34120-98J01 Suzuki KIT, SPEEDOMETER SUB

Crankshaft
Reconditioning of these crankshafts can be done by grinding the "journals" (bearing surface on the crankshaft for the connecting rod bearings and main bearings) .010 in. (0.25 mm), .020 in. (0.51 mm) or .050 in. (1.27 mm) "undersize" (smaller than the original size).The diameter of the "journals" for the connecting rod bearings is 2.7496 .0006 in. (69.840 0.015 mm). The diameter of the "journals" for the main bearings is 3.4995 .0006 in. (88.887 0.015 mm). The minimum permissible diameter of the "journals" for the connecting rod is 2.7486 in. (69.814 mm). The minimum permissible diameter for the "journals" for the main bearings is 3.4985 in. (88.862 mm). Measure each "journal" in several places around the diameter to find the maximum wear point. If the diameter of any "journal" is smaller than the minimum permissible diameter, grind all of the "journals." Before a crankshaft is ground, check to be sure the crankshaft is not bent. To check for a crankshaft that is bent, place crankshaft main bearing journals 2 and 4 on 5P8637 V-Blocks. Use a dial indicator and check the runout (total indicator reading) for main bearing journals 1, 3 and 5. The maximum total indicator reading is .005 in. (0.13 mm) for each journal. If the total indicator reading is more than .005 in. (0.13 mm) the crankshaft must be straightened before it is ground. Make reference to Guideline for Reusable Parts PROCEDURE TO MEASURE BENT CRANKSHAFTS, Form No. SEBF8030.Another procedure must be used to determine if a bent crankshaft can be straightened.Place the crankshaft main bearing journals 1 and 5 on 5P8637 V-Blocks. Use a dial indicator and check the runout (total indicator reading) of the center main bearing journal. If the total indicator reading is more than .050 in. (1.27 mm) the crankshaft cannot be straightened.If the total indicator reading is less than .050 in. (1.27 mm), the crankshaft can be straightened. Before the crankshaft is straightened it must be heated to 350 to 450°F (177 to 232°C). Make reference to Guideline For Reusable PartsPROCEDURE TO STRAIGHTEN BENT CRANKSHAFTS, Form No. SEBF8040.With the crankshaft installed in the cylinder block, check the end play for the crankshaft. End play for the crankshaft is .003 to .010 in. (0.08 to 0.25 mm). Maximum permissible end play for the crankshaft is .014 in. (0.36 mm). If end play for the crankshaft is more than the maximum permissible end play, check the crankshaft thrust bearing.Crankshaft Grinding Specifications
The dimensions and finish for grinding crankshafts are as follows:Diameter (A) for connecting rod bearing journals is:.010 in. (0.25 mm) Undersize ... 2.7396 .0006 in.(69.586 0.015 mm).020 in. (0.51 mm) Undersize ... 2.7296 .0006 in.(69.332 0.015 mm).050 in. (1.27 mm) Undersize ... 2.6996 .0006 in.(68.570 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (B) must be .100 .010 in. (2.54 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.
DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.Width (C) is 2.314 .003 in. (58.77 0.08 mm)Diameter (D) for main bearing journals is:.010 in. (0.25 mm) Undersize ... 3.4895 .0006 in.(88.633 0.015 mm).020 in. (0.51 mm) Undersize ... 3.4795 .0006 in.(88.379 0.015 mm).050 in. (1.27 mm) Undersize ... 3.4495 .0006 in.(87.617 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (E) must be .095 .010 in. (2.41 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (F) is 1.258 .002 in. (31.95 0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 18 micro inches (0.45 micrometers) or less.Width (F) is 1.268 + .020 - .010 in. (32.21 + 0.51 - 0.25 mm) for number 2, 3 and 5 main bearing journals.There is no width (F) for number 1 main bearing journal.When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.Crankshaft Gear Removal
Remove the gear using a 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B7561 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller Legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two) and 5P3100 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500°F (260°C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Front Oil Seal Removal
Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.
REMOVING FRONT OIL SEAL (Typical Example)Remove Crankshaft Rear Seal And Wear Sleeve
Remove the crankshaft rear oil seal with the 1P3075 Puller Group.
REMOVING REAR OIL SEALInstall a 5P7338 Distorter Ring from the 5P7318 Wear Sleeve Distorter Group, in the rear seal bore. Install 5P7312 Distorter between distorter ring and wear sleeve. Turn the distorter until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose. Remove the tools and wear sleeve.
REMOVING REAR WEAR SLEEVE (Typical Example)Install Crankshaft Rear Seal And Wear Sleeve
New seal groups must be installed dry (no lubrication). Seal groups that have been separated must not be used. Only new seal groups are acceptable for installation.
SEAL AND WEAR SLEEVE INSTALLATION
1. Locator. 2. Seal group. 3. Crankshaft. 4. Installer. 5. Nut.1. Install the crankshaft rear seal and wear sleeve assembly with tooling as follows:a. Install