31170-94520-0ED Suzuki UPPER COVER

start by:a) remove fuel injection lines1. Remove the hood. Remove the panel assembly from the left side of the rear frame.2. Turn the fuel valve to the "OFF" position. The valve location is under the fuel tank. 3. Disconnect rod assembly (1) from the governor control lever.4. Disconnect hose assembly (2) from the fuel filter base. Disconnect hose assembly (4) from the fuel injection pump housing.5. Remove the clip used to hold drain hose (3) in position at the cylinder block below the alternator. 6. Remove timing pin (6) from storage hole (5). Use the bolt that holds the crankshaft pulley to turn the crankshaft clockwise, as seen from the front of the engine. Turn the crankshaft until pin (6) can be installed in the groove (slot) of the fuel injection pump camshaft. Tool (A) can be used to turn the crankshaft. If tool (A) is used, remove the electric starting motor and install tool (A) in the flywheel housing. 7. Remove the timing hole plug from the flywheel housing and install a 3/8"-16 NC × 2 1/2 in. long bolt (7) into the threaded hole of the flywheel.
Never turn the crankshaft counterclockwise to install the bolt in the flywheel. If the crankshaft is turned counterclockwise the gear clearance (backlash) can cause the engine to be out of time when the fuel injection pump housing and governor are installed.
8. Remove one half of fan guard (8) from the left side of the machine.9. Loosen the bolts that hold the alternator in position and remove vee belts (9) from the alternator pulley. 9. Remove nuts (11) and cover (10) from the timing gear cover.10. Remove the bolt and washer that hold the drive gear to the fuel injection pump camshaft. Install tooling (C) on the end of the bolt. Install and tighten the bolt washer and tooling (C) to hold the sleeve on the end of the fuel injection pump camshaft. 11. Install tooling (B) on the drive gear. Tighten the center bolt of tooling (B) until the drive gear is loose. Remove tooling (B), the bolt and washers. The drive gear will stay in the timing gear cover. 12. Remove bolt (13) that holds the breather tube in position. Remove bracket (12) and adapter (14) from the engine. 13. Remove nuts (15) that hold the fuel injection pump housing and governor to the timing gear plate and remove fuel injection pump housing and governor (16). The weight of the fuel injection pump housing and governor is 45 lb. (20 kg).Install Fuel Injection Pump Housing And Governor
1. Make sure the timing pin is installed in the groove (slot) of the fuel injection pump camshaft. 2. Inspect the O-ring seal for the fuel transfer pump. Install a new seal if needed. Put clean engine oil on the seal. Put the fuel injection pump housing and governor in position on the engine. Install the nuts that hold it in place. 3. Put bracket (1) used for the fuel injection pump in position and install one bolt to hold it to the engine. 4. Put clean oil on the O-ring seals and install adapter (2) and the bolts to hold it.5. Install the second bolt in bracket (1) to hold it to the fuel injection pump housing.6. Install the bolt and clip that holds the breather tube to the fuel injection pump housing.7. Install the washer and bolt that hold the pump drive gear to the camshaft. Tighten the bolt finger tight only.
TYPICAL EXAMPLE8. Put a force of approximately 50 lb.ft. (70 N m) on the drive gear with tool (A). Tighten the bolt to a torque of 110 5 lb.ft. (149 7 N m).9. Check the timing to make sure it is correct: a) Remove the timing pin from the pump camshaft and the bolt from the flywheel.b) Turn the crankshaft clockwise (as seen from the front of the engine) approximately 1/2turn. Install the timing pin again.c) While the crankshaft is turned clockwise (as seen from the front of the engine), push on the timing pin until it slides into the groove (slot) in the pump camshaft.d) Install the bolt in the flywheel. The timing is correct when the bolt is installed in the flywheel and the timing pin is installed in the groove (slot) in the pump camshaft.e) Remove the timing pin and the bolt. Install the plug in the flywheel housing. Install the bolt in the cover on the pump housing. 10. Install cover (3). Install the nuts and washers that hold the cover in place. Tighten the nuts to a torque of 20 5 lb.ft. (25 7 N m). 11. Install fan guard (4) on the radiator.12. Put vee belts (5) in position on the alternator pulley. Make an adjustment of vee belts (5). See, Install Alternator.13. Remove the bolt from the flywheel and install the plug in the flywheel housing. 14. Remove timing pin (7) from the fuel injection pump housing and install it in the position shown. Install bolt (10) and O-ring seal in the hole from which the timing pin was removed.15. Connect fuel line (6) to the fuel filter base. Connect fuel line (9) and rod assembly (11) to the fuel injection pump housing and governor. Fasten the clip that holds drain line (8) below the alternator.16. Install the panel assembly and hood on the rear frame. 17. Turn the fuel valve (12) to the "ON" position.end by:a) install fuel injection lines