Suzuki: Engine K6A-YH6. Manual — part 22

7-42

REPAIR

7

Figure 7-97

NOTE

Apply clean oil to the connecting rod cap bearing and
crankshaft journal.

9.

Install connecting rod cap (17) and nuts (18). Tighten
to specification.

Connecting Rod Torque: 24 lb-ft (33 N•m)

10. Install crankshaft baffle. (See “Crankshaft Baffle” on

page 7-32.)

11. Install oil pump pickup. (See “Oil Pump Pickup” on

page 7-31.)

12. Install oil pan. (See “Oil Pan” on page 7-30.)

13. Install cylinder head. (See “Cylinder Head” on

page 7-24.)

Lower Crankcase, Cylinder Block,
and Crankshaft

Disassembly

See Figures 7-98 through 7-101.

1.

Remove cylinder head. (See “Cylinder Head” on
page 7-24.)

2.

Remove oil pan. (See “Oil Pan” on page 7-30.)

3.

Remove oil pump pickup. (See “Oil Pump Pickup” on
page 7-31.)

4.

Remove crankshaft baffle. (See “Crankshaft Baffle”
on page 7-32.)

Figure 7-98

5.

Using a 12-point 8 mm socket, remove six screws
and washers (1).

6.

Using a 12-point 10 mm socket, remove eight screws
and washers (2).

NOTE

The lower crankcase is located using four dowel pins and
is sealed to the cylinder block using Three Bond ™ 1215
sealant. The lower crankcase must be lifted off square.

7.

Use a soft face mallet to loosen lower crankcase (3)
from cylinder block. Remove lower crankcase from
cylinder block. Be sure to lift lower crankcase off
square.

TN0752

17

18

Required Tools

8 and 10 mm 12-point sockets

TN0755

1

1

2

2

1

2

3

2

REPAIR

7-43

7

Figure 7-99

8.

Remove rear main seal (4) and crankshaft (5).

Figure 7-100

9.

Remove crankshaft main bearings (6) and thrust
bearings (7).

Figure 7-101

10. Remove other half of crankshaft main bearings (9)

from lower crankcase (8).

TN0756

4

5

TN0757

6

6

7

7

TN0758

9

9

8

7-44

REPAIR

7

Inspection

Cylinder Block and Lower Crankcase

1.

Carefully inspect cylinder block and lower crankcase
for cracks or damage. Repair or replace as needed.

2.

Inspect cylinder liners for cracks or damage.

3.

Measure cylinder bores ID. Compare to specification
and piston OD specification. Repair or replace
as needed.

Cylinder Bore ID: 2.6771—2.6779 in.
(68.000—68.020 mm)

Cylinder Bore ID Limit: 2.6791 in.
(68.050 mm)

Piston OD: 2.675—2.676 in.
(67.970—67.990 mm)

NOTE

Oversized main and thrust bearings are available. The
bearing sets are color coded to identify size. Measure
components to determine the proper set for the
application.

4.

Inspect main bearing journals for damage.

5.

Measure main bearing journals ID. Compare
measurement to specification and crankshaft main
journal OD specification. Calculate or measure oil
clearance. Compare to specification and choose the
correct color coded main bearing set for the
application. Repair or replace as needed.

Cylinder Block Main Bearing Journal ID:
1.9291—1.9298 in. (49.000—49.018 mm)

Crankshaft Main Bearing Journal OD:
1.770—1.771 in. (44.982—45.000 mm)

Oil Clearance: 0.0007—0.0015 in.
(0.020—0.040 mm)

Oil Clearance Limit: 0.002 in. (0.065 mm)

6.

Inspect oil passages for debris or obstructions. Clean
as needed.

Crankshaft

1.

Inspect crankshaft for cracks or damage. Replace as
needed. Inspect main and rod journals for scratches,
wear, or damage. Repair or replace as needed.

2.

Measure crankshaft main bearing journals OD.
Compare measurement to specification and cylinder
block main bearing journals ID. Calculate or measure
oil clearance. Compare to specification and choose
the correct color coded main bearing set for the
application. Repair or replace as needed.

Crankshaft Main Bearing Journal OD:
1.770—1.771 in. (44.982—45.000 mm)

Cylinder Block Main Bearing Journal ID:
1.9291—1.9298 in. (49.000—49.018 mm)

Oil Clearance: 0.0007—0.0015 in.
(0.020—0.040 mm)

Oil Clearance Limit: 0.002 in. (0.065 mm)

3.

Measure crankshaft rod bearing journals OD.
Compare measurement to specification and
connecting rod large end ID specification. Calculate
or measure oil clearance and compare to
specification. Repair or replace as needed.

Crankshaft Connecting Rod Bearing Journal OD:
1.495—1.496 in. (37.982—38.000 mm)

Connecting Rod Large End ID: 1.6141—1.6148 in.
(41.000—41.018 mm)

Oil Clearance: 0.0007—0.0015 in.
(0.020—0.040 mm)

Oil Clearance Limit: 0.002 in. (0.065 mm)

Bearing Color

Size Range

Brown

0.0785—0.0787 in.
(1.996—2.000 mm)

Green

0.0787—0.0788 in.
(1.999—2.003 mm)

Black

0.0788—0.0789 in.
(2.002—2.006 mm)

No Color

0.0788—0.0789 in.
(2.002—2.006 mm)

Yellow

0.0790—0.0792 in.
(2.008—2.012 mm)

REPAIR

7-45

7

Assembly

See Figures 7-102 through 7-107.

NOTICE

Figure 7-102

NOTE

Thoroughly clean lower crankcase/cylinder block mating
surface.

1.

Thoroughly clean main bearing bores and install
main bearings (2) into lower crankcase (1). Be sure
to align bearing tangs (3) with recess in main bearing
bores.

2.

Apply a liberal amount of clean engine oil to main
bearing faces.

Figure 7-103

3.

Thoroughly clean cylinder block main bearing bores,
and install main bearings (4). Be sure to align
bearing tangs (5) with recess in main bearing bores.

4.

Install thrust bearings (6) with a small amount of
petroleum jelly to keep them in place.

5.

Apply a liberal amount of clean engine oil to main
and thrust bearing faces.

Figure 7-104

NOTE

Thoroughly clean cylinder block/lower crankcase mating
surface.

Thoroughly clean crankshaft journals before installation.

6.

Apply a liberal amount of clean engine oil to
crankshaft main journals (8) and connecting rod
journals (10).

7.

Install crankshaft (9) into cylinder block (11).

8.

Install four dowel pins (7).

Required Tools and Materials

8 and 10 mm 12-point sockets

Three Bond™ 1215 (Suzuki PN 99000-1080-15A) or
equivalent

Bushing, Bearing, and Seal Driver Tool

Prevent premature engine failure:

• Thoroughly clean all parts before assembly.

• Clean all gasket surfaces.

• Clean all sealant bonded mating surfaces.

• Tap cylinder block and lower crankcase

threaded holes. Use compressed air to clean
out debris, dirt, fluids, and dried sealant
fragments.

• Clean debris from threads of all fasteners.

TN0758

2

1

3

2

3

TN0757

4

4

6

6

5

5

TN0756

8

10

9

11

7