09205-10006 Suzuki PIN, CLUTCH LEVER

start by:a) remove fuel injection pumps 1. Remove elbow (1) and the plate (orifice) under the elbow.2. Remove rack (2) from the fuel injection pump housing. Spacers (3) are different thickness and are used to make a setting of the injection timing between cylinders. Spacers (3) and lifters (4) must be installed in the same bore in the pump housing from which they are removed. Put identification on the spacers and lifters as to their location in the pump housing.3. Remove spacers (3) and lifters (4) from the pump housing. 4. Remove bolt (5), the lock and plate (6) from the camshaft. 5. Remove spring (7) and gear (8) from the camshaft. 6. Remove camshaft (10) from the pump housing. 7. Remove bearings (9) and (11) from the pump housing.8. Use tooling (A) as shown to remove the bearings for the camshaft from the pump housing.Assemble Fuel Injection Pump Housing
Be sure all oil passages in the pump housing are clear. Put clean oil on all parts before assembly. 1. Install the camshaft bearings in the fuel injection pump housing with tooling (A). Install the bearing in the governor end of the housing so the lubrication hole in the bearing is in alignment with the lubrication hole in the housing. Install the camshaft bearings so they are 0.25 0.13 mm (.010 .005 in.) below the ends of the pump housing.
Install the rack bearing in the governor end of the housing with the small holes in the bearing parallel to the vertical centerline of the pump.
2. Install the rack bearing in the governor end of the housing with tooling (B). Install the bearing so it is 4.95 0.13 mm (.195 .005 in.) below the face of the housing.
Tooling (C) must be used to install the rack bearing in the drive end of the pump housing. This will put the tab on the bearing in its correct position and install the bearing to the correct depth.
3. Install the 5P1665 Plate, part of tooling (C), on the pump housing. Use the 9S6329 Driver, part of tooling (C), to install the rack bearing in the drive end of the pump housing.
Use extra caution when camshaft (1) is installed in the pump housing to prevent damage to the camshaft bearings.
4. Install camshaft (1) in the pump housing. 5. Put gear (3), spring (4) and plate (2) in position on the camshaft as shown. Install the lock and bolt that hold plate (2) in place. 6. Install lifters (5) and the spacers in their original position in the pump housing. Install the lifters with the pin in the lifter on the same side as the pin in the pump housing. If it is necessary to check the injection timing between cylinders, see OFF-ENGINE LIFTER SETTING procedure in TESTING AND ADJUSTING. 7. Install rack (6) in the pump housing with the groove near the end of the rack toward the governor end of the pump housing. 8. Be sure the hole in plate (orifice) (7) is open and install plate (7) in the pump housing. Install the elbow over the plate.end by:a) install fuel injection pumps