket cover by removing the bolts.

• Remove the speed sensor rotor

• Remove the engine sprocket nut © while depressing the rear brake pedal.

• Loosen the rear axle nut (D and chain adjusters ® to provide additional chain slack.

• Remove the engine sprocket.

• Remove the eight exhaust pipe bolts.

• Remove the muffler mounting bolts.

Suzuki Bandit Gear Position Sensor

Remove the oil cooler hose union bolts ©.

Bandit Oil Cooler Pipes Engine

• Remove the oil cooler by removing the mounting bolts (2).

Honda Cbr Engine Installation Removal

• Suppport the engine with a proper engine jack.

• Remove the frame down tube mounting bolts and nuts.

• Remove the engine mounting bolts, nuts, spacer and brackets.

• Gradually lower the engine.

Xjr 1300 Bolts


Reinstall the engine in the reverse order of engine removal.

• Insert the two long bolts from left side. Install the brackets, spacer, bolts and nuts properly, as shown in the following illustration.


The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. Be sure to use new nuts and tighten them to the specified torque.


Fuel Hose Routing Suzuki Gsf 600




180 mm (7.1 in)

Bolt (2)

130 mm (5.1 in)


55 mm (2.2 in)


55 mm (2.2 in)

Spacer RH ®

27 mm (1.1 in)











Other engine mounting bolts and frame down tube mounting bolts.


When reusing the removed engine mounting bolts ((2j and (§)), apply a small quantity of the THREAD LOCK "1342" to their threads.

tS 99000-32050: THREAD LOCK "1342"



• Tighten the oil cooler mounting bolts © to the specified torque. [5 Oil cooler mounting bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-ft)

• Tighten the oil cooler hose union bolts (2) to the specified torque.

H oil cooler hose union bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)

a caution

Use a new gasket washer to prevent oil leakage.


When installing a new exhaust pipe/muffler assembly connector, remove all of the old sealer from the exhaust pipe and from inside the muffler. Apply the exhaust gas sealer to both the inside and outside of the new exhaust pipe/muffler assembly connector.


• Install the exhaust pipe gaskets (3). a caution

Be sure to face the tabs ® on the exhaust pipe gasket (D to the inside when installing it.

• Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.

H Exhaust pipe bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft) Muffler mounting bolt: 29 N-m (2.9 kgf-m, 21.0 Ib-ft)

Thread Lock Supper

• Apply THREAD LOCK SUPER "1303" to the driveshaft.

99000-32030: THREAD LOCK SUPER "1303"

• Tighten the engine sprocket nut © to the specified torque.

H Engine sprocket nut ©: 115 Nm (11.5 kgf-m, 83.0 Ib-ft)

• Apply a small quantity of THREAD LOCK "1342" to the speed sensor rotor bolt.

tffl 99000-32050: THREAD LOCK "1342"

• Tighten the speed sensor rotor bolt (2) to the specified torque.

H Speed sensor rotor bolt (2): 20 N m (2.0 kgf-m, 14.5 Ib-ft)

• Before installing the engine sprocket cover, apply a small quantity of SUZUKI SUPER GREASE "A" to the clutch release mechanism.


• Install the spark plug caps onto the spark plugs. Make sure that each spark plug cap is installed in the correct location. The number on each spark plug cord refers to the appropriate cylinder.

• Position the carburetor clamps as shown.

Carburetor clamp position (air cleaner side)

Carburetor clamp position (air cleaner side)

Suzuki Gsf 600 Throttle Position Sensor

Carburetor clamp position (engine side)

• After remounting the engine, route the wire harness, cables and hoses properly. (CZT7-12)

Suzuki Tempter Clutch Cable Install

• Install the gearshift lever to the gearshift shaft in the correct position.

ESiJ Gearshift lever height ® Standard: 55 mm (2.2 in)

• Tighten the oil drain plug © to the specified torque. [5 Oil drain plug: 23 N-m (2.3 kgf-m, 16.5 Ib-ft)

• Pour 3.3 L (3.5/2.9 US/Imp qt) of SF or SG classified (API) engine oil, with a viscosity rating of 10W40 (SAE), into the engine after overhauling it.

• Start up the engine and allow it run for several minutes at idle speed and then stop the engine. Wait three minutes and then check that the oil level remains between the marks on the oil level inspection window.

Oil change

3 300 ml (3.5/2.9 US/Imp qt)

Oil and filter change

3 500 ml (3.7/3.1 US/Imp qt)

Engine overhaul

4 600 ml (4.9/4.0 US/Imp qt)

• Adjust the following items to specification.

• Adjust the following items to specification.

Throttle cable play CZ7=2-11

'Engine idle speed d?=2-11

'Carburetor synchronization CF4-23

*Drive chain CT2-15

'Clutch cable play (T7=2-13

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