DF90/115/140 “K3” (‘03) MODEL 13-25
CRANKCASE TO CYLINDER INSTALLATION
1. Clean mating surface of cylinder and crankcase.
2. Apply Suzuki Bond to mating surface of crankcase as shown
in figure.
D 99000-31140 : Suzuki Bond 1207B
Apply bond to mating surface only.
Do not allow bond to contact surface of bearing.
3. Install five (5) dowel pins 1.
4. Install crankcase to cylinder.
5. Apply engine oil lightly to crankcase bolts.
6. Tighten crankcase bolts in three (3) steps according to the
order shown below and in figure.
NOTE:
After tightening crankcase bolts, check to be sure that crankshaft
rotates smoothly when turned by hand.
" Crankcase bolt :
1st step 8 mm 5 N
.
m (0.5 kg-m, 3.5 lb.-ft.)
10 mm 11 N
.
m (1.1 kg-m, 8.0 lb.-ft.)
2nd step 8 mm 20 N
.
m (2.0 kg-m, 14.5 lb.-ft.)
10 mm 45 N
.
m (4.5 kg-m, 31.0 lb.-ft.)
Final step 8 mm 25 N
.
m (2.5 kg-m, 18.0 lb.-ft.)
10 mm 56 N
.
m (5.6 kg-m, 40.5 lb.-ft.)
Tightening order
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