Oil Pan

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

Removal

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

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

Loosen the two oil cooler bolts with a 14 mm socket. Remove the bolts and discard the sealing washers.

Loosen the 14 oil pan bolts evenly with a 5 mm Allen. Remove the bolts. The indicated bolt has a sealing washer.

Remove the oil pan from the bottom crankcase half.

Remove the oil pan gasket, shim and O-ring. Scrape off any remaining oil pan gasket material.

Oil Sump Filter

Note: The 750 models have a larger oil sump filter with four bolts. The bolts, oil sump filter cover and screen must be removed to access the oil sump filter mounting bolts.

Remove the two oil sump filter bolts with a 10 mm socket. Remove the oil sump filter and gasket from the engine. Scrape away any old gasket material.

Remove the three oil sump filter cover bolts with a 10 mm socket.

Clean the oil sump filter screen with a high flash-point solvent and compressed air. 

NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.

Oil Pressure Regulator

Loosen the oil pressure regulator with a 17 mm socket. Remove the oil pressure regulator and sealing washer.

Push in on the oil pressure regulator piston and make sure it moves in and out smoothly. Replace the regulator as needed.

Clean the oil pan with a high flash-point solvent and a lint free rag. Suzuki recommends using kerosene to clean the oil pan.

Installation

Oil Pressure Regulator

Install the oil pressure regulator with a new sealing washer. Tighten the regulator to specification with a 17 mm socket.

(Oil Pressure Regulator Torque: 28 N-m or 20 lb-ft)

Oil Sump Filter

Return the oil sump filter screen and cover to the body. Position the arrow so that it points towards the oil pickup. Tighten the bolts securely with a 10 mm socket.

Install the oil sump filter with a new gasket.

Tighten the two oil sump filter mounting bolts securely with a 10 mm socket.

Install a new O-ring and shim into the orifice.

Install a new oil pan gasket and the oil pan.

Install the 14 oil pan bolts. Use a new sealing washer with the indicated bolt. Tighten the bolts to specification evenly with a 10 mm socket.

(Oil Pan Bolt Torque: 14 N-m or 10 lb-ft)

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

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

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