32900-94711 Suzuki CDI UNIT ASSEMBLY

Dismantling:
8-4Remove V-belt and air cowling. Unscrew bolts and take down blower.Fig. 8-4Refitment:
8-51. Align blower to holes and attach to front-end cover.Fig. 8-5
8-62. Push idler pulley upward and install belt.Fig. 8-6Removing And Refitting Oil-Controlled Fan (As from 3-cylinder engine)
Removing Fan
Loosen generator and remove V-belt. Take down oil feed, vent and return piping. Unscrew bolts to remove fan.Refitting Fan
8-71. Align fan to holes and attach to front-end cover.Fig. 8-7
8-82. Fit oil return connector with new seal.Fig. 8-8
8-93. Connect oil return pipe with rubber sleeve and clips.Fig. 8-9 Fit new O-seal and coat with grease (arrow).Fig. 8-9
8-104. Connect vent pipe. Preload bolts.Fig. 8-10
8-115. Connect oil feed pipe. Preload bolts.Fig. 8-11
8-126. Secure clip as shown (arrow) and tighten all bolts.Fig. 8-12
8-137. Secure oil feed pipe to exhaust thermostat with new washers.Fig. 8-13Dismantling And Installing The Air Compressor And Bracket
Dismantling:
1. Remove the vee belts for the air compressor and generator. Disconnect the induction pipe attached to the air compressor and the oil line on the bracket.2. Remove the bracket with the air compressor. Disassemble the rubber O-seal on the bracket. Disassemble the air compressor from the bracket. Remove the rubber gasket from the contact surface of the air compressor.Installing:
8-141. Coat a new rubber gasket with grease and stick it in position on the air compressor.Fig. 8-14
8-152. Mount the air compressor on the bracket so that the oilholes of the compressor register with those of the bracket.Fig. 8-15
8-163. Apply grease to a new rubber gasket and stick it in position on the bracket.Fig. 8-16
8-174. Mount the bracket with air compressor to the front cover.Fig. 8-17
8-185. Fit new gasket on the oil line and connect it to the bracket.Fig. 8-18
8-196. Connect the induction line, fitted with a new gasket, to the air compressor, paying attention to the clamping cone.Fig. 8-19Tensioning, Replacing Air Compressor Vee-Belt
a) Single-Groove Pulley
1. Unscrew locking bolts from belt pulley, remove outer belt pulley and Vee-belt.
8-202. The belt tension is increased by removing shims from the collar of the inner belt pulley half.Fig. 8-203. Place removed shim on to outer belt pulley half.
8-214. Mount Vee-belt on collar. Fit outer belt pulley with inserted shims.Fig. 8-215. Fit bolts and tighten uniformly while turning the belt pulley.
8-226. Check Vee-belt tension. Make sure that the free movement midway between the belt pulleys is about 10 mm, when pressure is applied with the thumb.Fig. 8-227. If necessary, repeat the tensioning operation.b) Double-Groove Pulley
8-231. For tensioning the outer Vee-belt unscrew nuts and detach outer belt pulleyFig. 8-23
8-242. Remove one shim between outer belt pulley half and intermediate plate.Fig. 8-243. Place removed shim on the outside of the outer belt pulley half.4. Fit outer belt pulley half with shims and tighten nuts while turning the belt pulley.
8-255. For tightening the inner Vee-belt remove outer belt pulley half, shims and intermediate plate.Fig. 8-25
8-266. Remove inner belt pulley half and place one shim on to hub body.Fig. 8-26
8-277. Fit inner belt pulley half and remaining shims, inner Vee-belt.Fig. 8-278. Assemble intermediate plate, shims, outer Vee-belt and outer belt pulley half. Uniformly tighten nuts while turning the belt pulley.9. The Vee-belts are tensioned correctly if the free movement midway between the pulleys is about 10 mm, when pressure is applied with the thumb.10. If necessary, repeat tensioning operation individually for inner or outer Vee-belt or both Vee-belts together.Dismantling And Installing The Generator
Dismantling:
8-281. Slacken the fasteners securing the generator and remove the vee belt.Fig. 8-282. Remove generator.Refitment:
8-291. Position generator and check alignment of generator belt to crankshaft belt.Fig. 8-29
8-302. Correct any misalignment by bolt washers.Fig. 8-303. Install belt. Secure strap.Checking The Induction And Exhaust Manifolds
1. Check the induction and exhaust manifolds for cracks and damage.
8-312. Remove flame glow plug from induction manifold and seal all apertures so that they are air-tight. Check manifolds for leaks.Fig. 8-313. If the induction manifold is leaky renew it. If the exhaust manifold is damaged, repair or renew it.Dismantling And Reassembling The Cooling Air Blower
The cooling air blower is removed. Disassembling
1. Unscrew the securing bolt and remove the washer. Dismantle the vee-blet pulley, blower impeller, thrust washer and bearing shaft. Remove the circlip and press out the two grooved ball bearings and spacer sleeve.