55100-93900-02M Suzuki Case, Gear

Table 1
Required Tools
Tool Part Number Part Description Qty
A 279-3473 Barring and Mounting Gp 1
329-3831(1) Barring Tool 1
B 274-5875(2) Connecting Rod Guide 2
418-1340(3) Guide 2
339-6503 Bolt 2
E 322-3564(4) Cylinder Tool Gp 1
F 288-9169 Bracket As 1
2P-8260 Cylinder Liner Installer 1
G - Bel-Ray Molylube 67700 (5) -
H - Loctite LB8801 Silicone Lubricant -
(1) Optional
(2) Use for engine serial numbers 1-999 (type 1)
(3) Use for engine serial numbers 1000-99999 (type 2)
(4) Extended reach clamps 554–5056 are available for double seal cylinder liners
(5) Refer to the following link to order molylube specified above - www.belray.comNote: Ensure that the top O-ring seal for the liner is at least 20 °C (68 °F) before installation of liners into the cylinder block. Assembly with a cold seal may result in damage to the O-ring seal or to the installation tool.
Illustration 1 g06119953
Rotate the engine to position the piston toward top dead center for easy access. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Attach a suitable lifting device onto Tooling (E). The weight of the piston, the liner, and the connecting rod is approximately 50 kg (110 lb). Install Tooling (B) onto the connecting rod. Coat the liner bore of the cylinder block and the O-ring seals on the outside of the cylinder liner with Tooling (H). Install cylinder pack (4) into the cylinder block.Note: Inspect the connecting rod bearing for wear or for damage. If necessary, replace the connecting rod bearing. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Remove and Install" for the proper procedure. Position the connecting rod so that the chamfer is toward the crankshaft. Install the piston, the liner, and the connecting rod as a unit.
Illustration 2 g01765495
Remove Tooling (E).
Illustration 3 g01945551
Install Tooling (F). Use Tooling (F) to seat the liner into the cylinder block. Fully seat the cuff.
Illustration 4 g01240845
Remove Tooling (B) from the connecting rod.
Illustration 5 g03405954Note: Match the tabs on the ODD and EVEN connecting rod caps with the connecting rods.
Install connecting rod cap (3). Apply Tooling (G) under the connecting rod bolts (1), the rings, and to the threads of the bolts. Install connecting rod bolts (1) and spacers (2).
Use Tooling (A) to rotate the flywheel to access the connecting rod cap (3) that will be installed.
Illustration 6 g06095130
The arrow represents the front of the engine block
Bolt (1) is always identified as the center bolt on the bearing tab side of the connecting rod.
(A) Bearing tab side
(X) Odd numbered connecting rod
(Y) Even numbered connecting rod
Use the following procedure to tighten the connecting rod bolts:
Table 2
Torque Specifications
Use the following procedure to tighten the bolts of the connecting rod:
Apply Tooling (G) to the bolt with by fully coating the elastomer rings, threads, and the contact surface under the bolt head.
1. Install all the bolts into the spacers by pushing and rotating the bolt simultaneously.
Note: Rotating the bolt while pushing will avoid damage to the bolts.
2. Install the bolts into the connecting rod cap by pushing and rotating the bolt simultaneously.
3. Engage the threads by pushing and slowly rotating the bolt. Do not tap the bolt. All six bolts should have the threads engaged before the joint is drawn together on either side. The order of engaging the threads is bolts 1-2-3-4-5-6. Engaging bolt 1 and 2 first helps center the cap to the connecting rod. Once bo