Engine Removal

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Before removing the engine from the frame Suzuki recommends cleaning it with a steam cleaner or a pressure washer with a grease dissolving solvent.

Remove the seats. See the Seats topic for more information.

Remove the lower fairings. See the Lower Farings topic for more information.

Remove the side covers. See the Side Covers topic for more information.

Remove the carburetors. See the Carburetors topic for more information.

Drain the engine oil. See the Engine Oil topic for more information.

Remove the exhaust system. See the Exhaust System topic for more information.

Remove the spark plug caps. See the Spark Plug topic for more information.

Remove the battery. See the Charging System topic for more information.

Remove the airbox. See the Airbox topic for more information.

Remove the countershaft sprocket. See the Countershaft Sprocket topic for more information.

Remove the oil cooler. See the Oil Cooler topic for more information.

Unplug the negative battery connector.

Free the generator wire bands from the frame.

Unplug the generator connector.

Free the lower wire band from the generator wires. Move the generator wires out of the frame.

Unplug the neutral switch connector.

Pull back the rubber wire cover on the right side of the frame.

Disconnect the side stand switch connectors.

Unplug the signal generator and the oil pressure switch connectors.

Pull back the starter motor lead cover.

Loosen the starter lead nut with a 10 mm wrench. Disconnect the starter lead from the electric starter motor.

Set the motorcycle on its center stand and secure it so that it will not tip over. Place a jack under the engine.

Loosen the four down tube mounting bolts with a 12 mm socket.

Hold the down tube engine mounting nuts with a 14 mm wrench and loosen the mounting bolts with a 14 mm socket.

Remove the down tube mounting nuts and bolts.

Remove the lower engine mounting bolts with a 12 mm socket.

Remove the two (each side) rear down tube nuts and bolts. Hold the nuts with a 12 mm wrench and loosen the bolts with a 12 mm socket.

Remove the down tube from the frame.

Remove the two rear engine mounting nuts. Hold the bolts with a 14 mm socket and loosen the nuts with a 14 mm socket.

Use a punch and a hammer to tap the upper bolt out.

Remove the upper bolt spacer from the right side of the frame.

Remove the rear engine mounting bolts.

Make sure the chain is clear of the countershaft.

Use the jack to ease the engine out of the frame.

Discard the engine mounting nuts. These are special self-locking nuts that can only be used once.

To install the engine see the Engine Installation topic.

Copyright - Cyclepedia Press LLC

Note: If you are viewing this document offline be sure to visit the latest version online at http://www.cyclepedia.com before attempting any repairs. Updates are made without notice.