Outboard Bolt Holes - Suzuki XL7 2007 Service Manual

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Table of Contents

1D-240 Engine Mechanical:

Outboard Bolt Holes

Refer to "Safety Glasses Caution: ".

• Ensure the fixture plate is installed during

the machining and installation processes

of the insert.

• The use of a cutting type fluid GM P/N

1052864, (Canadian P/N 992881), WD 40®

or equivalent is recommended when

performing the drilling, counterboring and

tapping procedures.

When installed to the proper depth, the flange of the

insert will be seated against the counterbore of the

drilled/tapped hole.

1. Position the fixture plate (3) with the bushing (2)

installed over the crankshaft main cap bolt hole to be

2. Loosely install the fixture plate bolts (1) into the

remaining crankshaft main cap bolt holes.

3. Position the alignment pin (1) through the bushing

and into the crankshaft main cap bolt hole.

4. With the alignment pin in the desired crankshaft

main cap bolt hole, tighten the fixture retaining bolts

5. Remove the alignment pin (1) from the crankshaft

main cap bolt hole.

• During the drilling process, it is necessary

to repeatedly remove the drill and clean

chips from the hole and the flutes of the

• Drill the crankshaft main bolt hole until the

mark (1) on the drill aligns with the top of

the drill bushing (2).

6. Drill out the threads of the damaged hole.