11422-94700 Suzuki CAP

Installation of Tappets
(1) Apply engine oil to the outside surfaces of tappets, and insert them into the tappet bores in the crankcase. (2) Make sure the tappets rotate smoothly.
Installation of tappetInstallation of Main Bearings
(1) Install the main bearings (upper and lower halves) to the crankcase and main bearing caps by inserting them into the lug grooves. Install the bearings with lug groove to the crankcase, and the bearings without lug groove to the main bearing caps.(2) Install the flanged bearing to the aftermost (No. 4) journal.(3) Apply a small amount of engine oil to the inside surface of each bearing.
Installation of main bearingInstallation of Crankshaft
(1) Wash the crankshaft thoroughly with a cleaning solution, and dry it with compressed air. After washing the crankshaft, make sure there is no metal particles inside the oil holes or swelling of the chamfered sections of the oil holes.(2) Hold the crankshaft horizontally, and carefully place it into the crankcase.(3) Apply a small amount of engine oil to the crankshaft journals.
Installation of crankshaftInstallation of Main Bearing Caps
Fit the main bearings, making sure that the front marks (arrow) on the main bearing caps face the front of the engine and the cap numbers are in order from the front to the back.
Make sure the end faces of the bearing caps No.1, 4 are flush with the crankcase end faces.
Installation of main bearing capTightening of Bearing Cap Bolts
Tighten the main bearing cap bolts alternately to the specified torque.
Installation of main bearing cap boltInspection of Crankshaft for Smooth Rotation
Make sure that the crankshaft rotates smoothly
Inspection of crankshaft for smooth rotationMeasurement of Crankshaft End Play
(1) Measure the crankshaft end play. (2) If the end play is too small, loosen the cap bolts, and retighten them.(3) If the limit value is exceeded, replaced the flanged bearing.
Measurement of crankshaft end playAssembly of Pistons and Connecting Rods
(1) Assemble the piston and connecting rod by positioning the piston weight indication and the connecting rod matching mark face the same direction.(2) Coat the piston pin with engine oil, and install the pin to connect the connecting rod to the piston.
Assembly of piston and connecting rod (1)(3) Install the snap rings in the grooves in the piston using ring pliers. Check the snap rings for tension and proper fitting. The snap ring ends must be positioned toward the bottom of the piston.
Assembly of piston and connecting rod (2)Installation of Piston Rings
(1) Using piston ring pliers, install the compression rings (No. 1, No. 2) and oil ring on the piston. The marks on rings No. 1 and No. 2 (No. 1: RN, No. 2: R) must be positioned toward the top of the piston.
Installation of piston rings on piston(2) Install the oil ring in such a way that its ring end cap is positioned 180° from the joint of the oil spring.
Positioning of oil ring and coil springLaying Crankcase on its Side
Gently lay the crankcase on its side.
Laying of crankcase on its sidePreparation for Piston Installation
After cleaning the inside surface of the cylinder with a clean cloth, apply engine oil to the surface.
Preparation for piston installationInstallation of Connecting Rod Bolts and Bearings
(1) Before installing the bearing, insert the connecting rod bolts so that the notched face of the head is securely positioned.(2) Install the upper half of the connecting rod bearing to the big-end bore of the connecting rod by aligning the lug grooves, and apply engine oil to the inside surface.
Installation of connecting rod bearingInstallation of Pistons
(1) Apply engine oil to the piston rings.(2) Set the piston ring end gaps away from one another, also making sure that they do not align with the pin direction, thrust direction or counterthrust direction.
Installation of piston (1)
Installation of pistons (2)(3) Bring the cylinder No. 1 crankpin to the top dead center.(4) Align the piston guide with center of the cylinder, and hold it at the top surface of the crankcase by hand.
Installation of pistons (3)(5) Position the "Trigona" mark stamped on top surface of the piston toward the front of the crankcase, and insert the piston and connecting rod assembly into the cylinder using the installer. After inserting the piston, make sure that the direction of the connecting rod big-end bore matches the crankpin direction.(6) Lightly tap the top surface of the piston with the handle of a hammer to fit the connecting rod big-end bore to the crankpin. Make sure that the connecting rod bearing upper half is in place by feeling with a finger.
Be careful not to damage the crankshaft with the big-end bore of the connecting rod.
Installation of Connecting Rod Caps
(1) Install the connecting rod bearing lower half to the connecting cap by fitting it into the lug groove, and apply engine oil.(2) Install the connecting rod cap to the connecting rod (crankpin), making sure that the matching mark aligns with that on the connecting rod.(3) Tighten the connecting the connecting rod cap nuts finger tight.(4) Tighten the connecting rod nuts alternately to the specified torque using torque wrench.(5) Check the connecting rod end play, if the end play is too small, loosen the cap nuts and then retighten them.