09320-08062 Suzuki CUSHION

start by:a) remove electric starting motorb) remove fuel injection lines 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. 1. Install tooling (A) on flywheel housing as shown.2. To find top center compression stroke for No. 1 piston, first turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30 degrees. This procedure is to remove all play from the timing gears.3. Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (1) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 4 (No. 6 on 3306) pistons are now at top center position.
If you go past the bolt hole you must start over with Step 2.
4. Remove the valve cover.5. To see if the No. 1 piston is on the compression stroke, look at the valves of the No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You must be able to move the rocker arms up and down with your hand.6. If No. 1 piston is not on the compression stroke, remove the 3/8"-16 NC bolt (1) and turn the flywheel 360° counterclockwise. Install the 3/8" bolt as before. The No. 1 piston is now at top center (TC) on the compression stroke.7. To install tool (B) in the fuel injection pump housing, remove the 3/8"-16 NC bolt from the flywheel and turn the flywheel approximately 30° clockwise. 8. Remove bolt and install tool (B) in the governor housing. Turn the flywheel slowly in a counterclockwise direction until pin (B) goes into the notch in the camshaft.9. Put the 3/8"-16 NC bolt in the timing hole in the flywheel housing. If the bolt can be installed in the hole in the flywheel, the timing on the fuel injection pump is correct.10. Remove cotter pin and bolt (2) from linkage rod.11. Remove bolt (3) that holds clip to block. Panel (5) was removed for photo illustration. 12. Remove bolt (4) and move panel (5) forward for the removal of drive gear cover and drive gear.13. Disconnect fuel lines (6) and (7). 14. Remove nuts (9) and cover (8) from the front of the timing gear cover. 15. Remove bolt (11) and washer (10) that hold the drive gear to the fuel injection pump. 16. Install tooling (C) to loosen drive gear from drive sleeve. 17. Loosen the three nuts (17) that hold the fuel pump to the timing gear plate.18. Remove fuel line (12) and clip (16).19. Remove bolts and gaskets that fasten oil tubes assemblies (13) and (14) to turbocharger. Remove tube assembly (13).20. Remove two bolts (15). Remove tube assembly (14) and adapter (18) from block. 21. Remove three nuts (17). Remove the fuel injection pump housing and governor (19).Install Fuel Injection Pump Housing And Governor
1. Inspect the O-ring seal for damage in the transfer pump housing (2). Make a replacement if necessary.2. Put the fuel injection pump housing and governor (1) in position on the engine and against the timing gear plate. 3. Install the three nuts that hold the fuel injection pump housing to the timing gear plate. Do not tighten nuts until the adapter (4) and lower turbocharger oil tube assembly (3) is installed.4. Inspect the two O-ring seals on adapter and make a replacement if necessary.5. Put adapter (4) and tube assembly (3) in position and install two bolts to hold the adapter to block. Install gasket and two bolts to hold tube assembly (4) to the turbocharger. Tighten three nuts (5). 6. Put oil tube assembly (6) in position and install gasket and two bolts to fasten tube to turbocharger.7. Install fuel line (7) and clip (8) on the two turbocharger tube assemblies. 8. Install two fuel lines (9) and (10) to the fuel injection pump housing.9. Put clip on two drain lines in position and install bolt (12).10. Put linkage rod (11) in position and install bolt and cotter pin. 11. Put the drive gear (14) in position on the fuel injection pump and install washer and bolt finger tight. Be sure that tooling (B) is in the notch in the camshaft.12. Install a 3/8"-24 NF bolt, 1/2 in. long, in one of the holes (13) in the drive gear (14). 13. Put a torque wrench on the 3/8" bolt with the wrench in line with the center of the drive gear, and give it a torque of 45 to 50 lb.ft. (60 to 70 N m). While this torque is held, tighten the drive gear bolt to a torque of 110 5 lb.ft. (149 7 N m). Remove pin (B) from the fuel pump and the 3/8"-16 NC bolt from the flywheel.14. Turn the engine flywheel two complete revolutions with tooling (A). If the 3/8"-16 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. 15. Put gasket and cover (15) in position on the timing gear cover. Install nuts. Tighten nuts to a torque of 17 3 lb.ft. (23 4 mm) 16. Remove tooling (A) and the 3/8"-16 bolt (16) from the flywheel housing. 17. Put the panel (17) in place and install the bolts to hold it in place.