61111-94401-02M Suzuki Cover, Engine Lower

1. Remove two bolts (2), and pull housing (1) from the end of the tube to remove it from the engine. 2. Remove the bolts to remove cover (3) and the screen from housing (1). 3. Remove bolt (6) to remove clip (7) and bracket (5) from tube (4).4. Pull tube (4) from the scavenge pump, and remove tube (4) from the engine. Remove the O-ring seals from the tube. 5. Remove four bolts (9), and use two men to remove oil scavenge pump (8) from the engine. The weight of the pump is 32 kg (71 lb). The following steps are for installing the oil scavenge pump.6. Clean and inspect the filter screen before installation.7. Lubricate all seals with clean engine oil before assembly.8. Install the oil scavenge pump in the reverse order of removal.End By:a. install oil panDisassemble Oil Scavenge Pump
Start By:a. remove oil scavenge pump
Typical Example1. Remove bolt (1).2. Use Tooling (A) to the remove gear (2) from the pump assembly. 3. Put alignment marks on the pump body and cover (5) for correct assembly. Remove bolts (4) and cover (5) from the pump body. 4. If necessary, remove dowels (6) and bearings (7) from cover (5). 5. Remove drive shaft assembly (8) and idler shaft assembly (9) from the pump body. 6. If necessary, remove bearings (10) from the pump body.Assemble Oil Scavenge Pump
Put a thin coat of clean engine oil on the shaft assemblies and bearings when assembling the pump. 1. Position bearings (10) on the pump body with the bearing joint located as shown. Use Tool group (A) to install bearings (10) until they are 1.5 0.5 mm (.06 .02 in)below the bottom of the gear bores in the pump body.2. Check the inside diameter of bearings (10) after they are installed. The inside diameter must be 31.837 0.070 mm (1.2534 .0028 in). 3. Check the condition of the gears on shafts (8) and (9). If replacement is necessary, heat the new gears to a maximum temperature of 316° C (600° F), and install the gears on the shaft assemblies. The face of the gear on drive shaft assembly (8) must be 60.00 0.25 mm (2.362 .010 in)from the threaded end of the shaft. The ends of idler shaft assembly (9) must be 34.0 0.5 mm (1.34 .02 in)from the gear faces.4. Install idler shaft assembly (9) and drive shaft assembly (8) in the pump body. 5. Use Tool group (A) to install bearings (7) in cover (5). Install bearings (7) with the joints in the position shown. Make sure the bearings are 1.5 0.5 mm (.06 .02 in)below the surface of cover (5).6. Check the inside diameter of bearings (7) after they are installed. The inside diameter must be 31.837 0.070 mm (1.2534 .0028 in).7. Install dowels (6) in cover (5) until they are 6.4 0.5 mm (.25 .02 in)above the surface of cover (5) as shown. 8. Put cover (5) in position, and install the bolts to hold it to the pump body.
Typical Example9. Install gear (2). Install bolt (1).End By:a. install oil scavenge pump