37850-92E26 Suzuki PTT SWITCH ASSEMBLY

2. Turn the crankshaft until two pistons are at bottom center. Remove connecting rod caps (1) from the two connecting rods.3. Put tape or pieces of rubber hose over the threads of the connecting rod bolts. This will prevent the threads from causing damage to the crankshaft during removal of the pistons.
Do not let the connecting rods hit the bottom edge of the cylinder liners or the crankshaft during removal and installation of the pistons.
TYPICAL EXAMPLE4. Push the piston and connecting rod away from the crankshaft until the piston rings are above the cylinder liner. Remove the two pistons (2) and the connecting rods from the engine.5. Keep each connecting rod cap with its respective connecting rod and piston. Put identification on each connecting rod as to its location in the engine for use at assembly of the engine.6. Do Steps 2 through 5 for the remainder of the pistons.Install Pistons
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.3. Move the rings on the piston until the ring openings are approximately 90° apart.
Never install the ring compressor on the piston unless the cylinder liner is used as a guide. Damage to the piston rings can be the result.
4. Put ring compressor (A) in position on the cylinder liner. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.5. Push the piston into place while the connecting rod is put into position on the crankshaft. 6. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
When connecting rod caps are installed, make sure the number on the side of the caps is next to and respective with the number on the side of the connecting rod.
7. Follow the same above procedure for installation of the remainder of the pistons. end by:a) install oil pumpb) install oil pan platec) install cylinder headDisassemble Pistons
start by:a) remove pistons1. Remove the rings from the piston with tool (A). 2. Remove snap ring (3), piston pin (1) and connecting rod (2) from the piston.3. Remove the rod pin bearing from the connecting rod with a press and a drive plate and handle from tool group (B) that will fit the outside diameter of the bearing.4. Clean the piston ring grooves on old piston with tool (C) before new rings are installed. See SPECIAL INSTRUCTIONS Form No. GMG02394 and GMG02395 for information about the inspection and reconditioning of connecting rods. Also see the GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001.Assemble Pistons
1. Install a new rod pin bearing in the connecting rod with a press and a drive plate and handle from tool group (B) that will fit the outside diameter of the bearing. Use a pin boring machine to make the bearing the correct size. The bore in the bearing (new) must be 1.5017 .0003 in. (38.143 0.008 mm). The maximum permissible clearance between the bearing and piston pin (worn) must not be more than .003 in. (0.08 mm). 2. Install the connecting rod with the bearing tab groove (2) and number identification on the same side as the "V" mark (1) on top of the piston.3. Install the top piston ring that has the mark "UP- 1" in the top groove of the piston with tool (A). Make sure the mark is toward the top of the piston.4. Install the intermediate piston ring that has the mark "UP-2" in the middle groove of the piston with tool (A). Make sure the mark is toward the top of the piston.
Install the oil ring with the gap in the spring 180° away from the gap in the ring.
5. Install the oil ring in the piston with tool (A).6. Check the clearance between the piston ring grooves and the rings. The maximum permissible clearance between all of the rings and piston grooves must not be more than .006 in. (0.15 mm). The clearance between the top ring (new) and groove must be .0037 .0009 in. (0.0940 0.0229 mm). The clearance between the center ring (new) and groove must be .0032 .0009 in. (0.0813 0.0229 mm). The clearance between the oil ring (new) and groove must be .0025 .0010 in. (0.064 0.025 mm). Make sure all of the ring gaps are 90° apart before the pistons are installed.end by:a) install pistons