99011-95541-03A Suzuki DT75/85 OWNERS MANUAL

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-8221     Lifting Sling     1    Start By:
Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".
Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".
Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove".
If the engine is equipped with a balancer, remove the balancer. Refer to Disassembly and Assembly, "Balancer - Remove". If the engine is not equipped with a balancer, remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove and Install".
If the crankshaft has been reground or if the crankshaft has been replaced, the height of the piston above the cylinder block must be inspected. It is necessary to remove the cylinder head in order to inspect the height of the piston above the cylinder block.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The engine should be mounted on a suitable stand and placed in the inverted position.
If necessary, remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".If the cylinder head, the pistons and the connecting rods have not been removed, remove the connecting rod caps. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Remove".
Illustration 1 g01439628
Typical example
Remove allen head screws (1) . Remove bridge piece (2) .
Ensure that the main bearing caps are marked for the location and orientation.
Illustration 2 g01253719
Typical example
Remove bolts (3) and main bearing caps (4) from the cylinder block.
Illustration 3 g01253146
Typical example
Illustration 4 g01253137
Typical example
Remove lower main bearings (5) from main bearing caps (4) . Take care not to displace dowels (6) . For number three main bearing cap, remove thrust washers (7) . Keep the lower main bearings and the thrust washers with the respective main bearing caps.Note: The lower main bearings are plain bearings that have no oil holes. The dowels may remain in the main bearing cap or in the cylinder block.
Illustration 5 g01254099
Typical example
Attach Tooling (A) and a suitable lifting device to crankshaft (8) . Carefully lift the crankshaft out of the cylinder block. The weight of the crankshaft is approximately 30 kg (66 lb).Note: Do not damage any of the finished surfaces on the crankshaft. When the crankshaft is removed from the engine, the crankshaft must be supported on a suitable stand in order to prevent damage to the crankshaft timing ring.
Illustration 6 g01254104
Typical example
Illustration 7 g01889993
No. 1 Upper Main Bearing
Illustration 8 g03326558
Remaining Original Upper Main Bearing
Remove upper main bearings (9) from the cylinder block. Keep the upper main bearings with the respective main bearing caps.Note: Number one upper main bearing has an oil slot. See Illustration 7. If the engine is equipped with the original main bearing shells, all other upper shells except number one will have a slot and two oil holes. See Illustration 8.If the engine has had replacement main bearing shells, the upper main bearing shells will all have a groove and an oil slot.
Remove thrust washers (10) from number three main bearing in the cylinder block.
If necessary, remove the crankshaft timing ring. Refer to Disassembly and Assembly, "Crankshaft Timing Ring - Remove and Install".
If necessary, remove the crankshaft gear. Refer to Disassembly and Assembly, "Crankshaft Gear - Remove