Suzuki 1200 bandit, Service Manual

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1D-54 Engine Mechanical:
• Match the upper and lower crankcases.
• Install the right oil return pipe (1) with the bolt “1”.
• Install the copper washers onto bolts “9” and “11”.
• Install the two allen bolts at position “A”.
• Install the ten crankcase bolts (M8).
• Tighten the crankcase bolts (Crankshaft tightening bolts) in ascending order. Tighten each bolt a little at a time to
equalize the pressure.
Tightening torque
Crankcase bolt (M8) (Initial): 13 N·m (1.3 kgf-m, 9.5 lb-ft)
Crankcase bolt (M8) (Final): 22 N·m (2.2 kgf-m, 16.0 lb-ft)
• Tighten the main oil gallery plug (2) to the specified torque.
CAUTION
!
Replace the O-ring with a new one.
Tightening torque
Main oil gallery plug (a): 40 N·m (4.0 kgf-m, 29.0 lb-ft)
• Install the engine ground wire (3) to the correct position as shown.
• Tighten the lower and upper crankcase bolts (M6) and nuts to the specified torque.
Tightening torque
Crankcase bolt and nut (M6) (Initial): 6 N·m (0.6 kgf-m, 4.5 lb-ft)
Crankcase bolt and nut (M6) (Final): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
NOTE
• Install the copper washer at position “B”.
• After tightening the upper crankcase bolt (4), install the plug (5).
• Install the gasket washer at position “C”.
“A”
“10”
“12”
“11”
“9”
“5”
“6”
“2” “4”
“8”
“7”
“3” “1”
1
I649G1140159-04
(a)
2,
2
I649G1140326-02