25411-87D00 Suzuki SHIFT SPRING LOCK REV PLUNGER

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system. Drain the coolant from the radiator into a suitable container for storage or disposal. The capacity of the cooling system is 135 liters (35.1 U.S. gal). 2. Fasten a hoist to hood (1) as shown. Remove six bolts (2) that hold the hood in position. Remove the hood. The weight of the hood is 45 kg (100 lb). 3. Remove four bolts (3). Loosen clamp (5). Remove tube assembly (4) and the gasket.4. Loosen clamps (6) and (7). 5. Remove two clips (8). Move tube assembly (9) out of the way of the fan guards.6. Remove four bolts (10). Remove tube assembly (11) and the gasket. 7. Remove four bolts (13). Lay the fuel filter, fuel filter base and bracket (12) out of the way.8. Disconnect two hose assemblies (16) from the coolant conditioner filter base.9. Remove two bolts (14), the coolant conditioner filter and coolant conditioner filter base (15) as a unit. 10. Disconnect hose assembly (17) from the fan motor. Disconnect two hose assemblies (18) from the make-up valve group. 11. Remove twenty four bolts (19) and four fan guards (20). 12. Fasten two lifting straps and a hoist to the fan group as shown.13. Remove eight bolts (21).
Do not damage the hydraulic oil cooler core during removal of the fan group from the machine.
14. Carefully remove fan group (22) from the machine. The weight of the fan group is 193 kg (425 lb). 15. Put the fan group on wood blocks as shown.16. Remove bolt (23) and retainer (24). 17. Fasten a lifting strap and a hoist to fan spider assembly (25) as shown. Remove the fan spider assembly from the fan motor. The weight of the fan spider assembly is 68 kg (150 lb). 18. Remove six bolts (26), the washers and adapter (27) from the fan. 19. Turn the fan motor and support assembly over as shown. The weight of the unit is 125 kg (275 lb). 20. Remove eight bolts (28), the washers and make-up valve (29) from the fan motor.21. Disassemble make-up valve (29) as follows: a. Remove two O-ring seals (31) from the valve body.b. Remove plug assembly (30) from the valve body. c. Remove spring (32) and valve (33) from the valve body.d. Remove the O-ring seal from plug assembly (30). 22. Fasten a lifting strap and a hoist to fan motor (36) as shown.23. Remove two bolts (34), two spacers (35) and fan motor (36) from the support assembly. The weight of the fan motor is 34 kg (75 lb). The following steps are for the installation of the fan and fan motor. 24. Fasten a lifting strap and a hoist to fan motor (36). Put the fan motor in its original position on the support assembly. Install two spacers (35) and two bolts (34) that hold it.25. Assemble make-up valve (29) as follows: a. Check the condition of the O-ring seals used in the make-up valve. If any of the seals are worn or damaged, use new parts for replacement. b. Install the O-ring seal on plug assembly (30).c. Install valve (33), spring (32) and plug assembly (30) in the valve body as shown. d. Install two O-ring seals (31) in the valve body. 26. Reinstall make-up valve (29) on the fan motor. Install eight bolts (28) that hold it.27. Fasten a hoist to the fan motor and support assembly, and turn it over for installation of the fan spider assembly. 28. Install adapter (27) in the fan. Install six bolts (26) and the washers that hold it. 29. Fasten a hoist to fan spider assembly (25), and put it in position on the fan motor. Install retainer (24) and bolt (23) that hold it.
Do not damage the hydraulic oil cooler core during installation of the fan group in the machine.
30. Fasten two lifting straps and a hoist to fan group (22) as shown. Carefully put the fan group in position, and install the eight bolts which hold it. Be sure the fan is centered around the shroud after all mounting bolts have been tightened. 31. Reinstall four fan guards (20) and twenty four bolts (19) that hold them. Check the condition of all O-ring seal used in the hose assemblies for installation of the fan and fan motor. If any of the seals are worn or damaged, use new parts for replacement. 32. Connect two hose assemblies (18) to the make-up valve located on the bottom of the fan motor. Be sure the hose assemblies are in their original locations.33. Connect hose assembly (17) to the fan motor. 34. Put the coolant conditioner and coolant conditioner filter base (15) in position, and install two bolts (14) to hold it.35. Connect two hose assemblies (16) to the coolant conditioner filter base.36. Put the fuel filter, fuel filter base and bracket (12) in position. Install four bolts (13) that hold it. 37. Reinstall the gasket and tube assembly (11). Install four bolts (10) that hold the tube assembly.38. Put tube assembly (9) in position, and install two clips (8) that hold it. 39. Tighten clamps (6) and (7).40. Reinsall tube assembly (4). Tighten clamp (5), and install four bolts (3) to hold the tube assembly in position. 41. Reinstall hood (1).42. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.43. Start the engine, and check the operation of the fan group. Check for coolant and oil leaks.End By:a. install hood