67257-92E00 Suzuki LEVER CAP

1. Remove muffler.2. Remove guard (1). Disconnect oil drain line (6). Remove oil supply line (2).3. Remove clamp (5). Remove bolts (8) and nuts and remove coupling (4).4. Remove bolts (7) and nuts. Remove turbocharger (3).Install Turbocharger
1. Put turbocharger in position on the exhaust manifold. Put 9M3710 Anti-Seize Compound on the bolt threads. Install the bolts and nuts that hold turbocharger to exhaust manifold.2. Put coupling in position on the turbocharger. Install clamp. Install bolts and nuts that hold coupling to manifold bracket.3. Connect the oil drain line and oil supply line.4. Install guard. Install muffler.end by: a) install hoodDisassemble Turbocharger
start by: a) remove turbocharger 1. Install the turbocharger on tool (A).2. Put marks on the housings for correct installation at assembly.3. Loosen clamp (1). Remove compressor housing (2). Remove the clamp. 4. Remove bolts (3), locks (6) and plates (5).5. Remove the center section from turbine housing (4). 6. Install tool (C) in tool (B). Install the center section in tool (C) as shown.7. Remove nut (7) that holds the impeller to the shaft and wheel assembly. 8. Install tool (E) on tool (D). Heat tool (D) to 350°F (177°C). Install the impeller on tool (E).
Make sure only the impeller is in the hot oil.
9. Install tool (E) with the center section on tool (F). Remove impeller (9) with an arbor press (8) and tool (G). Step 9 must be done before the impeller gets cold. 10. Remove shaft and wheel assembly (10), shroud (11) and spacer (13) from center housing (12). 11. Remove bolts (14), locks (15) and plate (16) from the center housing. 12. Remove collar (17). 13. Remove two bearings (18) and three snap rings (19) from the center housing.Assemble Turbocharger
1. Clean all parts throughly before assembling. 2. Install snap ring (15), bearing (12) and snap ring (11) in center housing (10). Install snap ring (9) and bearing (8).3. Install shroud (13) and shaft and wheel assembly (16) in the center housing.
Use caution not to cause damage to ring seal (14) when installing the shaft and wheel assembly.
4. Install spacer (7) and collar (6).5. Put plate (5) in position on the center housing. Install bolts (4). Tighten the bolts to a torque of 35 5 lb.in. (40.4 5.8 cm.kg).6. Install spacer (3). Make sure the small inside diameter of the spacer is toward the impeller end of the shaft and wheel assembly.
Install spacer (3) with its small inside diameter toward the center housing will cause a restriction of oil flow to the chamber and rings. This will cause a failure to the turbocharger.
7. Heat impeller (1) in oil to a maximum temperature of 350°F (177°C). Install the impeller on the shaft and wheel assembly. 8. Install tool (C) in tool (B). Install the center section in tool (C). Install nut (2). Tighten the nut to a torque of 120 lb.in. (138.4 cm.kg). Let the temperature of the impeller get below 150°F (65°C). Loosen the nut. Put a light amount of oil on the threads of the shaft and wheel assembly. Tighten the nut again to a torque of 30 lb.in. (34.6 cm.kg). Put a mark on the nut and impeller. Tighten the nut 120° past the mark.
Do not put a bending force on the shaft and wheel assembly when tightening nut (2).
9. Install turbine housing (17) on tool (A). Install the center section in the turbine housing. Put the marks that were made at disassembly in alignment to make sure the housings are in their original position. 10. Put 9M3710 Anti-Seize Compound on the threads of bolts (21). Install plates (20), locks (19) and the bolts. Tighten the bolts to a torque of 175 15 lb.in. (201.8 17.3 cm.kg).11. Install a new O-ring seal (18) on the center housing. 12. Put clamp (23) over the center section. Put compressor housing (22) in alignment with the marks made at disassembly. Put the clamp in position over the housing. Tighten the clamp to a torque of 120 10 lb.in. (138.4 11.5 cm.kg).13. Put oil in the center section and turn the shaft and wheel assembly.end by:a) install turbocharger