33510-98600 Suzuki CAP, PLUG

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-7307 Engine Turning Tool 1
B 4C-9874 Spanner Wrench 1
C 6V-4186 Fuel Pump Timing Pin 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The No. 1 piston must be set at the top center position (TC) in order to perform all of the timing procedures.Note: The engine is seen from the flywheel end when the direction of the crankshaft rotation is given.
Illustration 1 g00460164
Remove the electric starting motor.
Install Tool (A) into the flywheel housing, as shown.
To find the TC position for the No. 1 piston, perform the following procedure:
Turn the flywheel clockwise or turn the flywheel in the opposite direction of the engine rotation for approximately 30 degrees. This removes all play from the timing gears. Note: If you go past the bolt hole, repeat Step 3a.
Illustration 2 g00460248
Remove plugs (1) and (2).
Illustration 3 g00460252
Turn the flywheel counterclockwise until a 3/8-16 X 3 1/2 NC bolt (4) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 6 pistons are now at the TC position. Plug (2) was removed for viewing through inspection hole (3). Note: The No. 1 piston is on the compression stroke when the valves of the No. 1 cylinder are closed. The rocker arms for the inlet valves and for the exhaust valves must have slight side-to-side movement.
In order to check the position of the inlet and exhaust valves, remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
If the No. 1 piston is not on the compression stroke, remove bolt (4) and turn the flywheel for 360 degrees counterclockwise. Install bolt (4). The No. 1 piston is now at the TC position.
Illustration 4 g00460258
Typical example
Install Tool (C) in the fuel injection pump housing, as shown. Push on Tool (C) and turn fuel injection pump camshaft (8). When Tool (C) engages the groove (slot) in the camshaft, the fuel injection pump is in the TC position for the No. 1 piston. Note: Check the condition of the O-ring seals. Replace the O-ring seals, if necessary.
Ensure that O-ring seals (5), (6), (7) and (9) are in position on the fuel injection pump housing and the governor. Put clean engine oil on the seals.
Illustration 5 g00460259
Attach a hoist and put the fuel injection pump housing and the governor in position on the timing gear plate and the oil manifold. Install three nuts (11), two bolts (10) and the washers. Ensure that Tool (C) remains in place.
Illustration 6 g00460341
Install washer (12) with the large side outward. Install bolt (13) finger tight. Ensure that Tool (C) is in the notch in the camshaft of the fuel injection pump.
Illustration 7 g00460342
Install Tool (B) on the fuel pump drive gear. Apply 68 N m (50 lb ft) of force to the fuel pump drive gear with timing bolt (3) in position in the flywheel and Tool (C) in position in the fuel system. Apply this force in a clockwise direction when the engine is viewed from the front. Use Tool (B) and a suitable torque wrench. Hold the 68 N m (50 lb ft) of force on Tool (B) and torque the drive gear bolt to a torque of 270 25 N m (200 18 lb ft). Remove Tool (B) and Tool (C) from the fuel pump and remove bolt (3) from the flywheel.
Use Tool (A) and turn the flywheel for two complete revolutions. When bolt (3) goes in the hole in the flywheel and Tool (C) is installed in the notch in the camshaft, the timing is correct.
Install plugs (1) and (2).
Remove Tool (A). Install the electric starting motor.
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
Illustration 8 g00460343
Put cover (14) and the gasket in position. Install four bolts (15).
Put the fuel filter base, the gasket, and fuel filter (16) in position. Install two bolts (19) and the washers.
Install tube assemblies (21) and (22). Connect wire (20). Connect hoses (17) and (18).