09404-06413 Suzuki Clamp, Stop Switch Read Cord

Illustration 1 g02727693
Illustration 2 g02727966
Remove bolts (1) from front cover (3). Note: Note the position of the different length bolts.
Remove front cover (3) from the front housing.
Remove gasket (2) (not shown).
Remove the crankshaft front seal using a suitable tool. Ensure that the front cover (3) is not damaged during the removal of the crankshaft front seal.
If necessary, follow Step 5.a through Step 5.c in order to remove crankcase pressure relief valve (5) from the front cover.
Remove bolts (4) from crankcase pressure relief valve (5).
Remove crankcase pressure relief valve (5) from the front cover (3).
Remove O-ring seal (6) from crankcase pressure relief valve (5).
If necessary, remove studs (7) from front cover (3). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Stud
M8 by 70 mm 2
B 460-8232 Front Cover Alignment Tool - Crankshaft 1
C 390-1132 Front Cover Alignment Tool - Crankcase Breather 1
Illustration 3 g02931736
If necessary, follow Step 1.a through Step 1.c in order to install crankcase pressure relief valve (5) to the front cover.
Install O-ring seal (6) to crankcase pressure relief valve (5).
Install crankcase pressure relief valve (5) to the front cover (3).
Install bolts (4) to crankcase pressure relief valve (5). Tighten the bolts to a torque of 10 N m (89 lb in).
If necessary, install studs (7) to front cover (3). Tighten the studs to a torque of 10 N m (89 lb in)
Thoroughly clean the gasket surface of the front housing.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 4 g02931738
Illustration 5 g02932042
Install Tooling (A) into the holes in Positions (X) in the front housing.
Position a new gasket (2) onto Tooling (A).
Position front cover (3) onto Tooling (A).
Install bolts (1) in the available locations finger tight.
Remove Tooling (A) and install remaining bolts (1).
Install the breather drive (9) and install nut (10) to fuel injection pump shaft (8).
Use a suitable tool in order to prevent the engine from rotating. Tighten nut (10) to a torque of 80 N m (59 lb ft).
Install Tooling (B) into the aperture for the crankshaft front seal.
Install Tooling (C) into the aperture for the crankcase breather.
Illustration 6 g02727967
Tighten bolts (1) in the sequence that is shown in Illustration 6 in two stages. Tighten the bolts to an initial torque of 8 N m (71 lb in).Tighten the nuts to a final torque of 25 N m (221 lb in).
Remove Tooling (B) and remove Tooling (C).
Install the crankshaft front seal to the front cover. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove and Install" for the correct procedure. End By:
Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install" for the correct procedure.
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install" for the correct procedure.
Install the camshaft position sensor. Refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install" for the correct procedure.
If the engine was equipped with a fan, install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure.