Suzuki 1200 bandit, Service Manual

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1D-16 Engine Mechanical:
Oil Jet (For the Cylinder Head)
• Make sure that the oil jets (1) in the upper crankcase
are not clogged.
Piston
• Install the pistons and piston pins in their original
cylinders. Refer to the scribe marks on each piston.
• Before installing the piston pins, apply molybdenum
oil solution to their surfaces.
M/O: Molybdenum oil (Molybdenum oil solution)
• Place a cloth beneath the piston, and install the
circlips (1).
NOTE
• Install the pistons with the arrow mark “A”
facing towards the exhaust side.
• Be sure to use new circlips.
• Install the dowel pins and the new cylinder gasket.
• Before installing the cylinder, oil the big and small
ends of each conrod and also the sliding surface of
each piston.
CAUTION
!
Use a new gasket to prevent oil leakage.
NOTE
Install the gasket with the “UP” mark facing
up as shown.
• Position the piston ring gaps as shown. Before
inserting each piston into its cylinder, check that the
gaps are properly positioned.
• Install each special tool as shown. Some light
resistance must be overcome to lower the cylinder
over the pistons.
Special tool
(A): 09916–74521 (Holder body)
(B): 09916–74550 (Band (bore 73 - 85 mm))
1
1
I649G1140055-02
“A”
1
I649G1140057-02
“B”: 2nd ring and lower side rail
“C”: Upper side rail
“D”: 1st ring and spacer
“UP”
#4 #3 #2 #1
I649G1140348-01
EX
IN
“C” “B”
“D”
I649G1140059-03