67200-92E05 Suzuki SINGLE BINNACLE CONTROL BOX

1. Loosen bolts (2) to release the tension and remove vee belt (1) from the air compressor pulley. 2. Disconnect air lines (3), (4) and (6) from the air compressor.3. Disconnect air line (5) from the air compressor governor.4. Remove four bolts (7) that hold the air compressor and remove the air compressor from the engine. The weight of the air compressor is 30 lb. (14 kg).Install Air Compressor
1. Put air compressor (1) and the gasket in position on the engine.2. Install four bolts (2) that hold air compressor (1). 3. Connect air lines (3), (4) and (6) to the air compressor.4. Connect air line (5) to the air compressor governor.5. Install vee belt (7) on the air compressor pulley. Tighten bolts (8) for the belt tightener to hold the correct tension on vee belt (7). To get the correct belt tension use a tension gauge such as Burroughs Tool Company Part No. BT-33-96-4-16 or an equivalent. The correct gauge indication is 120 5.Disassemble Air Compressor
start by:a) remove air compressor 1. Remove two bolts (2) and remove air compressor governor (1), the spacer and two gaskets from the air compressor. To disassemble governor (1) see REMOVE AIR COMPRESSOR GOVERNOR.2. Remove the cotter pin and nut (3) from the air compressor. 3. Remove pulley (4) from the air compressor with tool (A). Before the compressor is disassembled put identification marks on the crankcase, cylinder block, end covers, crankshaft, and cylinder head for correct installation and alignment at assembly. 4. Remove cap nuts (5), the springs and discharge valves.5. Remove bolts (6) and cylinder head (7). 6. Remove gasket (8) and inlet valve springs (9) from the cylinder head. 7. Remove inlet valves (10) from the cylinder block. 8. Turn the compressor over and put marks on bearing caps (12) and the connecting rods for correct installation and alignment at assembly.9. Bend the tabs of the locks from bolts (11). Remove the bolts and bearing caps (12). 10. Turn the compressor over and remove pistons (13) and the connecting rods from the top of the cylinder block. Connect the bearing caps to their connecting rods so they do not become mixed for assembly.11. Remove the rings from pistons (13). 12. Remove bearings (16) from the bearing caps and connecting rods (14).13. Remove lockwire (15). Use a press and remove pin (17) from piston (13). Remove connecting rod (14) from the piston. 14. Remove the six bolts that hold cylinder block (18) to the crankcase. Remove cylinder block (18) and the gasket. 15. Remove the two bolts and remove inlet elbow (19) and plate (20) from cylinder block (18).16. Remove inlet valve guides (21) from cylinder block (18). 17. Remove the unloader mechanism from the cylinder block as follows: a) remove spring (23).b) remove saddle (25).c) remove plungers (22) and pistons (24). 18. Remove key (27) from the crankshaft.19. Remove the four bolts and remove front cover (26) from the crankcase. 20. Remove the lip type seal (28) from front cover (26). 21. Remove four bolts (29) and remove cover assembly (30) from the rear of the crankcase. 22. Remove washer (31) and bearing (32) from cover assembly (30).23. Use a soft faced hammer to remove the crankshaft and bearing from the front of the crankcase. 24. Use tooling (B) and a press to remove bearing (33) from crankshaft (34).25. For more information about inspection, and usable parts see AIR COMPRESSORS (TU-FLO 400) FORM NO. REG00914 in VEHICLE SYSTEMS SECTION.Assemble Air Compressor
1. Heat bearing (2) in oil to a maximum temperature of 275°F (135°C) and install it on crankshaft (1). 2. Install crankshaft (1) in crankcase (3). 3. Install the bearing in rear crankshaft cover assembly (4) with tool group (A). 4. Install washer (5) in cover assembly (4). 5. Install cover assembly (4) on crankcase (3). 6. Use tool group (A) and install the seal in front cover (5) with the lip of the seal toward the inside as shown. 7. Install cover (5) on crankcase (3).8. Assemble the unloader mechanism in the cylinder block as follows: a) Make sure the seat for spring (7) is in position in the cylinder block.b) Put dimethyl polysiloxane lubricant (silicone grease) on pistons (10) and their bores before installation. If new unloader kits are installed, the pistons in the kit have lubricant already on them.c) Install unloader pistons (10) in their bores. Do not cut the grommets or cause distortion to the back-up rings on the pistons when they are installed.d) Put plungers (9) in guides (6) and install these units in pistons (10).e) Install saddle (8) between guides (6).f) Install spring (7). Make sure the spring is fitted correctly on the seat and saddle (8). 9. Install plate (12) and elbow (11) on cylinder block (14). Install inlet valve guides (13). 10. Put cylinder block (14) in position on the crankcase and install the six bolts that hold it. 11. If necessary use a press and install a new bushing in connecting rod (17). The new bushing must be made larger with a reamer after it is installed. For more detail see AIR COMPRESSORS (TU-FLO 400) Form No. REG00914 in VEHICLE SYSTEMS SECTION.12. Put piston (16) in position on connecting rod (17) and use a press to install pin (18). Make sure the hole in the pin is in alignment with the hole in the piston so the lockwire can be installed. Install lockwire (19).13. Install bearings (15) in connecting rod (17). 14. Install rings (20) on the pistons with the narrow side of the rings toward the top of the piston. 15. Put clean SAE 30 engine oil on the piston rings and connecting rod bearings. Turn the crankshaft so one of the connecting rod journals is in the "DOWN" position. Install tool (B) over the piston to put the piston rings under compression. Install piston assembly in cylinder bore. Make sure the connecting rod is over the crankshaft journal. 16. Check the clearance between the connecting rod