37141-92E20 Suzuki KEY (13)

start by:a) remove crankcase guardb) remove hood 1. Tooling (A) can be used to turn the engine to put the No. 1 piston on top center compression. If tooling (A) is used, remove the electric starting motor and install tooling (A) as shown. If tooling (A) is not used, the engine can be turned with the bolt that holds the pulley for the vibration damper.2. Put the No. 1 piston at top center compression as follows: a) Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (1) 3 1/2" long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft counterclockwise to install the bolt in the flywheel.b) Disconnect the breather from the valve cover. The rocker arms can be seen through the breather hole for No. 1 piston.c) Check to see if both rocker arms can be moved backward and forward by hand through the breather hole. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel and the rocker arms for the No. 1 piston can be moved backward and forward.d) If both rocker arms can not be moved, the No. 1 piston is not at the top center compression. Remove the bolt from the flywheel. Turn the engine clockwise as seen from the front of the engine one full turn 360° and install the bolt again.3. Remove the fuel injection pump housing and governor.4. Disconnect all fuel lines from accessory drive housing and remove fuel transfer pump. 5. Remove cover (2) from the timing gear cover. 6. Loosen bolt (3) until the washer is approximately 1/8 in. (3.2 mm) away from the drive gear. Do not remove the bolt at this time. 7. Install tooling (B) on the drive gear as shown. Tighten the center bolt in tooling (B) until the drive gear is loose. Remove tooling (B), bolt (3) and the washer. The drive gear will stay in the timing gear cover. 8. Remove the nuts (4) and bolts (5).9. Remove the accessory drive and shaft.Install Accessory Drive Housing And Shaft
1. Tooling (A) can be used to turn the engine to put the No. 1 piston on top center compression. If tooling (A) is used, remove the electric starting motor and install tooling (A) as shown. If tooling (A) is not used, the engine can be turned with the bolt that holds the pulley for the vibration damper.2. Put the No. 1 piston at top center compression as follows: a) Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (1) 3 1/2" long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft counterclockwise to install the bolt in the flywheel.b) Disconnect the breather from the valve cover. The rocker arms can be seen through the breather hole for No. 1 piston.c) Check to see if both rocker arms can be moved backward and forward by hand through the breather hole. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel and the rocker arms for the No. 1 piston can be moved backward and forward.d) If both rocker arms can not be moved, the No. 1 piston is not at the top center compression. Remove the bolt from the flywheel. Turn the engine clockwise as seen from the front of the engine one full turn 360° and install the bolt again. 3. Hold the accessory drive housing in position and install the accessory drive housing and shaft (2).4. Install nuts (3) and bolts (5).
TYPICAL EXAMPLE5. Turn the accessory drive shaft until tool (B) can be installed.6. Install the washer and bolt (4) on the shaft of the accessory drive finger tight.7. Put 50 lb. ft. (70 N m) torque on accessory drive gear in clockwise direction as viewed from front of the engine.8. While 50 lb. ft. (70 N m) torque is held on accessory drive gear, tighten the bolt (4) to 110 5 lb. ft. (149 7 N m). 9. Install the cover (6) on the timing gear cover.10. Install the fuel injection pump housing and governor. See the topic INSTALL FUEL INJECTION PUMP HOUSING AND GOVERNOR.