09117-06040-XC0 Suzuki BOLT

2. Remove mounting bolts (1).3. Remove fuel transfer pump (3).4. Remove service meter (2) from fuel transfer pump.Install Fuel Transfer Pump
1. Install service meter (1) on fuel transfer pump (2).2. Put the fuel transfer pump in position on the engine and install the bolts that hold it on the engine.3. Install the right side guard on the engine.Disassemble Fuel Transfer Pump
START BY:a) remove fuel transfer pump1. Remove the service meter from the transfer pump. 2. Remove nut (2), gear (3) and the key from the end of the shaft assembly.3. Remove cage assembly (1) from the shaft assembly.4. Remove the O-ring seals and the ring from the outside of cage assembly (1). 5. Use tool group (A) to remove the two seals and bushing from the inside of cage assembly (1).
Use care not to damage the contact surfaces of the body and cover assemblies when the pump is disassembled and assembled.
6. Remove the screws and make a separation of cover assembly (5) from the body assembly.7. Remove the bolt, gasket, spring and plunger assembly from the side of cover assembly (5).8. Remove the lip type seal from cover assembly (5).9. Remove gear (4) and shaft assembly (6) from the body assembly. 10. Use tool group (A) to remove the bushing from the body assembly.Assemble Fuel Transfer Pump
See SPECIAL INSTRUCTION Form GMG00578 for instructions to use tool group (C).1. Clean all parts thoroughly before the transfer pump is assembled. 2. Install bearing (2) in body assembly (1) with tooling (A). Make sure the face of the bearing is not beyond surface (D). 3. Put a thin layer of 8S6747 Gasket Sealer (Permatex No. 3) on the outside diameter of seal (4). Install the seal in cover assembly (3) with tooling (B). Make sure dimension (E) is .45 in. (11.4 mm). Make sure the rubber lip of the seal is toward surface (F). Put a light amount of clean diesel fuel on the rubber lip of the seal.4. Install the shaft assembly and gear in the body.5. Put a thin layer of 8S6747 Gasket Sealer (Permatex No. 3) on the surface of the body that makes contact with the cover.
Make sure the Permatex does not get on the inner surfaces of the transfer pump.
6. Install the cover assembly on the body assembly. Install the screws that hold the cover and body assemblies together. 7. Install seals (6) and (7) in the cage assembly with tooling (B). Make sure dimension (G) is .12 in. (3.0 mm). Make sure dimension (H) is .58 in. (14.7 mm). Make sure the rubber lip of seal (7) is toward the face (J) of the cage assembly. Make sure the rubber lip of seal (6) is opposite of face (J). Put a light amount of oil on the rubber lips of seals (6) and (7). 8. Install bushing (5) in the cage with tooling (A).9. Install the plunger, spring, gasket and bolt (9) in the cover. Tighten the bolt to a torque of 40 5 lb.ft. (55 7 N m). 10. Install O-ring seals (8) and the ring on the cage assembly.11. Install the seal guide that is part of tool (C) over the end of the shaft assembly. Install the cage assembly over the shaft assembly. 12. Install the key in the shaft assembly. Install gear (10) and nut (11) on the shaft assembly. Tighten the nut to a torque of 22 5 lb.ft. (28 7 N m).END BY:a) install fuel transfer pump