37721-87D03 Suzuki NEUTRAL SWITCH ASSEMBLY

1. Disconnect tube assemblies (1) and (2) from the fuel transfer pump. 2. Remove fuel transfer pump (3).3. Disconnect tube assemblies (5) and (7) from adapter (6). Remove tube assembly (4) from the adapter and the cylinder block. Remove adapter (6). The following steps are for installation of the fuel transfer pump.4. Make sure all the parts are clean. Inspect all parts for damage and make replacements if needed. Put clean oil on the O-ring seals. 5. Put the gasket in place and install adapter (6).6. Install tube assembly (4) on the adapter and the cylinder block.7. Connect tube assemblies (5) and (7) to the adapter. 8. Put the gasket in place and install fuel transfer pump (3). 9. Connect tube assemblies (1) and (2) to the fuel transfer pump.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove nut (1) that holds the gear on the shaft.2. Remove gear (2) from the shaft. 3. Remove key (3) from the shaft.4. Remove cage (4) from the body. 5. Remove O-ring seals (5) from the cage. Remove seals (6) and (7) from the cage. Remove bearing (8) from the cage. 6. Remove cover (9) from the body. 7. Remove bolt (12), spring (11) and plunger (10) from cover (9). Remove seal (13) from bolt (12). 8. Remove gear (14) from the body. 9. Remove shaft assembly (15) from the body. 10. Remove bearing (16) with tooling (A) from the body.11. Remove shaft (17) from the body.Assemble Fuel Transfer Pump
1. Make sure all parts are clean. Inspect all parts for damage and make replacements if needed. Put clean lubricant on the parts. 2. Use a press and install shaft (2) in body (3). The distance from surface (X) to the top of the shaft after assembly is .995 .003 in. (25.27 0.08 mm).3. Use tooling (A) and a press and install bearing (1) in body (3). Make sure the bearing does not extend beyond surface (X). 4. Put shaft assembly (4) in position in the body. 5. Put gear (5) in position in the body. 6. Install seal (8) on bolt (9). Install plunger (6), spring (7) and bolt (9) in cover (10). Tighten the bolt to a torque of 27 3 lb.ft. (38 4 N m).
Do not let the Permatex get into the pump.
7. Put a thin layer of No. 3 Aviation Permatex on the face of body (1). Install cover (10) on the body. After the cover bolts are tightened, the shaft must turn freely. 8. Use tool (B) to install seal (13) in cage (12) with the lip toward bearing (14). Dimension (E) is 1.31 in. (33.3 mm). 9. Use tool (B) to install seal (11) in the cage with the lip in the opposite direction of bearing (14). Dimension (D) is .81 in. (20.6 mm). 10. Use tooling (A) to install bearing (14) in cage (12).11. Install O-ring seals (15) on cage (12).12. Install tool (C) on shaft assembly (4).13. Put lubricant on the lip type seals, the O-ring seals and tool (C).14. Put cage (12) in position in the body. 15. Install key (16) in the shaft. 16. Put gear (18) in position and install nut (17). Tighten the nut to a torque of 22 5 lb.ft. (28 7 N m).end by:a) install fuel transfer pump