48650-97E00 Suzuki PISTON, FREE

Start By:a. remove fuel injection lines1. Remove the hood and muffler. The weight of the hood is approximately 225 Kg (500 lb.). The weight of the muffler is approximately 79 Kg (175 lb.). 2. Remove timing bolt (1) and bolt (4). Remove cover (2) from the right side of the flywheel housing.3. Remove plug (3). 4. Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until the No. 1 piston is at top center on compression stroke. Install timing bolt (1) in flywheel. See the topic, Finding Top Center Compression Position For No. 1 Piston in the Testing And Adjusting Manual. 5. Remove the plug from the front of the injection pump housing. Install tool (B) (as shown) through the hole in the pump housing and into the timing notch in the fuel injection pump camshaft. If the timing is correct, tool (B) will go into the notch in the fuel injection pump camshaft and the timing bolt will turn freely into the threaded hole in the flywheel. If timing is not correct, remove tool (B) and the timing bolt and do the procedure beginning with Step 6 of the "Fuel Injection Pump Housing And Governor (Earlier)" story.6. Turn the engine two complete revolutions and check the timing again. If tool (B) will not go into the notch of the fuel injection pump camshaft, do the procedure beginning with Step 6 of the "Fuel Injection Pump Housing And Governor (Earlier)" story again. 7. Remove the cotter and pin (6) to disconnect control linkage (5) from the governor.8. Disconnect air line (7) from the air-fuel ratio control.9. Disconnect fuel lines (9) and (10) from the fuel transfer pump.10. Remove the bolt that holds fuel line clip (8) in position. Disconnect fuel line (11) from the fuel injection pump housing.11. Disconnect wires (12) from the shutoff solenoid. 12. Remove cover (13) from the automatic timing advance cover. 13. Remove bolts (14) that hold the retainer and automatic timing advance unit to the fuel injection pump camshaft. 14. Remove bracket (15) and bolts (16) from the right side of the fuel injection pump housing.15. Remove the bracket and bolts from the left side of the fuel injection pump housing.16. Disconnect the drain line from the fuel transfer pump adapter.17. Fasten tooling (C) to the fuel injection pump housing with two 3/8" - 16 NC bolts 2 1/4" long. Fasten a hoist to tooling (C). Remove fuel injection pump housing and governor (17). The weight of the fuel injection pump housing and governor is 65 kg (145 lb.). The following steps are for the installation of the fuel injection pump housing and governor.18. Check the O-ring seal on the front of the housing for wear or damage and make a replacement if necessary. Put a small amount of 5P0960 Multipurpose Grease on the O-ring seal.19. Install tool (B) in the notch of the fuel injection pump camshaft.20. Fasten tooling (C) to the fuel injection pump housing with two 3/8" - 16 NC bolts 2 1/4" long. Fasten a hoist to tooling (C). Put fuel injection pump housing and governor in position on the top of the engine.21. Connect the drain line to the fuel transfer pump adapter.22. Install the bracket and bolts from the left side of the fuel injection pump housing.23. Install bolts (16) and bracket (15) to the right side of the fuel injection pump housing.24. Install bolts (14) to hold the automatic timing advance unit and retainer to the end of the fuel injection pump camshaft. Tighten bolts finger tight only.25. Install the bolt and nut to hold fuel line clip (8) in position. Connect fuel line (11) to the fuel injection pump housing.26. Connect wires (12) to the shutoff solenoid.27. Connect fuel lines (9) and (10) to the fuel transfer pump.28. Connect control linkage (5) to the governor with pin (6) and cotter.29. Connect air line (7) to the fuel ratio control.30. Check the engine timing. See Remove Fuel Injection Pump Housing And Governor, (Earlier), Steps 2 through 7.31. Install the gasket and cover (13) on the timing advance unit cover after the bolts have been tightened.32. Remove tool (B). Install the plug in the fuel injection pump housing.33. Remove tool (A). Install the cover and plug on the right side of the flywheel housing.34. Install the hood and muffler.End By:a. install fuel injection lines.