57621-87D02 Suzuki CLUTCH DOG SHIFTER

1. Disconnect air line (2) at fitting. Remove two bolts (1). Pull up and toward the front of the engine to remove the bolt of the fuel ratio from the groove (slot) in the collar for the governor. Remove fuel ratio control (3). Remove gasket from fuel ratio control. 2. Install a new gasket on fuel ratio control. Install fuel ratio control (3). Make sure bolt engages with stop collar in governor control. 3. Install two bolts (1). Connect air line (2) at fitting.Remove And Install Fuel Transfer Pump
Hoods and mufflers are removed for better photo illustration. 1. Disconnect fuel lines (1) from fuel transfer pump (3). Remove bolts (2). Remove fuel transfer pump (3). Remove gasket from fuel transfer pump.2. Install a new gasket on fuel transfer pump (3). Install fuel transfer pump on rear plate with the bolts (2) that hold it. Connect fuel lines (1) to the fuel transfer pump.Disassemble Fuel Ratio Control
start by:a) remove fuel ratio control 1. Remove two bolts (1) and the housing (2). 2. Remove valve assembly (3).3. Remove seal (4) and O-ring seal from valve.4. Remove the retainer (5) and two springs (6). 5. Remove three bolts (9) and cover (10).6. Remove valve (7), diaphragm (8), retainer and spring. 7. Remove pin (12) from valve (7).8. Remove cover (11) from the valve.9. Remove the seal from the cover (11).Assemble Fuel Ratio Control
1. Put clean engine oil on lip of seal. Install the seal (1) in cover (2). Install seal so lip of seal is toward the inside of the cover. 2. Install the valve (3) into cover (2).3. Install the pin that holds cover on valve. 4. Install spring (7) and the retainer (6) in cover (8).5. Install diaphragm (5) on the valve assembly (4) and in the cover. 6. Install cover and three bolts (11) that hold covers together.7. Put clean engine oil on seal and ring seal. Install the seals (10) on valve.8. Install the two springs (13), retainer, and valve assembly (12).9. Install housing (9) and two bolts.
Correct adjustment must be made to fuel ratio control before installation. See TESTING AND ADJUSTING.
end by:a) install fuel ratio controlDisassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Make a separation between cover (4) and pump body (2). 3. Remove lip type seal (6) from the cover. Remove plug (5), seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip type seals and the bottom bearing from pump body (1).8. Remove check valve (13).Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with tooling (B). The bushing must not be extended above the (gear) surface of the body.2. Install the check valve in the body with tooling (A).3. Install lip type seal (5) with tooling (C). Install the seal until it is .97 .02 in. (24.6 0.5 mm) from the bottom surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip type seal (6) with tooling (D). Install the seal until it is .56 .02 in. (14.2 0.5 mm) from the bottom surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with tooling (E). The bearing must be even with the surface of the pump body. 6. Heat gear (8) to a maximum temperature of 600°F (316°C). Install gear (8) on shaft (11) until dimension X is 1.957 .010 in. (49.71 0.25 mm).7. Install the drive shaft and gear in body (3). Install key, gear (10) and nut (9). Tighten the nut to a torque of 22 5 lb.ft. (28 7 N m).8. Install idler gear (12) in body (3).9. Install lip type seal (2) with tooling (C). Install the seal until it is .75 .02 in. (19.1 0.5 mm) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15), seal and plug (13) in pump cover (1). Tighten plug (13) to a torque of 27 3 lb.ft. (38 4 N m).11. Put 9M7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body (3).
Do not let the liquid gasket enter the pump.
The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install the service meter and/or tachometer drive on cover (1). end by: a) install fuel transfer pump