48641-94510 Suzuki Cylinder, trim

1. Remove the engine front hood. The weight of the hood is 84 kg (185 lb.).2. Drain the coolant from the cooling system. 3. Fasten a hoist on guard assembly (1) as shown. Remove the bolts and guard assembly (1) from the radiator guard. The weight of the guard assembly is 32 kg (70 lb.).
Always wear goggles when the air conditioning system is opened. This system is charged with Freon-12 (CCL2F2 Dichlorodifluoromethane) which is not toxic or flammable. There is however, reason for caution. When Freon-12 makes contact with a flame, lethal phosgene gas is made. INHALING FREON THROUGH A LIGHTED CIGARETTE CAN CAUSE VIOLENT ILLNESS. This system is under pressure at all times, engine running or not. HEAT MUST NEVER BE PUT ON A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual Form No. SENR7454 for more information on procedures and safety requirements on removal and installation of lines and refrigerant from the system.
4. Disconnect hose assemblies (3) from air conditioner condenser (2).5. Remove the bolts and disconnect the clips and hose assemblies (3) from the radiator guard.
To prevent possible personal injury, make sure all the pressure is released from the air system before any lines are disconnected.
6. Disconnect hose assembly (4) from the air horn.7. Remove the bolts and disconnect the clips and hose assembly (4) from the radiator guard. 8. Remove handle (6) from cable assembly (5).9. Remove nut (7) from cable assembly (5) and remove the cable assembly from the side of the radiator guard.10. Remove the bolts and disconnect the clips and cable assembly (5) from the bottom of the radiator guard. 11. Remove the bolts and disconnect coolant conditioner element (8) and base as a unit from the shield assembly. 12. Remove the bolts and disconnect elbows (9) from the radiator. 13. Remove the bolts and brace assemblies (10) from both sides of the machine. 14. Disconnect tube (11) from the ether start valve assembly. 15. Disconnect wire (12) from the wire harness. 16. Remove the bolts and guard assemblies (13) from the shield assembly. The left guard must be removed first. Rotate the right guard 180° to remove it from the left side of the machine. 17. Remove the bolts and disconnect elbow (14) from the bottom of the radiator. 18. Remove bolts (16) that hold the radiator guard to plate assembly (15). 19. Fasten tool (A) and a hoist on radiator and guard (18) as shown.20. Remove two bolts (17) from each side of the radiator guard that hold it to the machine.21. Make sure all wires, hoses and clips have been disconnected from the sides and bottom of the radiator and guard. Remove radiator and guard (18) from the machine. The weight of the radiator and guard is 601 kg (1325 lb.).Install Radiator Guard And Radiator
1. Fasten tool (A) and a hoist on radiator and radiator guard (1) and put it in position on the machine as shown. Install the two bolts on each side of the radiator guard that hold it. Tighten the bolts to a torque of 470 20 N m (347 15 lb.ft.). 2. Install the bolts that hold plate assembly (2) to the radiator guard. 3. Install the gasket and connect elbow (3) to the bottom of the radiator. 4. Install guard assemblies (4) on the shield assembly. 5. Connect wire (5) to the wire harness. 6. Connect tube (6) to the ether start valve assembly. 7. Install brace assemblies (7) to both sides of the radiator guard and the machine. Install and tighten the bolts that hold the brace assemblies to a torque of 250 15 N m (184 11 lb.ft.). 8. Install the gaskets and connect elbows (8) to the radiator. 9. Connect coolant conditioner element (9) and the base to the shield assembly. 10. Install cable assembly (10) in the radiator guard. Install locknut (11) and handle (12) on the cable assembly. 11. Connect hose assembly (13) to the air horn.12. Connect the clips and hose assembly (13) to the radiator guard. 13. Connect hose assemblies (14) to the air conditioner condenser.14. See Air Conditioning And Heating Service Manual, Form No. SENR7454, for the correct procedure for evacuating and charging the system.15. Connect the clips and hose assemblies to the radiator guard. 16. Fasten a hoist on guard assembly (15) and install it on the radiator guard.17. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.18. Install the front engine hood.