99011-87D28-03A Suzuki DT150/200 OWNERS MANUAL

TYPICAL EXAMPLE3. Remove the cylinder liner with tooling (A).Install Cylinder Liners
1. Clean the cylinder liners and block.2. Install the liners in the block without the O-ring seals.3. Install tooling (A) and two 5/8"-11 NC bolts 4 1/2 in. long. Tighten the bolts evenly in four steps: 5 lb.ft. (7 N m), 15 lb.ft. (20 N m), 25 lb.ft. (35 N m) and 50 lb.ft. (70 N m). 4. Check the liner (projection) height with tool group (B) at four locations around the liner. The difference between the four measurements must not be more than .002 in. (0.05 mm). 5. The liner (projection) height must be .0020 to .0056 in. (0.051 to 0.142 mm). The measurement between liners next to each other, must not be more than .002 in. (0.05 mm) difference. If the liner is turned in the bore, it can make a difference in the liner (projection) height. 6. If the liner (projection) height is not .0020 to .0056 in. (0.051 to .0142 mm), check the thickness of the liner flange (1) and depth of the liner bore (2) in the block (3). The thickness of the liner flange must be .4048 .0008 in. (10.282 0.020 mm). The depth of the liner bore in block must be .401 .001 in. (10.19 0.03 mm). If the liner bore in the block is worn and the measurement is not correct, the liner bore can be corrected with a cylinder block counterboring tool. See SPECIAL INSTRUCTIONS, FORM FM055228.7. Put a mark on the liner and block so the liner can be installed in the same position from which it was removed.
TYPICAL EXAMPLE8. Install new seals (4) on the cylinder liners. Put liquid soap on the seals and in the bores in the cylinder block.
The liners must be installed in the cylinder block immediately after band (5) is installed. Make sure the marks on the liners and the cylinder block are in alignment when the cylinder liners are installed.
9. Put clean engine oil on band (5) and install it on the liner as shown. Put clean SAE 30 oil on the liner and install it immediately in the cylinder block with tool group (C).end by: a) install pistonsRemove Cylinder Liners
start by: a) remove pistons1. Remove the coolant from the cylinder block.2. Put covers on journals of crankshaft for protection from dirt or water.3. Remove cylinder liners (1) with tooling (A).Install Cylinder Liners
1. Clean the cylinder liners (3) and the liner bores in the cylinder block.2. Install the cylinder liners in the block without the O-ring seals or filler bands.3. Check the cylinder liner projection as follows: a) Install the S1589 Bolts (2) and 1S379 Washers of tooling (B) on the cylinder block next to each liner. Tighten the bolts evenly, in four steps: 10 lb.ft. (14 N m), 25 lb.ft. (35 N m), 50 lb.ft. (70 N m) and 70 lb.ft. (95 N m).b) Put adapter plate on top of the liner and install the remainder of tooling (B). Tighten the 1D4595 Bolts (1) evenly in four steps: 5 lb.ft. (7 N m), 15 lb.ft. (20 N ), 25 lb.ft. (35 N m) and 50 lb.ft. (70 N m).c) Check to be sure the distance from the bottom edge of the crossbar to the top of the cylinder block is the same on both sides of the liner.d) Check the cylinder liner projection with tool group (C) at four locations around the liner.e) Liner projection must be .0013 to .0069 in. (0.033 to 0.175 mm). Measurements on the same liner must not be different by more than .002 in. (0.05 mm). Average measurements between liners next to each other must not be different by more than .002 in. (0.05 mm). If the liner is turned in the bore, it can make a difference in the liner projection.4. If the liner projection is not .0013 to .0069 in. (0.033 to 0.175 mm), check the thickness of the following parts: spacer plate, spacer plate gasket and cylinder liner flange. The thickness of the spacer plate must be .3925 .0010 in. (9.970 0.025 mm). The thickness of the spacer plate gasket must be .0082 .0010 in. (0.208 0.025 mm). The thickness of the cylinder liner flange must be .4048 .0008 in. (10.282 0.020 mm). If the liner projection changes from point to point around the liner, turn the liner to a new position in the bore. If the liner projection is still not to specifications, move the liner to a different bore.5. When the cylinder projection is correct, put a mark on the liner and block so the liner can be installed in the same position from which it was removed. Cylinder liner projection can be adjusted by the removal of material from (machining) the contact face of the cylinder block with the use of the 8S3140 Cylinder Block Counterboring Tool Arrangement. Machine to a minimum depth of .030 in. (0.76 mm) and to a maximum depth of .045 in. (1.14 mm). The instructions for the use of the tool group are in Special Instruction Form No. FM055228. Shims are available for the adjustment of the liner projection. See CYLINDER LINER PROJECTION in TESTING AND ADJUSTING for the shim thickness and part number.6. Remove tooling (B) and (C). Remove the liner. 7. Put liquid soap on bottom liner bore in block, on grooves in lower liner and on O-ring seals (4). Install O-ring seals on the liner.8. Put filler band (5) in clean SAE 30 oil for a moment and install on liner. Install cylinder liner immediately in the cylinder block (before expansion of filler band). 9. Make sure the mark on liner is in alignment with the mark on the block. Use tooling (A) to push the liner into position.10. Do Steps 5 through 9 for the remainder of the cylinder liners.end by: a) install pistons