57621-94512 Suzuki SHIFTER, CLUTCH DOG

START BY:a. remove oil pan 1. Turn the crankshaft until two pistons are at bottom center. Remove nuts (1) and connecting rod caps (2) from the two connecting rods. Remove the lower half of the bearings from the caps.2. Push the connecting rods away from the crankshaft, and remove the upper half of the bearings.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings only for final assembly.3. Clean the surfaces where the bearings fit. Install the upper half of the new bearings in the rods. Put the connecting rods in position on the crankshaft.4. Clean the surfaces where the bearings fit. Install the lower half of the new bearings in the caps without oil.The serviceman must be very careful to use Plastigage correctly. The following points must be remembered:... Make sure that the backs of the bearings and the bores are clean and dry.... Make sure that the bearing locking tabs are properly seated in their slots.... The crankshaft must be free of oil where the Plastigage touches it. ... Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing. ... Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.... Do not turn the crankshaft with the Plastigage installed.... Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.... Remove the Plastigage before installing the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.
When the connecting caps are installed, make sure that the numbers on the side of the caps are next to and respective with the number on the side of the connecting rods.
5. Check the bearing clearance with Plastigage (A). Put caps (2) in position on the connecting rods, and install the nuts. Tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60° 5° more.6. Remove the cap. Measure the width of the Plastigage. The rod bearing clearance must be 0.043 to 0.140 mm (.0017 to .0055 in.). The maximum permissible clearance is 0.15 mm (.006 in.).7. Put clean SAE 30 oil on the bearings and crankshaft journals. Put 2P2506 Thread Lubricant on bolt threads and contact surfaces of the nut and cap. Put the caps in position on the connecting rods, and install the nuts. Tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60° 5° more. An Impact wrench can be used for the final tightening torque.8. Do Steps 1 through 7 again for the other bearings.END BY:a. install oil pan