41240-87D02 Suzuki TILT LEVER ARM

1. Remove bolts and locks (1) and (2) that hold oil pump (3) in position. Use two persons to remove the oil pump. Weight is 70 lb. (32 kg).Install Oil Pump
1. Use two persons to put oil pump (1) in position on the engine. Install the locks and bolts that hold it in position.end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump 1. Remove elbow (1). 2. Remove elbow (1) from bell (2). 3. Remove screen assembly (3) from the bell.
There is spring force behind diffuser (4).
4. Remove diffuser (4) and the washer. 5. Remove spring (5) and the plunger.6. Remove body (6). 7. Remove baffle (7) from the cover. 8. Loosen nut (8) approximately 1/8 in. (3.18 mm). 9. Use tooling (A) to loosen gear (9). Remove tooling (A) and gear (9). 10. Remove cover (10) from the body. 11. Remove bearings (11) from cover (10). 12. Remove shaft assembly (12).13. Remove body (13). 14. Remove spacer (14) and shaft assembly (15) as a unit. 15. Remove the key from the shaft assembly. Remove shaft assembly (15) from spacer (14). 16. Remove gears (18) from body (17). 17. Remove body (17) from cover (16).18. Remove bearings (19) from cover (16).Assemble Oil Pump
1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. Put clean oil on the oil pump parts during assembly.
Install the bearings in the cover so the oil holes in the bearings are in alignment with the oil holes in the cover.
2. Use a press and tooling (A) to install bearings (1) in the cover. The bearings must be installed .062 .010 in. (1.58 0.25 mm) below surface (X). If dowels (2) were removed, the new dowels must be installed .25 .02 in. (6.35 0.51 mm) above surface (X). 3. Put body (4) in position on cover (5).4. Put gears (3) in position in the body. If dowels (8) were removed the new dowels must be installed .25 .02 in. (6.35 0.51 mm) above surface (Y). The dowels must be installed from the side of the spacer with the chamfers.5. Put shaft assembly (7) in position in spacer (6). Install the key in the shaft assembly. 6. Put the spacer and shaft assembly in position in the body. 7. Put body (9) in position.8. Put the shaft assembly in position in the body.
Install bearings (10) in the cover so that the bearing junctions (joints) are in the position shown. Make sure the oil holes are in correct alignment.
9. Use a press and tooling (A) to install bearings (10) in cover (11). The bearings must be installed .062 .010 in. (1.58 0.25 mm) below surface (Z). If dowels (12) were removed, the new dowels must be installed .25 .02 in. (6.35 0.51 mm) above surface (Z).10. Install cover (11) on the body. Make sure the bolts with the "X" mark on them are installed in the holes with the dowels. 11. Put the key in position on the shaft assembly. Install gear (13).12. Install the washer and the nut. Tighten the nut to a torque of 100 lb.ft. (135 N m). Tighten the nut more if necessary to install the cotter pin.13. Install baffle (14) with locks and bolts. 14. Install body (15).15. Install plunger (16) and spring (17) in the body. 16. Put washer (18) in position in diffuser (19).17. Install the diffuser on body (15). 18. Put the gasket and screen assembly (20) in position in bell (21). 19. Install the gasket and elbow (22) on bell (21). Use the locks and bolts to hold it in position. 20. Put the O-ring seal in position in elbow (22). Install elbow (22) and the bell on the body. Use the locks and bolts to hold it in position.
Before installation, lubricant must be in the oil pump and it must turn freely.
end by:a) install oil pump