48401-96J01 Suzuki PISTON ASSY

start by:a) remove governor 1. Bend the lock down. Remove two bolts (4) and torque spring (2).2. Remove high idle screw (3).3. Remove the two bolts and bracket (1). The bolt that holds the governor housing to the governor plate can be removed at this time. 4. Bend lock (7) down and remove the bolt from control lever (8). Remove shaft (5) and the control lever. Remove the lip type seals from housing (6). 5. Remove two bearings (9) from the housing. 6. Remove seat (10), spring washer (11), flat washer (12), spring washer (13) and spring (14). 7. Remove washer (16). Remove ring (17) from the seat. Remove the dowel from the seat and remove the governor bolt (15) and seat as a unit. 8. Remove the governor bolt, top washer (18), spring (19) and bottom washer (20) from the top of the servo piston.9. Remove the race, bearing and race from the bottom of the sleeve.10. Remove the lock from the flywheel assembly. Remove the flywheel assembly. 11. Bend locks (22) back. Remove bolts (25). Remove bracket (24) and pin (23) as a unit. 12. Remove shaft (26) from the bracket assembly with a hammer and punch.13. Remove levers (28) and spring (27) from the bracket assembly.14. Remove servo piston assembly (21) through the bottom of the governor plate. 15. Remove sleeve (31) from servo piston cylinder (29). Remove piston (32) from the cylinder. Remove the O-ring seals from cylinder (29) and seal (30) from the piston. 16. Remove dowel (36). Remove drive assembly (33) and stop (35). Remove the snap ring with tool (A) from the bottom of gear (34). Remove gear (34).17. Remove the bearing for gear (34) from the governor plate.Assemble Governor (Earlier)
1. If replacement of the dowels in the governor plate is necessary, see illustration for correct installation dimensions. 2. Install the bearing for drive gear (2) in the governor plate with tooling (A) until it is .020 in. (0.51 mm) from the top surface of the governor plate.3. Install drive gear (2). Install ring (1) with tool (B). 4. Put valve (4) in piston (5). Install piston (5) in sleeve (3).5. Install the O-ring seals on cylinder (6).6. Install the servo piston assembly valve (4), piston (5), sleeve (3) and cylinder (6) through the bottom of the governor plate. The valve, piston, sleeve and cylinder are parts of the servo piston assembly. Put the notch in cylinder (6) in alignment with the holes in lever (9). Install shaft (7). 8. Install pin (11) in bracket assembly (10) with the grooves in pin (11) engaged with lever (9). 9. Put the bracket assembly into position on the governor plate with pin (11) engaged with the servo piston assembly as shown. Install the bolts and locks that hold bracket assembly (10) to the governor plate. 10. Install the flyweight and gear assembly on the servo piston assembly. Install lock (22).11. Install race (17), bearing (20) and race (24) on sleeve (21). Install the ring under race (24) on the sleeve.12. Put sleeve (21) on valve (23). Put the hole in sleeve (21) in alignment with the hole in valve (23).13. Put top washer (14), spring and bottom washer in position on the top of valve (23) as shown.14. Install governor bolt (12) in seat (18). Put the seat and bolt in position on sleeve (21) with the hole in seat (18) in alignment with the hole in sleeve (21). Install dowel (19) and the ring to hold it in position.15. Install spring washer (13) over governor bolt (12) as shown (with the concave side up). Install spring (16), spring washer, flat washer and spring washer (not shown). Install seat (15). 16. Install bearing (25) until dimension "Z" is 1.708 .004 in. (43.38 0.10 mm) with tooling (D).17. Install bearing (26) until dimension "X" is .998 .005 in. (25.35 0.13 mm) with tooling (E).18. Check dimension "Y". Dimension "Y" must be 2.385 .005 in. (60.58 0.13 mm).19. Install the lip type seals in the governor housing with tooling (C). Install each seal with the lip toward the inside. 20. Put lever (27) into position in the governor housing. Install shaft (28). Install the lock, band assembly and bolt that hold lever (27) to shaft (28). 21. Install spacers (35), bar (36), retainer (34), contact (33), insulation (32), retainer (29), lock (31) and bolts (30) on the governor housing.22. Install the high idle screw and low idle screw.23. Check the governor adjustment. See GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING.end by:a) install governor