32900-94700 Suzuki CDI UNIT ASSEMBLY

Dismantling:
1. Disconnect the fuel line attached to the solenoid valve. Disconnect the flexible tubing delivering fuel to the feed pump and injection pump. Dismantle the fuel line connecting the fuel filter with the injection pump. Disconnect the leak-off line and the fuel delivery lines attached to the injection pump.
7-9 Immediately the pipes are disconnected, plug the bores and fit caps over the connecting stubs of the fuel system.Fig. 7-9
7-102. Unscrew the nuts securing the injection pump drive to the injection pump shaft. (For slotted nut use double spanner No. 110330).Fig. 7-103. Remove the spring lockwasher. Make sure that it does not drop into the crankcase. Important:As from 1975, the hub was modified in the case of rigid drive.(The thread for attachment of universal device No. 110340 with sleeve has been omitted).See: DISMANTLING AND INSTALLING INJECTION PUMP WITH MODIFIED HUB FOR RIGID DRIVE (as from 3-cylinder engine)4. Remove gearwheel fastening screws.
7-115. If the engine has an injection timer mount the tool without sleeve on the injection pump drive. If the engine has no injection timer, mount the tool with sleeve on the injection pump drive. (Universal device No. 110340).Fig. 7-11
7-126. Pull the injection pump drive from the injection pump shaft.Fig. 7-12 left and right Do not rotate the crankshaft.7. Unscrew the nuts on the injection pump and remove the injection pump. Remove the rubber O-seal on the injection pump. If necessary, dismantle the cut-out system attached to the injection pump.Installing:
7-131. Re-install the automatic stop system removed from the injection pump.Fig. 7-132. Check whether the Woodruff key is fitted to the injection pump shaft. If it is not, install one.
7-143. Assemble a new rubber O-seal to the injection pump.Fig. 7-14
7-154. Install the injection pump so that the Woodruff key in the injection pump shaft engages in the groove of the injection pump drive and the connections for the fuel delivery lines face diagonally upwards.Fig. 7-15
7-165. Line up the notches in the injection pump and intermediate flange. Assemble the nuts.Fig. 7-16
7-176. Screw the nuts on the fuel-injection pump drive. (Use a 19 mm socket spanner or double spanner No. 110330).Fig. 7-17 Attention:Slotted nut replaced as from 1977 by clamping nut 13a/fl. For tightening instructions, see Technical Data.
7-187. Assemble and tighten the union of the injection delivery line, so that the latter is free from tension.Fig. 7-18
7-198. Connect the leak-off line and the line connecting with the solenoid valve, and at the same time fit a new gasket.Fig. 7-199. Assemble new gaskets and connect the fuel pipes or flexible tubing leading from the fuel feed pump to the delivery filter and from this filter to the injection pump.
7-2010. If the engine is equipped with an automatic cut-out, install the return spring thereof.Fig. 7-2011. Adjust the fuel-injection point in accordance with the instructions given in this manual. (See Section 2).Dismantling And Installing Injection Pump With Modified Hub For Rigid Drive (as from 3-cylinder engine)
It is assumed that the V-belt tensioner or cover is dismantled. Dismantling:
1. Disconnect fuel line attached to solenoid valve. Disconnect flexible tubing delivering fuel to feed pump and injection pump. Dismantle fuel line connecting filter with injection pump. Disconnect leak-off line and fuel delivery lines attached to injection pump.
7-21 Close immediately bores and connections of fuel system.Fig. 7-21
7-222. Loosen and remove screws securing gear.Fig. 7-22
7-233. Unscrew nuts securing injection pump and remove injection pump.Fig. 7-23 Do not rotate crankshaft anymore.
7-244. Pull hub off injection pump.Fig. 7-24Installation:
7-251. Check whether Woodruff key is fitted to injection pump shaft. If not, install one.Fig. 7-25
7-262. Push hub onto camshaft of injection pump. Turn up nut and tighten in accordance with Tightening Instructions.Fig. 7-26
7-273. Renew gasket at pump flange.Fig. 7-27
7-284. Install injection pump and tighten down nuts, taking care to position in centre of elongated holes.Fig. 7-28
7-295. Position one of the screws for securing gear and tighten down.Fig. 7-29
7-306. Rotate crankshaft to TDC position, cylinder No. 1.Fig. 7-307. Remove cover of injection pump. Loosen and remove screw securing gear.
7-318. Rotate crankshaft until 1st plunger of injection pump is in TDC position.Fig. 7-319. Position other screws securing gear and tighten down.
7-3210. Install cover of injection pump. Assemble and tighten unions of injection delivery lines so that latter are free from tension.Fig. 7-3211. Connect fuel lines and flexible tubing, as well as leak-off lines.12. Adjust commencement of delivery.See Section 2.Removing And Refitting The Distributor-Type Injection Pump (Current Type)
Vee-belt tensioner and cover have been removed. Dismantling:
1. Set piston of No. 1 cylinder to TDC. Disconnect fuel and injection lines.
7-33 Uncovered sockets and pipe connections must be sealed immediately.Fig. 7-33
7-342. Unscrew nut from pump shaft at the pump drive.Fig. 7-343. Remove spring lockwasher. Do not drop spring lockwasher into the housing.
7-354. Position device (with sleeve) at the pump drive and pull off drive from the shaft.Fig. 7-35 Do not revolve the crankshaft. Important:Starting 1975, the hub has been modified: the thread for tool No. 110340 has been dispensed with.See: REMOVING AND REFITTING DISTRIBUTOR TYPE INJECTION PUMP (NEW TYPE WITH NEW HUB)
7-365. Loosen fastening nuts on flange of distributor-type fuel injection pump and remove pump.Fig. 7-36