57635-95503 Suzuki Stopper

Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3939 Link Bracket 2
D 8T-5096 Dial Indicator 1
E 8T-3052 Degree Wheel 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01150312
Install dowel (8) in the crankshaft.Protrusion of dowel (8) from the crankshaft face ... 8.4 mm (0.33 inch)
Install dowel (9) in the crankshaft.Protrusion of dowel (9) from the crankshaft ... 4.1 0.5 mm (0.16 0.02 inch)
Install crankshaft gear (7) on the crankshaft with the keyway in alignment with dowel (9). Timing Mark "V" of the gear should face away from crankshaft (6).Note: Install the main bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the main bearings for final assembly.
Install the upper halves of the main bearings in the cylinder block.Note: Ensure that the main bearings are installed so that the bearing tabs fit into the notch in the cylinder block. The upper halves of the main bearings have the oil groove and the oil hole.
Illustration 2 g01150344
Install Tooling (A) and a suitable lifting device on each end of crankshaft (6). The weight of crankshaft (6) is approximately 188 kg (415 lb).
Install crankshaft (6) with Timing Mark "V" on the crankshaft gear in alignment with Timing Mark "V" on the cluster gear.
Install the thrust plates on each side of the No. 4 main bearing.Note: Install the thrust plates with the words "Block Side" toward the cylinder block.
Install the lower halves of the crankshaft main bearings in the main bearing caps.Note: Ensure that the main bearings are installed so that the bearing tabs fit into the notch in the main bearing cap.
Position main bearing caps (4) on the crankshaft.Note: Ensure that the numbers on the main bearing caps match the numbers on the cylinder block. Also ensure that the arrows on the main bearing cap are installed pointing toward the front of the cylinder block.
Lubricate the threads of bolts (3) with clean engine oil. Install bolts (3) and the washers.
Lubricate the threads of bolts (5) and the seal of the washer with clean engine oil. Install bolts (5) and the washers.Note: Inspect the washers that go on bolts (5).
Tighten bolts (3) and bolts (5) for the main bearing caps, as follows:
Tighten Bolt (A) to a torque of 122 14 N m (90 10 lb ft).Note: Bolt (A) is on the bearing tab side of the main bearing cap.
Tighten Bolt (B) to a torque of 122 14 N m (90 10 lb ft).Note: Bolt (B) is on the opposite side of the bearing tab of the main bearing cap.
Tighten Bolt (B) for an extra 180 5 degrees (2 flats).Note: If Tooling (E) is not used, place an index mark on the bolt and the main bearing cap.
Tighten Bolt (A) for an extra 180 5 degrees (2 flats).Note: If Tooling (E) is not used, place an index mark on the bolt and the main bearing cap.
Tighten Bolt (D) to a torque of 80 10 N m (59 7 lb ft).Note: Bolt (D) is on the opposite side of the bearing tab of the main bearing cap.
Tighten Bolt (C) to a torque of 80 10 N m (59 7 lb ft).Note: Bolt (C) is on the bearing tab side of the main bearing cap.
Rotate the crankshaft to ensure that the crankshaft turns freely.
Use Tooling (D) to check the crankshaft end play. Ensure that Tooling (D) is against a machined surface. The end play is controlled by the thrust plates of No. 4 main bearing (center).Crankshaft end play (new thrust plates) ... 0.10 to 0.60 mm (0.004 to 0.024 inch)Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the connecting rod bearings for final assembly.
Illustration 3 g01150364
Position the connecting rod against the crankshaft. Install connecting rod bearing cap (2) on the connecting rod.Note: Ensure that the number on the side of the connecting rod bearing cap is on the same side as the number on the connecting rod. The bearing tabs of the connecting rod bearing cap and the connecting rod are on the side opposite of the piston cooling jet.
Lubricate the threads of bolts (1) with clean engine oil. Install the bolts.
Tighten bolts (1), as follows:
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Tighten Bolt (B) and Bolt (D) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (B) and Bolt (D) for an extra 60 5 degrees (1/6 turn).Note: If Tooling (E) is not used, place an index mark on each bolt and connecting rod cap.
Tighten Bolt (A) and Bolt (C) again to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (A) and Bolt (C) for an extra 60 5 degrees (1/6 turn).Note: If Tooling (E) is not used, place an index mark on each bolt and connecting rod cap.
Rotate the crankshaft to ensure that the crankshaft turns freely.End By:
Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
Install the rear housing. Refer to Disassembly and Assembly, "Housing (Rear) - Install".
Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".