12110-93210 Suzuki Piston

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-7409 Eyebolt 1
B 8T-0914 Guide Pin 2
C 5J-7910 Bolt 2
D - Loctite
C5-A Anti-Seize Lubricant -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01225162
Remove the guards from the space around flywheel (1).
Disconnect the drive coupling from the flywheel.
Turn the crankshaft until the dash marks on the crankshaft and the flywheel face upward. This action will place the 3/4 inch tapped hole for Tooling (A) at the top of the flywheel.
Do not use the timing pin in order to hold the crankshaft while loosening the flywheel bolts. Remove the two front opposite crankcase inspection covers, and place a 102 mm (4 inch) by 102 mm (4 inch) board under the connecting rod in order to keep the crankshaft from turning.
Remove two bolts (3). Install Tooling (B).
Attach Tooling (A) and a suitable lifting device to flywheel (1). The weight of flywheel (1) is approximately 499 kg (1100 lb).
Remove remaining bolts (3) from the flywheel.
Raise the suitable lifting device in order to support the weight of flywheel (1).
Use Tooling (C) to position flywheel (1) on Tooling (B) for removal. Some flywheels do not have tapped holes for Tooling (C). If necessary, pry between the rear housing and the back of the flywheel in order to position flywheel (1) on Tooling (B) for removal.
Remove flywheel (1) from Tooling (B).
Inspect ring gear (2). If the ring gear replacement is necessary, remove the bolts and the washers that hold ring gear (2) to flywheel (1). Installation Procedure
Illustration 2 g01225162
Install a new ring gear (2) on flywheel (1) so that the tooth chamfer is oriented toward the front of the engine. Install the weights in the original location.
Install the bolts and the washers that hold ring gear (2) to flywheel (1). Note: Two different ring gears are available for the engine. The type of the ring gear depends on the rotation of the engine. Ensure that the correct ring gear is installed.
Install Tooling (B) in the crankshaft.
Attach Tooling (A) and a suitable lifting device to flywheel (1). The weight of flywheel (1) is approximately 499 kg (1100 lb).
Align the mark on the flywheel with the dash mark on the crankshaft.
Be sure that the mounting surfaces of the flywheel exhibit the following conditions: clean, dry and free of nicks or burns.
Position flywheel (1) on Tooling (B), and check the alignment of the bolt holes. There are four unequally spaced holes on the back of the flywheel. These holes give clearance for the heads of the bolts that hold the seal adapter to the crankshaft. Be sure that the bolts are aligned with the holes.
Move flywheel (1) into position on the Tooling.
Apply Tooling (D) on the washer face and the bolt threads. Install bolts (3). Remove Tooling (B) and install remaining bolts (3).
Do not use the timing pin in order to hold the crankshaft while loosening the flywheel bolts. Remove the two front opposite crankcase inspection covers, and place a 102 mm (4 inch) by 102 mm (4 inch) board under the connecting rod in order to keep the crankshaft from turning.
Tighten the bolts to a torque of 800 80 N m (590 60 lb ft). Turn the bolts for an additional 90 5 degrees (1/4 turn).
Connect the drive coupling to the flywheel. Refer to Specifications, "Flexible Coupling" for the correct tightening procedure for your drive coupling.
Install the guards around flywheel (1).