01560-06127 Suzuki BOLT

1. Remove the plug from location (1). Install tool (A) in the hole with the square end down. Move the governor control to the "ON" position until the rack stops against tool (A). The racks are now in center (zero) position. 2. Disconnect lines (2) from the fuel injection pumps. Remove washers (3). Put caps on all fuel openings.3. Remove bushing (4) with tool (B).
When the injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
4. Remove the fuel injection pump with tool (C). Remove spacer (8).
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
5. Disassemble the fuel injection pump. Remove ring (6). Separate bonnet (5) from the plunger and barrel assembly (7).6. Remove the gear segment, washer and spring from the barrel.7. Remove the ring, spring, collar and valve from the barrel.Install Fuel Injection Pumps
Make sure the fuel racks are in the center (zero) position before the fuel injection pumps are installed. 1. Put plunger (10), washer (5) and spring (9) in position on barrel (4). Put check valve assembly (7), spring (3) and collar (8) in position in bonnet (6). Connect bonnet (6) and barrel (4) together with ring (2). Keep seal (1) with the bonnet for use at installation.2. Put spacer (13) into position in the pump housing bore. Make sure the correct spacer is with each pump.3. Put the space in gear segment (11) in alignment with the groove in barrel (4).4. Put the injection pump straight down into the housing bore so the space in gear segment (11) is in alignment with pin (12) and the groove in barrel (4) is in alignment with dowel (14). Use tool (C) to install the pump.5. Install seal (1) and bushing (15) in the pump housing bore. If the pump is in the correct position, bushing (15) with turn into the threads of the pump housing with the fingers until it is even with the housing. Tighten bushing (15) to a torque of 205 14 N m (150 10 lb.ft.) with tool (B).6. Install washers (16).7. Connect the fuel lines to the injection pumps, and tighten the fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.) with tool (D).8. Check for correct installation of the injection pumps with the engine stopped. See Installation Of Injection Pump in Testing And Adjusting.
If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine if first started. Make preparations to close off the air intake to stop the engine if necessary.
9. Remove the timing pin [Tool (A)], and install the plug in the injection pump housing.