48503-96J01 Suzuki MANIFOLD SUB ASSY


48503-96J01 MANIFOLD SUB ASSY Suzuki DF150, DF150, DF150, DF175, DF175, DF175 MANIFOLD
48503-96J01 MANIFOLD SUB ASSY Suzuki
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17-03-2025

US: FiveStarMarine
Five Star Marine Suzuki 48601-94900 - Piston/RAM Assy 48503-92J00 48503-93J10 48503-96J01 FSM075-2
Five Star Marine
Number on catalog scheme: 4
 

Compatible models:

DF150   DF175   Suzuki

Suzuki entire parts catalog list:

DF150 2006,2007,2008,2009
DF150 2010
DF150 2011
DF175 2006,2007,2008,2009
DF175 2010
DF175 2011

Information:

1. Disconnect two fuel lines (1) from the fuel transfer pump. 2. Remove two bolts (3) and fuel transfer pump (2).Install Fuel Transfer Pump
1. Put fuel transfer pump (1) in position and install the two bolts that hold it to the fuel pump housing. 2. Connect two lines (2) to the fuel transfer pump.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove bolts (1) that hold transfer pump cover (2) to transfer pump body (5).2. Remove bolts and clamps (4) from the tachometer drive adapter. Remove tachometer drive adapter (3) from the cover. 3. Remove lip type seal (6) from the cover. Remove plug and O-ring seal (7), seat (8), spring (9) and valve (10) from the cover. 4. Remove nut (14) on end of shaft (11) and remove gear (17) and key (12) from the shaft. Remove O-ring seal (13) and the shaft from the body (5).5. Remove idler gear (15) from shaft (16).6. Remove the bearings and the two lip type seals from the body.7. Remove the check valve and shaft (16) from the body.Assemble Fuel Transfer Pump
1. Clean the openings (ports) for the fuel passage in body (3).2. Install shaft (1) and check valve (2) in the body with tooling (A).3. Install smaller bearing (4) in the body with tooling (B). Install the bearing until it is even with the machined surface of the body. 4. Install seal (5) in the body with tooling (C). Install the seal until it is .969 in. (24.6 mm) from the top surface of the body and with the lip toward bearing (4) as shown.5. Install seal (6) in body (3) with tooling (D). Install the seal until it is .563 in. (14.3 mm) from the top surface of the body and with the lip toward the top surface of body (3) as shown. 6. Install the large bearing in body (3) with tooling (E). Install the bearing even with the outside surface of the body. 7. Install the seal in cover (7) with tooling (C). Install the seal with the lip toward the inside of the cover and until it is .750 in. (19.1 mm) below the outside surface of the cover.8. Install the fuel bypass valve, the valve, spring, seal, O-ring seal and plug (14) in the cover. Tighten the plug to a torque of 27 3 lb.ft. (38 4 N m).9. Install shaft (9) in the body. Install gear (13) on the shaft to make an alignment with the gear on the shaft.10. Put 7M7260 Liquid Gasket Material on surface of cover (8). Install the cover on the body.
Do not let liquid gasket material enter the pump.
11. Install the six bolts that hold the cover (7) to the body. Install the O-ring seal to the body. The shaft must turn freely after the bolts that hold the cover in position are tightened.12. Install key (12) on the shaft. Install gear (8) on shaft and in alignment over the key. Install nut (11) on the shaft. Tighten the nut to a torque of 22 5 lb.ft. (28 7 N m).13. Install tachometer drive adapter (10) on the cover.end by:a) install fuel transfer pump


Parts manifold Suzuki:

48641-96J01
 
48641-96J01 MANIFOLD, PTT
DF140, DF140, DF140, DF140T, DF140T, DF140Z, DF140Z, DF140Z, DF140Z, DF150, DF150, DF150, DF175, DF175, DF175, DF200, DF200, DF225, DF225, DF250, DF250
13110-96J00
 
13110-96J00 MANIFOLD, INTAKE
DF150, DF150, DF150, DF150TX, DF150ZX, DF175, DF175, DF175, DF175TX, DF175ZX
48641-96J00
 
48641-96J00 MANIFOLD, PTT
DF150, DF150, DF150TX, DF150ZX, DF175, DF175, DF175TX, DF175ZX
48503-96J03
 
48503-96J03 MANIFOLD SUB ASSY
DF140A, DF150, DF175
48641-96J02
 
48641-96J02 MANIFOLD, PTT
DF140A, DF150, DF175, DF200, DF225, DF250
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