19181-98101-01J Suzuki Lever, Throttle

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8S-2269 Ridge Reamer 1
B 1U-6684 Piston Ring Compressor 1
C 8T-3052 Degree Wheel 1 Start By:
Remove the cylinder head.
Remove the engine oil pump.
Remove the piston cooling jets.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Rotate the crankshaft until the crank pin is at the bottom center position.
Use Tooling (A) to remove the carbon ridge from the top inside surface of the cylinder bore.
Illustration 1 g01341291
The connecting rod and the connecting rod cap should have an etched Number (X) on the side. The number on the connecting rod and the connecting rod cap must match. Ensure that connecting rod (1) and connecting rod cap (2) are marked for the correct location. If necessary, make a temporary mark on the connecting rod and the connecting rod cap to identify the cylinder number. Note: Do not stamp the connecting rod assembly. Stamping or punching the connecting rod assembly could cause the connecting rod to fracture.
Remove bolts (3) and connecting rod cap (2) from connecting rod (1).
Illustration 2 g01341292
Carefully push piston (4) and the connecting rod out of the cylinder bore. Lift piston (4) out of the top of the cylinder block. Note: Do not push against the fracture split surfaces of the connecting rod as damage may result.
Repeat Step 1 through Step 5 for the remaining pistons and connecting rods. Note: Fracture split connecting rods should not be left without the connecting rod caps installed. Temporarily install connecting rod cap (2) and bolts (3) to connecting rod (1) when the assembly is out of the engine. Ensure that the etched number on connecting rod cap matches the etched number on connecting rod . Ensure the correct orientation of the connecting rod cap . The locating tab for the upper bearing shell and the lower bearing shell should be on the same side. Tighten bolts (3) to a torque of 20 N m (14 lb ft).Installation Procedure
If the connecting rod caps were temporarily installed, remove the connecting rod caps. If necessary, thoroughly clean all of the components.
Apply clean engine oil to the cylinder bore, the piston rings, the outer surface of the piston, and the bearing shells for the connecting rod. Position the piston ring gaps at 120 degrees away from each other. Note: Install the bearing shells for the connecting rods dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil to the bearing shells for the connecting rods during final assembly.Note: Ensure that the piston and the connecting rod assembly is installed in the correct cylinder.
Rotate the crankshaft until the crankshaft pin is at the bottom center position. Lubricate the crankshaft pin with clean engine oil.
Illustration 3 g01341299
Install Tooling (B) onto piston (4). Note: Ensure that Tooling (B) is installed correctly and that piston (4) can easily slide from the tool.Note: The arrow on the top of the piston must be toward the front of the engine. The locating tab for the bearing shell of the connecting rod must be on the same side of the engine as the piston cooling jet.
Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the crankshaft pin. Note: Do not damage the finished surface of the crankshaft pin.
Illustration 4 g01341300
Install connecting rod cap (2) onto connecting rod (1). Note: Ensure that etched Number (X) on connecting rod cap (2) matches etched Number (X) on connecting rod (1). Ensure the correct orientation of connecting rod cap (2). The locating tab for the upper bearing shell and the lower bearing shell should be on the same side.
Install new bolts (3) to connecting rod (1). Tighten the bolts evenly to a torque of 18 N m (13 lb ft). Note: Do not reuse the old bolts to secure the connecting rod cap.
Tighten the bolts evenly to a torque of 70 N m (52 lb ft).
Turn the bolts through an additional 120 degrees. Use Tooling (C) to achieve the correct final torque.
Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding.
Repeat Step 2 through Step 10 in order to install the remaining pistons and connecting rods.
Check the height of the pistons above the top face of the cylinder block. Refer to System Operation, Testing and Adjusting, "Piston Height - Inspect" for the correct procedure. End By:
Install the piston cooling jets.
Install the engine oil pump.
Install the cylinder head.