09404-10204 Suzuki CLAMP

1. Install two 5/8"-18 NF × 4 in. long bolts (2) to hold the crankshaft rear gear (1) in position. 2. Fasten a hoist to the exhaust manifold assembly (4) and remove the clamps that fasten exhaust tube (3) and elbow (5) in place. 3. Disconnect hose assembly (6) from the flywheel housing. 4. Install tooling (A) and fasten a hoist to the flywheel housing.5. Remove bolts (7) that fasten flywheel housing (8) in position and remove the flywheel housing. Weight of the flywheel housing is 154 kg (340 lb.).Install Flywheel Housing
1. Install a new gasket on the cylinder block. Remove gasket material that extends past the bottom of the cylinder block.2. Put clean engine oil on the crankshaft rear wear sleeve and seal. Install tool (A) in the crankshaft rear seal.3. Install tool (B) and a hoist on the flywheel housing.4. Put the flywheel housing (1) in position and use hole (2) to visually make an alignment of the "V" marks on the balancer gear and the crankshaft rear gear with the number one cylinder at top center. 5. Install plug (3) and bolts (4) that fasten the flywheel housing to the cylinder block. 6. Tighten the flywheel housing bolts as follows:a) Tighten bolts 1 through 8 in number sequence to a torque of 135 14 N m (100 10 lb.ft.).b) Tighten bolts 9 through 21 in number sequence to a torque of 55 7 N m (40 5 lb.ft.).c) Tighten bolts 1 through 8 again in number sequence to a torque of 135 14 N m (100 10 lb.ft.).d) Tighten bolts 9 through 21 again in number sequence to a torque of 55 7 N m (40 5 lb.ft.). 7. Install hose assembly (5) on the flywheel housing. 8. Install a hoist on the exhaust manifold (6) and put it in position. Tighten clamps (7) in position as shown.Disassemble Flywheel Housing
START BY:a) remove flywheel housing 1. With the flywheel housing in the position shown remove bolts (1) from shafts (2).
The bearing toward the flywheel housing will fall when the gears are removed. Hold these bearings in position when the gears are removed.
2. Remove balancer gear (4) and idler gear (3). 3. Disassemble balancer gear (4) as follows:a) Remove shaft (2), bearing cones (5) and (7) and spacer (6) from gear (4). b) Remove bearing cups (8) and (11) and spacer (9) from gear (4). The bearing cups will have damage after removal. Use new parts for replacement.c) If necessary remove ring (10) from gear (4).4. Disassemble idler gear (3) the same as in Steps 3a through 3c.Assemble Flywheel Housing
1. Assemble balancer gear (3) as follows:a) Install ring (2) in gear (3).b) Install spacer (1) in gear (3) from the timing mark side of the gear as shown. c) Use a press and tool (A) to install the bearing cones until they are in contact with the spacer. Install the bearing cone in the timing mark side of gear (3) first to hold the spacer in position.d) Install the spacers, bearing cones and shaft in gear (3).2. Assemble idler gear (4) the same as in Steps 1a through 1d. 3. Put idler gear (4) and balancer gear (3) in position on the flywheel housing. Make sure the oil holes in shafts (6) are in alignment with the oil holes in the flywheel housing. Install balancer gear (3) with the timing mark toward the flywheel housing.4. Install bolts (5) to hold the shafts.END BY:a) install flywheel housing