09103-06278 Suzuki BOLT (6X25)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Camshaft Gear for the Fuel Injection Pump
Note: If the crankshaft was rotated and the gear for the fuel injection pump was removed, the top center position of number 1 piston on the compression stroke must be set.
Illustration 1 g00653747
Ensure that all bearing surfaces are clean. Carefully install the camshaft for the fuel injection pump into the engine cylinder block.
Illustration 2 g06465415
If the idler gear is not installed, proceed to Step 3. Ensure that the timing marks of the following components are aligned. The No. 1 cylinder is at the top center position when these marks are in alignment.
Camshaft gear for the fuel injection pump (2)
Camshaft gear (3)
Idler gear (4)
Crankshaft gear (5)
Illustration 3 g00653916
Loosen the bolt (14) and rotate the bearing retaining ring (15) at 180 degrees.
Tighten the bolt (14) against the bearing retaining ring (15). This will hold the bearing in position.
Install the governor weight assembly. Refer to Disassembly and Assembly, "Governor - Assemble".
Install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Install".
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".Idler Gear
Illustration 4 g00650568
Use a suitable press and Tool (A) to install new bushings (7) (not shown) into idler gear (4).
Illustration 5 g00650995
The front face of the bushing must protrude from the face of the gear. The protrusion (Z) should have a measurement of 1.5 to 2.0 mm (0.06 to 0.08 inch). Note: The positions of the cut-outs (11) are not important when the bushing is installed.
The bore (Y) of a new bushing can have a diameter of 27.425 to 27.610 mm (1.0797 to 1.0870 inch). Machine the bushings to be installed onto the idler gear hub. The finished bore (Y) of the bushing should have a diameter of 28.077 to 28.098 mm (1.1054 to 1.1062 inch).
Illustration 6 g00650715
Install idler gear hub (6) onto the cylinder block.Note: When the idler gear hub is installed, ensure that the oil hole (9) of the idler gear hub is up. If necessary, cool the idler gear hub to 0 °C (32 °F) before installation. The temperature of the idler gear hub is lowered to ease the installation of the idler gear hub.
Install the thrust washers (8) onto the idler gear (4).Note: Ensure that the oil grooves (10) are facing outward away from the idler gear (4).
Illustration 7 g06465415
Install idler gear (4) onto the idler gear hub.Note: Ensure that the timing marks (1) on the following components are aligned. The No. 1 cylinder is at the top center position when these marks are in alignment.
Camshaft gear for the fuel injection pump (2)
Camshaft gear (3)
Idler gear (4)
Crankshaft gear (5)Note: See the following list for the installation of the other gears in the front gear group.
To install the camshaft gear, refer to Disassembly and Assembly, "Camshaft - Install".
To install the crankshaft front gear, refer to Disassembly and Assembly, "Crankshaft Gear - Remove and Install".End By:
Install the front cover. Refer to Disassembly and Assembly, "Housing (Front) - Install".