61111-93904-02M Suzuki Cover, Engine Under

Installation Procedure
In the field the machine can be moved onto a platform, or parked over a ditch if available. This will make the rework easier.
Illustration 1 g06095079
Locations for the wood pads
Illustration 2 g06095080
(A) Middle pad 400 mm (15.75 inch)
(B) Front pad 200 mm (7.9 inch)
If not applicable, wood pads (A) and (B) must be placed under the front instruments and middle of the chassis to raise and brake the machine as shown in the illustrations above.
The machine articulation should be disabled/locked out by using the turning prevent bar.
Illustration 3 g06095096
Drain the engine oil when the engine is still warm.Note: For safety, let the engine cool down to 50° C (122° F) before performing the rework.
Illustration 4 g06095265
(1) Cable straps
(2) Air compressor oil return line adapter
(3) Speed/Timing sensor
Remove cable straps (1) from the two locations shown in Illustration 4. Disconnect air compressor oil return line adapter (2) and speed/timing sensor (3) before removing the oil pan.
Illustration 5 g06095281
(4) Engine oil pan
(5) Oil suction tube assembly
Remove engine oil pan (4) while not taking care not to damage oil suction tube assembly (5). Remove the oil suction tube assembly after removing the oil pan.
Illustration 6 g06095287
(6) Clutch disengagement tool
(7) Engine turning tool
Use clutch disengagement tool (6) to disengage the clutch before turning the engine over.
Use engine turning tool (7) to turn the engine over during the rework procedure to expose different sets of connecting rod caps.
Illustration 7 g06095295
(8) Serial number batch number
(9) Connecting rod cap alignment number
Illustration 7 shows pistons number 1 and 6 at the lowest points in the engine rotation. At this point the serial number batch number (8) and connecting rod cap alignment number can be recorded.
Illustration 8 g06095313
(10) Connecting rod bolts
Replace connecting rod bolts (10). Follow the procedure below for the replacement of the connecting rod bolts.Note: Do not remove the connecting rod cap at any point of this rework procedure. Removal of the rod cap could disturb the connecting rod to connecting rod cap joint.
Remove the bolt on the tab side of the connecting rod and replace it with a new connecting rod bolt.
Tighten the bolt to 130 7 N m (96 5 lb ft).
Remove and replace the other bolt in the connecting rod cap. Tighten the second bolt to 130 7 N m (96 5 lb ft).
Turn the first bolt an extra 60° 5°. Then turn the second bolt an extra 60° 5°.
Repeat this process for each additional set of connecting rods until all connecting rod bolts have been replaced.
Illustration 9 g06095373
Clean the oil pan and cylinder block contact surface. Apply Loctite 596 to the 4 corners of the cylinder block as shown in Illustration 9.
Illustration 10 g06095377
(5) Oil suction tube assembly
Reinstall oil suction tube assembly (5) back onto the engine. Install a new oil pan isolation seal gasket onto the contact surface of the cylinder block.
Illustration 11 g06095382
(4) Oil pan
Reinstall engine oil pan (4) back onto the engine.
Perform the final inspection of verification of the repair.
Refill the engine with new engine oil.
Perform an inspection of the machine and engine before starting the machine.
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