57521-94400 Suzuki Gear, Reverse

Start By:a. remove hood Remove the mounting of the air condition condenser core and set core out of the way on the left side. 1. Disconnect line (2) from the quick drop valve.2. Remove the bolts and clips holding line (1) and re-position line (1) out of the way. 3. Disconnect two hose assemblies (3).4. Remove two allen bolts (4) and re-position the hoses and bracket out of the way. 5. Remove three nuts (5) and remaining nut on opposite side and remove crossbar (6). 6. Remove side panel (7) from each side. 7. Remove two bolts and washers (8) and guard (9). 8. Remove two bolts and washers (10) and guard (11).9. Unbolt fan (12) from fan drive and wire the fan to fan guard (13). 10. Remove bolts and washers (14) holding two piece grille (15) in place. 11. The grille can be opened and placed in the lock position or attach a lifting strap and remove the grille sections as shown. The weight of each section is 55 kg (120 lb). 12. Using two people, remove four bolts and washers (16) and front guard (17). The weight of front guard (17) is 17 kg (38 lb). 13. Remove bolt, washer and bracket (18) holding the breather hose to the radiator. 14. Remove two bolts and washers (19) and re-position the assembly out of the way.15. Disconnect wire harness (20).16. Remove bolt and washer (21) and re-position wire harness out of the way. 17. Remove bolt and washer (22) holding clip to the radiator (two places). 18. Loosen clamp (23) on the bottom radiator hoses on both sides. 19. Remove two bolts and washers (24) and pin retainer (25) on each side. 20. Attach Tooling (A) and a load leveler as shown. 21. Remove pin (26) from each side. 22. Remove two bolts and washers (27), pin retainer (28) and pin (29) from each side.23. Remove the radiator guard assembly. The weight of the radiator guard is approximately 1670 kg (3700 lb). Use care when removing the guard assembly not to damage the fan assembly. 24. If necessary remove and replace two rear bushings (30) one on each side of machine and front bushing (31) one on each side of machine. 25. If necessary remove and replace two bushings (32) one on each side of radiator guard. The following steps are for the installation of the radiator guard. 26. If bushings (32) were removed, replace with new bushings one on each side of radiator guard. 27. If bushings were removed, replace with new rear bushings one on each side of machine and front bushing one on each side of machine. 28. Attach Tooling (A) and a load leveler as shown. 29. Install the radiator guard assembly. The weight of the radiator guard is approximately 1670 kg (3700 lb).29. Install pin (29) on each side, pin retainer and two bolts and washers (27). Use care when installing the guard assembly not to damage the fan assembly. 30. Install pin (26) on each side. 32. Install pin retainer (25) on each side and two bolts and washers (24). 33. Tighten clamp (23) on the bottom radiator hoses on both sides. 34. Install bolt and washer (22) holding clip to the radiator (two places). 35. Install assembly, two bolts and washers (19).36. Connect wire harness (20).37. Install wire harness, bolt and washer (21). 38. Install bolt, washer and bracket (18) holding the breather hose to the radiator. 39. Using two people, install front guard (17) using four bolts and washers (16). The weight of front guard (17) is 17 kg (38 lb). 40. If the grille was removed attach a lifting strap and install the grille sections as shown. The weight of each section is 55 kg (120 lb). If the grille was opened and placed in the locked position, remove lock arm and close grille. 41. Install two piece grille (15) in place using bolts and washers (14). 42. Install guard (11) using two bolts and washers (10).43. Remove fan (12) from fan guard (13) and bolt fan (12) to fan drive. 44. Install guard (9) using two bolts and washers (8). 45. Install side panel (7) on each side. 46. Install crossbar (6) using three nuts (5) and remaining nut on opposite side. 47. Connect two hose assemblies (3).48. Install the hoses and bracket using two button head bolts (4). 49. Connect line (2) to the quick drop valve.50. Install the bolts and clips holding line (1).End By:a. install hood