03211-0520A Suzuki SCREW

Removing The Engine
INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURIES. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH BEFORE WORKING ON THE ENGINE.
1. Set the battery switch at "Off".2. Disconnect the battery ground (-) cable from the battery, then disconnect the battery cable from the starter.3. Support the front engine cowling, disconnect the chains and swing the cowling down out of the way. If necessary, cut the cowling hinge from the mainframe and move the cowling away.4. Unbolt the water spray system valve bracket from the engine cowling, unbolt the engine cowling from the mainframe and rear engine cowling. Attach a lifting device to the engine cowling, then lift the engine cowling away. 5. Disconnect the air cleaner indicator hose from the air tube. Cover the openings in the hose and air tube to keep dirt out.6. Disconnect the air tube from the air cleaners and turbocharger and move the air tube away. Cover the openings in the air cleaners, air tube and turbocharger to keep dirt out.
THE EXHAUST PIPE CAN BE EXTREMELY HOT AND CAUSE SERIOUS BURNS IF TOUCHED. ALLOW THE PIPE TO COOL BEFORE TOUCHING IT.
7. Disconnect the exhaust elbow from the turbocharger and the exhaust expansion elbow, and move the exhaust elbow away. Cover the opening in the turbocharger to keep dirt out.8. Attach a lifting device to the rear engine cowling, unbolt the cowling from the mainframe, and lift the cowling away. 9. Drain the coolant from the engine and radiator, then remove the hoses from between the engine and radiator. 10. Remove the fan guard and pump drive gearbox belt guard.11. Thoroughly clean around the hose connections at the hydraulic oil cooler, disconnect the hoses, and cap or plug all openings.12. Attach a lifting device to the radiator, unbolt the radiator from the mainframe, and lift the radiator and attached oil cooler away. Be careful not to bend any cooling fins. 13. Loosen the gearbox support clamping bolts and the jam nuts on the adjusting bolts, then turn the adjusting bolts alternately and evenly to relieve the belt tension. 14. Remove the bolts that hold the coupling and coupling adaptor together. Loosen the gearbox drive sheave support mounting bolts and move the support far enough back to remove the coupling. Remove the bolts that hold the coupling to the engine sheave, then remove the coupling and lay it aside. Move the gearbox drive belts out of the way.15. Loosen the water pump mounting bolts, relieve the tension in the drive belt, and remove the belt from the pump sheave. Secure the belt to the fan drive belts to keep it out of the way. 16. Disconnect the throttle cable and lay the cable aside where it will not interfere with engine removal.
DIESEL FUEL IS VOLATILE AND COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS. NEVER SMOKE OR HAVE AN OPEN FLAME WHILE WORKING ON THE FUEL SYSTEM.
17. Close the fuel supply shutoff valve, disconnect the supply hose at the engine, place the end of the hose in a suitable container, then open the valve and drain the fuel from the tank. After the fuel has drained, disconnect the fuel return hose from the engine. Cap or plug the openings in the hoses and at the engine. 18. Disconnect all wiring harness wires from the terminals at the following engine components: a. Starterb. Fuel solenoidc. Oil pressure senderd. Oil pressure switch e. Water temperature senderf. Alternator 19. Open the cutter belt guard, loosen the front nut on the adjusting bolt, turn the nut until the belt tension is relieved, then remove the belts from the power take-off sheave.
AIR ESCAPING FROM THE SYSTEM CAN CAUSE PERSONAL INJURY. STAY CLEAR WHEN DRAINING RESERVOIR.
20. Open the drain on the air reservoir and allow all the air to flow out, then disconnect the air hose from the fitting on the power take-off shaft. Remove the air hose from the hose bracket and lay the hose aside where it will not interfere with engine removal. Remove the hose bracket from the power take-off support.21. Check for and disconnect any remaining wires or hoses that might interfere with engine removal.
USING THE POWER TAKE-OFF AS A LIFT POINT COULD CAUSE THE POWER TAKE-OFF TO FAIL, ALLOWING THE ENGINE TO DROP AND CAUSE PERSONAL INJURY. DO NOT USE ANY PART OF THE POWER TAKE-OFF AS A LIFT POINT FOR THE ENGINE ASSEMBLY.
22. Attach a lifting device to the engine lifting lugs and take enough of a strain in the lifting lines to support the engine.23. Remove the pump drive gearbox drive sheave and support, so they will not be damaged during engine removal. Remove the bolts that connect the engine supports and power take-off support to the mainframe, then lift the engine away. If possible, keep all shims in the position in which they were installed, to aid engine installation.
PR-450 POWERPACKBuilding The Engine Up
The simplest way to build up a new engine is to position the new engine beside the old one and properly support both so they can safely be worked on. Then remove one component at a time from the old engine and install it on the new engine until all required components have been transferred to the new engine. Components that may have to be transferred include: 1. The fan bracket. Do not install the water pump belt and fan belts until after the initial installation and alignment of the engine.2. The power take-off. See pages 5.0-1 and 5.0-4 for removal and installation procedures.3. The throttle bracket.4. The fuel solenoid, bracket, yoke, springs and hardware.5. The engine oil pressure switch and sender.6. The engine coolant temperature sender.7. Radiator hoses and elbows.8. The engine supports and power take-off support.Installing The Engine
Before installing the engine, be sure all necessary components are in place on