21120-89L00 Suzuki LEVER, CLUTCH NOTCH

2. Turn the crankshaft until the timing mark "C" on crankshaft gear (1) is in alignment with the timing mark "C" on camshaft gear (2) as shown in the inset. 3. Remove nuts (4), the connecting rod bolts and connecting rod caps (3) from the connecting rods.
If the piston and connecting rod assemblies are pushed down too far in the cylinder liners, the piston can hit the fuel injection nozzle or the inlet exhaust valve which can cause damage to the fuel injection nozzle or the piston.
If the inlet and exhaust valves are closed, it can be difficult to push the piston and connecting rod assembly down in the cylinder liner.4. Push the pistons that are not at top center down far enough to clear the crankshaft.5. Remove main bearing cap bolts (5) and main bearing caps (6) from the engine. 6. Remove thrust bearings (7) from the rear main bearing. 7. Install Tooling (B) on crankshaft (8) as shown, and fasten a hoist to it. Lift the crankshaft straight up from the cylinder block. The weight of the crankshaft for 3304 Engines is 65 kg (143 lb). The weight of the crankshaft for 3306 Engines is 95 kg (210 lb). 8. Use Tooling (C), and remove crankshaft gear (1) from the crankshaft.
If the bearings are to be removed, put identification marks on them as to their location for installation purposes.
9. If necessary, remove the main bearings from the cylinder block and main bearing caps. If necessary, remove the connecting rod bearings from the connecting rods and connecting rod caps.Install Crankshaft
1. Put the engine in position on Tooling (A). Install the bearings dry when the clearance checks are made. Put clean engine oil on all the bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.
2. If the bearings were removed from the engine, clean the bearing surfaces in the cylinder block and the connecting rods. Install the upper halves of connecting rod bearings (1) and main bearings (2). 3. Heat crankshaft gear (3) to a maximum temperature of 316°C (600°F). Install the gear on the crankshaft. 4. Install Tooling (B) on the ends of the crankshaft and fasten a hoist to it.5. Make an alignment of the connecting rods with the crankshaft. Make an alignment of the "C" marks on crankshaft gear (3) and camshaft gear (4). When the connecting rods and the "C" marks are in alignment, lower the crankshaft on to the main bearings, and remove Tooling (B). When the bearing clearance is checked and the engine is in a vertical position, such as in a vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct measurement. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances. For complete details concerning measuring bearing clearances, see Engine Bearings & Crankshafts, SEBD0531.6. Check the main bearing clearances with Plastigage (C) as follows: a. Put a piece of Plastigage (C) in position as shown.
Make sure the part number on the main bearing cap is toward the front of the engine, and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
Do not turn the crankshaft when Plastigage (C) is in position.b. Install main bearing cap (5). Put clean engine oil on the bolt threads and the face of the washers, and install the bolts. Tighten the bolts to a torque of 41