09204-01001 Suzuki Cotter Pin, Clutch Rod

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 1U-6684 Piston Ring Compressor 1
C 227-4390 E12 Torx Socket 1
D 8T-3052 Degree Wheel 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Discard all used Connecting Rod bolts.
If the connecting rod caps were temporarily installed, remove the connecting rod caps. If necessary, thoroughly clean all the components.
Apply clean engine oil to the cylinder bore, piston rings, outer surface of the piston and the bearing shells for the connecting rod.Note: Install the bearing shells for the connecting rods dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for the correct procedure. Apply clean engine oil to the bearing shells for the connecting rods during final assembly.Note: Ensure that the piston and the connecting rod assembly are installed in the correct cylinder.
Use Tooling (A) to rotate the crankshaft until the crankshaft pin is at the bottom center position. Lubricate the crankshaft pin with clean engine oil.
Illustration 1 g02013213
Install Tooling (B) onto piston (4).Note: Ensure that Tooling (B) is installed correctly and that piston (4) can easily slide from the tool.Note: The arrow on the top of the piston must be toward the front of the engine. The locating tab for the bearing shell of the connecting rod must be on the same side of the engine as the piston cooling jet.
Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the crankshaft pin.Note: Do not damage the finished surface of the crankshaft pin.
Illustration 2 g06021020
Illustration 3 g06021018
Bolt (3a) are Torx
Bolt (3b) are Bi-Hex
If bolts (3a) were removed, new bolts (3a) must be installed.If bolts (3b) were removed, new bolts (3b) must be installed.
Install connecting rod cap (2) onto connecting rod (1).Note: Ensure that dot punched number in Position (X) on connecting rod cap (2) matches dot punched number in Position (X) on connecting rod (1). Ensure the correct orientation of connecting rod cap (2). The locating tab for the upper bearing shell and the lower bearing shell should be on the same side.
Install new bolts (3a) or (3b) to the connecting rod. Tighten the bolts evenly to a torque of 18 N m (13 lb ft).Note: Do not reuse the old bolts to secure the connecting rod cap.
Tighten bolts (3a) evenly to a torque of 40 N m (30 lb ft).Turn bolts (3a) through a further 120 degrees. Use Tooling (C) and Tooling (D) to achieve the correct final torque.
Tighten bolts (3b) evenly to a torque of 70 N m (52 lb ft).Turn bolts (3b) through a further 120 degrees. Use Tooling (C) and Tooling (D) to achieve the correct final torque.
Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft to ensure that there is no binding.
Repeat Step 2 through Step 11 to install the remaining pistons and connecting rods.End By:
Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install" for the correct procedure.
Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install" for the correct procedure.