11301-95530-02M Suzuki Cylinder, Crankcase Assembly

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 230-6284 Timing Pin (Camshaft) 1
C 364-9107 Fuel Injection Pump Timing Pin 1
D 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
E 298-5564 T40 Torx Socket 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.Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. Care must be taken to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure to remove the gear group.
Illustration 1 g01992076
Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.
Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Install Tooling (D) through Hole (W) to lock the crankshaft.
Remove Tooling (D).
Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
Illustration 2 g03453525
Use Tooling (E) to loosen threaded inserts (4) on all rocker arms (3). Unscrew threaded inserts (4) on all rocker arms (3) until all valves are fully closed.Note: Ensure that ALL threaded inserts are fully unscrewed.
Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Install Tooling (D) through Hole (W) to lock the crankshaft. Refer to Illustration 1.
Illustration 3 g03453527
Install Tooling (B) through Hole (X) in camshaft gear (5) into the front housing. Use Tooling (B) to lock the camshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Install Tooling (D) into Hole (W) in the cylinder block. Use Tooling (D) to lock the crankshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.Note: Do not use excessive force to install Tooling (D). Do not use Tooling (D) to hold the crankshaft during repairs.
Use Tooling (C) to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
Illustration 4 g03453528
Mark gear (5), gear (6), gear (7), and gear (8) to show alignment. Refer to Illustration 4.Note: Identification will ensure that the gears can be installed in the original alignment.
Remove Tooling (B), Tooling (C), and Tooling (D).
Remove camshaft gear (5). Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.
Remove idler gear (6). Refer to Disassembly and Assembly, "Idler Gear - Remove and Install" for the correct procedure.Installation Procedure
Table 2
Required Tools