48570-95E00 Suzuki CAP

Start By:a. remove radiator and guardb. remove ROPS (roll-over protective structure) or cabc. remove seat Drain the oil from the hydraulic tank and the transmission. 1. Remove the floor plate under the seat when machine is equipped with ROPS.2. Loosen clamp (1). Remove two bolts (3) that hold the muffler in place. Remove muffler (2). 3. Remove bolt (4) and pin (5) to disconnect the accelerator linkage.4. Disconnect two fuel lines (6) from the engine.5. Remove bolts holding clamps (7) and (8) to firewall (9).6. Remove two rubber flanges (10) and then pull fuel lines (6) through the firewall.7. Remove six bolts (11) that hold firewall (9) in place. Remove firewall (9). 8. Disconnect starter ground wire (18) and the smaller wire in the same connection.9. Disconnect electrical connection (13). Remove clamp bolt (12).10. Remove bolt (19) holding the clamp for the two wire connections.11. Disconnect two wire connections (20).12. Disconnect battery positive cable (15) and wire (14) from the starter.13. Disconnect wire (16) from the underside of the starter.14. Remove bolt and clamp (17).15. Disconnect two wire connections (18). 16. Remove two bolts (22). Remove battery disconnect (21). 17. Disconnect oil line (23) from the transmission.
Typical Example 18. Disconnect oil line (32) from the hydraulic tank. Leave the line with the transmission.19. Disconnect oil lines (28), (29), and (30).20. Disconnect oil line (26) and leave the line with the engine and the transmission.21. Remove dipstick tube (27) and transmission filler tube (25).22. Remove four bolts (31) that hold tube (24) to the side of the charge pump. See Illustration C30910P1 for a closer view of bolts (31) and tube (24).23. Remove accelerator linkage rod (33).
Typical Example24. Disconnect oil line (35) and leave the line with the engine.25. Disconnect oil line (34) from the steering cylinder for clearance purposes.26. Disconnect two wires (37) from manifold (36). Remove manifold (36).
Typical Example27. Disconnect wires (38).28. Remove bolts (39) and (40) that hold bracket (41) in place. Pull bracket (41) off to one side and away from the transfer housing. 29. Disconnect universal shaft (42). 30. Remove universal shaft (43) and dipstick fitting (44). 31. Fasten tool (A) and a hoist to the engine, transmission and transfer gears as shown.32. Remove bolts (45) from the front mounting support. 33. Loosen bolt (46) on rear mounting support bracket enough so that the engine can be lifted slightly to properly adjust tooling (A).34. After proper balance has been achieved with tooling (A), remove four bolts (47) that hold mounting brackets (48) to the transfer case.35. After removing four bolts (47) from both mounting brackets (48), remove the one (46) that holds the mounting bracket directly above the transfer case drain plug and remove bracket (48).
Inspect the areas in and around the engine and power train unit to make sure all disconnections and removals have been made before the engine and power train unit are to be lifted from the mounting frame.
36. Slowly lift engine, transmission and transfer gears out of the machine. The weight of engine and power train unit (49) is 1558 kg (2125 lb). Once the engine and power train unit has cleared hoses, wiring and machine frames, move the unit away and support it in a proper, safe and suitable manner.Install Engine, Transmission & Transfer Gears
1. Fasten tool (A) and a hoist to engine and power train unit (49) and put it in position in the machine frame. 2. Install mounting brackets (48) with bolts (46) and (47) that hold them. Leave the bolts loose at this time. 3. Install bolts (45) on the front mounting supports. Remove tool (A) from the power train unit. Tighten all mounting support bolts. 4. Install dipstick fitting (44) and universal shaft (43). Torque bolts to a torque of 70 15 N m (50 11 lb ft). 5. Connect universal shaft (42). Torque bolts to a torque of 70 15 N m (50 11 lb ft).
Typical Example6. Put bracket (41) in position with bolts (39) and (40). Connect wires (38).
Typical Example7. Install manifold (36). Connect two wires (37) to it.8. Connect oil line (34) to the steering cylinder and connect oil line (35).
Typical Example 9. Install accelerator linkage rod (33).10. Install tube (24) on the side of the charge pump with four bolts (31). See Illustration C30910P1 for a closer view of bolts (31) and tube (24).11. Install transmission filler tube (25) and dipstick tube (27).12. Connect oil lines (26), (28), (29) and (30).13. Connect oil line (32) to the hydraulic tank. 14. Connect oil line (23) to the transmission. 15. Install battery disconnect (21) with two bolts (22). 16. Connect two wire connections (18) and install clamp (17) and bolt.17. Connect wire (16) to the underside of the starter.18. Connect wire (14) and battery positive cable (15) to the starter.19. Connect two wire connections (20). Install bolt (19) holding the clamp for the two wire connections.20. Install clamp bolt (12). Connect electrical connection (13).21. Connect starter ground wire (18) and the smaller wire. 22. Put firewall (9) in position and install six bolts (11) that holds the firewall in place.23. Install two rubber flanges (10) and then pull fuel lines (6) through the firewall.24. Install bolts holding clamps (7) and (8) to the firewall.25. Connect two fuel lines (6) to the engine.26. Connect the accelerator linkage with pin (5) and bolt (4). 27. Install muffler (2) with two bolts (3) and clamp (1) that hold the muffler in place.28. Install the floor plate under the seat on machines equipped with ROPS. Fill the transmission and hydraulic tank with oil to the correct level. See the Operation & Maitenance Manual SEBU6284-01.End By:a. install seatb. install ROPS (roll-over protective structure) or cab.c. install radiator and guard