09103-08188 Suzuki BOLT

start by: a) remove center frame *b) remove radiator and radiator guardc) remove crankcase guards (front)d) remove power take-off*This operation is in the PIPELAYER PORTION DISASSEMBLY AND ASSEMBLY SECTION. 1. Loosen nuts (1) on rear crankcase guard enough to install tool (B) under it. Remove the nuts and rear crankcase guard (2).2. Drain the oil from the torque divider and transmission. 3. Remove bolts and floor plates (3). 4. Remove brake control rod (4). Remove steering clutch control rods (5). Remove seat cushion to disconnect steering clutch control rod from under seat frame. Remove bracket (6). Remove brake control rod (8). 5. Fasten a hoist to the brake pedal and support assembly (10). Remove bolts (9). Remove brake pedal and support assembly and shims (7). Weight of the assembly is 90 lb. (41 kg). 6. Disconnect vent line (13) from the torque divider.7. Disconnect pressure line (12).8. Disconnect line (14) for the transmission hydraulic controls.9. Loosen two clamps and slide the hose down on the tube assembly (17). Remove tube assembly (17) from the torque divider.10. Disconnect line (15) from the torque converter outlet relief valve.11. Disconnect line (16).12. Fasten a hoist to the universal joint. Remove the bolts that hold it in position. Remove universal joint (11). Weight of the universal joint is 50 lb. (22.7 kg). 13. Disconnect line (18) from the transmission magnetic screen. 14. Remove tool box (20) and the brackets that hold it.15. Disconnect fuel line (19) at the primary fuel filter.16. Disconnect wires (21) from the electric starting motor. Put identification on the wires so they will not be mixed at assembly. 17. Disconnect oil lines (22) and (23) from under the oil pan. 18. Remove two bolts (24) from junction block. 19. Remove clamp (26) from counterweight cylinder hoses (25). 20. Lift counterweight cylinder hoses (25) up to remove bolts (27) and (28). Remove support block (29). 21. Remove front support bolts (30). 22. Remove rear support bolts (31). Make a final check to be sure that all removals and disconnections have been made. 23. Fasten a hoist and tool (A) to the engine. Remove the engine and torque divider (32) as a unit. Weight of the unit is 8500 lb. (3856 kg). Remove the shims from the frame of the machine. Put identification on the shims so they will not be mixed at assembly. Bolts that hold the rear supports to the flywheel housing must be checked. Tighten bolts to a torque of 150 lb.ft. (205 N m). Put a mark on the bolt head and support and turn the bolt an additional 120° 5°.Install Engine And Torque Divider
1. Fasten tool (A) to a hoist. Fasten tool (A) and the hoist to the engine and torque divider (1). Put the engine and torque divider in position over the frame of the machine. Do not lower engine and torque divider on to the frame at this time. Keep support and bolt-washer areas free of dirt and paint.2. Put shims in the correct position under the engine front support and under the flywheel housing at the rear of the engine. Lower the engine down on to the frame.3. Install four bolts in the front support. Tighten the bolts to a torque of 350 25 lb.ft. (470 35 N m).4. Install the rear support bolts and tighten them to a torque of 950 50 lb.ft. (1300 70 N m). 5. Install universal joint (2) between torque divider and transmission. Install bolts (3) and tighten them to a torque of 120 5 lb.ft. (162.7 6.8 N m). After installation of the engine and universal joint is complete, check alignment of the universal joint as it is turned. If the rotation characteristics of the universal joint gives an indication of misalignment use the following procedure. Misalignment of the universal joint can be made correct by addition or removal of shims as necessary between the frame and engine supports, or by movement of the engine accordingly. 6. Connect line (8).7. Connect line (7) to the torque converter outlet relief valve.8. Install tube assembly (9) on the torque divider.9. Connect line (6) for the transmission hydraulic controls.10. Connect pressure line (4).11. Connect vent line (5) to the torque divider. Connect line to the transmission magnetic screen. 12. Install support block (11) and the bolts (10) that hold it. 13. Install clamp (13) on the counterweight cylinder hoses (12). 14. Install and tighten the two bolts (14) that hold the junction block for the counterweight cylinder hoses. 15. Connect oil lines (15) and (16) that have a location under oil pan. 16. Connect wires (19) to the electric starting motor.17. Connect fuel line (17) to the primary fuel filter.18. Install tool box (18) and the brackets that hold it. 19. Install brake pedal and support assembly (20) with a hoist. Install the bolts that hold the assembly. 20. Install brake control rod (23). Install bracket (22).21. Install steering clutch control rods (24). Install seat cushion that was removed to disconnect the steering clutch control rods.22. Install brake control rod (21). 23. Install the floor plates (25). Install the rear crankcase guards with tool (B).end by:a) install power take-offb) install crankcase guards (front)c) install radiator and radiator guardd) install center frame **This operation is in the PIPELAYER PORTION DISASSEMBLY AND ASSEMBLY SECTION.