99105-00008 Suzuki Cable, Remote Control

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Lifting Bracket 1
B - Guide Stud
(M10 x 1.25 by 80 mm) 2 Start By:
Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure.
Remove the primary speed/timing sensor. Refer to Disassembly and Assembly, "Primary Engine Speed/Timing Sensor - Remove and Install" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03795183
Install Tooling (A) and a suitable lifting device to flywheel (2). The weight of the flywheel is approximately 42 kg (93 lb).
Remove two bolts (1) from Positions (X) on the flywheel.
Install Tooling (B) in Positions (X) on the flywheel.
Remove the remaining bolts (1) and remove flywheel (2).Note: A roll pin (3) is located between the crankshaft and the flywheel.
Inspect ring gear (4) and flywheel (2) for wear or damage. If the ring gear or the flywheel is worn or damaged, use new parts for replacement.
Illustration 2 g03795192
To remove ring gear (4) from flywheel (2), place the flywheel on a suitable support. Use a hammer and a punch (5) to remove the ring gear from the flywheel.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Lifting Bracket 1
B - Guide Stud
(M10 x 1.25 by 80 mm) 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Always wear protective gloves when handling parts that have been heated.
Illustration 3 g03795238
If the ring gear was removed, follow Steps 1.a through 1.c to install ring gear (4) to flywheel (2).
Identify the orientation of the new ring gear to install the ring gear correctly onto the flywheel.Note: The chamfered side of Gear Teeth (Y) must face toward the starting motor when the flywheel is installed. The chamfered will ensure the correct engagement of the starting motor.
Heat ring gear (4) in an oven to a maximum temperature of 150°C (302°F) prior to installation. Note: Do not use a torch to heat the ring gear.
Ensure that ring gear (4) orientation is correct and quickly install the ring gear onto flywheel (2).
Illustration 4 g03795183
Thoroughly clean the flywheel housing. Inspect the crankshaft rear seal for leaks. If crankshaft rear seal has any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove and Install" for the correct procedure.
Install Tooling (B) to Positions (X) in the crankshaft.
Install Tooling (A) and a suitable lifting device to flywheel (2). The weight of the flywheel is approximately 42 kg (93 lb).
Position flywheel (2) onto Tooling (B).Ensure that roll pin (3) is installed to the crankshaft and that the roll pin is free from damage. Align the hole in the flywheel with the roll pin in the crankshaft.
Install bolts (1) finger tight.
Remove Tooling (B) and install the two remaining bolts (1).
Use a suitable tool to prevent flywheel (2) from rotating. Tighten bolts (1) to a torque of 74 N m (54 lb ft).
Remove Tooling (A) and the lifting device from the flywheel.End By:
Install the primary speed/timing sensor. Refer to Disassembly and Assembly, "Primary Engine Speed/Timing Sensor - Remove and Install" for the correct procedure.
Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install" for the correct procedure.