19851-94401 Suzuki LEVER, NSI

2. Remove the plug from location (2). Install tool (A) in the hole with the square end down. With a light force push down on tool (A) as the governor control lever is moved forward to the "FUEL ON" position. Rack travel will stop inthe center (zero) position. Hold a light forward force on the governor control lever to keep the fuel racks in the center (zero) position. 3. Disconnect line (3) from the fuel injection pumps. Put caps on all fuel line openings. 4. Remove washer (4). 5. Use tool (B) to remove bushing (5). 6. Remove the O-ring seal from under bushing (5).7. Use tool (C) to remove the fuel pump.
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
8. Disassemble the fuel injection pump as follows: Remove ring (6). Make a separation of bonnet (7) from barrel (8). Remove spring and check assembly from bonnet. Remove plunger (9), washer and spring from barrel (8).
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
9. Remove spacer (10) from the fuel injection pump housing. Make a note of the position from which each spacer was removed so each spacer can be installed in its original position.Install Fuel Injection Pumps
1. Put the fuel racks in the center (zero) position by a light push down on tool (A) as the governor control lever (1) is moved forward (direction of arrow) to the "FUEL ON" position. Rack travel will stop in the center (zero) position. Hold a forward force on governor control lever (1) to keep the fuel racks in the center (zero) position.
Do not slide bonnet (2) across the face of barrel (6) when ring (10) is installed. The check assembly in the bonnet can put scratches in the face of barrel (6).
2. Put plunger (9), washer (8) and spring (7) in position on barrel (6). Put check valve assembly (5), collar (4) and spring (3) in position in bonnet (2). Connect bonnet (2) and barrel (6) together with ring (10).3. Put spacer (13) into position in the pump housing bore. Make sure the correct spacer is with each pump. If a replacement of any component of the fuel injection pumps is made, find the correct thickness for spacer (13) as given in FUEL SYSTEM TESTING AND ADJUSTING in SYSTEMS OPERATION TESTING AND ADJUSTING. The lobe on the cam must be at its lowest position for easy installation of the injection pumps.4. Put the space in gear segment (11) in alignment with the groove in barrel (6).5. Put the injection pump straight down into the housing bore so the space in gear segment (11) is in alignment with pin (12) and the groove in barrel (6) is in alignment with dowel (14). Use tool (C) to install the pump. 6. Install seal (16) and bushing (15) in the pump housing bore. If the pump is in the correct position, bushing (15) will turn into the threads of the pump housing with the fingers until it is even with the housing. Tighten bushing (15) to a torque of 205 14 N m (150 10 lb.ft.) with tool (B). 7. Install the washer (17) on bushing (15). 8. Connect the fuel lines to the injection pumps and tighten fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.).9. Check the correct installation of the injection pumps with the engine stopped. See CHECK FUEL RACK TRAVEL.10. Remove the timing pin [tool (A)] and install the plug in the injection pump housing.
If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary.
Check Fuel Rack Travel
The following procedure is given to check for correct fuel injection pump installation.
If one or more of the injection pumps have been installed wrong, damage to the engine is possible because there is no control of engine speed.
start by:a) remove governor 1. Install tooling (A) and (B).2. With a light force push down on tool (A) as fuel rack (1) is moved to the rear. Rack travel will stop in the center (zero) position. 3. Hold a light force toward the rear on fuel rack (1) and put the indicator of tooling (B) on the center (zero) position.4. Lift tool (A) and move fuel rack (1) to the rear. See the chart for correct rack travel indication for movement from the center position. 5. Lift tool (A) and move fuel rack (1) forward. See the chart for correct rack travel indication for total rack travel. If the indications from Steps 4 and 5 are not the same as the chart (0 teeth off), the injection pump will have to be removed and then installed correctly. 6. Remove tooling (A) and (B). 7. Install plug (2).end by:a) install governor