09202-08011 Suzuki PIN, CLUTCH DOG SHIFTER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 371-1079 Lift Plate 1
B 339-9352 Inj. Sys. Cap Kit 1
265-2256 Wipers 1
D 312-2840 Socket 1 Note: When Tooling (B) is removed, be careful to prevent contamination. Cleanliness is an important factor. Before assembly, clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected always.
Illustration 1 g02149623
Illustration 2 g06151585Note: Reuse dowel components after cleaning using clean solvent.
Do not use dowels that have been removed from the block. Use a dead blow hammer to install new dowel assembly in block. Install new dowel assembly by lightly tapping the dowel until the dowel assembly is flush with the block surface. Excessive force can damage the dowel or block. Refer to illustration 2. If only the top part of the dowel has been removed, Use a screwdriver to install the dowel and apply a torque of 2 N m (18 lb in).Remove the O-ring seals from dowel assembly (14). Clean and inspect the O-ring seals. If necessary, replace the O-ring seals with new O-ring seals. Remove Tooling (B) and clean oil supply hole. Install dowel assembly (14).Note: Important to replace fire ring with new fire ring.
Replace fire ring (15) with new fire ring (15). Install fire ring (15). Install a new gasket (13) onto the cylinder block.
Illustration 3 g06151438Note: Clean the bottom surface of the cylinder head and the top surface of the cylinder block.
Attach Tooling (A) and a suitable lifting device onto cylinder head (3). The weight of cylinder head (3) is approximately 68 kg (150 lb). Position cylinder head (3) onto the cylinder block.
Illustration 4 g06151461
Illustration 5 g06151463Note: Ensure that the sleeve is installed with the chamfer facing downward. The sleeve must be flush with the top of the cylinder head surface.
Install sleeves (16) in cylinder head (3). Sleeves (16) are installed in the two bolt holes as shown in illustration 4.
Illustration 6 g06151466
Illustration 7 g02161103
Lubricate the threads of bolts (4) with oil. Install bolts (4) and the washers. Hand tighten all bolts (4) in the numerical sequence to a maximum torque of 15 N m (11 lb ft). Use Tooling (D) to tighten bolts (4) in the numerical sequence to a torque of 100 10 N m (75 7 lb ft). Tighten bolts (4) again in the numerical sequence to a torque of 250 15 N m (185 11 lb ft). Tighten bolts (4) in the numerical sequence for an extra 180 5 degrees.
Install the unit injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Illustration 8 g02090762
Illustration 9 g01285695
Apply clean engine oil to area (X). Repeat for the opposite collar. Apply clean engine oil to the ends of tube assembly (6). Install tube assembly (6). Replace external O-ring seals on tube assembly (6) and lubricate the O-ring seals on the tube assembly with clean engine oil. Install tube assembly (6).Note: Do not allow the quill tube to contact any part of the engine while assembling.
Install new bolts (10) and new bolts (7) hand tight.
Evenly tighten new bolts (10) to a torque of 20 N m (15 lb ft) in increments no greater than 90 degrees. Evenly tighten new bolts (7) to a torque of 20 N m (15 lb ft) in increments no greater than 90 degrees.
Evenly tighten new bolts (10) to a torque of 40 N m (30 lb ft) in increments no greater than 45 degrees. Evenly tighten new bolts (7) to a torque of 40 N m (30 lb ft) in increments no greater than 45 degrees.
Connect harness assembly (9). Replace the O-ring seals on both ends of the tube assembly (5). Install tube assembly