SUZUKI DF150 175 Service Man 3

POWER UNIT 6-1
POWER UNIT
CONTENTS
RING GEAR COVER AND AIR INTAKE SILENCER CASE ....................................... 6- 2
REMOVAL .......................................................................................................... 6- 2
INSTALLATION ................................................................................................. 6- 2
INTAKE MANIFOLD ASSEMBLY ............................................................................... 6- 3
REMOVAL .......................................................................................................... 6- 3
INSTALLATION ................................................................................................. 6- 5
DISASSEMBLY .................................................................................................. 6- 8
REASSEMBLY ................................................................................................... 6- 9
CYLINDER HEAD COVER .......................................................................................... 6-11
REMOVAL .......................................................................................................... 6-11
INSTALLATION ................................................................................................. 6-13
POWER UNIT ............................................................................................................... 6-15
REMOVAL .......................................................................................................... 6-15
6
INSTALLATION ................................................................................................. 6-21
OIL PUMP .................................................................................................................... 6-26
REMOVAL .......................................................................................................... 6-26
DISASSEMBLY .................................................................................................. 6-27
INSPECTION ......................................................................................................6-28
MEASURING PUMP COMPONENTS ............................................................... 6-28
ASSEMBLY ........................................................................................................ 6-29
INSTALLATION ................................................................................................. 6-30
TIMING CHAIN/BALANCER CHAIN (VVT model) ..................................................... 6-31
REMOVAL .......................................................................................................... 6-31
INSPECTION ......................................................................................................6-35
INSTALLATION ................................................................................................. 6-37
TIMING CHAIN/BALANCER CHAIN (Non-VVT model) ............................................. 6-44
REMOVAL .......................................................................................................... 6-44
INSPECTION ......................................................................................................6-48
INSTALLATION ................................................................................................. 6-50
CYLINDER HEAD ASSEMBLY ................................................................................... 6-57
REMOVAL .......................................................................................................... 6-57
ASSEMBLY ........................................................................................................ 6-58
DISASSEMBLY .................................................................................................. 6-62
INSPECTION/SERVICING .................................................................................6-63
REASSEMBLY ................................................................................................... 6-73
COUNTER-BALANCER MECHANISM ....................................................................... 6-75
REMOVAL .......................................................................................................... 6-75
DISASSEMBLY .................................................................................................. 6-76
INSPECTION ......................................................................................................6-77
ASSEMBLY ........................................................................................................ 6-78
INSTALLATION ................................................................................................. 6-81
CYLINDER/CRANKSHAFT/PISTON ........................................................................... 6-82
DISASSEMBLY .................................................................................................. 6-82
INSPECTION/SERVICING .................................................................................6-85
REASSEMBLY ................................................................................................... 6-97
THERMOSTAT ............................................................................................................ 6-105
REMOVAL ......................................................................................................... 6-105
INSPECTION ..................................................................................................... 6-105
INSTALLATION ................................................................................................ 6-106
OPERATION ............................................................................................................... 6-107
WATER COOLING SYSTEM ............................................................................ 6-107
ENGINE LUBRICATION SYSTEM ................................................................... 6-108
1
6-2 POWER UNIT
RING GEAR COVER AND AIR INTAKE SILENCER CASE

REMOVAL
Prior to removing Ring gear cover:
• Disconnect battery cables from battery.
1. Loosen the clamp securing breather hose 1, then remove

the breather hose from cylinder head cover 2.
2. Disconnect the intake air temp. sensor lead wire connector
3 at intake air temp. sensor.
3. Remove the four (4) bolts securing ring gear cover 4.

4. Remove the ring gear cover and intake silencer case.
INSTALLATION
Installation is reverse order of removal.
2
POWER UNIT 6-3
INTAKE MANIFOLD ASSEMBLY

REMOVAL
Before removing intake manifold:
• Relieve fuel pressure. (See page 5-3.)
• Remove both side covers. (See page 7-2.)
1. Remove ring gear cover and air intake silencer case 1.

(See page 6-2.)
Remove the three (3) bolts and fuel hose guard 2.
2. Remove the two (2) bolts and front panel 3.

Remove fuel vapor separator 4. (See page 5-7.)
3. Remove fuel injectors 5 and fuel delivery pipe 6.

(See page 5-14.)
4. Disconnect fuel outlet hose 7 from low pressure fuel pump

8.
3
6-4 POWER UNIT
5. Disconnect VSV (Vacuum Switching Valve) connector from

VSV 9.
6. Disconnect MAP sensor connector 0.

Disconnect IAC valve connector A.
Disconnect TPS (Throttle Position Sensor) connector B.
7. Disconnect vacuum hoses from vacuum tank C.
8. Remove the two bolts D securing throttle drum E to intake

manifold.
Remove the throttle link connector F from throttle drum.
9. Disconnect water inlet hose G from fuel cooler H.
4
POWER UNIT 6-5
10. Disconnect cooling water outlet hose I from balancer water

jacket cover J.
11. Disconnect water outlet hose K and water return hose L

from water return union M.
12. Remove eight (8) bolts and two (2) nuts and then remove
intake manifold assembly N.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
!
Do not reuse gasket once removed.
Always use a new gasket.
• Install gaskets 1 into groove of intake manifold assembly 2.
5
6-6 POWER UNIT
• Install intake manifold assembly 2, then tighten bolts and

nuts securely.
" Intake manifold bolt & nut: 23 N·m (2.3 kg-m, 16.5 lb-ft)
1. Check valve
NOTE:
Refer to figure at right when connecting check valve between
vacuum hoses.
1 Check valve 2 Green side
3 White side 4 To vacuum chamber
5 From intake manifold assembly
• Install fuel injectors and fuel delivery pipe. (See page 5-15.)
6
POWER UNIT 6-7
• Install fuel vapor separator. (See page 5-8.)
• Check to ensure that all removed parts are back in place.
FINAL ASSEMBLY CHECK

• Check fuel and water hose routing. (See page 11-11 to
11-17.)
• Check wire routing. (See page 11-4 to 11-10.)
• Check for fuel leakage.
• Check for water leakage.
7
6-8 POWER UNIT
DISASSEMBLY
Remove bolts and high pressure fuel filter 1.
Remove bolts and fuel cooler 2.
Remove screws and MAP sensor 3.

Remove screws and IAC valve 4.
Remove flame arrester 5.

Remove bolts and throttle body assembly 6.
Remove screws and depression chamber 7.
8
POWER UNIT 6-9
Remove the seventeen (17) screws and intake

manifold cover 8.
REASSEMBLY
Reassemble in reverse order of disassembly paying special
attention to the following steps.
!
Do not reuse gasket, always replace with new one.
• Install new cover gasket 1 to intake manifold cover.
• Install intake manifold cover 2 to intake manifold, then

tighten manifold cover screws securely.
• Install spacer 3 to intake manifold.
9
6-10 POWER UNIT
• Install the lever 4 onto the pivot shaft 5, use care to align
hole in lever with pivot shaft end.
• Install depression chamber 6, then tighten screws securely.
• Install seal ring 7 and throttle body 8.

Securely tighten the four (4) throttle body bolts to specified
torque.
" Throttle body bolt: 23 N·m (2.3 kg-m, 16.6 lb-ft)

• All parts removed have been returned to their original posi-
tions.
10
POWER UNIT 6-11
CYLINDER HEAD COVER

REMOVAL
Before removing cylinder head cover:
• Remove both side covers. (See page 7-2.)
1. To remove the cover 1, pull the upper part outward, then lift
up.
2. Remove the ring gear cover and air intake silencer case.
(See page 6-2.)
3. Disconnect ignition coil connectors 2.
Remove the bolts securing the ignition coils.
Remove all ignition coils 3 and spark plugs.
4. Disconnect inlet hose 4 and outlet hose 5 from low pres-

sure fuel pump.
Remove bolts and low pressure fuel pump 6.
(See page 5-17.)
5. Remove the two bolts securing filter bracket 7, then remove

low pressure fuel filter 8 and filter bracket.
11
6-12 POWER UNIT
6. On DF175 model;
disconnect IN. CMP sensor lead wire connector 9 at sen-
sor.
Remove bolt and IN. CMP sensor 0.
7. Disconnect EX. CMP sensor lead wire connector A at sen-
sor.
Remove bolt and EX. CMP sensor B.
8. Remove the bolt securing lead wire clamp plate C.
9. Remove the two bolts securing lead wire clamp plate D.
10. On DF175 model, disconnect OCV lead wire connector E at

OCV.
Remove the four (4) bolts securing OCV F, then remove
OCV and discard OCV gasket.
NOTE:
DF150 model is not equipped with OCV.
11. Remove the fourteen (14) bolts securing cylinder head cover 13 14
G to the cylinder head, then remove the cylinder head 3
cover. 7 10
1
5 6
2
9 8
4 12
11
12
POWER UNIT 6-13
INSTALLATION
• Clean sealing surface on cylinder head and cover.
• Remove oil, old sealant, and dust from sealing surfaces.
• After cleaning, apply sealant to cylinder head sealing surface
area as shown in figure.
# 99000-31140: SUZUKI BOND “1207B”
• Install new cylinder head cover gasket 1 to head cover.

NOTE:
Examine cylinder head cover gasket for damage.
Always replace gasket with new one.
• Install cylinder head cover 2 to cylinder head, then tighten

cylinder head cover bolts to specified torque.
" Cylinder head cover bolt: 11 N·m (1.1 kg-m, 8.0 lb-ft)
13 14
3
7 10
1
5 6
2
9 8
4 12
11
13
6-14 POWER UNIT
• On the DF175 model, install new gasket 3 and OCV 4, then

tighten bolts securely.
NOTE:
Position the OCV gasket tab as shown at right.
!
Do not reuse the OCV gasket, always replace with new
one.
" OCV bolt: 12 N·m (1.2 kg-m, 8.7 lb-ft)

tions.
• Wire and hose routing match’s service manual illustration.
• No oil leakage is evident during final test running.
14
POWER UNIT 6-15
POWER UNIT
REMOVAL
Before removing power unit;
• Relieve fuel pressure. (See page 5-3.)
• Drain engine oil.
Remove the fuel vapor separator 1. (See page 5-7.)
Remove the fuel injectors and intake manifold assembly 2.

(See page 6-3 to 6-5.)
Disconnect ignition coil connectors 3.

Remove bolts securing the ignition coils 4.
Remove all ignition coils 4 and spark plugs.
Remove the cylinder head cover 5. (See page 6-11 to 6-12.)
15
6-16 POWER UNIT
Remove the electric parts holder 6. (See page 4-30.)
Remove starter motor 7. (See page 4-17.)
Remove flywheel 8. (See page 3-66.)

$ 09916-99311: Flywheel holder
Remove battery charge coil 9. (See page 4-9.)
Disconnect charge output lead wire connector from Rectifier &

regulator.
Remove six bolts and Rectifier & regulator 0.
Remove the bolt securing lead wire clamp plate A.
16
POWER UNIT 6-17
Disconnect EX. manifold temperature sensor lead wire connec-

tor.
Remove EX. manifold temperature sensor B.
Disconnect cylinder temperature sensor lead wire connector.

Remove cylinder temperature sensor C.
Remove screws and CKP sensor D.

Disconnect CKP sensor lead wire connector.
Loosen screw and disconnect blue lead wire E from oil pres-
sure switch F.
Remove the two bolts securing lower ring gear cover G, then
remove ring gear cover with wiring harness.
17
6-18 POWER UNIT
Remove the bolt securing GND lead wire terminals.
Remove the screws securing hose and harness holder 1.

Disconnect water inlet hose 2 from balancer water jacket cover
3.
Disconnect shift position sensor lead wire connector 4.

Disconnect neutral switch lead wire connector 5.
Remove three (3) bolts, thermostat cover 6 and thermostat 7.
Disconnect pilot water hose 8 from cylinder block.

Disconnect water inlet hose 9 from cylinder block.
18
POWER UNIT 6-19
Remove oil level dipstick 0.

Remove bolt and oil dipstick tube A.
Remove water flush hose B from cylinder block.
[From engine upper side]

• Remove five (5) bolts 1.
19
6-20 POWER UNIT
[From engine under side]

• Remove sixteen (16) bolts 2.
Lift up and remove power unit from engine holder.
20
POWER UNIT 6-21
INSTALLATION
the following step.
!
Do not reuse gaskets, O-rings and seals.
Always replace with new parts.
POWER UNIT
• Install dowel pins 1, gasket 2.
Apply Water Resistant Grease to driveshaft splines.
% 99000-25160: SUZUKI WATER RESISTANT GREASE
• Install O-ring 3 to mount oil seal cover, then apply Water

Resistant Grease on O-ring.
• Install the engine holder seal 4.
NOTE:
Install seal 4 with lip facing upward.
NOTE:
Before installing power unit, apply sealant to the six hatched
areas shown in the illustration at right.
# 99000-31140: SUZUKI BOND “1207B”
• Lower the power unit onto engine holder.
NOTE:
Rotate crankshaft to aid alignment of driveshaft and counter
shaft splines.
21
6-22 POWER UNIT
• Apply Suzuki Silicone seal to power unit mounting bolts and

tighten bolts to specified torque.
& 99000-31120: SUZUKI SILICONE SEAL
" Power unit mounting bolt:
8 mm 23 N·m (2.3 kg-m, 16.5 lb-ft)
10 mm 50 N·m (5.0 kg-m, 36.0 lb-ft)
22
POWER UNIT 6-23
THERMOSTAT
• Assemble thermostat 1 and thermostat cover 2 to cylinder
block and secure with bolts.
• Connect water return hose 3, then secure the hose to ther-

mostat cover with hose clamp.
FLYWHEEL
• Install lower ring gear cover 1, then tighten bolts securely.
• Install CKP sensor 2. (See page 3-68.)
• Install battery charge coil 3. (See page 4-10.)
• Install flywheel and tighten flywheel bolts to specified torque.

(See page 3-67.)
" Flywheel bolt: 118 N·m (11.8 kg-m, 85.3 lb-ft)
23
6-24 POWER UNIT
CYLINDER HEAD COVER

• Install cylinder head cover. (See page 6-13.)
INTAKE MANIFOLD
• Install gaskets and intake manifold, then tighten bolts and
nuts to specified torque.
For intake manifold assembly installation, see page 6-5.
" Intake manifold bolt/nut: 23 N·m (2.3 kg-m, 16.5 lb-ft)
FUEL INJECTORS
• Install fuel injectors and fuel delivery pipe. (See page 5-15.)
VAPOR SEPARATOR
• Install vapor separator. (See page 5-8.)
24
POWER UNIT 6-25

Perform the following checks to ensure proper and safe opera-
tion of the repaired unit.
tions.
• Fuel and water hose routing match’s service manual illustra-
tion. (See page 11-11 to 11-17.)
• Wire routing match’s service manual illustration.
(See page 11-4 to 11-10.)
• No fuel leakage is evident when fuel system is pressurized.
(See page 5-4.)
• No water leakage is evident during final test running.
25
6-26 POWER UNIT
OIL PUMP
REMOVAL
1. Remove the power unit. (See page 6-15 to 6-20.)
2. Remove the four (4) bolts securing oil pump 1, then remove
the oil pump.
Account for shim washer 2.
3. Remove the oil pump driven gear 3.

NOTE:
For oil pump drive gear removal, see page 6-31.
26
POWER UNIT 6-27
DISASSEMBLY
1. Remove the two (2) screws 1 securing oil pump rotor plate
2 to the oil pump case, then remove the oil pump rotor
plate.
2. Take out inner rotor 3 and outer rotor 4.
3. Remove the pin 5 and inner rotor 3.
27
6-28 POWER UNIT
INSPECTION
OIL PUMP ASSEMBLY
Check outer and inner rotors, rotor plate and oil pump case for
excessive wear or damage.
Replace as necessary.
NOTE:
If any repair is required on outer rotor, inner rotor and oil pump
case/plate, replace them as an assembly.
DRIVEN SPROCKET
Check teeth of sprocket for wear or damage.
Replace as necessary.
MEASURING PUMP COMPONENTS

RADIAL CLEARANCE
Using a feeler gauge, measure radial clearance between outer
rotor and case.
Radial clearance:
Service limit: 0.31 mm (0.0122 in)
If measurement is not within specifications, replace the outer
rotor and/or case.
SIDE CLEARANCE
Using straightedge and feeler gauge, measure side clearance.
Side clearance:
If measurement is not within specifications, replace the outer
rotor and/or pump case.
28
POWER UNIT 6-29
ASSEMBLY
1. Wash, clean and then dry all disassembled parts.
2. Apply thin coat of engine oil to inner and outer rotors, inside
surfaces of oil pump case and plate.
3. Assemble pin 1 and inner rotor 2 to oil pump shaft.
4. Install outer 3 and inner rotor 2 to pump case.

NOTE:
When installing outer and inner rotors, the punch mark on each
rotor must face rotor plate.
Punch mark
5. Install dowel pins 4 and rotor plate 5, and then tighten

screws 6 securely.
After mounting the rotor plate, make sure that each rotor
turns smoothly by hand.
6. Pour approx. 50 ml (1.7 oz.) of engine oil into pump case for
initial lubrication.
29
6-30 POWER UNIT
INSTALLATION
following steps.
• Install oil pump driven gear 1.
• Install washer 2 and oil pump assembly 3, then tighten four

(4) bolts securely.
" Oil pump bolt: 23 N·m (2.3 kg-m, 16.5 lb-ft)
• Pour approx. 50 ml (1.7 oz.) of engine oil into pump case for
initial lubrication.
30
POWER UNIT 6-31
TIMING CHAIN/BALANCER CHAIN (VVT model)

REMOVAL
Prior to this service work:
• Remove the power unit. (See page 6-15 to 6-20.)
1. Crankshaft/Drive gear/Balancer drive gear

2. Driven gear/Timing sprocket
3. Driven gear holder
4. Chain tensioner adjuster
5. Timing chain tensioner
6. Timing chain guide
7. Timing chain
8. IN. camshaft timing sprocket 7
9. EX. camshaft timing sprocket
10. Balancer driven sprocket
11. Balancer chain tensioner 8
12. Balancer chain guide 9
13. Balancer chain
6 4
13
11
12 10
31
6-32 POWER UNIT
1. Remove the oil pump. (See page 6-26.)

2. Loosen the bolts securing IN./EX. camshaft timing sprockets
to each cam shaft.
1
1
NOTE:
• Sprocket bolt is LH thread.
• Hold camshaft by placing a wrench on the hexagon area of the
camshaft.
1. Sprocket bolt
3. Remove the four (4) bolts 1 securing driven gear holder 2,

then remove the driven gear holder.
4. Remove bolts 3 and balancer chain guide 4.
5. Remove bolt 5, balancer chain tensioner 6 and spring 7.
32
POWER UNIT 6-33
6. Loosen and remove the bolt 8 securing balancer drive

sprocket 9 to crankshaft.
NOTE:
To hold the crankshaft, use special tool and flywheel as shown
in figure.
7. Remove the balancer drive sprocket 9 and balancer chain

0.
8. Turn the crankshaft in its normal running direction (R_LH

direction) until the match mark (•) on the crankshaft drive
gear points to 12 o’clock (toward cylinder head).
!
When timing chain has been removed, never turn
crankshaft or camshaft.
= Match mark ( ) on crankshaft drive gear

4 Engine normal running direction
9. Remove bolts A and timing chain guide B.
33
6-34 POWER UNIT
10. Remove bolts C and chain tensioner adjuster D.
11. Remove bolt E and timing chain tensioner F.
12. Remove bolt G, EX. camshaft timing sprocket H and timing

chain I.
Remove oil pump drive gear J.
13. Remove bolt K and IN. camshaft timing sprocket L.
14. Remove driven gear M.
34
POWER UNIT 6-35
15. Remove drive gear N.
INSPECTION
NOTE:
If any component is worn excessively, cracked, defective or
damaged in any way, it must be replaced.
TIMING CHAIN
• Inspect timing chain.
Replace if worn excessively or damaged.
BALANCER CHAIN
• Inspect balancer chain.
TENSIONER ADJUSTER
• Inspect tensioner adjuster for smooth operation.
Replace if faulty.
Check oil delivery passage to tensioner.
1. Latch
2. Tooth surface
3. Oil passage
TIMING CHAIN TENSIONER/CHAIN GUIDE

• Check chain guide shoe for wear or damage.
If excessive wear or other damage is found, replace it.
35
6-36 POWER UNIT
CAMSHAFT TIMING SPROCKET

• Check teeth of sprocket for wear or damage. VVT actuator
!
The VVT actuator is non-repairable.
Do not attempt to remove bolts or disassemble the
VVT actuator.
If excessive wear or other damage is found, replace it. Bolt
DRIVEN GEAR HOLDER

• Check driven gear holder.
If cracks or other damage is found, replace holder.
• Check driven gear bearing.
Replace bearing if pitted, noisy, or rough condition.
• Check oil seal.
If excessive wear or other damage is found, replace oil seal.
NOTE:
Install oil seal lip (spring side) facing as shown in figure.
DRIVE GEAR/DRIVEN GEAR/BEARING

• Inspect drive and driven gears.
Replace gear if damaged or worn excessively.
BALANCER SPROCKET
• Check teeth of sprocket for wear or damage.
POWER UNIT 6-37
BALANCER CHAIN TENSIONER/CHAIN GUIDE

• Check tensioner for wear or damage.
• Check chain guide for wear or damage.
OIL PUMP DRIVE GEAR

• Inspect drive gear.
Replace gear if damaged or worn.
INSTALLATION
Installation is reverse of removal with special attention to follow-
ing steps.
1. Install the drive gear 1 on crankshaft so that dowel pin hole
a aligns with match mark (•) b on the drive gear as shown
in illustration.
2. Check that match mark (•) c on the crankshaft drive gear

points to 12 o’clock (towards cylinder head).
3. Install the driven gear 2 on the cylinder block so that match

mark (•) c aligns with match mark (•) d on the driven gear
as shown in illustration.
6-38 POWER UNIT
4. Fit the dowel pin 3 onto IN. camshaft. Fit IN. camshaft tim-
ing sprocket 4 and temporarily tighten the sprocket bolt.
Check that match marks (•) e·f are correctly aligned as
shown in illustration.
(•)
5. Fit the dowel pin 5 onto the EX. camshaft.

6. Install oil pump drive gear 6.
7. Align the yellow plate of timing chain 7 with the match mark
(•) d on the driven gear and fit the chain onto the driven
gear.
1
1. Yellow plate
8. As shown in the illustration, fit the timing chain with one blue
plate aligned with the match mark ( ) (•) e onto the IN. 2
camshaft timing sprocket.
2. Blue plate
POWER UNIT 6-39
9. While aligning the one blue plate of timing chain with the 3
match mark (•) g on the EX. camshaft timing sprocket 8, fit
the chain onto the sprocket.
3. Blue plate
10. Install the EX. camshaft timing sprocket 8 on the EX. cam-
shaft, then temporarily tighten the sprocket bolt.
11. Insert the spacer 9 into the chain tensioner 0.

Install chain tensioner, then tighten bolt A securely.
Apply engine oil to chain tensioner.
12. With latch of tensioner adjuster B pushed in and plunger

1 2
pushed back into body, insert stopper into latch and body. 4
2 3
After inserting stopper, check to make sure that plunger will
not come out.
1. Plunger 3. Body
2. Latch 4. Stopper
13. Install timing chain tensioner adjuster B, then tighten bolts

C to specified torque.
" Tensioner adjuster bolt: 11 N·m (1.1 kg-m, 8.0 lb-ft)
Stopper
Apply engine oil to timing chain.
14. Remove the stopper from tensioner adjuster.

6-40 POWER UNIT
15. Install timing chain guide D, then tighten bolts securely.

Apply engine oil to chain guide.
16. Turn the crankshaft two (2) complete rotations in direction

shown in figure.
As shown in the illustration, check that all match marks are
in alignment as started below when the match mark (•) c on
the drive gear is pointing to 12 o’clock.
• The match mark ( ) (•) e on the IN. sprocket aligns with
the match mark f on the camshaft housing.
• The match mark (engraved line) h on the EX. sprocket
aligns with the mating face i between cylinder head and
lower camshaft housing.
18. Check that match mark (•) j on the balancer driven

sprocket points to 6 o’clock as shown in the illustration.
POWER UNIT 6-41
19. Fit the dowel pin E on the crankshaft.
20. Align the yellow plate of balancer chain F with the match
mark (•) j on the balancer driven sprocket and fit the chain
on the sprocket.
Yellow plate
21. Align the yellow plate of balancer chain with the match mark Yellow plate
(•) k on the balancer drive sprocket G and fit the chain on
the sprocket.
22. Install the balancer drive sprocket G on the crankshaft, then Yellow plate
temporarily tighten the sprocket bolt and washer.
Check that match marks j and k are correctly aligned as
Yellow plate
23. Install balancer chain guide H, then tighten bolts I

securely.
6-42 POWER UNIT
24. Assemble tensioner spring J and balancer chain tensioner

K.
Install chain tensioner K, then tighten bolt L securely.
25. Tighten crankshaft drive gear bolt M to specified torque.

" Crankshaft drive gear bolt: 48 N·m (4.8 kg-m, 34.7 lb-ft)
NOTE:
in figure.
26. Tighten IN. camshaft timing sprocket bolt to specified torque.

" IN. camshaft timing sprocket bolt:
60 N·m (6.0 kg-m, 43.4 lb-ft)
!
Do not over tighten to avoid damaging VVT actuator.
POWER UNIT 6-43
27. Tighten EX. camshaft timing sprocket bolt to specified

torque.
" EX. camshaft timing sprocket bolt:
78 N·m (7.8 kg-m, 56 lb-ft)
28. Install driven gear holder N, then tighten four (4) bolts
securely.
6-44 POWER UNIT
TIMING CHAIN/BALANCER CHAIN (Non-VVT model)

REMOVAL
Prior to this service work:
1. Crankshaft/Drive gear/Balancer drive gear

2. Driven gear/Timing sprocket
3. Driven gear holder
4. Chain tensioner adjuster
5. Timing chain tensioner
6. Timing chain guide
7. Timing chain
8. IN. camshaft timing sprocket 7
9. EX. camshaft timing sprocket
10. Balancer driven sprocket
8
11. Balancer chain tensioner
12. Balancer chain guide 9
13. Balancer chain
6 4
13
11
12 10
POWER UNIT 6-45
1. Remove the oil pump. (See page 6-26.)

2. Loosen the bolts securing IN./EX. camshaft timing sprockets
to each cam shaft.
1 1
NOTE:
• Sprocket bolt is LH thread.
• Hold camshaft by placing a wrench on the hexagon area of the
camshaft.
1. Sprocket bolt
3. Remove the four (4) bolts 1 securing driven gear holder 2,

then remove the driven gear holder.
4. Remove bolts 3 and balancer chain guide 4.
5. Remove bolt 5, balancer chain tensioner 6 and spring 7.

6-46 POWER UNIT
6. Loosen and remove the bolt 8 securing balancer drive

sprocket 9 to crankshaft.
NOTE:
in figure.
7. Remove the balancer drive sprocket 9 and balancer chain

0.
8. Turn the crankshaft in its normal running direction (R_LH

direction) until the match mark (•) on the crankshaft drive
gear points to 12 o’clock (toward cylinder head).
!
When timing chain has been removed, never turn
crankshaft or camshaft.
= Match mark ( ) on crankshaft drive gear

4 Engine normal running direction
9. Remove bolts A and timing chain guide B.
POWER UNIT 6-47
10. Remove bolts C and chain tensioner adjuster D.
11. Remove bolt E and timing chain tensioner F.
12. Remove bolt G, EX. camshaft timing sprocket H and timing

chain I.
Remove oil pump drive gear J.
13. Remove bolt K and IN. camshaft timing sprocket L.
14. Remove driven gear M.

6-48 POWER UNIT
15. Remove drive gear N.
INSPECTION
NOTE:
TIMING CHAIN
• Inspect timing chain.
BALANCER CHAIN
• Inspect balancer chain.
TENSIONER ADJUSTER
• Inspect tensioner adjuster for smooth operation.
Replace if faulty.
Check oil delivery passage to tensioner.
1. Latch
2. Tooth surface
3. Oil passage
TIMING CHAIN TENSIONER/CHAIN GUIDE

• Check chain guide shoe for wear or damage.
POWER UNIT 6-49
CAMSHAFT TIMING SPROCKET

DRIVEN GEAR HOLDER

• Check driven gear holder.
If cracks or other damage is found, replace holder.
• Check oil seal.
If excessive wear or other damage is found, replace oil seal.
NOTE:
Install oil seal lip (spring side) facing as shown in figure.
DRIVE GEAR/DRIVEN GEAR/BEARING

• Inspect drive and driven gears.
Replace gear if damaged or worn excessively.
BALANCER SPROCKET
6-50 POWER UNIT
BALANCER CHAIN TENSIONER/CHAIN GUIDE

• Check tensioner for wear or damage.
• Check chain guide for wear or damage.
OIL PUMP DRIVE GEAR

• Inspect drive gear.
Replace gear if damaged or worn.
INSTALLATION
Installation is reverse of removal with special attention to follow-
ing steps.
1. Install the drive gear 1 on crankshaft so that dowel pin hole
a aligns with match mark (•) b on the drive gear as shown
in illustration.

3. Install the driven gear 2 on the cylinder block so that match

mark (•) c aligns with match mark (•) d on the driven gear
as shown in illustration.
POWER UNIT 6-51
4. Fit the dowel pin 3 onto IN. camshaft. Fit IN. camshaft tim-
ing sprocket 4 and temporarily tighten the sprocket bolt.
Check that match marks (•) e·f are correctly aligned as
5. Fit the dowel pin 5 onto the EX. camshaft.

6. Install oil pump drive gear 6.
7. Align the yellow plate of timing chain 7 with the match mark
(•) d on the driven gear and fit the chain onto the driven
gear.
1
1. Yellow plate
8. As shown in the illustration, fit the timing chain with one blue 2
plate aligned with the match mark (•) e onto the IN. cam-
shaft timing sprocket.
2. Blue plate
6-52 POWER UNIT
9. While aligning the one blue plate of timing chain with the
3
match mark (•) g on the EX. camshaft timing sprocket 8, fit
the chain onto the sprocket.
3. Blue plate
10. Install the EX. camshaft timing sprocket 8 on the EX. cam-
shaft, then temporarily tighten the sprocket bolt.
11. Insert the spacer 9 into the chain tensioner 0.

Install chain tensioner, then tighten bolt A securely.
Apply engine oil to chain tensioner.
12. With latch of tensioner adjuster B pushed in and plunger

1 2
pushed back into body, insert stopper into latch and body. 4
2 3
After inserting stopper, check to make sure that plunger will
not come out.
1. Plunger 3. Body
2. Latch 4. Stopper
13. Install timing chain tensioner adjuster B, then tighten bolts

C to specified torque.
" Tensioner adjuster bolt: 11 N·m (1.1 kg-m, 8.0 lb-ft)
Stopper
Apply engine oil to timing chain.
14. Remove the stopper from tensioner adjuster.

POWER UNIT 6-53
15. Install timing chain guide D, then tighten bolts securely.

Apply engine oil to chain guide.
16. Turn the crankshaft two (2) complete rotations in direction

shown in figure.
As shown in the illustration, check that all match marks are
in alignment as stated below when the match mark (•) c on
the drive gear is pointing to 12 o’clock.
• The match mark (•) e on the IN. sprocket aligns with the
match mark f on the camshaft housing.
• The match mark (engraved line) h on the EX. sprocket
aligns with the mating face i between cylinder head and
lower camshaft housing.
18. Check that match mark (•) j on the balancer driven

sprocket points to 6 o’clock as shown in the illustration.
6-54 POWER UNIT
19. Fit the dowel pin E on the crankshaft.
20. Align the yellow plate of balancer chain F with the match
mark (•) j on the balancer driven sprocket and fit the chain
on the sprocket.
Yellow plate
21. Align the yellow plate of balancer chain with the match mark Yellow plate
(•) k on the balancer drive sprocket G and fit the chain on
the sprocket.
22. Install the balancer drive sprocket G on the crankshaft, then Yellow plate
temporarily tighten the sprocket bolt and washer.
Check that match marks j and k are correctly aligned as
Yellow plate
23. Install balancer chain guide H, then tighten bolts I

securely.
POWER UNIT 6-55
24. Assemble tensioner spring J and balancer chain tensioner

K.
Install chain tensioner K, then tighten bolt L securely.
25. Tighten crankshaft drive gear bolt M to specified torque.

" Crankshaft drive gear bolt: 48 N·m (4.8 kg-m, 34.7 lb-ft)
NOTE:
in figure.
26. Tighten IN. and EX. camshaft timing sprocket bolt to speci-
fied torque.
" IN. and EX. camshaft timing sprocket bolt:
78 N·m (7.8 kg-m, 56 lb-ft)
6-56 POWER UNIT
27. Install driven gear holder N, then tighten four (4) bolts
securely.
POWER UNIT 6-57
CYLINDER HEAD ASSEMBLY

(Cylinder head/valve/camshaft)
REMOVAL
Prior to removing cylinder head:
• Remove the timing chain. (See page 6-31 or 6-44.)
1. On the DF150 model, remove the four (4) bolts and plate 1.
2. Remove two (2) plugs 2.
3. Remove the bolts securing the camshaft housing 3 to cylin-

der head, then remove each camshaft housing.
NOTE:
For ease of assembly, note position of each individual camshaft
housing.
6-58 POWER UNIT
4. Remove intake/exhaust camshafts, tappets and tappet

shims.
NOTE:
All tappets and tappet shims must be installed in their original
positions.
For ease of assembly, lay out tappets and record shim thickness
for each individual cylinder/valve position.
5. Loosen and remove twenty (20) cylinder head bolts in the 4 5 8 10 9 7

order indicated in figure.
6
Remove cylinder head assembly and head gasket.
13 17 19 15 11
3
2 14 16 20 18 12
NOTE:
Do not forget to remove all bolts in shown figure.
3
2
ASSEMBLY
1
Assemble in reverse order of removal paying special attention to 1
!
Do not reuse gasket. Always use a new gasket.
2
1. Insert the dowel pins and place a new cylinder head gasket
1. Dowel pin
into position on the cylinder. 2. Cylinder head gasket
NOTE:
Before installing cylinder head gasket, apply sealant to both sur-
faces of the hatched areas shown in illustration.
# 99000-31140: SUZUKI BOND “1207B”
POWER UNIT 6-59
2. Position cylinder head on cylinder.

3. Apply engine oil to cylinder head bolts and tighten them
gradually as follows.
NOTE:
Do not forget to install all bolt shown in figure.
(a) Tighten all bolts to 50 percent (%) of specified torque 17 16 13 11 12 14

according to sequence in figure.
15
" Cylinder head bolt:
1st step 12 mm 43 N·m (4.3 kg-m, 31.1 lb-ft) 8 4 6 10
2
8 mm 12 N·m (1.2 kg-m, 8.7 lb-ft) 18
(b) Loosen all bolts to 0 N·m (0 kg-m, 0 lb-ft) according to

19 7 5 1 3 9
reverse sequence in figure.
(c) Again tighten all bolts to 50 percent (%) of specified
20
torque according to sequence in figure.
3rd step 12 mm 43 N·m (4.3 kg-m, 31.1 lb-ft)
8 mm 12 N·m (1.2 kg-m, 8.7 lb-ft)
(d) Finally tighten all bolts to specified torque according to

sequence in figure.
Final step 12 mm 86 N·m (8.6 kg-m, 62.2 lb-ft)
8 mm 23 N·m (2.3 kg-m, 16.6 lb-ft)
4. Apply engine oil around tappets and install in their original

position.
Install tappet shims in their original position.
6-60 POWER UNIT
NOTE:
Before installing camshafts, turn crankshaft until the match mark
(•) on the crankshaft drive gear points to 12 o’clock (toward cyl- 1
inder head). 1
2
1. Match mark ( ) on drive gear

2. Dowel pin
5. Apply engine oil to the surface of each camshaft lobe and

journal, then install them as shown in figure.
NOTE:
2
When installing the camshaft, align dowel pin on the IN. cam-
3
shaft with match mark on lower camshaft housing and engraved
line on EX. sprocket align with lower camshaft housing mating 1
face.
1. Dowel pin on camshaft
2. Match mark on lower camshaft housing
3. Engraved line on EX. sprocket
6. Install camshaft housing pins as shown in figure.
Pin
7. Apply sealant to lower camshaft housing sealing surface Apply Bond

area as shown in figure. marked
line.
# 99000-31140: SUZUKI BOND “1207B”
POWER UNIT 6-61
8. Install the lower camshaft housing. 1
1. Lower camshaft housing
9. Check position of camshaft housing.

• Embossed marks are provided on each camshaft housing I : Intake side
E : Exhaust side
indicating position and direction of installation.
Position from flywheel
Install housings as indicated by these marks. magneto side
Pointing to flywheel
magneto side
10. Apply engine oil to housing bolts. 21

11. Lightly seat all housing bolts at first.
Following sequence in figure, tighten bolts to 1/3 of specified
19 10 2 6 14
torque, then 2/3 of specified torque and finally to full speci- 17 9 1 5 13
fied torque.
18 11 3 7 15
" Camshaft housing bolt: 12 N·m (1.2 kg-m, 8.7 lb-ft) 20 12 4 8 16
22
12. Install plugs 1 in lower camshaft housing.

13. On the DF150 model, install gasket and plate 2, tighten
bolts securely.
14. Install timing chain and balancer chain.

(See page 6-37 or 6-50.)
15. Install oil pump assembly. (See page 6-30.)
16. Check tappet clearance and adjust as necessary.
(See page 2-9.)
6-62 POWER UNIT
DISASSEMBLY
1. Remove tappets with shims.
NOTE:
All tappets and tappet shims must be installed in their original
positions.
For ease of assembly, lay out tappets and record shim thickness
for each individual cylinder/valve position.
2. Using valve lifter and attachment, remove valve cotters 1

while compressing valve spring.
$ 09916-19030: Valve lifter
09916-14521: Attachment
09916-84511: Tweezers
3. Remove valve spring retainer 2, valve spring 3 and valve

4.
4. Remove valve stem seal 5 and valve spring seat 6.

NOTE:
Reassemble each valve and valve spring in their original posi-
tions.
POWER UNIT 6-63
INSPECTION/SERVICING
NOTE:
If cracks, excessive wear or other damage is found on any com-
ponent, replace component.
CYLINDER HEAD
Remove all carbon from combustion chambers.
NOTE:
• Do not use any sharp edged tool to scrape carbon off cylinder
head or its components.
• Be careful not to scuff or nick metal surfaces when decarbon-
izing.
Check cylinder head for cracks in intake and exhaust ports,

combustion chambers, and head surface.
Valve seat
Check valve seat, if cracks or other damage is found, replace
cylinder head.
Cylinder head distortion

Using a straightedge and thickness gauge, measure cylinder
head distortion (gasket surface) at a total of six (6) locations as
shown.
$ 09900-20803: Thickness gauge
Cylinder head distortion
If measurement exceeds service limit, resurface or replace cylin-

der head.
6-64 POWER UNIT
Manifold seating faces distortion

Using a straightedge and thickness gauge, check cylinder head
to manifold seating faces.
Manifold seating faces distortion
der head.
Water jackets
Check water jackets. If clogged or obstructed, clean water jack-
ets.
CAMSHAFT
Cam face
Inspect cam face for scratches and wear.
Cam wear
Using micrometer, measure cam height H.
$ 09900-20202: Micrometer
Cam height
Standard:
DF175 IN. 44.420 – 44.580 mm (1.7488 – 1.7551 in)
EX. 44.420 – 44.580 mm (1.7488 – 1.7551 in)
DF150 IN. 42.520 – 42.680 mm (1.6740 – 1.6803 in)
EX. 42.420 – 42.580 mm (1.6701 – 1.6764 in)
Service limit
DF175 IN. 44.320 mm (1.7449 in)
EX. 44.320 mm (1.7449 in)
DF150 IN. 42.420 mm (1.6701 in)
EX. 42.320 mm (1.6661 in)
If measurement exceeds service limit, replace camshaft.
POWER UNIT 6-65
Camshaft identification IN. EX.

DF150 and DF175 camshafts differ as indicated below.
Identification mark
Model
IN. EX.
DF150 0 A
DF175 1 B
I.D. mark I.D. mark
Camshaft runout
Support camshaft on a surface plate using a set of V-blocks.
Measure runout using a dial gauge.
$ 09900-20606: Dial gauge
: “V” block set
09900-20701: Magnetic stand
Camshaft runout
If measurement exceeds service limit, replace camshaft.
CAMSHAFT JOURNAL
Check camshaft journals and camshaft housing for pitting,
scratches, wear or damage.
If any of the above conditions are found, replace camshaft or
cylinder head with housing.
NOTE:
Camshaft housing and cylinder head must be replaced as a set.
Camshaft journal oil clearance

Check journal oil clearance using Plastigauge as follows.
1. Clean housing and camshaft journals.
2. Install camshaft to cylinder head.
3. Place Plastigauge across the full width of camshaft journal
(parallel to camshaft).
$ 09900-22302: Plastigauge
4. Install camshaft housing. Tighten housing bolts in 3 steps 21

(1/3 of specification, 2/3 of specification, full torque specifica-
tion) in the indicated order.
19 10 2 6 14
" Camshaft housing bolt: 12 N·m (1.2 kg-m, 8.7 lb-ft) 17 9 1 5 13
NOTE: 18 11 3 7 15
Do not rotate camshaft while Plastigauge is installed. 20 12 4 8 16
22
6-66 POWER UNIT
5. Remove camshaft housing.

6. Using scale on Plastigauge envelope, measure Plastigauge 1 2
at its widest point.
Camshaft journal oil clearance
Standard: 0.043 – 0.085 mm (0.0017 – 0.0033 in)
1. Plastigauge
2. Scale
If journal oil clearance exceeds the service limit, measure cam-

shaft journal (outside dia.) and camshaft housing (inner dia.).
Based on measurements, replace camshaft and/or cylinder
head with camshaft housing.
$ 09900-20202: Micrometer (25 – 50 mm)
Camshaft journal outside diameter
Standard: 25.936 – 25.957 mm (1.0211 – 1.0219 in)
Camshaft journal (housing) inside diameter

Standard: 26.000 – 26.021 mm (1.0236 – 1.0244 in)
TAPPET/TAPPET SHIM
Wear of tappet and shim
Check tappet and shim for pitting, scratches, or damage.
If any above conditions are found, replace component.
POWER UNIT 6-67
Measure cylinder head bore and tappet outside diameter to

determine cylinder head to tappet clearance.
If measurement exceeds service limit, replace tappet or cylinder
head.
Cylinder head bore to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.0026 in)
Tappet outer diameter
Standard: 33.959 – 33.975 mm (1.3370 – 1.3376 in)
Cylinder head bore
Standard: 34.000 – 34.025 mm (1.3386 – 1.3396 in)
VALVE/VALVE GUIDE
Valve guide to valve stem clearance
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check guide to stem clearance.
Be sure to take readings at more than one place along the
length of each stem and guide.
Valve stem outside diameter

Using micrometer, measure valve stem outside diameter.
Valve stem outside diameter
Standard:
IN. 5.465 – 5.480 mm (0.2152 – 0.2157 in)
EX. 5.440 – 5.455 mm (0.2142 – 0.2148 in)
Valve guide inside diameter

Using a small bore gauge, measure valve guide inside diameter.
Valve guide inside diameter
Standard:
IN. 5.500 – 5.512 mm (0.2165 – 0.2170 in)
EX. 5.500 – 5.512 mm (0.2165 – 0.2170 in)
6-68 POWER UNIT

Standard:
IN. 0.020 – 0.047 mm (0.0008 – 0.0019 in)
EX. 0.045 – 0.072 mm (0.0018 – 0.0028 in)
Service limit:
IN. 0.070 mm (0.0028 in)
EX. 0.090 mm (0.0035 in)
If measurement exceeds service limit, replace valve and/or
valve guide.
NOTE:
For valve guide replacement, see “VALVE GUIDE REPLACE-
MENT” section on page 6-71.
Valve stem deflection

If unable to measure valve guide inside diameter, check “Valve
stem deflection”.
$ 09900-20606: Dial gauge
Y
Measure valve stem deflection as follows: X
(1) Install valve into valve guide.
(2) Position valve head at approx. 5 mm away from valve seat.
(3) Move valve head in the direction “X – Y”, and measure
deflection.
Valve stem deflection
Service limit:
IN. 0.14 mm (0.0055 in)
EX. 0.18 mm (0.0071 in)
If measurement exceeds service limit, replace valve.
If measurement still exceeds service limit with new valve,
replace valve guide.
Valve stem end

Inspect valve stem end face for pitting and wear.
If pitting or wear is found, valve stem end may be resurfaced.
Use caution when resurfacing, do not grind away stem end
chamfer.
When chamfer has been worn away, replace valve.
POWER UNIT 6-69
Valve stem runout

Measure valve stem runout.
$ 09900-20606: Dial gauge
09900-21304: “V” block set
Valve stem runout
Valve head radial runout

Measure valve head radial runout.
$ 09900-20606: Dial gauge
09900-21304: “V” block set
Valve head radial runout
Valve head thickness

Measure thickness T of valve head.
$ 09900-20101: Vernier calipers
Valve head thickness
Standard:
IN. 1.1 mm (0.0433 in)
EX. 1.0 mm (0.0394 in)
Service limit: 45˚
IN. 0.7 mm (0.0276 in)
EX. 0.7 mm (0.0276 in)
Valve seat contact width

Measure valve seat contact width as follows:
(1) Remove all carbon from valve and seat.
(2) Coat valve seat evenly with Prussian blue (or equivalent).
(3) Install valve into valve guide.
(4) Put valve lapper on valve.
$ 09916-10911: Valve lapper
(5) Rotate valve while gently tapping valve contact area against
seat.
(6) Continuously pattern on valve seating face with Prussian
blue.
(7) Measure valve seat contact width A.
6-70 POWER UNIT

Valve seat contact width A
Standard:
IN. & EX. 1.1 – 1.3 mm (0.0433 – 0.0512 in)
If measurement exceeds specification, repair valve seat.
NOTE:
For valve seat repair, see “Valve seat servicing” section on page
6-70.
VALVE SEAT SERVICING

If valve seat contact width is out of specification, reface valve IN., EX.
seat as follows:
Valve seat angle
Intake side : 15°, 45°, 60° 60˚
Exhaust side : 15°, 45°, 60° 45˚
15˚
$ : Valve seat cutter (NEWAY128) 45°
: Valve seat cutter (NEWAY212) 15°
09916-22420: Valve seat cutter (NEWAY114) 60°
Solid pilot (NEWAY, N-150-5.5)
09916-24450: Solid pilot (NEWAY. N-100-5.52) • Too high (wide)
09916-54910: Handle (N-505)
NOTE:
Turn cutter clockwise, never counterclockwise.
(1) Remove all carbon from valve and valve seat.
(2) Using 45° angle cutter, reface valve seat.
(3) Check valve seat contact width A.
See the “Valve seat contact width” section on page 6-69.
(4) • If width A is too high (or wide), reface valve seat using • Too low (narrow)
15° angle cutter.
• If width A is too low (or narrow), reface valve seat using
60° angle cutter.
(5) Clean up any burrs using 45° angle cutter very lightly.
!
Cut seat areas minimally only.
Do not cut more than necessary.
POWER UNIT 6-71
(6) Lap valve on seat in two steps, first with coarse grit lapping
compound applied to face and the second with fine grit
compound.
(7) Recheck valve seat contact width A.
NOTE:
Clean and assemble cylinder head and valve components.
Fill intake and exhaust ports with solvent to check for leaks
between valve seat and valve.
If any leaks occur, inspect valve seat and face for burrs or other
things that could prevent valve from sealing.
VALVE GUIDE REPLACEMENT

!
Be careful not to damage cylinder head when replac-
ing valve guide.
(1) Using valve guide remover, drive valve guide out from com-
bustion chamber side towards valve spring side.
$ 09916-44310: Valve guide remover
NOTE:
Do not reuse valve guide once it has been removed.
Always use a new valve guide (oversize) when assembling.
(2) Ream valve guide hole with '10.5 mm reamer to true hole
and remove burrs.
$ 09916-37320: Valve guide reamer ('10.5 mm)
09916-34542: Reamer handle
NOTE:
Turn reamer clockwise, never counterclockwise.
6-72 POWER UNIT
(3) Install valve guide to cylinder head.

• Heat cylinder head to a temperature of 80 – 100 °C (176 –
212 °F).
Apply heat uniformly so that head will not be distorted.
• Use special tools to drive new valve guide into hole.
Drive in new valve guide until special tool (valve guide
installer attachment) contacts cylinder head.
• After installing, check valve guide protrusion H.
$ 09916-57330: Valve guide installer handle A
09916-56011: Valve guide installer attachment B
Valve guide protrusion H
Standard:
IN. & EX. 11.5 mm (0.4528 in)
(4) Ream valve guide bore with '5.5 mm reamer.
$ 09916-34550: Valve guide reamer ('5.5 mm)
09916-34542: Reamer handle
NOTE:
Clean and oil valve guide bore after reaming.
VALVE SPRING
Valve spring free length
Check spring strength by measuring free length.
Valve spring free length
Standard:
IN. & EX. 40.20 mm (1.5827 in)
Service limit:
IN. & EX. 38.60 mm (1.5200 in)
If lower than service limit, replace valve spring.
Valve spring preload

Measure valve spring preload.
Valve spring preload
Standard:
IN. & EX. 147 – 173 N (15.0 – 17.7 kg, 33.0 – 38.9 lbs)
for 31.1 mm (1.22 in)
Service limit:
IN. & EX. 136 N (13.9 kg, 30.6 lbs)
for 31.1 mm (1.22 in)
If lower than service limit, replace valve spring.
POWER UNIT 6-73
Valve spring squareness

Use a square and surface plate to check each spring for square-
ness (clearance between end of valve spring and square).
Valve spring squareness
Service limit:
IN. & EX. 2.0 mm (0.079 in)
If measurement exceeds service limit, replace valve spring.
REASSEMBLY
Reassemble in reverse order of disassembly paying special
attention to the following steps.
VALVE
Install valve spring seat 1 to cylinder head.
After applying engine oil to stem seal 2 and spindle of special

tool (Installer attachment), fit stem seal to spindle.
Then, pushing special tool by hand, install stem seal to valve
guide.
Check to be sure that seal is properly fixed to valve guide.
$ 09917-98221: Installer attachment A
09916-57330: Installer handle B
!
Do not reuse stem seal once removed.
Always install new seal.
Apply engine oil to stem seal, valve guide bore and valve stem.
Install valve 3 to valve guide.
NOTE:
Reassemble each valve and valve spring to their original posi-
tion.
6-74 POWER UNIT
Install valve spring 4, and valve retainer 5.

3 1. Large-pitch
NOTE: 2. Small-pitch
1 3. Valve spring
Set valve spring in place with narrow spiral area facing valve
retainer side
seat. 4. Valve spring
seat side
Hold valve spring compressed with special tool and install valve
cotters 6.
Make sure valve cotters are properly seated in groove A.

$ 09916-19030: Valve lifter
09916-14521: Attachment
09916-84511: Tweezers
POWER UNIT 6-75
COUNTER-BALANCER MECHANISM
REMOVAL
Prior to removing counter-balancer mechanism
assembly:
• Remove the balancer chain. (See page 6-31 or 6-44.)
1. Remove bolts and water jacket cover 1 (if necessary).
2. Remove the bolts securing balancer cover 2 to crankcase,

then remove balancer cover.
3. Remove the seven (7) bolts securing counter-balancer

mechanism assembly 3 to crankcase, then remove
counter-balancer mechanism assembly.
6-76 POWER UNIT
DISASSEMBLY
1. Remove the three (3) bolts and upper housing 1.
2. Remove the three (3) bolts and lower housing 2.
NOTE:
Before removing STBD balancer shaft 3 and/or PORT balancer
shaft 4, insert special tool (pin) through hole A on No.1 gear 5
and hole B on No.2 gear 6 as shown.
$ 09917-29610: Scissors gear alignment tool set
3. Remove STBD balancer shaft assembly 3.

Remove PORT balancer shaft assembly 4.
4. Remove circlip 7, washer 8 and No.2 gear 6.
5. Remove scissors spring plate 9 from No.1 gear 5.

POWER UNIT 6-77
6. Secure STBD balancer shaft in a vise, then remove bolt 0,

washer A and driven sprocket B.
Account for dowel pin C.
INSPECTION
NOTE:
BALANCER GEAR
Inspect gears. Replace gear if damaged, worn excessively or
other abnormal condition.
BEARING
Check bearings for pitting, scratches, wear or damage.
If any improper condition is found, replace both upper and lower
halves.
Always replace both bearing halves, never replace only one half
of a bearing set.
BALANCER SHAFT JOURNAL

Check balancer shaft journals for pitting, scratches, wear or
damage.
If any of the above condition are found, replace balancer shaft.
6-78 POWER UNIT
HOUSING
Check base housing, upper housing and lower housing.
If cracks or other damage are found, replace housings as a set.
NOTE:
Base housing, upper housing and lower housing must be
replaced as a set.
ASSEMBLY
Assembly is reverse order of disassembly with special attention
to the following steps.
1. Wash, clean and then dry all disassembled parts.
2. Put scissors spring plate 1 onto No.1 gear 2 as shown.
3. Install No.2 gear 3 on the PORT balancer shaft so that the

pin c on No.2 gear contacts with end of scissors spring
plate 1.
Check that both scissors spring plate ends contact to pins c
and d on each gear as shown.
4. Secure PORT balancer shaft in a vise.

Turn the No.2 gear 3 counterclockwise by using special tool
until hole A on No.1 gear 2 aligns with hole B on No. 2
gear 3.
POWER UNIT 6-79
5. Insert special tool (pin) through hole A on No.1 gear 2 and

hole B on No.2 gear 3 as shown.
6. Install washer 4 and circlip 5.
7. Secure STBD balancer shaft in a vise.

Install dowel pin 6, driven sprocket 7 and washer 8, then
tighten bolt 9 to specified torque.
" Balancer driven sprocket: 48 N·m (4.8 kg-m, 34.7 lb-ft)
8. Install bearings C in base housing 0, upper housing A and

lower housing B.
Apply molybdenum oil solution to each bearing.
( MOLYBDENUM OIL SOLUTION
Mix equal amounts of engine oil and SUZUKI MOLY PASTE
(p/no, 99000-25140) in a ratio of 1:1
NOTE:
• Align bearing tab a with notch in each housing.
• Assemble each bearing in its original position.
6-80 POWER UNIT
9. Apply molybdenum oil solution to balancer shaft journals.

10. Install dowel pins D.
11. Install PORT balancer shaft assembly E in base housing.

12. Install STBD balancer shaft F in base housing so that
match mark (•) on STBD balancer gear aligns with match
mark (•) on No.2 PORT balancer gear as shown in illustra-
tion.
1 1
1. Match mark
13. Install upper housing A to base housing 0 with arrow mark

on upper housing toward flywheel side.
Install lower housing B to base housing 0.
14. Apply engine oil to housing bolts.

15. Lightly seat all housing bolts at first. 5
Following sequence in figure, tighten bolts in 2-steps. 6
Tighten bolts to 1/2 of specified torque, then to full specified 1
torque. 2
" Balancer housing bolt: 30 N·m (3.0 kg-m, 21.7 lb-ft) 3
4
POWER UNIT 6-81
16. Remove the special tool (pin) from PORT balancer No.1
gear 2 and No.2 gear 3.
INSTALLATION
!
Do not reuse gaskets. Always replace with new one.
1. Insert the dowel pins 1 and place counter-balancer mecha-

nism assembly 2 into position on the crankcase.
2. Apply engine oil to balancer housing bolts. 2

5
3. Lightly seat all balancer housing bolts at first.
Following sequence in figure, tighten bolts in 3-steps. 7
Tighten bolts to 1/3 of specified torque, then 2/3 of specified
torque and finally to full specified torque. 4
" Balancer mechanism mounting bolt:

6 1
25 N·m (2.5 kg-m, 18.1 lb-ft) 3
6-82 POWER UNIT
CYLINDER/CRANKSHAFT/PISTON
DISASSEMBLY
Before performing service work in this section:
• Remove power unit. (See page 6-15 to 6-20.)
• Remove timing chain and balancer chain.
(See page 6-31 or 6-44.)
• Remove cylinder head. (See page 6-57.)
• Remove counter-balancer mechanism.
(See page 6-75.)
Remove oil filter 1.

$ 09915-47341: Oil filter wrench
Remove the three (3) bolts securing oil filter housing 2, then
remove oil filter housing 2.
Remove oil pressure switch 3.

POWER UNIT 6-83
Remove ten (10) bolts 1.

Remove ten (10) bolts 2.
Remove crankcase from cylinder block.
NOTE:
For proper assembly, mark cylinder number on all pistons, con-
rods, and conrod caps, using quick drying paint.
3
1
4
Remove all conrod cap bolts 1 and conrod caps 2.
Remove crankshaft 3.
Remove oil seal 4 from crankshaft.
Mark cylinder number on pistons using quick dry paint.

Push piston (with conrod) out through the top of cylinder bore.
1
NOTE:
3
• To prevent damage to piston rings, decarbon top of cylinder

bore wall before removing piston.
• Reassemble each conrod cap to its original position after
removing piston from bore.
6-84 POWER UNIT
Remove two compression rings (top and 2nd) and oil ring from
piston.
Mark cylinder number on conrod using quick dry paint.
Remove piston pin from piston and conrod using special tool Piston pin remover set
and arbor press as shown.
NOTE:
1
• The piston pin is press fit into conrod small end.
• Reassemble each piston, piston pin and conrod in their origi-
2 3
nal combination and position.
$ 09910-39610: Piston pin remover & installer set 1. Base
2. Collar
3. Driver handle
1. Base
2. Collar
3. Driver handle
POWER UNIT 6-85
INSPECTION/SERVICING
NOTE:
If cracks, excessive wear or other damage is found on any com-
ponent, replace component.
CYLINDER
• Cylinder distortion
Using a straightedge and thickness gauge, measure cylinder
distortion (gasket surface) at a total of six (6) locations as
shown.
Cylinder distortion

der.
• Water jackets
Check water jackets.
If clog or obstruction is found, clean water jacket.
• Driven gear bearing

Inspect driven gear bearing. Replace bearing if pitted, noisy
or rough.
6-86 POWER UNIT
• Cylinder bore
Inspect cylinder walls for scratches, roughness, or ridges
which indicate excessive wear.
If cylinder bore is very rough, deeply scratched or ridged, bore
cylinder and use oversize piston.
• Cylinder bore wear (difference)

Using telescoping gauge, measure cylinder bore in both axial 1
(vertical line, following crankshaft) and transverse (horizontal

line across crankshaft) directions at two positions as shown in
figure.
NOTE:
Purchase a commercially available telescoping gauge for this
measurement.
1. Telescoping gauge
Check for followings:

• Difference between measurements at the two positions
(taper). 1
• Difference between axial and transverse measurement

(out-of-round). 2
Cylinder bore wear (difference)

If measurement exceeds service limit, bore or replace cylinder. 1. 50 mm (1.96 in)
2. 90 mm (3.54 in)
PISTON TO CYLINDER CLEARANCE

(1) Measure the piston diameter at a point 9 mm (0.354 in)
above the piston skirt at a right angle to the piston pin bore.
9 mm
z
Piston skirt diameter
Standard: 96.905 – 96.925 mm (3.8152 – 3.8159 in)
(2) Measure the cylinder bore at 50 mm (1.969 in) below the cyl-
inder head gasket surface at a right angle to the crankshaft
pin.
1 50 mm
NOTE:
Purchase a commercially available telescoping gauge for this
measurement.
Cylinder bore diameter
Standard: 97.000 – 97.020 mm (3.8189 – 3.8197 in)
1. Telescoping gauge
POWER UNIT 6-87
(3) Calculate the piston/cylinder clearance (Clearance equals

difference between piston diameter and cylinder bore mea-
surements).
Piston to cylinder clearance
Standard: 0.085 – 0.105 mm (0.0033 – 0.0041 in)
If clearance exceeds service limit, replace piston and/or cylin-
der or bore cylinder.
Identification of oversize piston/piston ring

One oversize piston/piston ring components, 0.50 mm, is avail-
able.
Oversize piston/piston ring are marked as shown, below.
• Piston I.D. mark

50
Oversize I.D. mark
0.50 mm 50
• 1st & 2nd Piston ring

I.D. mark
Oversize I.D. mark
0.50 mm 50
1st, 2nd ring
• Oil ring
Oversize I.D. mark

0.50 mm One (1) Red paint
I.D. mark
Oil ring spacer

6-88 POWER UNIT
PISTON
• Inspect piston for faults, cracks or other damage. Damaged or
faulty piston(s) should be replaced.
• Piston ring to groove clearance

Before checking, piston grooves must be clean, dry and free
Piston ring
of carbon.
Fit piston ring into piston groove, and measure clearance
between ring and ring groove using thickness gauge.
Piston ring to groove clearance
Standard:
1st 0.030 – 0.070 mm (0.0012 – 0.0028 in)
2nd 0.020 – 0.060 mm (0.0008 – 0.0024 in)
Service limit:
1st 0.12 mm (0.0047 in)
2nd 0.10 mm (0.0039 in)
If measurement exceeds service limit, replace piston and/or pis-
ton ring.
Piston ring groove width

Standard:
1st 1.22 – 1.24 mm (0.0480 – 0.0488 in)
2nd 1.21 – 1.23 mm (0.0476 – 0.0484 in)
Oil 2.51 – 2.53 mm (0.0988 – 0.0996 in)
Piston ring thickness
Standard:
1st 1.17 – 1.19 mm (0.0461 – 0.0469 in)
2nd 1.17 – 1.19 mm (0.0461 – 0.0469 in)
PISTON RING
Piston ring end gap
Measure piston ring end gap with piston ring in the lowest posi-
tion of cylinder bore. Cylinder

Piston ring end gap
Standard:
Piston ring
1st 0.20 – 0.30 mm (0.0079 – 0.0118 in)
2nd 0.30 – 0.45 mm (0.0118 – 0.0177 in)
Service limit:
1st 0.70 mm (0.0276 in)
2nd 1.00 mm (0.0394 in)
If measurement exceeds service limit, replace piston ring.
POWER UNIT 6-89
Piston ring free end gap

Measure piston ring free end gap using vernier calipers.
Piston ring free end gap
Standard:
1st Approx. 13.5 mm (0.5315 in)
2nd Approx. 13.6 mm (0.5354 in)
Service limit:
1st 10.8 mm (0.4252 in)
2nd 10.9 mm (0.4291 in)
If measurement exceeds service limit, replace piston ring.
PISTON PIN/PISTON PIN HOLE/CONROD SMALL END

BORE
• Check piston pin, conrod small end bore and piston pin hole
for wear or damage.
If badly worn or damaged, replace component.
• Apply engine oil on piston pin so that the piston pin can move
smoothly in the piston pin hole.
If improper condition is found, replace the piston pin and/or
piston.
• Measure the following item:
09900-20605: Dial calipers
Piston pin outside diameter
Standard: 21.995 – 22.000 mm (0.8659 – 0.8661 in)
Piston pin hole diameter

Standard: 22.006 – 22.014 mm (0.8664 – 0.8667 in)
Conrod small end bore
Standard: 21.968 – 21.979 mm (0.8649 – 0.8653 in)
NOTE:
The piston pin is press-fit into the conrod small end bore.
There must be a negative clearance between the piston pin out-
side diameter and conrod small end inner diameter.
If measurement is out of specification, replace.

6-90 POWER UNIT
CONROD BIG END SIDE CLEARANCE

Measure conrod big end side clearance with conrod installed on
crank pin as shown.
Conrod big end side clearance
Standard: 0.300 – 0.450 mm (0.0118 – 0.0177 in)
If measurement exceeds service limit, replace conrod and/or
crankshaft.
Conrod big end width
Standard: 22.750 – 22.800 mm (0.8957 – 0.8976 in)
Crank pin width
Standard: 23.100 – 23.200 mm (0.9094 – 0.9134 in)
CRANK PIN A ab
Inspect crank pin for uneven wear or damage.
Measure crank pin for out-of-round or taper with micrometer. B
If crank pin is damaged, out-of-round or taper is out of service
limit, replace crankshaft.
Out-of-round : A – B
Taper :a–b
Out-of-round and taper
Crank pin diameter
Standard: 53.982 – 54.000 mm (2.1253 – 2.1260 in)
CONROD BEARING
Inspect bearing shell for proper contact pattern and signs of
fusion, pitting, burning or flaking.
Bearing shells found in defective condition must be replaced.
Conrod big end oil clearance

Check conrod big end oil clearance as follows;
(1) Clean surface of conrod, conrod cap, conrod bearing, and 1
crank pin.
(2) Install conrod bearing onto conrod and conrod cap.
NOTE: 1
• Reassemble each bearing and conrod cap to their original
position.
• Do not apply oil to bearing. 1. Dowel pin
POWER UNIT 6-91
(3) Place a piece of Plastigauge on crank pin parallel to crank-

shaft. Avoid placing Plastigauge over oil hole.
(4) Install conrod cap (with bearing) to conrod with the arrow Arrow mark (>)
mark on cap toward flywheel side. Flywheel side
Match mark
(5) Apply engine oil to conrod bolts and tighten bolt in two steps.
" Conrod cap bolt:
1st step 31 N·m (3.1 kg-m, 22.4 lb-ft)
Final step 63 N·m (6.3 kg-m, 45.6 lb-ft)
NOTE:
Do not rotate conrod with Plastigauge in place.
(6) Remove conrod and conrod cap from crank pin.

Scale
(7) Using scale on Plastigauge envelope, measure Plastigauge
width at its widest point.
Conrod big end oil clearance
Standard: 0.045 – 0.063 mm (0.0018 – 0.0025 in)
Plastigauge
If measurement exceeds service limit, replace conrod bear-
ing.
CRANKSHAFT
■ Crankshaft runout
Using a dial gauge, measure runout at center journal.
$ 09900-20606: Dial gauge
Crankshaft runout
If measurement exceeds service limit, replace crankshaft.
6-92 POWER UNIT
■ Crankshaft thrust play

Measure thrust play with crankshaft, thrust bearing, journal
bearing and crankcase/cylinder block assembled in a normal
manner.
Tighten crankcase bolts to specified torque.
" Crankcase bolt:
Outside (10 mm) 37 N·m (3.7 kg-m, 26.8 lb-ft)
Inside (11 mm) 58 N·m (5.8 kg-m, 41.9 lb-ft)
Use a dial gauge to read displacement in axial (thrust) direction

of crankshaft.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in)
If measurement exceeds service limit, replace crankshaft thrust
bearing.
Crankshaft thrust bearing thickness
Standard: 2.425 – 2.475 mm (0.0955 – 0.0974 in)
■ Out-of-round and taper (uneven wear) of journals

An unevenly worn crankshaft journal shows up as a difference in
diameter at a cross section or along its length (or both).
This difference, if any, is determined by taking micrometer read-
ings.
If any journal is badly damaged or if measurements exceed ser-
vice limit, replace crankshaft. A ab
$ 09900-20203: Micrometer B
Out-of-round: A – B
Taper :a–b
Out-of-round and taper
Crankshaft journal outside diameter
Standard: 64.982 – 65.000 mm (2.5583 – 2.5591 in)
CRANKSHAFT MAIN BEARING

Check bearings for pitting, scratches, wear or damage.
If any improper condition is found, replace both upper and lower
halves.
Always replace both bearing halves, never replace only one half
of a bearing set.
POWER UNIT 6-93
CRANKSHAFT JOURNAL OIL CLEARANCE

Check clearance using Plastigauge according to the following
procedure.
NOTE:
Assemble each bearing in its original position before checking
clearance.
(1) Clean surface of bearing holder (crankcase, and cylinder),
bearing, and main bearing journal.
(2) Install main bearing to cylinder and crankcase.

NOTE:
• Align tab a of bearing with notch in cylinder and crankcase.
• Do not apply engine oil to bearing.
• Install lower bearing half with oil hole/groove towards cylinder
side.
Oil hole/groove
(3) Install crankshaft to cylinder.

(4) Place a piece of Plastigauge across full width of bearing
(parallel to crankshaft) on journal.
Do not place Plastigauge over oil hole.
NOTE: Plastigauge
Do not rotate crankshaft while Plastigauge is installed.
(5) Assemble crankcase to cylinder.

(6) Apply engine oil to crankcase bolts.
Tighten crankcase bolts in three (3) steps following the order 9 10
indicated below.
NOTE: 5 6
Tighten 11 mm (0.433 in) thread diameter bolts first (following
the order shown in figure), then tighten 10 mm (0.394 in) thread
diameter bolts. 1 2
" Crankcase inside bolt (11 mm thread diameter):
3 4
2nd step 46 N·m (4.6 kg-m, 33.3 lb-ft)
" Crankcase outside bolt (10 mm thread diameter): 7 8
6-94 POWER UNIT
NOTE:
Crankcase must be torqued to specification in order to assure
proper compression of Plastigauge and accurate reading of
clearance.
(7) Remove crankcase from cylinder.

(8) Using scale on Plastigauge envelope, measure Plastigauge Scale
width at its widest point.
Crankshaft journal oil clearance
Standard: 0.030 – 0.050 mm (0.0012 – 0.0020 in)
Plastigauge
If measurement exceeds service limit, replace crankshaft main
bearing.
NOTE:
For bearing replacement, see the “SELECTION OF MAIN
BEARING” section on page 6-95.
POWER UNIT 6-95
SELECTION OF MAIN BEARING

Whenever a bearing requires replacement, select a new bearing
according to following procedure.
(1) First, check journal diameter. No.1 Journal
As shown in figure, upper (flywheel side) crank web of No.1 code
cylinder has five (5) stamped code numerals. No.2 Journal
code
The numerals (1, 2 & 3) represent the journal diameters No.3 Journal
shown below. code
No.4 Journal
Numeral stamped Journal diameter code
64.994 – 65.000 mm
1 No.5 Journal
(2.5588 – 2.5591 in) code
64.988 – 64.994 mm
2
(2.5586 – 2.5588 in)
64.982 – 64.988 mm
3
(2.5583 – 2.5586 in)
(2) Next, check bearing holder inside diameter without No.5 Holder code
bearing. No.4 Holder code
As shown in figure, the cylinder block PORT side has five (5) No.3 Holder code
stamped code letters. No.2 Holder code
No.1 Holder code
The letters (A, B & C) represent the bearing holder inside
diameters shown below.
Crank bearing holder inside

Code
diameter (w/o bearing)
70.000 – 70.006 mm
A
(2.7559 – 2.7561 in)
70.006 – 70.012 mm
B
(2.7561 – 2.7564 in)
70.012 – 70.018 mm
C
(2.7564 – 2.7566 in)
(3) There are five (5) main bearings available, each of differ-
ing thickness.
To distinguish them, a color mark is painted at the position
indicated in figure.
Each color represents the following thickness measured at
the center of the bearing.
Color mark Bearing thickness

2.496 – 2.500 mm Color mark
Black
(0.0983 – 0.0984 in)
2.499 – 2.503 mm
No color mark
(0.0984 – 0.0985 in)
2.502 – 2.506 mm
Yellow
(0.0985 – 0.0987 in)
2.505 – 2.509 mm
Blue
(0.0986 – 0.0988 in)
2.508 – 2.512 mm
Pink
(0.0987 – 0.0989 in)
6-96 POWER UNIT
(4) Select crankshaft main bearing referring the below

table.
Numeral stamped on crank web
(journal outside diameter)
1 2 3
Code stamped on A Black No color Yellow
cylinder block
B No color Yellow Blue
(Bearing holder
inside diameter) C Yellow Blue Pink
NOTE:
Measure crankshaft journal oil clearance again after installing
new bearing selected. (See page 6-93.)
CRANKSHAFT DRIVE GEAR

Inspect drive gear. Replace gear if damaged or worn.
OIL SEAL
Inspect condition. If cracked, cut or damaged, replace.
SEAL RING
Inspect seal ring.
Replace if worn, nicked, cut or other abnormal condition.
POWER UNIT 6-97
REASSEMBLY Flywheel side
Assembly is reverse order of disassembly paying special atten- Up mark “O”

tion to the following steps.
96J
If original components are not replaced, each piston,
piston pin and conrod is to be assembled and
installed in its original order and position.
PISTON TO CONROD
Apply engine oil to piston pin 1, piston pin bore and conrod 2.
Assemble conrod 2 to piston 3 as shown in figure.
NOTE:
• “96J” mark on conrod and up mark ( ) on piston dome must
face toward flywheel side.
Use special tool and arbor press shown in figure. Piston pin installer set
Press fit the piston pin 1 to conrod (with piston) until the line (A)
on driver handle is flush with the flat surface of piston.
1
$ 09910-39610: Piston pin remover & installer
2 3
1. Base
2. Collar
3. Driver handle
3: Driver
handle
(Piston pin)
Piston
Conrod
2: Collar
1: Base
6-98 POWER UNIT
Piston
Line (A)
Piston pin
Conrod
PISTON RING TO PISTON

Oil ring
• Apply engine oil to piston rings.
• Install spacer 1 first, then side rails 2 to piston.
!
When installing spacer, do not allow spacer ends to
Incorrect
overlap in groove.
Correct
1st and 2nd piston ring

• Apply engine oil to piston ring. “R”
• Install 2nd ring and 1st ring to piston. “R” 1
NOTE: 2
• 1st and 2nd ring differ in shape and color as shown in figure. Mark 3
• Also indicated in figure, the 1st and 2nd ring are marked with
the letter “R” which must face towards top of piston. 1. 1st ring
2. 2nd ring
3. Oil ring
POWER UNIT 6-99
Ring gap direction

Position piston rings so gaps are staggered at approximately 90 Up mark “O”
degree angles as shown.
1 1st ring 3 2nd ring
2 Oil ring lower side rail 4 Oil ring upper side rail
!
Failure to stagger piston ring gaps may result in
crankcase oil dilution.
PISTON TO CYLINDER
Install conrod bearing to conrod and conrod cap.
!
• Assemble each conrod bearing to its original posi-
tion.
• Do not apply oil between conrod and bearing or
between bearing cap and bearing.
Apply engine oil to piston and cylinder walls.
Insert piston and conrod assembly into cylinder bore from cylin-
der head side using special tool.
$ 09916-77310: Piston ring compressor
NOTE:
Flywheel side
Position the “circle” mark ( ) on piston head to flywheel side.
Circle mark
6-100 POWER UNIT
CRANKSHAFT TO CYLINDER
Install crankshaft main bearings in cylinder and crankcase.
Apply molybdenum oil solution to bearings.
Mix equal amounts of engine oil and SUZUKI MOLY
PASTE (P/no. 99000-25140) in a ratio of 1:1.
!
• Assemble each bearing to its original position.
• Assemble main bearing half containing oil
groove/hole to cylinder block.
Assemble the half without oil groove to crankcase.
• Do not apply MOLYBDENUM OIL SOLUTION
between crank bearing holder and crank main bear-
ing.
NOTE:
Align bearing tab a with notch in cylinder and crankcase.
Oil hole/groove
Thrust bearing 1
Apply molybdenum oil solution to the thrust bearing and install in
cylinder block overlaping both sides of the No.4 main journal.
Oil groove on the thrust bearing must face towards crank webs.
2
1. Thrust bearing
2. Oil groove
Crankshaft drive gear

To assemble the drive gear on crankshaft, align the dot (•) mark
on drive gear with the dowel pin hole on crankshaft.
1
1. Dot ( ) mark
2. Dowel pin hole
POWER UNIT 6-101
Crankshaft
Apply engine oil to upper oil seal lip.
Install upper oil seal to crankshaft.
!
Do not reuse seal removed. Be sure to use new seal.
NOTE:
Install upper oil seal with its spring/lipped side facing inward.
1. Oil seal 1
Apply molybdenum oil solution to crank pin and crankshaft main

journal and install crankshaft in cylinder.
NOTE:
When installing crankshaft to cylinder, be sure to fit tab of seal in
groove of cylinder.
CONROD CAP
Apply molybdenum oil solution to crank pin and conrod bearing.
Install dowel pins and conrod cap (with bearing) to conrod with
arrow mark on cap toward flywheel side.
!
1
Reassemble each conrod cap to its original position.
1
1. Dowel pin
Apply engine oil to conrod bolts. Arrow mark (>)

Flywheel side
Tighten conrod cap bolts in two steps.
" Conrod cap bolt:
Match mark
6-102 POWER UNIT
CRANKCASE TO CYLINDER
Install the balancer gallery O-ring 1.
Clean mating surface of cylinder and crankcase.

Apply Bond marked line.
Apply SUZUKI BOND to mating surface of crankcase as shown.
!
Apply bond to mating surface only.
Do not allow bond to contact surface of bearing.
# 99000-31140: SUZUKI BOND “1207B”
Install five (5) dowel pins 2.

POWER UNIT 6-103
Install crankcase to cylinder.

Apply engine oil to crankcase bolts.
Tighten crankcase bolts in three (3) steps following the order 9 10
indicated below.
NOTE: 5 6
Tighten 11 mm (0.433 in) thread diameter bolts first (following
the order shown in figure), then tighten 10 mm (0.394 in) thread
diameter bolts. 1 2
3 4
7 8
" Crankcase inside bolt (11 mm thread diameter):

" Crankcase outside bolt (10 mm thread diameter):
NOTE:
After tightening crankcase bolts, check to be sure that crank-
shaft rotates smoothly when turned by hand.
OIL FILTER HOUSING

• Install seal ring 1 to oil filter housing 2.
• Install oil filter housing to cylinder block and secure with bolts
3.
6-104 POWER UNIT
COUNTER-BALANCER MECHANISM
Install counter-balancer mechanism. (See page 6-81.)
CYLINDER HEAD
Install cylinder head. (See page 6-58 to 6-61.)
TIMING CHAIN/BALANCER CHAIN

Install timing chain and balancer chain. (See page 6-37 to 6-43 or 6-50 to 6-56.)
OIL PUMP
Install oil pump assembly. (See page 6-30.)
POWER UNIT
Install power unit. (See page 6-21 to 6-25.)
POWER UNIT 6-105
THERMOSTAT
REMOVAL
• Remove the ring gear cover and air intake silencer case.
(See page 6-2.)
• Remove the flame arrester 1.
• Remove the three (3) bolts 2 securing the thermostat cover
3, then remove the cover 3 and thermostat 4.
INSPECTION
• If salt deposits, corrosion, wear or other damage is found,
clean or replace.
• Thermostat operation
Check thermostat opening temperature as follows:
Thermometer
• Insert a length of thread between thermostat valve/body
and suspend thermostat in a container filled with water.
• Place thermometer in container and heat water.
Observe water temperature when thermostat valve opens Heater
and releases thread.
Thermostat operating temperature
Standard: 58 – 62 °C (136 – 144 °F)
6-106 POWER UNIT
INSTALLATION
• Assemble thermostat 1 and thermostat cover 2 to cylinder
block and secure with bolts 3.
" Thermostat cover bolt: 10 N·m (1.0 kg-m, 7.2 lb-ft)
• Check to ensure that all removed parts are back in place.
POWER UNIT 6-107
OPERATION
WATER COOLING SYSTEM
The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil
pan water pressure valve, power unit water passages and thermostat.
This system cools both the power unit and exhaust and is shown in schematic form below.
If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion
build-up or component damage.
Component inspection Refer to page

Water pump/Impeller........................ 9-11, 10-11
Water tube........................................ 7-11
Thermostat ....................................... 6-105
Water pressure valve ....................... 7-28
Cylinder head ................................... 6-63
Cylinder block................................... 6-85
Engine holder Return hose Thermostat
Thermostat Open
Balancer Fuel return

cover pipe Cylinder block Cylinder head
Oil pan
Engine holder Block oil cooler
Oil pan
Water jacket cover Oil pan Pressure valve Pilot water
hole
Driveshaft
housing Water tube
Water pump
Propeller exhaust outlet Water intake
WATER
6-108 POWER UNIT
ENGINE LUBRICATION SYSTEM

The engine lubrication system uses a camshaft-driven trochoid oil pump that pressure feeds engine oil to
the engine’ moving parts. The chart below shows the lubrication system oil flow.
Engine oil is drawn up by the oil pump through the oil strainer. After passing through the oil filter, engine oil
flows to the main gallery from which various passages distribute oil for lubrication and other engine functions
requiring engine oil pressure to operate.
Oil from the main gallery:
• Lubricates crankshaft journal bearings #1 through #5.
• Lubricates crank pins #1 through #4 and all pistons and cylinder walls.
• Lubricates counter- balancer shaft journals.
• Passes through cylinder head oil passage to lubricate IN. and EX. camshaft journals and cam faces.
• Supplies pressurized engine oil to operate the VVT system.
Oil flows to the VVT actuator through ECM controlled OCV to advance, retard or retain the intake valve
timing.
POWER UNIT 6-109
ENGINE OIL LUBRICATION CHART
Oil Pressure Switch
#1 Cam #1 Cam #1 Crank Journal #1 Crank Pin #1 Piston

#1 Journal #1 Journal
face E I face
X N M #2 Crank Journal #2 Crank Pin #2 Piston
#2 Cam . . #2 Cam A
face C C face
I
#3 Crank Journal #3 Crank Pin #3 Piston
A A N
#3 Cam M M #3 Cam
face S S face #4 Crank Journal
G
H H A
#4 Cam A A #4 Cam #5 Crank Journal #4 Crank Pin #4 Piston
#4 Journal #4 Journal L
face face
F F L
T T E Main chain Tensioner
#5 Journal Lower cam Housing R
Y Balancer Lower Housing
Lower cam Housing VVT OCV
Upper Shaft Lower Shaft
Cylinder Head Journal Journal
Oil Filter
Oil Pump Pressure Regulator
Oil Strainer
OIL PAN

SUZUKI DF150 175 Service Man 3

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SUZUKI DF150 175 Service Man 3

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POWER UNIT 6-1

RING GEAR COVER AND AIR INTAKE SILENCER CASE

1. Loosen the clamp securing breather hose 1, then remove

3. Remove the four (4) bolts securing ring gear cover 4.

INTAKE MANIFOLD ASSEMBLY

1. Remove ring gear cover and air intake silencer case 1.

2. Remove the two (2) bolts and front panel 3.

3. Remove fuel injectors 5 and fuel delivery pipe 6.

4. Disconnect fuel outlet hose 7 from low pressure fuel pump

5. Disconnect VSV (Vacuum Switching Valve) connector from

6. Disconnect MAP sensor connector 0.

7. Disconnect vacuum hoses from vacuum tank C.

8. Remove the two bolts D securing throttle drum E to intake

9. Disconnect water inlet hose G from fuel cooler H.

10. Disconnect cooling water outlet hose I from balancer water

11. Disconnect water outlet hose K and water return hose L

• Install gaskets 1 into groove of intake manifold assembly 2.

• Install intake manifold assembly 2, then tighten bolts and

• Install fuel vapor separator. (See page 5-8.)

• Check to ensure that all removed parts are back in place.

FINAL ASSEMBLY CHECK

Remove bolts and fuel cooler 2.

Remove screws and MAP sensor 3.

Remove flame arrester 5.

Remove screws and depression chamber 7.

Remove the seventeen (17) screws and intake

• Install new cover gasket 1 to intake manifold cover.

• Install intake manifold cover 2 to intake manifold, then

• Install spacer 3 to intake manifold.

• Install depression chamber 6, then tighten screws securely.

• Install seal ring 7 and throttle body 8.

FINAL ASSEMBLY CHECK

CYLINDER HEAD COVER

4. Disconnect inlet hose 4 and outlet hose 5 from low pres-

5. Remove the two bolts securing filter bracket 7, then remove

9. Remove the two bolts securing lead wire clamp plate D.

10. On DF175 model, disconnect OCV lead wire connector E at

• Install new cylinder head cover gasket 1 to head cover.

• Install cylinder head cover 2 to cylinder head, then tighten

• On the DF175 model, install new gasket 3 and OCV 4, then

" OCV bolt: 12 N·m (1.2 kg-m, 8.7 lb-ft)

FINAL ASSEMBLY CHECK

Remove the fuel vapor separator 1. (See page 5-7.)

Remove the fuel injectors and intake manifold assembly 2.

Disconnect ignition coil connectors 3.

Remove the cylinder head cover 5. (See page 6-11 to 6-12.)

Remove the electric parts holder 6. (See page 4-30.)

Remove starter motor 7. (See page 4-17.)

Remove flywheel 8. (See page 3-66.)

Remove battery charge coil 9. (See page 4-9.)

Disconnect charge output lead wire connector from Rectifier &

Disconnect EX. manifold temperature sensor lead wire connec-

Disconnect cylinder temperature sensor lead wire connector.

Remove screws and CKP sensor D.

Remove the bolt securing GND lead wire terminals.

Remove the screws securing hose and harness holder 1.

Disconnect shift position sensor lead wire connector 4.

Remove three (3) bolts, thermostat cover 6 and thermostat 7.

Disconnect pilot water hose 8 from cylinder block.

Remove oil level dipstick 0.