11300-87D68-0ED Suzuki CRANKCASE ASSEMBLY

1. Put the engine in position on tool (A).2. Install two 5/8 "-18 NF x 4 in. long bolts to hold the crankshaft rear gear in position.3. Remove the three bolts and nuts (2).4. Remove the eight bolts (4) and (6).5. Remove exhaust pipes (1) and (3) with couplings (5) and (7). 6. Remove oil line (8). 7. Install two 3/8 "-16 NC forged eyebolts in flywheel housing (9) and fasten a hoist to the flywheel housing.8. Remove plug (11) from flywheel housing (9) for installation purposes.9. Remove the twenty-one bolts (10) that hold flywheel housing (9) in position and remove the flywheel housing. Weight of the flywheel housing is 154 kg (340 lb).Install Flywheel Housing
1. Install a new gasket on the cylinder block.2. Put clean engine oil on the crankshaft rear wear sleeve and seal. Install tool (A) in the crankshaft rear seal.3. Install two 3/8 "-16 NC forged eyebolts in the flywheel housing and fasten a hoist to the flywheel housing.4. Put the flywheel housing in position and use hole (1) to visually make an alignment of the "V" marks on the balancer gear and the crankshaft rear gear with cylinder number one at top center. 5. Remove tool (A) and install bolts (3) that hold the flywheel housing in position.6. Install plug (2) in the flywheel housing.7. Install the oil line to the cylinder block and flywheel housing. 8. Make a replacement of the seal rings on couplings (7) and (8) if necessary.9. Install couplings (7) and (8), exhaust pipes (5) and (6) and the bolts to hold them.10. Put gasket (4) in position between exhaust pipes (5) and (6).11. Put 5P3931 Anti-Seize Compound on the three bolts and nuts that hold the exhaust pipes together and install them.12. Remove the two bolts used to hold the crankshaft rear gear in position.13. Cut the flywheel housing gasket even with the oil pan rail.End By:a. install pump drivesb. install oil panc. install electric starting motord. install flywheele. install turbochargerf. install engineDisassemble Flywheel Housing
Start By:a. remove flywheel housing 1. With the flywheel housing in the position shown remove bolts (1) from shafts (2).
The bearing toward the flywheel housing will fall when the gears are removed. Hold these bearings in position when the gears are removed.
2. Remove balancer gear (4) and idler gear (3). 3. Disassemble balancer gear (4) as follows:a. Remove bearing cups (8) and (11) and spacer (9) from gear (4). The bearing cups will have damage after removal. Use new parts for replacement.c. If necessary remove ring (10) from gear (4).4. Disassemble idler gear (3) the same as in Steps 3a through 3c.Assemble Flywheel Housing
1. Assemble balancer gear (3) as follows:a. Install ring (2) in gear (3).b. Install spacer (1) in gear (3) from the timing mark side of the gear as shown.c. Use a press and tool (A) to install the bearing cones until they are in contact with the spacer. Install the bearing cone in the timing mark side of gear (3) first to hold the spacer in position.d. Install the spacers, bearing cones and shaft in gear (3).2. Assemble idler gear (4) the same as in Steps 1a through 1d.3. Put idler gear (4) and balancer gear (3) in position on the flywheel housing. Make sure the oil holes in shafts (6) are in alignment with the oil holes in the flywheel housing. Install balancer gear (3) with the timing mark toward the flywheel housing.4. Install bolts (5) to hold the shafts.End By:a. install flywheel housing