51140-98J00-0EP Suzuki COVER, ENGINE HOLDER (X,XX)

Introduction
This Special Instruction is intended to provide a rework of the engine hood to install an additional latch. The additional latch creates a stronger joint to protect the hood from excessive vibration and movement.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Required Parts
Table 1
Parts List
Qty Part Number Part Name
1 524-4925 Bracket As.
1 524-4928 Bracket As.
1 525-6086 Cover As.
1 375-8750 Latch As
6 8T-4908 Bolt
4 5P-4116 Hard Washer
2 096-4129 Cushion
4 9X-8256 Washer
4 8T-6693 Screw
1 526-7133 Bracket As.
2 4I-0118 Hook
6 8T-4224 Hard Washer
4 8T-4189 Bolt The following parts are only necessary if they are found to be damaged or missing.
Table 2
Parts List
Qty Part Number Part Name
1 366-7176 Engine Compartment Hood
1 096-4129 Cushion
2 8T-6693 Screw
2 9X-8256 Washer
387 cm (152 inch) 124-3243 Seal
1 375-8749 Latch As
1 375-8750 Latch As Installation Procedure
If the engine hood is cracked around the shell near the latch or hinge, or if the bonded iron plate has been dropped from the hood assembly, replace the hood with new one.
Illustration 1 g06165014
(1) 096-4129 Cushion
(2) 8T-6693 Screw
(3) 9X-8256 Washer
(4) 375-8749 Latch As
(5) 375-8750 Latch As
(6) 366-7176 Engine Compartment Hood
(7) 124-3243 Seal
Inspect seal (7). If the seal is damaged or missing, replace the seal. The length of the seal is 387 cm (152 inch).
Inspect cushion (1) at latch (4). Replace the cushion if missing or damaged. Check for missing screws (2) at the cushion. If a screw (and washer) is missing, loose, or damaged, replace the screw and washer. Apply thread lock to the screw before installation. The following threadlockers are allowed:
Loctite 263
Loctite 270
Threebond TB#2471
Threebond TB#1305Tighten the screw to 3 N m (27 lb in).
Inspect latches (4) and (5). If damage is found, replace the latches.
Illustration 2 g06165236
Drill four, 13 mm holes at the locations shown in Illustration 2.
Illustration 3 g06165247
(1) 096-4129 Cushion
(2) 8T-6693 Screw
(3) 9X-8256 Washer
(5) 375-8750 Latch As
(8) 8T-4908 Bolt
(9) 5P-4116 Hard Washer
(10) 524-4925 Bracket As.
(11) 8T-4224 Hard Washer
(12) 524-4928 Bracket As.
Position bracket (10) on the outside of the hood where the holes were drilled. Position bracket (12) on the inside of the hood where the holes were drilled. Align the holes and secure the two brackets to the hood using four bolts (8) and washers (9).
Install latch (5) to bracket (10) using two bolts (8) and washers (11).
Install cushion (1) to bracket (12) using two screws (2) and washers (3). Apply thread lock to the threads of the screws before assembly. Approved thread lock compounds are listed in Step 3. Tighten the screws to 3 N m (27 lb in).
Illustration 4 g06165274
(1) 096-4129 Cushion
(2) 8T-6693 Screw
(3) 9X-8256 Washer
(13) 526-7133 Bracket As
Replace the existing bracket with bracket (13). Install a new cushion (1) using two screws (2) and washers (3). Apply thread lock to the threads of the screws before assembly. Approved thread lock compounds are listed in Step 3. Tighten the screws to 3 N m (27 lb in).