Suzuki 1200 bandit, Service Manual

Page: 85 / 447

Engine Mechanical: 1D-17
• With pistons #2 and #3 in place, install pistons #1 and
#4, and then insert them into the respective cylinders.
NOTE
Do not overtighten the bands or piston
installation into the cylinders will be difficult.
Cylinder
• Tighten the cylinder base nut (1) to the specified
torque.
Tightening torque
Cylinder base nut (a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
• Install the dowel pins, new O-rings and cylinder head
gasket.
NOTE
Install a gasket with the “UP” mark facing up
as shown.
CAUTION
!
Replace the O-rings and gasket with new
ones to prevent oil leakage.
• Install the new O-rings (2) onto the oil return pipes
and apply SUZUKI SUPER GREASE “A” to the O-
rings.
CAUTION
!
Replace the O-rings (2) with new ones to
prevent oil leakage.
: Grease 99000–25010 (SUZUKI SUPER
GREASE A or equivalent)
• Install the right and left oil return pipes.
Cylinder Head
• Place the cylinder head onto the cylinder.
• Place the cylinder head plate (1) onto the cylinder
head.
• Cylinder head nuts and washers must be installed in
the correct position as shown.
(A)
(B)
(B)
I649G1140060-02
(a)
1,
I649G1140061-02
“UP”
I649G1140062-02
“A”: Copper washer with cap nut (4 pcs)
“B”: Steel washer with normal nut (4 pcs)
“C”: Copper washer with normal nut (4 pcs)
2
2
I649G1140063-02
“C”
“B”
“B”
“A”
“A”
“C”
“C”
“C”
“B”
“B”
“A”
“A”
Exhaust side
1
I649G1140064-03