08310-00107 Suzuki NUT

Dismantling And Reassembling
1. Remove the following engine auxiliaries: starter, generator, V-belt tensioning pulley, oil bath air filter, overflow oil lines, injector lines, Fig. 9-1, fuel filter with fuel line to the injector pump, intake manifold, exhaust manifold, air deflector hood, oil cooler, lateral covering shields and oil filter.
9-1 Note for Refitment:As soon as the lines have been removed, seal the connecting part of the injector valves and the pressure valve holder of the injector pump to prevent the entry of any foreign bodies.2. Remove the cooling fan (see also chapter 8).3. Depending on the model, remove the flow plug(s) from the engines with two phase combustion.4. Unscrew the nut(s) and remove the clamping bridge.5. Withdraw the injector valve(s) from the cylinder head with extractor tool No. 110030 in conjunction with tool No. 150800. Fig. 9-26. Remove the sealing ring left behind in the cylinder head with tool No. 120630.Fig. 9-2
9-27. Remove cylinder headcover and rocker arm pedestal.Fig. 9-3
9-38. Remove the pushrods and locking bolts.Fig. 9-4
9-49. Use socket spanner No. 120040/120050 to loosen and remove cylinder head bolts gradually in an crosswise rotation.Fig. 9-5
9-510. Raise the cylinder head and withdraw the pushrod protecting tubes. Lift off the cylinder head.Fig. 9-6
9-611. Remove the crankcase cover and loosen the connecting rod bearing bolts.Fig. 9-7
9-712. Carefully tap the connecting rod bearing bolts (which are still screwed in) with a plastic hammer until the connecting rod bearing cover has been freed from the foot of the connecting rod. Note for Refitment:Counterhold the cylinder.13. Unscrew the connecting rod bearing bolts. Remove the bearing cover and the bearing shells. Note for Refitment:Protect the bearing shells against damage. In the case of two cylinder engines, mark the bearing shells according to the connecting rods to which they belong.14. Remove the cylinder together with the piston and connecting rod from the crankcase.Fig. 9-8
9-815. Remove the injector pump. Note for Refitment:The injector pump can only be removed provided that the control for supplying additional fuel when starting has not been engaged.Fig. 9-9
9-916. Remove the V-belt pulley and flywheel.17. Remove the front casing. Fig. 9-10. In the case of manually started engines, first remove the starting bandle and the crank socket.
9-10 Note for Refitment:The bolt has a left-hand thread.18. Remove the regulator plate and the centrifugal weights from the drive shaft.Fig. 9-11
9-1119. Remove the crankshaft gear.Fig. 9-12
9-1220. Remove camshaft.Fig. 9-13
9-13 Note for Refitment:All tappets must be in the TDC position in order to ensure that the camshaft can be moved and removed without difficulties.21. Remove tappets.22. Undo the oil pump mounting bolt.Fig. 9-14
9-1423. Turn the oil pump in such a way that it can be removed complete with the intake pipe.Fig. 9-15
9-1524. Undo the drive shaft mounting bolt.Fig. 9-16
9-1625. Pull out the drive shaft together with the small spacer ring.Fig. 9-17
9-1726. In the case of engines with a power take-off, remove the carrier plate and remove the large spacer ring.Fig. 9-18
9-1827. Use a conventional extractor tool to remove the ball bearing, Fig. 9-19.
9-1928. In the case of the 2 cylinder engine, remove the bolt from the bearing block.Fig. 9-20
9-2029. Unscrew the rear bearing plate and withdraw from the crankcase using extractor tool No. 141000, Fig. 9-21 and remove the crankshaft.
9-2130. Remove the thrust ring from the crankcase and the bearing plate.31. Remove the fuel pump, Fig. 9-22 and the crankcase breather.
9-2232. Remove the oil pressure control valve.Fig. 9-23
9-2333. Before cleaning the crankcase unscrew the sealing plugs from the lubricating oilway.Fig. 9-24
9-24Reassembling The Engine
34. Fit the oil pressure control valve.Fig. 9-25
9-2535. Coat the sealing plug of the lubricating oilway with sealant and screw in.Fig. 9-26
9-2636. In the case of 2 cylinder engines, mount the bearing block on the crankshaft and ensure that the marking on the bearing block and the bearing block cover match.Fig. 9-27
9-2737. Allocate the bearing shells and insert. Note for Refitment:The bearing shell with the lubricating groove is fitted in the cover of the bearing block.Fig. 9-28
9-2838. Wet the bearing shells with engine oil. Fit the bearing block cover (with the bearing shell inserted and with the bearing shell of the bearing block) to the main bearing journal of the crankshaft. Note for Refitment:Ensure that the recesses of the bearing shells abut perfectly with the dowel pin.Fig. 9-29
9-2939. Fit the bearing block, screw in the bolts with internal hexagonal holes and steel washers and tighten and retighten according to the specification. Note for Refitment:In the case of 2 cylinder engines, the bearing block should be fitted in such a way that the oil injector nozzle faces the spur gear side.Fig. 9-30
9-3040. Fit the thrust ring in the crankcase according to the groove for the fixing lug. Note for Refitment:Lubricating oil grooves must always face the thrust shoulder of the crankshaft. Fig. 9-31. Stick the thrust ring with grease in order to prevent it from falling out of the recess.
9-3141. Oil the main bearing bushes and insert the crankshaft.42. In the case of 2 cylinder engines, align the bearing block with the hole for the mounting bolts. Screw in the bolt, together with a steel washer, Fig. 9-32 and tighten and retighten as specified.Fig. 9-32
9-3243. Fit the thrust ring into the bearing plate so that it lines up with the groove for the fixing lug.Fig. 9-33
9-33 Note for Refitment:The lubricating oil grooves must always face the thrust shoulder of the crankshaft. Stick the thrust ring with grease in order to prevent it from falling out of the recess.44. Fit the bearing plate to the crankcase with new seals.Fig. 9-34
9-34 Note for Refitment:Seals are available in 0.