61461-98810-02M Suzuki STARBOARD ENGINE COVER

Start By:a. remove fuel transfer pump1. Drain the coolant from the engine cooling system. 2. Remove the connector for wire (5) from the support bracket and disconnect. Remove the cable strap holding wire (5).3. Disconnect heater hose (3) from the valve.4. Remove clips (1) that fasten the fuel lines to the adapter (2).5. Remove four bolts (4) that fasten adapter (2) to the water pump. Remove adapter (2).
Typical Example6. Remove the four bolts that fasten elbow (6) to the oil pump. Remove elbow (6).
Typical Example7. Disconnect hose (12) from bonnet (8).8. Loosen two bolts (10) to provide clearance for removal of bonnet (8). Remove bolts (9) and remove bonnet (8) and tube (7). 9. Remove fuel line (16) from the primary fuel filter.10. Remove bolts (13) and (14) and remove bracket (18).11. Remove four bolts (15) that fasten elbow (17) to the bottom of the oil pump. 12. Install tooling (A) and attach a hoist. Remove the last bolt that fastens oil pump (19) to the accessory drive and remove the pump. The weight of the pump is 34 kg (74 lb.).13. Check all seals and gaskets for wear or damage and replace if necessary.14. Lubricate all seals with clean engine oil or glycerin during assembly.15. The oil pump must turn freely by hand before installation.16. Fill the oil pump with clean engine oil before installation of elbow (6).17. Install the engine oil pump in the reverse order of removal.End Bya. install fuel transfer pumpDisassemble Oil Pump
Start By:a. remove oil pump
Cover (2) holds a spring in compression. Sudden release of a spring in compression can cause personal injury. To prevent personal injury, loosen bolts (1) slowly and evenly to relieve the tension beneath the cover (2).
1. Remove bolts (1), cover (2), gasket (3), spring (4) and valve spool (5) from the pump body. 2. Remove cover assembly (6) and the gasket from the pump body. 3. Remove cover assembly (7) from the pump body. 4. Use tooling (A) to remove bearings (8) from cover assembly (7). 5. Remove shaft assemblies (10) from body assembly (9). 6. Use a press to remove gears (11) from the shaft assemblies. 7. Use tooling (A) to remove bearings (12) from body assembly (9).Assemble Oil Pump
1. Make an alignment of bearings (1) so that the joints are 45 15° from a line through the center of the bearing bores as shown.2. Use tooling (A) to install bearing (1) in the body assembly until they are 1.5 0.5 mm (.06 .02 in.) below the gear bore in the body assembly. Check the inside diameter of the bearings after installation. The diameter must be 31.811 0.013 mm (1.2524 .0005 in.). 3. Heat gears (2) to a maximum temperature of 316° C (600° F).4. Install the gears on shaft assemblies (3) until they are 64.0 0.5 mm (2.52 .02 in.) from the cover end of the shaft assemblies to the face of the gears and 47.0 0.5 mm (1.85 .02 in.) from the fuel pump drive end of shaft assembly (4). 5. Install shaft assemblies (3) and (4) in the body assembly. 6. Make sure dowels (5) and (8) are installed in cover assembly (6) so they extend 6.0 0.5 mm (.24 .02 in.) above the surface of the cover assembly.7. Use tooling (A) to install bearings (7) in cover assembly (6) with the joints of the bearings in the positions as shown. 8. Put cover assembly (6) in position, and tighten the bolts to hold it to the body assembly. 9. Make sure the two pins in cover assembly (9) are installed so they extend 6.0 1.0 mm (.24 .04 in.) above the surface of the cover assembly. Install the gasket and cover assembly (9) on the body assembly. 10. Put clean engine oil on valve spool (13). Install valve spool (13), spring (12), gasket (11), cover (10) and the bolts in the body assembly.End By:a. install oil pump