09103-10007 Suzuki Bolt, Gear Case

Illustration 1 g06411569
Illustration 2 g06411572
Tightening sequence
Table 1
Item Qty Part Specification Description
1 4 5B-0213 Bolt Torque to 55 10 N m (41 7 lb ft).
2 1 228-5814 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 209-8621 Bearing is bearing is 88.090 0.013 mm (3.4681 0.0005 inch).
Installation depth of the bushing is 3.0 0.5 mm (0.12 0.02 inch).
3 1 230-6202 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 224-9664 Bushing is 71.035 0.013 mm (2.7967 0.0005 inch).
4 - - With the number one piston in the top dead center position, align the timing marks. The mark on the camshaft gear must be in alignment with the mark in the rear housing.
5 1 564-6673 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 209-8621 Bearing is bearing is 88.090 0.013 mm (3.4681 0.0005 inch).
Installation depth of the bushing is 3.0 0.5 mm (0.12 0.02 inch).
6 1 226-6036 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 226-6052 Bushing is 88.090 0.013 mm (3.4681 0.0005 inch).
Installation depth of the bushing is 3.2 0.5 mm (0.13 0.02 inch).
7 - - With the number one piston in the top dead center position, align the timing marks. The mark on the camshaft gear must be in alignment with the mark in the rear housing.
8 4 1A-2029 Bolt Torque to 55 10 N m (41 7 lb ft).
9 1 228-5813 Crankshaft Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
Extension of the 4N-0684 Dowel is 6.5 2.0 mm (0.26 0.08 inch).
Illustration 3 g06411577
Table 2
Item Qty Part Specification Description
10 1 6V-5141 O-Ring Seal Before assembly, lubricate the bore and seal lightly with the fluid that is being sealed.
11 1 224-1221 Stub Shaft Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
12 2 117-8801 O-Ring Seal Before assembly, lubricate the bore and seal lightly with the fluid that is being sealed.
13 16 7B-3235 Bolt Torque to 135 20 N m (100 15 lb ft).
14 6 0S-1590 Bolt Torque to 55 10 N m (41 7 lb ft).
15 6 3B-1915 Bolt
16 1 509-1082 Shaft Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
17 1 545-9395 Stub Shaft
18 1 185-1497 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 224-9664 Bushing is bearing is 71.035 0.013 mm (2.7967 0.0005 inch).
Installation depth of the bushing is 2.6 0.5 mm (0.10 0.02 inch).
19 1 545-9396 Stub Shaft Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
20 1 5P-8429 O-Ring Seal Before assembly, lubricate the bore and seal lightly with the fluid that is being sealed.
21 6 6J-2515 Bolt Torque to 135 20 N m (100 15 lb ft).
22 1 227-0159 Stub Shaft Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
23 6 7K-6058 Bolt Torque to 135 20 N m (100 15 lb ft).
24 1 5F-7403 Lockwasher Use the following procedure to tighten the lockwasher:
1. Torque to 406 68 N m (299 50 lb ft).
2. Bend the tab on the lock that aligns with the slot in the nut.
25 1 229-1663 Thrust Plate Install the plate with the side marked "OUT" away from the gear face.
26 1 5F-7404 Bearing Locknut Use the following procedure to tighten the locknut:
1. Torque to 406 68 N m (299 50 lb ft).
2. Bend the tab on the lock that aligns with the slot in