65700-87D21 Suzuki CLIP

1. Drain the front oil pan.2. Remove the four bolts that fasten tube and elbow (1) to the oil pump. Remove tube and elbow (1). 3. Remove bolts (2) and push hoses (3). Move toward the frame of the machine. 4. Disconnect hose (5) from the water pump and move it to one side.5. Remove bolts (4). Remove elbow and adapter (6). 6. Fasten tooling (A) and a hoist to the oil pump as shown. 7. Remove bolts (8). Pull oil pump (7) back and lower it. Weight is 39 Kg (86 lb.). For installation of the oil pump, reverse the procedures of Steps 1 through 7.End By: a. install fuel transfer pumpb. install engine side guardsc. install hood assemblyDisassemble Oil Pump
Start By: a. remove oil pump
Cover (2) has spring tension under it. To prevent personal injury, loosen bolts (1) slowly and the same amount to remove the tension under the cover.
1. Remove bolts (1), cover (2), gasket (3), spring (4) and valve spool (5) from the pump body. 2. Remove cover assembly (6) and the gasket from the pump body. 3. Remove cover assembly (7) from the pump body. 4. Use tooling (A) to remove bearings (8) from cover assembly (7). 5. Remove shaft assemblies (10) from body assembly (9). 6. Use a press to remove gears (11) from the shaft assemblies. 7. Use tooling (A) to remove bearings (12) from body assembly (9).Assemble Oil Pump
1. Make an alignment of bearings (1) so that the joints are 45 15° from a line through the center of the bearing bores as shown.2. Use tooling (A) to install bearing (1) in the body assembly until they are 1.5 0.5 mm (.06 .02 in.) below the gear bore in the body assembly. Check the inside diameter of the bearings after installation. The diameter must be 31.811 0.013 mm (1.2524 .0005 in.). 3. Heat gears (2) to a maximum temperature of 316° C (600° F).4. Install the gears on shaft assemblies (3) until they are 64.0 0.5 mm (2.52 .02 in.) from the cover end of the shaft assemblies to the face of the gears and 47.0 0.5 mm (1.85 .02 in.) from the fuel pump drive end of shaft assembly (4). 5. Install shaft assemblies (3) and (4) in the body assembly. 6. Make sure dowels (5) and (8) are installed in cover assembly (6) so they extend 6.0 0.5 mm (.24 .02 in.) above the surface of the cover assembly.7. Use tooling (A) to install bearings (7) in cover assembly (6) with the joints of the bearings in the positions as shown. 8. Put cover assembly (6) in position, and tighten the bolts to hold it to the body assembly. 9. Make sure the two pins in cover assembly (9) are installed so they extend 6.0 1.0 mm (.24 .04 in.) above the surface of the cover assembly. Install the gasket and cover assembly (9) on the body assembly. 10. Put clean engine oil on valve spool (13). Install valve spool (13), spring (12), gasket (11), cover (10) and the bolts in the body assembly.End By: a. install oil pump