61512-95600-064 Suzuki IGNITION TIMING MARK

1. Disconnect tube assemblies (1) and (3) from the fuel transfer pump.2. Remove fuel transfer pump (2). 3. Disconnect tube assemblies (5) and (6) from adapter (4). Remove tube assembly (7) from the adapter and the cylinder block. Remove the adapter. 4. Remove plug (8) from adapter (4).5. Remove valve assembly (9) from the adapter.6. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. Put clean engine oil on the O-ring seals.7. Install valve assembly (8) in the adapter. Install the plug in the adapter. 8. Put gasket (10) in position. Install the adapter on the fuel injection pump housing.9. Install tube assembly (7) on the adapter and the cylinder block.10. Connect tube assemblies (5) and (6) to the adapter. 11. Put gasket (11) in position. Install the fuel transfer pump.12. Connect tube assemblies (1) and (3) to the fuel transfer pump.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove nut (1).2. Remove gear (2).3. Remove the key from the shaft. 4. Remove cage (3) from the body. Remove the O-ring seals from the cage. 5. Remove seals (4) and (5) from cage (3).6. Remove bearing (6) from the cage. 7. Remove cover (7). 8. Remove cover (8) from the body. 9. Remove seal (9) from cover (8). 10. Remove bolt (10), spring (11) and plunger (12). 11. Remove shaft assembly (14) and gear (15) from body (13).12. Remove the shaft and the bearing from body (13).Assemble Fuel Transfer Pump
1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. Put clean lubricant on the parts that move. 2. Use a press to install shaft (3) in body (1). The distance from surface (X) to the top of the shaft after assembly is .995 .003 in. (25.27 0.08 mm).3. Use tool (A) to install bearing (2) into the body. The top of the bearing must not be above surface (X). 4. Put gear (5) and shaft assembly (4) in position in the body. 5. Install plunger (8), spring (7) and bolt (6) in the cover. Tighten the bolt to a torque of 27 3 lb.ft. (38 4 N m). 6. Use tool (B) to install the seal in the cover. The seal must be installed with the lip toward surface (Z). The distance from the top of the seal to surface (Y) must be .75 .02 in. (19.1 0.5 mm).
Do not let the sealer get into the pump.
7. Put a thin layer of 8S6747 Gasket Sealer on the face of body (1). Install the cover on the body. After the cover bolts are tightened, the shaft must turn freely.8. Install the O-ring seal on cover (9). Install the cover. 9. Use tool (B) to install seal (12) in cage (10) with the lip toward bearing (13). Dimension (E) is 1.31 in. (33.3 mm). 10. Use tool (B) to install seal (11) in the cage with the lip in the opposite direction of bearing (13). Dimension (D) is .81 in. (20.6 mm). 11. Use tooling (A) to install bearing (13) in cage (10).12. Install the O-ring seals on cage (10).13. Install tool (C) on shaft assembly (4).14. Put lubricant on the lip type seals, the O-ring seals and tool (C).15. Put cage (10) in position in the body. 16. Put the key and gear (14) in position on the shaft assembly.17. Install the nut on the shaft assembly. Tighten the nut to a torque of 22 5 lb.ft. (28 7 N m).end by:a) install fuel transfer pump