09205-05001 Suzuki Pin, Clamp Handle

Table 1
Required Tools
Tool Part Number Part Description Qty
B 138-7573 Link Bracket 2
D - Guide Stud
5/8 - 11 NC by 8 inch 2
E - Loctite 5127 -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Refer to Engine News, 27, March 2006, "Sealing and Installing the Flywheel Housing" for more information.
Ensure that the mating surface of the flywheel housing and the engine block are clean. Both mating surfaces must be clean, dry, and free of any oil before Tooling (E) is applied.
Illustration 1 g01259519
Apply a 6.0 mm (0.25 inch) bead of Tooling (E) to the mating surface of the flywheel housing. Refer to Illustration 1.
Install Tooling (D) into the cylinder block.
Illustration 2 g00912883
Install Tooling (B) onto flywheel housing (2). Attach a suitable lifting device to Tooling (B). The weight of flywheel housing (2) is approximately 251 kg (553 lb).
Lift flywheel housing (2) into position onto Tooling (D). Note: For the correct positions of the bolts, see Illustration 3 or Illustration 4.
Install the bolts and the hard washers that secure flywheel housing (2) to the cylinder block. Remove Tooling (D) and install the remaining bolts and the remaining hard washers.
Illustration 3 g01259521
(A) 1/2 - NC
(B) 1/2 - NC
(C) 1/2 - NC
(D) 1/2 - NC
(E) 1/2 - NC
(F) 5/8 - NC
Illustration 4 g01259551
(G) 1/2 - NC
(H) 1/2 - NC
(I) 1/2 - NC
(J) 5/8 - NC
(K) 5/8 - NC
(L) 5/8 - NC
Tighten the bolts in flywheel housing (2) evenly. Tighten the 1/2 - NC bolts to a torque of 135 20 N m (100 15 lb ft). Tighten the 5/8 - NC bolts to a torque of 270 40 N m (200 30 lb ft). The torque for plugs (3) is 70 15 N m (50 11 lb ft).
Install the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Install".
Place the camshaft timing pins in position. Place the timing bolt in the flywheel with the No. 1 piston at the top center position on the compression stroke.
Illustration 5 g01226902
Use the following procedure in order to install camshaft drive gears (1).
Clean the taper of the camshaft and the tapered bore of the camshaft gear with a lint free cloth saturated with solvent to remove oil. Clean the parts again with a lint free alcohol wipe in order to remove any residue. The alcohol wipe will dirty after cleaning the parts. Clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe. Note: The taper of the camshaft and the tapered bore of the camshaft gear must be clean, dry, and free of residue before assembly.
Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.
Place camshaft drive gears (1) in position. Remove the backlash by rotating the gears in the opposite direction of camshaft rotation. Note: For "Standard Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears CLOCKWISE.
Install the bolt and the plate for the camshafts.
Install the bolt and the timing ring for the camshafts. Ensure that the hole in the timing ring is properly seated on the locating pin.
Tighten the bolts to a torque of 360 N m (265 lb ft).
Place a Mark on the bolts.
Place a driver against the retaining plate of the camshaft gear. Strike the driver solidly with a hammer 3 to 4 times.
Tighten the bolts again to a torque of 360 N m (265 lb ft).
Repeat Steps 10.h and 10.i until the Mark has turned at least 90 degrees.
Remove the timing pins from the camshafts and the flywheel.
Install the gaskets and camshaft covers. End By:
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".
If the exhaust elbow was removed, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".
Install the starting motors. Refer to Disassembly and Assembly, "Air Starting Motor - Install" or Disassembly and Assembly, "Electric Starting Motor - Remove and Install".