09491-95008 Suzuki Jet, Main 95

Start By:a. remove spacer platesb. remove piston cooling jets The front end of the engine is opposite the flywheel end. The No. 1 cylinder is the front right cylinder, and the No. 2 cylinder is the front left cylinder. Put identification marks on each piston by cylinder number. Also mark each piston as to its respective position to the front of the cylinder block. This is done if the piston assembly is to be removed from the rod assembly.1. Remove the cover from the front right side of the flywheel housing, and use tool (A) to turn the flywheel until all four bolts in the bearing caps can be removed.2. Put identification marks on each rod assembly as to its cylinder number. The rods are to be marked at location (X) and the rod cap at location (Y). These marks are on the same sides as the bearing tab slots.
Typical Example3. Remove bolts (1) and bearing cap (2) from the connecting rod.
Typical Example4. Push the piston up until the piston rings are clear of the cylinder liner. Remove piston (3) and the connecting rods.
Typical Example5. Use tool (B) to remove the rings that hold piston pin (4) in position. Remove pin (4). Remove piston (3) from connecting rod (5).6. Remove the bearings from the bearing cap and connecting rod (5).
Typical Example7. Use tool (C) to remove piston rings (6) from piston (3).8. Clean the piston ring grooves on the piston with an acceptable ring groove tool. 9. Position piston (3) as shown. Remove the piston skirt from piston crown (3).10. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295-02 for more information about removal and installation of piston pin bearings.11. Heat the connecting rod in an oven to a temperature of 175° C to 260° C (350° F to 500° F). Never use a direct flame to heat the connecting rod. 12. Put 6V3043 Spacer (14) in the base plate. Put the connecting rod on the base plate of tooling (D).13. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (D). Install pin (9) in the center of the bore for the connecting rod bearing.14. Install 5P8649 Adapter (12). Put the hole in the adapter in alignment with the hole in the base plate of tooling (D).15. Install clamp bar (13) and clamp pin (10). The old bearing is pushed out by tooling (D) as the new bearing is installed.16. Put 6V3042 Pusher Adapter (11) in position as shown with the taper side down. The piston pin bearing joint must be in alignment with the hole in adapter (12) and the base plate of tooling (D).17. Put pusher (7) on adapter (11).18. Use tooling (D) to push the new piston pin bearing (8) into the connecting rod until adapter (11) of tooling (D) makes full contact with the connecting rod surface.19. Remove the connecting rod and the old piston pin bearing from tooling (D).
The piston has an elliptical (not round) pin bore. When measuring the pin bore diameter of the piston, make the measurement only in the vertical position. The pin bore diameter of the piston should measure 69.983 0.005 mm (2.7552 0.0002 in). Refer to the Specifications module, Form No. SENR5595 for further information when measuring the piston and connecting rod bearing pin bores.
20. Check the inside diameter of the connecting rod pin bearing bore after the bearing is installed. The correct dimension is 70.000 0.008 mm (2.7559 .0003 in.). 21. Position piston (3) as shown. Install the piston skirt onto piston crown (3). Also see the topic "Piston Group" in the Specification module, Form No. SENR5595 for additional information when installing the piston rings.22. Use tool (C) to install the oil ring on piston (1). The oil ring spring ends are 180° from the gap in the ring. The white colored section of the oil ring spring must be visible at the ring end gap. 23. Install the two compression rings on piston (3). Install the rings with the side marked "UP" toward the top of the piston.24. The middle piston ring (lower compression) must be installed with the green color strip to the right of the ring end gap.25. The top piston ring (upper compression) must be installed with the yellow color strip to the right of the end gap.26. The three piston ring end gaps must be approximately 120° apart after installation. 27. Put clean engine oil on pin (4), the pin bearing in rod (5) and the pin bore in piston (3). Position rod (5) in piston (3). Install pin (4). Use tool (B) to install the retaining rings on each side of pin (4).28. Install the upper half of the connecting rod bearing in the connecting rod, and put clean engine oil on it. Make sure the tab on the back of the bearing fits in the groove of the rod.
Typical Example29. Put clean engine oil on the piston rings and cylinder liner bore. Use tool (E) to put the piston rings under compression, and install the pistons and connecting rods in the cylinder liners.
Make sure the piston assembly is installed with the chamfer side (X) of the connecting rod bore next to the crankshaft thrust surface. The square shouldered side (Y) of the connecting rod bore must be next to the other connecting rod on the same crankshaft journal.
30. Put 334-0519 Grease or FelPro C100 Lubricant on the bolt threads and contact surfaces of the bolts and caps (2).31. Install the lower half of the connecting rod bearing in cap (2). Lubricate the bearing with clean engine oil. Make sure the tab on the back of the bearing fits in the groove of the cap.32. Check the side clearance between two connecting rods on the same crankshaft journal. The side clearance must be 0.850 0.232 mm (.0335 .0091 in.). Refer to the topic "Install Connecting Rod Bearings" in this module, and