48520-87D10 Suzuki SPOOL

2. Remove bolts (1), the washers, plate (2) and the gasket from the timing gear cover.3. Remove bolt (3) and the washer that holds the guide for the oil level gauge. 4. Remove bolts (5) and the washers to remove alternator bracket (4) from the engine. 5. Remove tube assemblies (6) and (7) from the engine.6. Remove nut (8) and move junction block (9) to the rear of the machine. Make sure all fuel line openings are covered to keep dirt and foreign material out of the fuel system. 7. Remove clamp (11) from water sleeves (10) in each cylinder head. Push the water sleeves into the timing gear cover with tool (A).
Make sure the fuel injection nozzles are removed before the cylinder heads are removed. The fuel injection nozzles go through the cylinder heads and the nozzle tips can be broken off if the nozzles are not removed from the heads.
8. Install a locknut on each eyebolt and install two 3/8" x 16 NC and one 7/16" x 14 NC forged eyebolts in the cylinder head as shown. 9. Fasten a hoist to the cylinder head and remove the bolts that hold it in position. Remove the cylinder head and gasket. The weight of the cylinder head is 120 lb. (54 kg).Install Cylinder Heads
1. Clean the contact surfaces of the cylinder head and cylinder block. Make sure the surfaces are clean and dry. Install a new cylinder head gasket. Clean the bore in the cylinder head for the water sleeves. Put oil on the seals of the water sleeves.2. Install a locknut on each eyebolt and install two 3/8" x 16 NC and one 7/16" x 14 NC forged eyebolts in the cylinder head and fasten a hoist as shown. Put the cylinder head in position on the cylinder block. 3. Put 9M3710 Anti-Seize Compound on the bolt threads and install the bolts that hold the cylinder head in place. Tighten the bolts in the cylinder head according to the following HEAD BOLT CHART. 4. Install water sleeves into cylinder heads with tool (A). Install the clamps on the water sleeves. 5. Put the fuel line junction block in position and install nut (3) to hold it.6. Install fuel lines (1) and (2) on the engine. 7. Put alternator bracket (4) in position and install the three bolts and washers to hold it.8. Install bolt (6) and the washer to hold the guide for the oil level gauge. 9. Put the gasket and plate (5) for the air compressor in position on the timing gear cover and install the four bolts and washers to hold it.10. Fill the cooling system with coolant to the correct level.end by:a) install fuel injection nozzlesb) install rocker shafts and push rodsc) install fuel injection lines and air inlet manifoldd) install exhaust manifolde) install belt tightener (water pump)f) install air cleaner housing and panel assemblyg) install air compressorh) install alternatorDisassemble Cylinder Heads
start by:a) remove cylinder heads 1. Fasten a hoist and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valve springs under compression with tool (C).3. Remove the locks from the valves.4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head. 5. Check the valve spring force with tool (B). Spring force must be 35 5 lb. (155 22 N) when the length of the spring force is 1.715 in. (43.56 mm).6. Do Steps 2 through 5 for the remainder of the valves. 7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide .75 in. (19.0 mm) from the outside edge on both ends of each valve guide. The bore must be .3745 .0005 in. (9.512 0.013 mm). The maximum permissible bore is .3760 in. (9.550 mm). Valve guides worn more than the maximum specification can be made to the original size by knurling. See RECONDITIONING PROCEDURES FORM NO. REG00867.Assemble Cylinder Heads
1. Clean and remove burrs and all foreign material from the valve seat bores. 2. Lower the temperature of the valve seat inserts and install them with tooling (A).
Do not make the diameter of the extractor (part of tooling A) in valve seat insert larger when the insert is installed in the cylinder head.
3. Grind the valve inserts according to specifications given in ENGINE SPECIFICATIONS. 4. Put clean engine oil on the valve stem. Install the valve, washer (3), spring (2) and retainer (1) in the cylinder head. 5. Put the valve spring under compression with tool (C).6. Install the locks on the valve stem with tool (B).
Make sure locks (4) are in their correct position on the valve. The locks can be thrown from the valve when tool (C) is released if the locks are not in their correct position on the valve.
7. Remove tool (C) and hit the valve with a rubber hammer to be sure the locks are in their correct position.8. Do Steps 4 through 7 for the remainder of the valves.end by:a) install cylinder heads