Suzuki GSX-R750, Service Manual

Page: 115 / 495

ENGINE 3-67
ENGINE REASSEMBLY
• Reassemble the engine in the reverse order of disassembly.
• The following steps require special attention or precautionary
measures should be taken.
NOTE:
Apply engine oil to each running and sliding part before reassem-
bling.
• Be sure to install the following items to the crankcase.
* Crankshaft journal bearing ( 3-63)
* Gearshift fork ( 3-57)
* Gearshift fork shaft ( 3-57)
* Gearshift shaft bearing ( 3-56)
* Gearshift cam bearing ( 3-56)
* Gearshift fork bearing ( 3-56)
* Gearshift cam ( 3-56)
* Bearing retainer ( 3-57)
* Oil jets ( 3-59)
PISTON AND CONROD
• Position the gaps of the three rings as shown. Before inserting
each piston into the cylinder, check that the gaps are so located.
• Rub a small quantity of molybdenum oil solution onto each pis-
ton pin.
O O O O O
MOLYBDENUM OIL
• Assemble the piston and conrod.
NOTE:
When installing the pistons, the indent
A
on the piston head must
be faced to another side of ID code
B
on conrod face.
• Install the pistons.
NOTE:
Be sure to install the pistons in the cylinders from which they were
removed in disassembly, refer to the cylinder numbers, “1” through
“4”, scribed on the piston.
• Install the piston pin circlips
1
.
#
Use new piston pin circlips to prevent circlip failure which
will occur with a bend one.
NOTE:
End gap of the circlip should not be aligned with the cutaway in the
piston pin bore.
• Apply engine oil to the sliding surface of the pistons and cylin-
• 2nd ring
• Lower side
rail
• Upper side
rail
• Top ring
• Spacer
EX
IN
120°
120° 120°