09408-00111 Suzuki CLAMP

Table 1
Specifications for 346-1734 Gear Case and 371-1220 Gear Case    
Callout     Part Number     Part Name     Specification Description    
10     6I-0217     Bolt     Torque to...................28 N m (248 lb in)
Tighten the bolts in the sequence that is in illustration 6.    
11     101-3895     Bolt     Torque to...................
28 N m (248 lb in)
Tighten the bolts in the sequence that is in illustration 6.    
12     6I-0645     Bolt     Torque to...................
28 N m (248 lb in)
Tighten the bolts in the sequence that is in illustration 6.    Removal Procedure
Start By:
Remove the fan. Refer to Disassembly and Assembly, "Fan" for the correct procedure.
Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley" for the correct procedure.
Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan" for the correct procedure.
If the engine has an accessory drive, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive" for the correct procedure.
Remove the water pump. Refer to Disassembly and Assembly, "Water Pump" for the correct procedure.
Remove the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front)" for the correct procedure.
Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g02488340
Slide locking tab (1) (not shown) into the unlocked position.
Disconnect harness assembly (2) from coolant temperature sensor (3) .
Cut cable strap (4) and remove harness assembly (2) from bypass tube (5) .
Remove bolts (6) that secure bypass tube (5) to front housing (7) .
Remove bypass tube (5) from the cylinder head. Remove O-ring seal (8) and O-ring seal (9) from bypass tube (5) .
Illustration 2 g02488341
Remove bolts (10) , bolts (11) and bolts (12) from front housing (7) .Note: The bolts are three different lengths. Note the positions of the different bolts.
Remove front housing (7) from the cylinder block.
Remove gasket (13) .
Illustration 3 g02488356
Remove thrust washer (14) from cylinder block (15) .Installation Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-6640     Sealant     1    
B     -     Guide Studs
M8 by 80 mm     2    
C     319-6486     Alignment Tool     1    
- Bolts
M10 by 50 mm     3    
D     1U-6396     O-Ring Assembly Compound     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing.If necessary, install blanking plugs to a new front housing. Use Tooling (A) in order to seal all D-plugs.
Clean all the gasket surfaces of the cylinder block.