38100-87D01-0ED Suzuki PTT MOTOR ASSEMBLY

1. Remove two bolts and disconnect elbow (1) for the suction tube from the oil pump.2. Remove the four retaining bolts that hold the oil pump. The idler gear on the pump will fall if it is not held when the pump is removed.3. Remove oil pump (2). Weight of the oil pump is 35 lb. (16 kg).Install Oil Pump
1. Turn the crankshaft until the No. 1 piston is at the top center compression position. See INSTALL FUEL INJECTION PUMP HOUSING AND GOVERNOR. 2. Turn both balancer shafts until the flat part on each shaft is away from the oil pan plate. Install two 3/8"-16 NC bolts (1) 11/2" long through the oil pan plate and into the holes in the balancer shafts. This will prevent the shafts from movement. Do not tighten the bolts against the bottom of the holes in the shafts.3. Put oil pump (2) in position on the block and install the locks (left side only) and bolts that hold the oil pump in place. Connect the suction tube to the oil pump.4. Remove bolts (1). Check to see that the balancer shaft timing is correct. The balancer shaft timing is correct when the holes in the balancer shafts are in alignment with the holes in the oil pan plate, and No. 1 piston is at the top center compression position.end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump 1. Remove idler gear (2). Remove bearing from gear with tooling (B).2. Remove suction bell (1).3. Remove the bolt and the washer from the oil pump drive gear. 4. Remove the drive gear from the shaft with tooling (A).5. Remove the key from the pump shaft.6. Remove bolts (3) from the pump body. 7. Remove body (8), two gears (7), keys and spacer (4) from the pump.8. Remove two shafts (5) and the gears.9. Remove bolts (6), the cover and the pressure relief valve from the body. 10. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with tooling (C).Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with tooling (A) as follows: a) Put bearings (1) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing as shown. Install the bearing until it is .060 in. below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body assembly as shown.2. Install the bearings in oil pump body assembly with tooling (A) as follows: a) Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on the bearings as shown. Install the bearings until they are even with the outside surface of the oil pump body assembly.3. Check the condition of the relief valve. Check the condition and specification for all the parts of the oil pump before it is assembled. See OIL PUMP (2P1785) in SPECIFICATION.4. Put clean engine oil on all parts of the oil pump. 5. Install pressure relief valve (3), cover (4) and bolt (5) in the oil pump body assembly.6. Install gears and shafts (5) in the oil pump body assembly. 7. Install spacer (7) and the two keys in shafts (6). 8. Install two gears and scavenge pump body assembly (8).9. Install key (9), drive gear (11), the washer and bolt (10). Tighten the bolt to a torque of 32 5 lb. ft. (43.4 6.8 N m).10. Install the bearing in the idler gear with tooling (B) until it is even with the outside surface of the gear.11. Install the idler gear.
The oil pump must turn freely by hand after it is assembled.
end by:a) install oil pump