09160-06085 Suzuki Washer

Introduction
The problem that is identified below has a known solution. Use the solution that is identified below.Problem
Illustration 1 g06509244
Examples of bolt hole depth for connecting rod
(A) Incorrectly drilled connecting rod bolt hole
(B) Correctly drilled connecting rod bolt holeDuring the manufacturing drilling operation on some connecting rod assemblies, the bolt holes were drilled too deep as shown above. This incorrect drilling process leads to a thin wall condition near the edge of the connecting rod which can result in premature failures.The following connecting rods and/or cylinder packs could have been affected by this incorrect process.
Table 1
Affected Parts
Part Number Part Name
434-0488 Connecting Rod Gp
434-0489 Connecting Rod Gp
20R-2806 Connecting Rod Gp
20R-2805 Connecting Rod Gp
20R-2807 Cylinder Pack Gp
20R-2808 Cylinder Pack Gp
20R-2809 Cylinder Pack Gp
20R-2810 Cylinder Pack Gp Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The manufacturing process has been corrected to prevent the defect from happening again during the drilling process.
Illustration 2 g06509268All factory in process connecting rod inventory has been inspected for bolt hole depth and marked with a green paint mark as shown above. Connecting rods marked with a package date code after 03 January 2020should have the correct bolt hole depth as well.
Illustration 3 g06509623
Example of the date code, (DxxMxxYxx)
All connecting rods or cylinder packs with a date code prior to 03 January 2020will need to be inspected. Use the process below to measure the bolt hole depth.Inspection Procedure
All connecting rods or cylinder packs in dealer or customer inventory should be inspected prior to use or before reuse in an engine. Only one of the bolt holes need to be inspected as the all the bolt holes were drilled to the same depth during the manufacturing process.Use appropriate PPE during the inspection process. Ensure that a proper lifting device is used and the device does not contact the machined bore surfaces during the inspection. A 10 or 12 in Vernier caliper should be used that is certified and calibrated.
Illustration 4 g06509279
Select one of the bolt hole locations and remove the bolt from the connecting rod.
Place the depth checking end of the caliper flush on the top of the 366-5649 Spacer.Note: The spacer must be in place during the measurement.
Measure to the bottom of the bolt hole targeting the center of the hole.Note: The bolt hole has a hemispherical bottom so the center of the hole should be used for the measurement.
The acceptable measurement for the bolt hole depth is 178.725 0.50 mm (7.036 0.020 inch) including the retainer.
If the bolt hole for the connecting rod is within the acceptable range, mark the connecting rod with a green paint dot next to the connecting rod serial number.
If a bolt hole is found not to be in the acceptable range, set the caliper back to zero. Measure the bolt hole again making sure that the center of the hole is being used to take the depth.
If the bolt hole is found not to be in the acceptable range again, mark the connecting unacceptable for reuse.