09381-19002 Suzuki CLUTCH ROD CONNECTOR STOPPER

3. Make an adjustment of the legs on tool (A) for the length of the cylinder liner.
Be careful not to damage the piston cooling tube at the bottom of the cylinder liner.
4. Install tool (A) and remove the cylinder liner. 5. Remove filler band (2) and O-ring seals (1) from the cylinder liner.Install Cylinder Liners
1. Clean the cylinder liners and liner bores in the block.2. Install the liners in the block without seals or filler bands. 3. Check the cylinder liner projection as follows:a. Install the 3/4 "-16 NF bolts and 2F126 washers of tooling (A) on the spacer plate around each cylinder liner as shown. Tighten the bolts evenly in four steps. 1. Tighten to a torque of 14 N m (10 lb ft).2. Tighten to a torque of 35 N m (25 lb ft).3. Tighten to a torque of 70 N m (50 lb ft).4. Tighten to a torque of 95 N m (70 lb ft).b. Put the adapter plate and one plate of tooling (A) on top of the liner and install the remainder of tooling (A). Be sure the crossbar is in position at the center of the liner. Tighten the bolts that hold tooling (A) evenly in four steps: 1. Tighten to a torque of 7 N m (5 lb ft).2. Tighten to a torque of 20 N m (15 lb ft).3. Tighten to a torque of 35 N m (25 lb ft).4. Tighten to a torque of 70 N m (50 lb ft).c. Check to be sure the distance from the bottom edge of the bar to the top of the cylinder block is the same on both sides of the cylinder liner.d. Check the cylinder liner projection with tooling (B) at four locations around the cylinder liner.e. Liner projection must be 0.13 0.08 mm (.005 .003 in). Measurements on the same liner must not be different by more than 0.05 mm (.002 in). Average measurements between liners next to each other must not be different by more than 0.05 mm (.002 in). If the liner is turned in the bore it can make a difference in the liner projection. 4. If the liner projection is not 0.13 0.08 mm (.005 .003 in) check the thickness of the following parts: spacer plate, spacer plate gasket and cylinder liner flange. The thickness of the spacer plate must be 8.59 0.03 mm (.338 .001 in). The thickness of the spacer plate gasket must be 0.20 0.03 mm (.008 .001 in). The thickness (1) of the cylinder liner flange must be 8.890 0.020 mm (.3500 .0008 in). The cylinder liner projection can be changed if a counterbore is made in the block to a minimum depth of 0.76 mm (.030 in) with a cylinder block counter boring tool. See Special Instruction, Form No. FM055228. Shims are available for the adjustment of the liner projection. See Projection Of Cylinder Liner in Testing And Adjusting for the shim thickness and part number.5. Put a mark on the liner and block so the liner can be installed in the same position as it was removed.6. Remove tooling (A) and tool (B). Remove one liner. 7. Put liquid soap on O-ring seals, grooves of the liner and the bore of the cylinder block. Install O-ring seals (2) on the cylinder liner.8. Put (dip) filler band (3) completely in clean SAE 30 oil and install immediately. Install the filler band on the cylinder liner.
Cylinder liner must be installed in the block immediately after the filler band is installed on the liner. The filler band gets larger after it has been put in oil and can be damaged when installed if there is a time delay in installation.
9. Install the liner immediately after the filler band is installed. Make sure the mark on the liner is in alignment with the mark on the block. Use tooling (C) to push the liner into position.10. Do Steps 6 through 9 for remainder of the cylinder liners.End By:a. install pistons