09401-08411 Suzuki CLIP, FUEL HOSE

start by:a) remove fuel linesb) remove air inlet manifold
Make sure all foreign material is kept out of the inlet manifold openings.
1. Remove fuel lines (1), (2) and (3) from the engine. 2. Remove bolt (4). 3. Install tool (A). Turn the crankshaft clockwise (as seen from the front of the engine) until the timing pin drops into the groove (slot) in the injection pump camshaft. For the correct timing procedure, see TESTING AND ADJUSTING, FUEL SYSTEM ADJUSTMENTS. 4. Remove nuts (6), then remove the tachometer cover (5). 5. Remove tachometer drive shaft (7) and washer (8). 6. Install tooling (B) into the camshaft drive gear for the fuel injection pump. Turn tooling (B) until the drive gear is free of the shaft. Remove tooling (B). 7. Remove the plug from the timing hole in the front cover and install a 5/16"-18 NC bolt (9) 2-1/2 in. long. Turn the crankshaft (clockwise as seen from the front of the engine) until bolt (9) can be installed into the timing gear and is in the center of the timing hole. 8. Remove two bolts (11) and fuel injection pump housing and governor (10) from the engine.Install Fuel Injection Pump Housing And Governor
1. Make sure O-ring seals (1) and (2) are in position. 2. Put fuel injection pump housing and governor (3) in position and install the bolts that hold it. 3. Install the washer (5) and tachometer drive shaft (4). Tighten the shaft to a torque of 110 10 lb. ft. (149 14 N m).4. Check the timing, see FUEL SYSTEM ADJUSTMENTS in TESTING AND ADJUSTING. 5. Install the tachometer cover (6) and the nuts (7) that hold it in place. 6. Remove tool (A) from the pump and install bolt (10). 7. Install fuel lines (8), (9), (11) and the clips that hold them.end by:a) install air inlet manifoldb) install fuel linesSeparation Of Fuel Injection Pump Housing From Governor
start by:a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A).2. Remove bolts (1) that hold governor housing assembly (2) to the fuel injection pump housing.3. Remove governor housing assemblies (2) and gasket. 4. Remove two springs (5) and (4) and seat (3).5. Remove the springs from the seat.6. Remove the bolts from the shaft. 7. Remove shaft assembly (8), lever (6) and washers (9) from housing (7). 8. Remove seal (10) and bushing (11) from the governor housing. 9. Remove piston assembly (12). 10. Remove spring (14) from seat (13) and seat (15).11. Remove snap ring (18) from seat (15) with tooling (B).12. Remove ring (17) and spool (16) from the seat. 13. Remove the bolts and cover (19). 14. Remove shaft (21) and lever (22).15. Remove O-ring seal (20) from the shaft. 16. Remove spring (23) and riser assembly (24). 17. Remove ring (27), races (28) and bearing (26) from riser (25). 18. Remove the bolts, cover (29) and the gasket. 19. Remove nut (30) and bolt (31).20. Remove torque spring assembly (32). 21. Remove shim (36), insulators (33) and (37), and contact (35) from bar (34).22. Remove the stop assembly if necessary. 23. Remove rod (38). 24. Remove lockring (39) and the lever.
Pull on the shield only a small amount in each location so it will not have distortion or damage. The metal of the shield is moved (staked) around the camshaft and the shield can be damaged when it is removed. If the shield has damage, use a new part for replacement.
25. Remove shield (40) from the camshaft with tooling (C). 26. Install tooling (D) into the camshaft.27. Remove three bolts (41) and the carrier assembly. 28. Remove dowel (42) from rod (43). Remove rod (43). 29. Remove pins (46) and weight (44) from carrier (45).Connection Of Fuel Injection Pump Housing To Governor
1. Put weights (2) in position and install pins (1) into carrier (3). 2. Put shaft (4) in position. Install dowel (5) in the shaft. 3. Make an alignment of dowel (5) with the groove (slot) in the carrier.4. Install tooling (A) in the camshaft.5. Put carrier assembly (6) in position and install the bolts. Tighten the bolts to a torque of 85 12 lb.in. (10 1 N m). 6. Put shield (7) in position. 7. Install the shield with tooling (B). Move the metal over on (stake) the shield on to the camshaft in alignment with the groove on the camshaft. Use an 1/8" screwdriver with a taper ground on the bottom edge so the screwdriver fits evenly against the flyweight assembly cover to stake it in two places 180° 5° apart. 8. Put lever (8) in position and install lockring (9). 9. Install pin (10). 10. Put contact (13), insulators (11) and (14) and shim (15) in position on bar (12). 11. Install torque spring assembly (16). Install the nut and bolt. 12. Put the gasket in position and install cover (17) and the bolts. 13. Put race (18), bearing (19), race (20) and ring (22) on riser (21). 14. Install riser assembly (23) and spring (24). 15. Put lever (25) in position. Make an alignment of the bolt socket in the housing with the ball on the lever. Also, make an alignment of the lever with the riser assembly.