38111-97E00 Suzuki HOLDER, PTT CABLE

start by:a) remove fuel injection lines1. Use the following procedure to put the No. 1 piston at top center on the compression stroke. 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 flywheel rotation is given. Do not turn the flywheel backward. a) Remove plug (1) from the flywheel housing and the breather from the valve cover. b) Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (2) at least 2.5 in. long can be installed in the flywheel through the hole in the flywheel housing. Do not turn the flywheel backward. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.c) Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. 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 backward and forward by hand.d) If both rocker arms can not be moved by hand, the No. 1 piston is not at top center on the compression stroke. Remove the bolt from the flywheel and turn the flywheel counterclockwise one full turn (360°). Install the timing bolt in the flywheel again. Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. 2. Remove the cover on the fuel injection pump housing and install timing pin (B). Turn the camshaft until timing pin (B) goes in the groove in the camshaft as shown. 3. Put identification on wires (3) and (6). Disconnect wires (3) and (6).4. Remove fuel filter (5) from the engine.5. Remove the nuts and cover (4). 6. Remove fuel lines (7) and (8). 7. Disconnect governor linkage (9) at the governor.8. Remove bracket (10) from the governor. 9. Install tooling (A) and loosen the timing gear on the camshaft in the fuel injection pump housing. 10. Remove two bolts (11) and three nuts (12) that hold the fuel pump housing in place. 11. Use two persons to remove fuel pump housing (13) from the engine. The weight of the fuel pump housing is 26 kg (58 lb.).Install Fuel Injection Pump Housing And Governor
TYPICAL EXAMPLE1. Be sure O-ring seals (1) and (2) are in position on the fuel injection pump housing and governor and put clean oil on the O-ring seals. 3. Put the fuel injection pump housing and governor in position on the timing gear plate and the oil manifold. Install the three nuts that hold the fuel injection pump housing to the timing gear plate and the two bolts that hold the governor housing to the oil manifold.
After the fuel injection pump housing and governor are installed on the timing gear plate, be sure the rack is free to move. The O-ring seal on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely, remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Install bracket (4) on the governor.5. Connect linkage (3) to the governor. 6. Install tube assemblies (5) and (6). 7. Connect wires (7) to the shutoff solenoid.8. Connect wires (8) to the sending unit. 9. Install fuel filter (9) on the fuel injection pump housing. 10. Install the bolt and washer (10) as shown to hold the timing gear to the camshaft. Install washer (10) with the larger outside diameter toward the bolt head. Tighten the bolt finger tight only. 11. Install two nuts on stud (11). Put a spacer (round stock) in one of the lightening holes in the pump drive gear. Use a prybar to put a torque of approximately 68 N m (50 lb.ft.) on the pump drive gear in a clockwise direction (as seen from the front of the engine). With the clockwise torque on the pump drive use tooling (B) to tighten the bolt to a torque of 270 25 N m (199 18 lb.ft.). 12. Put the gasket and cover (12) in position. 13. Remove tooling (A) from the fuel injection pump housing. 14. Remove bolt (13) from the flywheel.15. Turn the engine flywheel counterclockwise (as seen from rear of engine) two complete revolutions. If the timing pin goes into the notch in the camshaft and the 3/8" - 16 NC timing bolt goes into the flywheel at the same time, the timing is correct.16. If the timing pin and bolt can not both be installed at the same time the timing procedure must be done again. Loosen the fuel injection pump drive gear on the camshaft and do Steps 10 through 12 again. 17. Put the gasket in position and install cover (14) and the bolts.18. Install the plug in the flywheel housing.end by:a) install fuel injection lines