13203-87DF2 Suzuki 3RD CARBURETOR ASSEMBLY

1. Disconnect line (1) from the flywheel housing.2. Remove ground wire (2) from the starter.3. Use two people to remove the starter. Remove three 12 point bolts (4) and starter (3). Remove the starter gasket. Starter weight is kg (75 lb). 4. Attach a lifting strap to pump assembly (6) as shown. Remove two mounting bolts and washers (5) and pump assembly (6). Weight is 63 kg (140 lb). Drain the engine oil. 5. Remove nuts, washers and bolts (7) and (8) and rear oil pan assembly (9). If the oil pan gasket is damaged during the removal of the rear oil pan assembly it may be necessary to remove the front oil pan assembly and install a new oil pan gasket. 6. Raise the rear of the engine. Remove the supporting stands and replace with a support under the engine block as shown. 7. Remove four bolts (10) and one bolt (11) at the turbocharger support bracket.8. Remove two bolts (13) and tube assembly (12).9. Remove four bolts (14) at the air cleaner support bracket. Remove coupling and shaft (15). 10. Remove front bolt (16) and loosen the rear one. Pivot bracket (17) up and tighten rear bolt (16) to hold it up away from the flywheel housing. 11. Loosen two bolts (19) and wedge a screw driver (20) between the two brackets to raise bracket (18) up from the flywheel housing. 12. Remove six bolts and washers (23) holding drive assembly (24) to the housing.13. Remove six bolts (21) from drive assembly (22). Steps 12 and 13 are used only on the clutch brake tractor. 14. Remove nuts, bolts and washers (26) and plate (25).15. Install two 3/8" - 16 NC forcing screws (27) and remove drive gear assembly (24). The weight of the drive gear assembly is 25 kg (55 lb).16. Use forcing screws (27) to remove drive gear assembly (22). The weight of this drive gear assembly is 30 kg (65 lb). 17. Remove twenty bolts (28) and leave the one bolt in place at th top of the housing. 18. Attach Tooling (A) and a hoist. Remove the last bolt and the flywheel housing. The weight of housing is 193 kg (425 lb).19. After removal of the flywheel housing remove rear engine supports (29) if necessary.20. Put the flywheel housing in the position shown. 21. Remove bolts (30) from shafts (32).
Bearings (33) can fall out of gears (31) when the gears are removed from the flywheel housing.
22. Remove gears (31) from the flywheel housing. 23. Remove shafts (32), bearing cones (35) spacers (34) and bearing cones (33) from gears (31). 24. If necessary, remove bearing cups (36) and (38), spacers (37) and the snap rings from gears (31). The bearing cups will have damage after removal. Use new parts for replacement.Install Flywheel Housing
1. Install the snap rings in the groove in idler gear (2).2. Install the spacers for bearing cups (1) in gears (2) from the side of gears (2) that have the part number. Make sure the notches in the spacers are toward the snap rings. The snap rings are not in the center of the gear bores. The spacers must be installed in the gear bores that have the longer measurement from the snap ring to the surface of the gear.3. Lower the temperature of bearing cups (1) and install them in gears (2) until they make contact with the spacers. 4. Put the flywheel housing in the position shown and install bearing cones (3). 5. Put idler gears (2) in position on the bearing cones. Make sure the side of gears (2) with the part number is toward the flywheel housing. 6. Put spacer (4) on the inner race of the bearing cone. 7. Install bearing cones (5) in the gears. 8. Install shafts (6) and the bolts to hold them. Front face of flywheel housing both sides of flywheel housing gasket and rear face of block must be free of oil, fuel, water, gasket adhesive, assembly compound and any other contaminant during assembly. 9. Attach Tooling (B) to the flywheel housing. Remove plug (7) from the housing. 10. Locate the timing mark on balancer gear (8) and mark it for identification. 11. Locate the timing mark on crankshaft gear (9) and mark for identification. Turn the crankshaft until the timing mark is in the position shown. Apply sealant to fill space at cylinder block, flywheel housing, oil pan joint. 12. Using the hole where plug (7) was removed, turn balancer gear (8) until the timing marks are in alignment and put the flywheel housing in position on the engine block. 13. Install the flywheel housing bolts as follows:a. Tighten bolts 1 through 21 in numerical sequence to 40 10 N m (30 7 lb ft).b. Tighten bolts 1 through 8 in numerical sequence to 135 20 N m (100 15 lb ft).c. Tighten bolts 9 through 21 in numerical sequence to 55 10 N m (40 7 lb ft). 14. Install plug (7) in the flywheel housing. 15. Install pump drive assembly (12) and bolts (11). Check the O-ring seal and replace if necessary. Step 15 used only for the clutch brake tractor.16. Install pump drive assembly (16) and bolts and washers (15). Check the O-ring seal and replace if necessary.17. Install plate (14) and bolts and nuts (13). Check the O-ring seal and replace if necessary. 18. Remove screwdriver (19). Tighten bolts (18) to pull bracket (17) back in position. 19. Loosen rear bolt (20). Put bracket (21) in position and tighten the rear bolt. Install front bolt (20) in the bracket. 20. Install bolts (21), (22) and (25).21. Put tube assembly (23) in position and install bolts (24) and coupling and shaft (26). 22. Raise the engine, remove blocking (27) and install Tooling (A) under the rear engine supports. 23. Install rear oil pan (30) and nuts and bolts (28) and (29). Install the starter ground wire in the position