09491-97004 Suzuki JET, MAIN (#97.5)

1. Turn the valve on the air reservoir to the "OPEN" position and remove (bleed) the air pressure from the system.2. Drain the coolant from the cooling system to a level below the air compressor. 3. Disconnect water lines (1) and (2) from the air compressor.4. Disconnect air lines (3) and (4). 5. Disconnect oil drain line (5). Remove three nuts (6). Remove air compressor (7) from the accessory drive.Install Air Compressor
1. Install a new gasket on the accessory drive. 2. Put a small amount of SAE 30 oil on the O-ring seal and install air compressor (1) on the accessory drive. 3. Connect water lines (2) and (3) to the air compressor.4. Connect air lines (4) and (5).5. Connect oil drain line (6).6. Fill the cooling system with coolant to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.7. Turn the valve on the air reservoir to the "CLOSED" position.Disassemble Air Compressor
start by:a) remove air compressor 1. Remove elbow (1) and adapter. Remove the gasket, screen and gasket from behind the flange.2. Remove air compressor governor (2).3. Put a mark on the head assembly and block for correct assembly. 4. Remove six bolts (3). Remove head assembly (4). 5. Remove inlet valve springs (5) from the head assembly.6. Remove discharge valve seats (6). 7. Remove discharge valves (7). Remove springs from behind the valves. Check the discharge valve stops for wear or damage. If the discharge valve travel exceeds .057 in. (1.45 mm), make a replacement of the head assembly. 8. Remove inlet valves (8) from guides. Remove guides (9) from around the inlet valve seats. 9. Remove unloader spring (10), spring seat and spring saddle (12).10. Remove unloader plungers (11) and guides. 11. To remove unloader pistons (13) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad unloader port (14). 12. Check inlet valve seats (15) and unloader bore bushings (16) for damage or wear. If necessary, make a replacement. 13. Remove bolts (17). Remove cover (18) and gasket from the crankcase assembly.14. Put marks on the rod bearing caps and rods for correct assembly. 15. Remove bolts (19) and locks. Remove rod bearing caps (20). Push the pistons and rods through the top of the crankcase assembly. 16. Remove rod pin (21) from the piston. Remove rod (23).17. Remove bearings (22) from the rods and caps. 18. Use tooling (A) to remove bushing (24) from the rod. 19. Remove buttons (25) from each end of the rod pins. 20. Remove piston rings (26) from piston (27) with an approved ring expander. 21. Remove O-ring seal (29) from the crankshaft.22. Remove bolts (28). Remove adapter (30) from the crankcase assembly. 23. Remove three O-ring seals (32) from the adapter.24. Remove thrust bearing (31). 25. Use tooling (A) and a press to remove the bearing from the adapter.
Do not cause damage to the bearing surfaces of the crankshaft when it is removed from the crankcase assembly.
26. Remove crankshaft (33) from the crankcase assembly. 27. Remove bolts (34). Remove cover (35). Remove two O-ring seals from the crankcase assembly. 28. Remove O-ring seal (37) from the cover.29. Remove thrust bearing (36). 30. Remove bearing (38) from the cover.Assemble Air Compressor
1. Check all parts for damage or wear. If necessary, make a replacement with a new part.2. Make sure all parts are clean and free of dirt and foreign material. 3. Use tool (A) and a press to install the bearing in cover (1). 4. Install O-ring seal (3) on the cover.5. Install thrust bearing (2). 6. Install O-ring seals (4) in the crankcase assembly.7. Put a small amount of SAE 30 oil on the O-ring seal and install the cover on crankcase assembly (5). Tighten the bolts to a torque of 25 to 35 lb.ft. (35 to 45 N m). 8. Put crankshaft (6) in position in the crankcase assembly. 9. Use tool (A) and a press to install the bearing in adapter (7). 10. Install O-ring seal (9) on the adapter.11. Install thrust bearing (8). 12. Install O-ring seals (10) in the crankcase assembly.13. Put adapter (7) in position on the crankcase assembly. Install the bolts that hold it. Tighten the bolts to a torque of 38 to 45 lb.ft. (49 to 60 N m). 14. Use tooling (A) to install the bushings in the rods. Make sure the oil hole in the bushing is in alignment with the oil hole in the rod. The bushing inside diameter must be .5314 to .5317 in. (13.498 to 13.505 mm).15. Install buttons (14) in each end of the rod pins. 16. Put rod (13) in position in piston (11). Install rod pin (12) in the piston. 17. Install piston rings (15) and oil ring (16) on the pistons. Check all groove and ring gap clearance. The correct groove clearance for the piston rings is .002 to .004 in. (0.05 to 0.10 mm). The correct groove clearance for the oil ring is .001 to .003 in. (0.03 to 0.08 mm). The correct ring gap clearance is .002 to .010 in. (0.05 to 0.25 mm). 18. Install bearings (17) in the rods.19. Put clean SAE 30 oil on the piston rings and rod bearings. Turn the crankshaft so one of the rod journals is in the "DOWN" position. Install tool (B) on the piston to put compression on the piston rings. Install the rod in the crankcase assembly and over the crankshaft journals. 20. Install bearings (18) in the bearing caps.21. Check the clearance between the rod bearings and crankshaft journals with tool (C). Put the Plastigage on the cap bearing as shown. Install the bearing caps on their respective rods. Tighten the bolts to a torque of 100 to 115 lb.in. (11.3 to 13.0 N m).22. Remove the bearing caps and measure the Plastigage. The correct clearance is .0003 to