09117-08071 Suzuki BOLT (8X35)

1. Remove the bolts and tube assembly (1) from the flywheel housing.2. Remove the bolts, the nuts and support assembly (2) from the flywheel housing. 3. Remove the nuts and adapter (4) from the flywheel housing.4. Remove the nuts, the spacer and cover (3) from the flywheel housing. 5. Fasten tool (A) to the cylinder block next to the flywheel housing as shown.6. Use two suitable jacks (5) and a wooden block as shown to hold the rear of the engine when the engine supports are removed. 7. Remove the bolts and caps (6) from the support assembly. 8. Remove the bolts and left and right support assemblies (7). 9. Remove the bolt and disconnect clip (8) and the wire harness from the side rail. 10. Remove the bolts and adapter assembly (9) from the flywheel housing. 11. Fasten tool (B) and a hoist on flywheel housing (10) as shown.12. Remove the bolts, flywheel housing (10) and the gasket from the cylinder block. The weight of the flywheel housing is 59 kg (130 lb.).Install Flywheel Housing
1. Make sure all gasket surfaces are clean and free of foreign material. 2. If stud (2) was removed, put 9S3263 Thread Lock on the threads that are installed into the flywheel housing. Install the stud.3. Install two 1/2"-13 NC × 4" guide bolts (3) in the cylinder block.4. Fasten tool (B) and a hoist on flywheel housing (1). Put the new gasket in position and install flywheel housing (1) on the cylinder block. Make sure the gasket is even with the cylinder block. 5. Install the bolts and washers that hold the flywheel housing in position. Tighten bolts 1 through 15 in the sequence which follows: Bolts 16 and 17 are not included in the procedure which follows.a) Tighten bolts 1 through 8 in number sequence to a torque of 136 14 N m (100 10 lb.ft.).b) Tighten bolts 9 through 15 in number sequence to a torque of 54 7 N m (40 5 lb.ft.).c) Again, tighten bolts 1 through 8 in number sequence to a torque of 136 14 N m (100 10 lb.ft.).d) Again, tighten bolts 9 through 15 in number sequence to 54 7 N m (40 5 lb.ft.). 6. Put the gasket in position and install adapter assembly (4) on the bottom of the flywheel housing. 7. Connect the wire harness and clip (5) to the side rail. 8. Install left and right support assemblies (6) on the side rails as shown. 9. Install caps (7) on the support assemblies. 10. Remove tool (A) from the cylinder block. 11. Make sure studs (9) are tightened into the flywheel housing to a torque of 54 7 N m (40 5 lb.ft.).12. Install the O-ring seal on cover (8) and put clean engine oil on it.13. Install cover (8) on the flywheel housing with the spacer and the nuts that hold it. Tighten nuts (10) to a torque of 54 7 N m (40 5 lb.ft.).14. Install the O-ring seal on adapter (11) and put clean engine oil on it.15. If studs (12) were removed, put 5P3413 Thread Sealant on the threads that are to be installed into the flywheel housing and install them.16. Put adapter (11) on the flywheel housing and install the nuts that hold it. 17. Put support assembly (13) on the flywheel housing. Install the bolts and the nuts that hold it. Tighten the six bolts in the numbered sequence shown to a torque of 55 7 N m (41 5 lb.ft.).18. Make sure the O-ring seals are in position on tube assembly (14). Install the gasket and install the elbow and tube assembly as a unit on the flywheel housing.END BY:a) install crankshaft rear seal and wear sleeve (earlier and later)b) install electric starting motorc) install oil pan