63111-93205-02M Suzuki Handle, Tiller

Introduction
Ensure that you read and fully understand the information that follows before ordering any parts or performing any procedures.This Special Instruction contains the procedures to replace the previous engine alternator mounting group with the new engine alternator mounting group. This change will help prevent vibration damage present in the previous alternator mounting groups design.286-8180
Illustration 1 g06002338
(1) 186-3651 Bracket
(2) 6V-2605 Taperlock Stud
(3) 9S-8752 Full Nut
(4) 1S-9130 Stud
(5) 2A-1531 Bolt
(6) 5P-8245 Hard Washer
(7) 1F-7958 Full Nut
(8) 4L-4648 V-Belt
(9) 0S-1585 Bolt
(10) 6B-6684 Full Nut
(11) 4N-4942 Adjustment Rod
(12) 282-6844 Bracket
(13) 0S-1591 Bolt
(14) 5M-2894 Hard Washer
(15) 1W-1456 Alternator Pulley
(16) 1A-1460 Bolt
(17) 8S-5383 Block
(18) 1A-2029 Bolt
(19) 479-0175 Bracket
(20) 437-7746 Mount
(21) 054-3788 Washer
(22) 0S-1588 Bolt
(23) 2B-0947 Bolt
(24) 7W-5520 Block
(25) 481-2522 Block
(26) 9X-6458 Hard Washer
(27) 0S-1587 Bolt
(28) 444-6549 Rod As
(29) 7X-3374 Full Nut
(30) 451-8195 RodRefer to Illustration 1 for the installed location of the new parts and the reused parts.Refer to Table 1 for a list of new parts that are required to complete the update to 286-8180-01.Note: Some parts will be reused from the disassembly of the 286-8180-00.
Table 1
286-8180 Alternator Mounting Gp
Quantity New Part Number New Part Name
1 054-3788 Washer
NOT USED 0L-1329 Bolt
1 0S-1587 Bolt
2 0S-1588 Bolts
1 1F-7958 Full Nut
1 2B-0947 Bolt
2 437-7746 Mounts
1 444-6549 Rod As
1 451-8195 Rod
1 479-0175 Bracket
1 481-2522 Block
NOT USED 481-3933 Block
1 5L-5012 V-Belt Set
2 5P-8245 Hard Washers
1 6V-2605 Taperlock Stud
3 7X-3374 Full Nut
NOT USED 9H-8260 Bolt
2 9X-6458 Hard Washers
Install bracket (19) using taperlock studs (2) and the previously removed nuts to the front housing.
Lubricate mounts (20) with 207-1601 Rubber Lubricant before installation. Assemble the alternator to the support assembly (19) using the bolt, washer, and nut that was previously removed.Note: : Place a washer (21) on the inside next to support assembly (19) on the nut side.Note: Torque of the bolt (5) is 105 20 N m (77 15 lb ft). Leave hand tight till Step 5.
Mount block (25) with rod assembly (30) and secure with bolt (27) and bolts (18).
Assemble adjusting rod (30) and two jam nuts (29) to the rod assembly (28). Tighten the assembly to the proper torque.Note: Use a backup wrench to secure the rod end (30) when tightening the jam nut against the rod end. Torque of the jam nut (29) is 40 N m (30 lb ft). Leave hand tight till Step 5.Note: Assemblies in Step 5 are to be assembled hand tight, so that the alternator V belt can be adjusted prior to final torque of the components.
Install the alternator on adjustment rod (30) attaching to block (17).
Install the V-belt and adjust belt tension according to the following procedure:
With both rod adjustment jam nuts (29) loose, release rod block bolt (23) by 180 degrees.
Drape belt around the alternator pulley first then the crankshaft pulley.
Check that the belt fits in the pulley grooves.
Set belt tension 800 44 N (180 10 lb).
Torque rod block bolt (23).
Torque outside jam nut (29) while holding the inside jam nut (29) to maintain correct positioning. Torque to 40 N m (30 lb ft).286-8179
Illustration 2 g06002496
(1) 186-3651 Bracket
(2) 6V-2605 Taperlock Stud
(3) 9S-8752 Full Nut
(4) 1S-9130 Stud
(5) 2A-1531 Bolt
(6) 5P-8245 Hard Washer
(7) 1F-7958 Full Nut
(8) 7N-3948 V-Belt
(9) 9S-1366 Bolt
(10) 6B-6684 Full Nut
(11) 4N-4942 Adjustment Rod
(12) 282-6844 Bracket
(13) 0S-1591 Bolt
(14) 5M-2894 Hard Washer
(15) 1W-1456 Alternator Pulley
(16) 1A-1460 Bolt
(17) 8S-5383 Block
(18) 1A-2029 Bolt
(19) 479-0175 Bracket
(20) 437-7746 Mount
(21) 054-3788 Washer
(22) 0S-1588 Bolt
(23) 2B-0947 Bolt
(24) 481-3933 Block
(25) 7W-5520 Block
(26) 481-2522 Block
(27) 9X-6458 Hard Washer
(28) 0L-1329 Bolt
(29) 444-6549 Rod As
(30) 7X-3374 Full Nut
(31) 451-8195 Rod
(32) 9H-8260 BoltRefer to Illustration 2 for the installed location of the new parts and the reused parts.Refer to Table 2 for a list of new parts that are required to complete the update to 286-8179-01.Note: Some parts will be reused from the disassembly of the 286-8179-00.
Table 2
286-8179 Alternator Mounting Gp
Quantity New Part Number New Part Name
1 054-3788 Washer
1 0L-1329 Bolt
NOT USED 0S-1587 Bolt
2 0S-1588 Bolts
1 1F-7958 Full Nut
1 2B-0947 Bolt
2 437-7746 Mounts
1 444-6549