13300-88D90 Suzuki THROTTLE BODY ASSEMBLY

Be careful not to cause damage to the piston cooling tube when tooling (A) is installed and removed.
1. Put covers on journals of the crankshaft for protection from dirt and water. 2. Remove cylinder liners (1) with tool (A) as shown.3. Remove the spacer plate and gasket. See REMOVE SPACER PLATE. See GUIDELINE FOR REUSABLE PARTS, PISTON AND CYLINDER LINERS, FORM NO. SEBF8001.Install Cylinder Liners
The surfaces of the spacer plate, cylinder block and the spacer plate gasket must be clean and dry. Do not put liquid gasket or another material on the surfaces.
1. Install spacer plate (1) and a new gasket. See INSTALL SPACER PLATE.2. Make sure the cylinder liners and the cylinder block are clean. Put cylinder liners (2) in position in the cylinder block without the O-ring seals or filler band.3. Check the cylinder liner height (projection) as follows: To keep the bolts and washers so they are not moved as each liner is checked, install two bolts with washers on each side of each cylinder liner, along the complete length of the top plate. a) Install the 3/4"-10 NC bolts, 3 in. long and the 2F126 Washers of tooling (A) on the cylinder block next to each cylinder liner to hold the spacer plate to the cylinder block. Tighten the bolts evenly, in four steps: 10 lb.ft. (14 N m), 25 lb.ft. (35 N m), 50 lb.ft. (70 N m) and then to 70 lb.ft. (95 N m).b) Put the puller plate and one plate of tooling (A) on top of the cylinder liner and install the remainder of tooling (A). Be sure the bar is in position at the center of the cylinder liner. Tighten both bolts evenly, in four steps: 5 lb.ft. (7 N m). 15 lb.ft. (20 N m), 25 lb.ft. (35 N m) and then 50 lb.ft. (70 N m).c) Check to be sure the distance from the bottom edge of the bar to the top of the cylinder block is the same on both sides of the cylinder liner.d) Check the cylinder liner projection with tooling (B) at four locations around the liner. SPECIAL INSTRUCTION (GMG00623) is included with the tool.e) The liner projection must be within .0020 to .0076 in. (0.05 to 0.19 mm). Measurements on the same cylinder liner must not be different by more than .002 in. (0.05 mm). Average measurements between liners next to each other must not be different by more than .002 in. (0.05 mm). If the liner projection is different from point to point around the cylinder liner, make a rotation of the cylinder liner to a new position within the bore. If it is still not within specifications, move the cylinder liner to a different bore. f) If the liner projection is not .0020 to .0076 in. (0.05 to 0.19 mm), check the thickness of the following parts: cylinder liner flange (3), spacer plate (1) and spacer plate gasket. The thickness of the cylinder liner flange is .5260 .0008 in. (13.36 0.02 mm), spacer plate .5142 .0010 in. (13.06 0.03 mm) and spacer plate gasket .008 .001 in. (0.20 0.025 mm). The cylinder liner projection can be changed by a counterbore made in the block to a minimum depth of .030 in. (0.76 mm) with a cylinder block counterboring tool. The maximum depth of the counterbore is .045 in. (1.14 mm). See SPECIAL INSTRUCTION FORM FM055228. Shims are available for the adjustment of the cylinder liner projection. 4. Put a mark on the cylinder liner and spacer plate so the liner can be installed in the same position from which it was removed.5. Remove tooling (A) and (B). Remove the cylinder liner. Install new O-ring seals on the cylinder liners. Do not put 7M7260 Liquid Gasket Material on the cylinder block. Put the .030 in. (0.76 mm) shim on top of the shim package if more than one shim is used. Put 7M7260 Liquid Gasket Material on the top and bottom of the shim package. 6. Put liquid soap on the O-ring seals and on the cylinder bores. Put filler band (4) in SAE 30W oil. Then immediately install the filler band on the cylinder liner and immediately install the cylinder liner in the cylinder block with tooling (C) before expansion of the band.end by:a) install pistons