07120-08257 Suzuki BOLT

start by:a) remove flywheel housing 1. Remove thrower (1) from the crankshaft. See REMOVE THROWER.
LATER ENGINE SHOWN2. Remove pump drive gear (2). Remove the washer from the pump drive gear.
EARLIER ENGINE SHOWN3. Remove cover (3) from the adapter.
EARLIER ENGINE SHOWN4. Remove bearing (4) (if necessary) from the adapter. 5. Remove cluster gear shaft (5). If necessary, install a 1/2"-13 NC forged eyebolt in the shaft to remove it. 6. Remove cluster gear (6) and the washer behind the gear. 7. Remove bearing (7) (if necessary) from cluster gear (6).
EARLIER ENGINE SHOWN
LATER ENGINE SHOWN8. Remove cover (8).
EARLIER ENGINE SHOWN9. Remove studs (10) for earlier models only.
LATER ENGINE SHOWN10. Remove O-ring seals (9) and (11) from the three tubes.
LATER ENGINE SHOWN11. Remove plate (12) from the rear of the engine block.
EARLIER ENGINE SHOWN
LATER ENGINE SHOWN12. Remove tube assembly (14).13. Remove shaft (13) from the idler gear.
EARLIER ENGINE SHOWN The fuel pump drive gear (16) can not be removed. Remove the timing pin in the fuel injection pump camshaft before fuel pump drive gear (15) is turned.14. Remove idler gear (16). Remove the bearing (if necessary) from the idler gear.15. If the rear crankshaft gears needs to be removed, see REMOVE REAR CRANKSHAFT GEAR.Install Rear Timing Gears And Plate
1. Make sure all parts are clean. Inspect all parts for damage and make replacements if needed. Put clean oil on the O-ring seals.2. Install the rear crankshaft gear if it was removed. See INSTALL REAR CRANKSHAFT GEAR.
Make sure the notch in the bearing is in alignment with the notch in the idler gear within 2°.
3. Use tooling (A) and a press and install the bearing in idler gear (1). Make sure the bearing does not extend beyond either face of the idler gear. The inside diameter of the bearing after assembly must be 3.2510 .0019 in. (82.575 0.048 mm).
EARLIER ENGINE SHOWN
LATER ENGINE SHOWN4. Put idler gear (1) in position. Install shaft (2), the lock and the bolts. Install tube assembly (3).
Make sure the pin is installed (if removed) in its correct position in the fuel injection pump camshaft after idler gear (1) is in position.
6. Put the gasket in position on the engine block. Make sure the gasket is even with the bottom of the engine block.
EARLIER ENGINE SHOWN Make sure the two bolts (not shown) that hold plate (4) to the flywheel housing under the exhaust manifold are in position before the plate is installed for earlier models only.7. Put plate (4) in position on the engine. Install the locks and the bolts.
LATER ENGINE SHOWN8. Install O-ring seals (5) and (6) on the three tubes.
EARLIER ENGINE SHOWN
LATER ENGINE SHOWN9. Install the gasket and cover (7).10. Install studs (8) for earlier models only. 11. Use tooling (A) and a press and install the bearing in cluster gear (9). Install the bearing to a depth of .060 in. (1.52 mm) below the outside surface. The inside diameter of the bearing after assembly must be 2.5000 .0019 in. (63.50 0.048 mm).
Make sure the timing marks on cluster gear (9) and the crankshaft gear are in alignment. Always be sure that the No. 1 piston is at top center compression stroke, the timing pin is installed in fuel injection pump camshaft and the timing pin is installed in timing groove (slot) in right inlet camshaft before installation of cluster gear. Damage to engine can be the result if the above procedure is not followed.
12. Put clean grease on washer (10) to hold it in position. Put cluster gear (9) and washer (10) in position. Make sure the "V" marks on the crankshaft gear and cluster gear are in alignment. Make sure the hole in the engine block is in alignment with the hole through the center of cluster gear (9). Make sure washer (10) is in alignment also. 13. Install shaft (11). The adapter for the earlier engines does not have the "V" mark on it. For later engines it will be necessary to remove the adapter to see the "V" mark.
LATER ENGINE SHOWN14. Use tooling (B) to install bearing (12) in the adapter. Install the bearing with the bearing junction (joint) in alignment within 3° of the "V" mark on the adapter for later engines. Install the bearing with the bearing junction (joint) 90° from the vertical toward the inside of the engine for earlier engines. Install the bearing to a depth of .03 in. (0.762) below the surface. The inside diameter of the bearing after assembly must be 2.5010 .0015 in. (63.525 0.038 mm). 15. Install cover (13).
LATER ENGINE SHOWN16. Put washer (14) in position on the pump drive gear (15). Install pump drive gear (15) in the adapter. 17. Install thrower (16). See INSTALL THROWER.end by:a) install flywheel housingb) check the timing of the engine (see CHECKING FUEL INJECTION PUMP TIMING ON ENGINE in TESTING AND ADJUSTING)