63610-95511 Suzuki THROTTLE CABLE ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1861(1)
or
139-9039(2) Retaining Ring Pliers 1
B 7M-3978(3)
or
149-7179(4) Ring Expander 1
C 5P-8639 Hydraulic Press (Connecting Rod Bearing) 1
8F-0024 Hose Assembly 1
1P-2375 Connecting Coupler 1
1P-2376 Connecting Coupler 1
5P-8651 Spacer 1
5P-8649 Adapter 1
5P-8650 Bushing Adapter 1
9U-6600 Hydraulic Pump 1
(1) Use with one-piece piston
(2) Use with two-piece piston
(3) Use with C-15 Engines
(4) Use with C-16 EnginesNote: Prior to removal from the engine, the pistons and connecting rod assemblies were marked. The components must be reassembled together. The components must be installed in the original location in the engine. Do not interchange any of the components.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
One-piece piston
Illustration 1 g01033568
Use Tooling (B) to install the piston rings on piston (1). Position the rings so the gaps are 120 degrees from each other.
Assemble piston (1) and connecting rod (4). Install pin (3).
Use Tooling (A) to install retaining ring (2).
Install bearings (5) in connecting rod (4) and connecting rod cap (6). Make sure that bearings (5) are installed with the bearing tabs fit into the notches in connecting rod (4) and connecting rod cap (6).Two-piece piston
Illustration 2 g01033642
Install a new piston pin bearing (10) in connecting rod (12) and remove the old piston pin bearing, as follows:
The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch.
Illustration 3 g01033643
Heat Length (Y) of connecting rod (12) to a temperature of 175 to 260 °C (347 to 468 °F). (Y) Maximum Length for heating the connecting rod ... 85 mm (3.4 inch)
Use Tooling (C) to remove the old bearing and install the new bearing at the same time. The adapter of Tooling (C) should make full contact with the surfaces of the connecting rod.Note: Orient the bearing joint within 5 degrees of either Location (X).
Allow the connecting rod and the bearing to cool to room temperature.
Use a pin boring machine to machine the bore of the piston pin bearing to the correct diameter.Diameter of piston pin bore ... 55.035 0.008 mm (2.1667 0.0003 inch)
Illustration 4 g01033611
Check the clearance between the ends of piston rings (7), (8), and (9). Refer to Specifications, "Piston and Rings" for the specifications.
Install oil ring spring (9) in the oil ring groove of the piston.
Position oil ring (9) over the oil ring spring. Position the oil ring so that the gap is 180 degrees from the joint in the oil ring spring. Install the oil ring on the piston with Tooling (B).
Use Tooling (B) to install intermediate piston ring (8) with the side that has the identification “UP-2” toward the top of the piston.
Use Tooling (B) to install top piston ring (7) with the side that has the identification “UP-1” toward the top of the piston.
Position piston rings (7), (8), and (9) so the gaps are 120 degrees from each other.
Position piston crown (11) on piston skirt (13).Note: Ensure that piston pin bearing (10) is in the correct position in connecting rod (12).
Position the piston on connecting rod (12). Apply clean engine oil to piston pin (15) and install the piston pin. Install retainer rings (14) with Tooling (A). Make sure that the retainer rings are fully seated in the grooves of the piston.
Install connecting rod bearings (16) in connecting rod (12) and connecting rod cap (17). Make sure that bearings (16) are installed with the bearing tabs fit into the notches in connecting rod (12) and connecting rod cap (17).
Install dowel (18) in connecting rod cap (17).End By:
Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install" for the procedure.