65000-99J00 Suzuki TANK ASSY, FUEL (12L)

1. Remove plug (1) from the fuel injection pump housing. 2. Install Tool (A) into the fuel injection pump housing with the square end down. Use a small amount of hand force to push down on Tool (A) while the fuel control lever is moved forward to the "FUEL ON" position until Tool (A) seats itself. The fuel rack will stop in the center "zero" position. 3. Remove wire tie (2). 4. Remove five bolts and washers (3) fastening adapter group (4) to housing assembly (5). 5. Remove gasket (6) from housing assembly (5). 6. Remove seven bolts (7) fastening housing assembly (5) to plate group (8).
There is spring force under collar (9). Remove socket head bolt (10) slowly while holding collar (9) in place to allow the spring force to be released gradually.
7. Remove socket head bolt (10) from collar (9) while holding collar (9) in place to prevent sudden release of the spring force.8. Remove spring (11). 9. If necessary, remove nut and screw (12) from collar (9). 10. Remove gasket (13) from the bottom of housing (5). 11. Remove locknut (14). 12. Remove cotter pin and pin (15). 13. Remove throttle control rod (16) from bracket (17). 14. Remove locknut (18) from throttle control rod (16).15. Remove spacer and spring (19) from throttle control rod (16).
Shaft (20) is under spring force. Remove shaft (20) from handle (21) slowly while holding shaft (29) in place to prevent possible personal injury.
16. Remove shaft (20) from handle (21) by turning counterclockwise.17. Remove the spring from shaft (20).18. Remove handle (21) from guide (22).19. Remove two screws (23) from bracket (17). 20. Remove guide (22), quadrant control (24), hub (25), ratchet (26) and bracket (17) from the shaft. 21. Remove two socket head bolts (27).22. Remove lock (28).23. Remove retainer (29).24. Remove insulator (30).25. Remove contact (31).26. Remove retainer (32).27. Remove shim (33).28. Remove bar (34).29. Remove insulator (35).30. Remove cover (36).31. Remove bolt (37) and cover (38). 32. Remove gasket (40). Mark locations of idle screws (39) and (41) prior to removal from the housing.33. Make alignment mark on high idle screw (39) and remove high idle screw (39) counting the number of turns until removed.34. Make alignment mark on low idle screw (41) and remove low idle screw (41) counting the number of turns until removed. 35. Remove two socket head screws (44) fastening bracket (43) to the housing.36. Remove felt washer (42) from the shaft. 37. Remove bolt (45).38. Remove shaft (47) and lever assembly (46).
Pin (48) has a large amount of spring force behind it. The spring force will not release slowly during removal of pin (48). Remove pin (48) very carefully to avoid possible personal injury.
39. Remove pin (48) slowly and carefully due to the large spring force behind it.40. Remove the spring and the stop plunger inside lever assembly (46). 41. Remove two seals (49) from both sides of the housing.42. If necessary, remove plug (50) and the O-ring seal. 43. Remove bearing sleeve (51) and (52) 44. Remove valve body (53) from the housing. 45. Remove valve (55) from valve body (53).46. Remove O-ring seal (54) from valve (55).47. Remove O-ring seal (56) from valve body (53). 48. Remove seat (57) and spring (58). 49. Use Tool (B) to remove retaining ring (59).50. Remove spacer ring (60). 51. Remove spool (61) and spring (62). 52. Use Tool (B) to remove retaining ring (63). 53. Remove spring seat (65) and bolt stop (64) from the governor. 54. Disassemble spring seat (65) and bolt stop (64) as follows:a. Remove retaining ring (68) from spring seat (65).b. Remove bearing (67) from spring seat (65).c. Remove bolt stop (64) from spring seat (65).d. Remove spacer (66) from spring seat (65). 55. Remove lockring (70) from governor weight (69). 56. Remove governor weight (69) from the governor. 57. Remove four bolts (72).58. Remove adapter plate (71) from the fuel injection pump housing. 59. Remove pin assembly (74) fastening drive assembly (73) to gear (75).60. Remove drive assembly (73) from gear (75) Make a note of alignment marks on stop (76) used for installation purposes.61. Remove stop (76) from gear (75). 62. Remove dowel (78) from guide (77).63. Remove guide (77) from adapter plate (71).64. Remove the O-ring seal inside guide (78).