09401-11403 Suzuki CLIP

Start By:a. remove fuel injection linesb. remove fuel transfer pump 1. Remove the six nuts, washers, gasket and cover (1) for the fuel pump drive gear from the timing gear cover.2. Disconnect fuel lines (2).3. Remove the cotter pin and pin that fasten governor control cable (3) to the governor lever. Remove the two bolts that fasten bracket (4) to the governor, and move the governor control cable and bracket out of the way. 4. Remove bolt (5) and the washer from the fuel injection pump camshaft. Install tooling (B) and bolt (5) until there is gap of 3.18 mm (.125 in.) between tooling (B) and the fuel pump drive gear.5. Install tooling (A) as shown. Tighten the stud to pull the fuel pump drive gear from the taper on the fuel injection pump camshaft. Remove tooling (A), bolt (5) and tooling (B). 6. Fasten a hoist and nylon strap to the fuel injection pump housing and governor.7. Remove two bolts (7) and three nuts (8), and remove the fuel injection pump housing and governor from the engine. The weight of the fuel injection pump housing and governor is 29 Kg (64 lb.). The following steps are for installation of the fuel injection pump housing and governor. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of crankshaft rotation is given.8. Put clean engine oil on the four O-ring seals for the fuel injection pump housing and the governor, and install them in their correct locations.9. Use a nylon strap and hoist to put the fuel injection pump housing and governor in position on the timing gear plate and oil manifold. Install two bolts (7) and three nuts (8).10. Remove timing cover (6) and the gasket from the fuel injection pump housing. Install tooling (C) in the timing hole in the housing. Push on tooling (C) and turn the fuel injection pump camshaft. When tooling (C) engages the groove (slot) in the camshaft, the fuel injection pump is in the No. 1 piston top center position.11. Put the fuel pump drive gear in position on the fuel injection pump camshaft, and install tooling (D) and bolt (5) finger tight.
Typical Example12. Remove the electric starting motor. See the topic, Remove and Install Electric Starting Motor.13. Install tooling (E) as shown in the flywheel housing.14. Use tooling (E), and turn the flywheel in the direction of engine rotation until bolt a 3/81/2 " - 16 NC x 2 " NC bolt (9) can be installed in the flywheel. Do not turn the crankshaft counterclockwise to get the bolt hole alignment.15. If you go past the bolt hole in the flywheel, turn the crankshaft counterclockwise, opposite the direction of engine rotation, (as seen from the front of the engine), approximately 30°. This procedure will permit the backlash (gear clearance) to be removed from the timing gears when the crankshaft is turned in the direction of engine rotation (clockwise).16. Loosen the hose clamp, and remove the bolt that holds the breather cap to the valve cover. Remove the breather cap and O-ring seal from the valve cover. The No. 1 piston is at top center on the compression stroke when the bolt can be put in the flywheel through the hole in the flywheel housing, and both rocker arms for the No. 1 piston can be moved by hand (have clearance with the valve stem). 17. Install a 3/81/2 " - 24 x 1 " NF bolt in one of the tapped holes in the fuel pump drive gear.18. Put a torque wrench on the 3/8 " bolt with the wrench in line with the center of the fuel pump drive gear. While holding a torque of 68 N m (50 lb.ft.) on the 3/8 " bolt, tighten fuel pump drive gear bolt (5) to a torque of 270 25 N m (200 18 lb.ft.). Remove tool (C) from the fuel pump and the 3/81/2 " - 16 x 2 " NC bolt (9) from the flywheel.19. Remove the 3/81/2 " - 24 x 1 " NF bolt from the fuel pump drive gear. Remove fuel pump drive gear bolt (5) and tooling (D). Install the original washer with the large diameter away from the fuel pump drive gear, and install fuel pump drive gear bolt (5). Tighten the bolt to a torque of 270 25 N m (200 18 lb.ft.).20. Turn the engine flywheel two complete revolutions with tooling (E). If the 3/81/2 " - 16 x 2 " NC bolt goes in the hole in the flywheel when the timing pin is installed in the notch in the camshaft, the timing is correct. Remove tooling (E). Install the gasket and timing cover (6) on the fuel injection pump housing.21. Install the O-ring seal and breather cap on the valve cover. Tighten the breather cap bolt to a torque of 14 3 N m (10 2 lb.ft.). Tighten the hose clamp on the breather cap.22. Put bracket (4) and governor control cable (3) in position on the governor, and install the two bolts that hold the bracket in place. Install the cotter pin and pin that fasten governor control cable (3) to the governor lever.23. Connect fuel lines (2).24. Install the gasket, cover (1) and the nuts for the fuel pump drive gear from the timing gear cover.End By:a. install electric starting motorb. install fuel transfer pumpc. install fuel injection lines