09492-72004 Suzuki JET, PILOT (72.5)

3. Remove pipe (4) from muffler to precleaner.4. Remove precleaner (3).5. Fasten a hoist to muffler (2). Loosen clamp (1) and remove bolts (5) that hold the muffler brackets to the flywheel housing and cylinder block. Remove the muffler. Weight is 170 lb. (77 kg). 6. Disconnect oil line (6) for the oil pressure gauge and wires (7) from the cylinder block. Remove the bolts and fasteners (8) that hold the oil line and wire to the cylinder block.7. Remove the coolant from the engine. 8. Disconnect the sending unit (9) for the water temperature gauge from the cylinder head.9. Remove radiator inlet tube (10).10. Disconnect two heater hoses (11) from the engine. 11. Loosen clamp (12) that holds radiator outlet pipe (13) to the water pump. Remove the two bolts that hold pipe (13) to the engine front support.12. Disconnect water line (14) from the water pump. 13. Disconnect the main fuel line (15) from the primary fuel filter and move it clear of engine.14. Disconnect the wire (16) from the sending unit for the air cleaner indicator and remove any fasteners that hold it to the engine.15. Disconnect glow plug wire (17) from both ends of the cylinder head and remove any fasteners that hold the wire to the engine.16. Remove the oil from the hydraulic tank until the level of the oil in the tank is below the pilot system oil pump. 17. Disconnect oil lines (18) and (26) from the pilot system oil pump.18. Disconnect wires (21) from the alternator. Move the wires clear of the engine.19. Disconnect line (19) and move it clear of the engine.20. Disconnect line (20) and move it clear of the engine.21. Remove cotter pin and pin that hold governor linkage (23) to the governor. Remove the bolts that hold bracket (22) to the governor.22. Disconnect wires (25) from the starter and move the wires clear of the engine.23. Remove the bolts (24) that hold the engine front support to the frame. 24. Remove the fastener that holds battery cable (28) to the flywheel housing.25. Remove clamps (27) and (29) that hold the oil lines for the pilot system oil pump to the frame.26. Remove the oil supply line (18) for the pilot system oil pump.27. Fasten a hoist and tool (A) to the engine. 28. Remove the bolts (30) that hold the flywheel housing to the pump drive.29. Remove the engine. Weight is 3200 lb. (1,451 kg).Install Engine
1. Fasten a hoist and tool (A) to the engine as shown.2. Put the engine in position in the machine. Turn the crankshaft to put the ring drive on the flywheel in alignment with teeth on the spider of the pump drive. Be careful not to damage the b rubber blocks on the teeth of the spider.3. Install the bolts (5) that hold the flywheel housing to the pump drive. Remove tool (A) and hoist.4. Connect the wire (4) to the sending unit for the air cleaner indicator.5. Connect the main fuel line (3) to the primary fuel filter. 6. Put bracket (1) in position on the governor. Install the bolts that hold it.7. Put the governor linkage (2) in position on governor. Install the pin and cotter pin that hold it in position.8. Connect the wires (6) to the starter.9. Install bolts (12) that hold the engine from support to the frame. Tighten the bolts to a torque of 200 25 lb.ft. (270 35 N m). 10. Connect the glow plug wires (7) to both ends of the cylinder head. Install the fasteners that hold the wires to the engine.11. Connect the wires (11) to the alternator.12. Put the oil supply line (8) in position on the pilot system oil pump and install the bolts that hold it. Connect oil line (13) to the pilot system oil pump.13. Connect lines (9) and (10) to the fuel injection pump housing.14. Install bolts (15) that hold the two sections of oil supply line (8) together. Install the clamps that hold the oil lines for the pilot system oil pump to the frame. 15. Install the fastener (14) and bolt that hold the battery cable to the flywheel housing.16. Fill the hydraulic tank with oil to the correct level. 17. Tighten clamp (16) that holds radiator outlet pipe (17) to the water pump. Install the bolts that hold pipe (17) to the engine front support.18. Connect water line (18) to the water pump. 19. Put tube (19) in position on the engine and radiator. Install the bolts and clamp that hold it.20. Install the sending unit (20) in the cylinder head for the water temperature gauge.21. Connect heater hoses (21) to the engine.22. Fill the cooling system to the correct level. 23. Connect the oil line (22) for the oil pressure gauge and wires (23) to the cylinder block. Install the fasteners (24) and bolts that hold the wires and oil line to the cylinder block. 24. Put the muffler and brackets (26) in position on the machine as a unit. Install bolts (29) that hold the muffler brackets to the flywheel housing and cylinder block. Tighten clamp (25).25. Install precleaner (27).26. Install the pipe (28) from the muffler to the precleaner.27. Install the hood sections over the engine.28. Connect the battery cables at the batteries.end by:a) install the fan