36890-92E00 Suzuki WIRE HARNESS

2. Disconnect tachometer drive (2) at the fuel transfer pump.3. Disconnect fuel supply hose (1) at the fuel transfer pump, and install protective covers.4. Disconnect fuel return hose (3) at the fuel transfer pump, and install protective covers.5. Remove the bolts that hold the fuel transfer pump to the fuel transfer pump drive.6. Lift fuel transfer pump (4) out of the fuel transfer pump drive. The following steps are for installation of the fuel transfer pump.7. Install fuel transfer pump (3) with a new gasket and O-ring seal.8. Install the bolts to hold the fuel transfer pump.9. Remove the protective covers, and connect fuel return hose (3) and fuel supply hose (1).10. Connect the tachometer drive to the fuel transfer pump.11. Remove (bleed) the air from the fuel system. Use the fuel priming pump to remove air from the system.Disassemble Fuel Transfer Pump
START BY:a. remove fuel transfer pump 1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Separate cover (4) and pump body (2). 3. Remove lip-type seal (6) from the cover. Remove plug (5), the 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 (2).8. Remove check valve (13).Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with tooling (B). The bushing must be .80 .50 mm (.031 .020 in.) below 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 26.19 .13 mm (1.031 .005 in.) from the bottom (drive gear) 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 14.2 0.5 mm (.559 .020 in.) from the bottom (drive gear) 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 bottom (drive gear) surface of the pump body. 6. Heat gear (8) to a maximum temperature of 315°C (600°F). Install gear (8) on shaft (11) until dimension (X) is 49.71 0.25 mm (1.957 .010 in.).7. Install the drive shaft and gear in body (3). Install the key, gear (10) and nut (9). Tighten the nut to a torque of 30 7 N m (22 5 lb.ft.).8. Install idler gear (12) in body (3).9. Install lip-type seal (2) with tooling (C). Install the seal until it is 22.61 .05 mm (.890 .002 in.) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15) and seal and plug (13) in pump cover (1). Tighten plug (13) to a torque of 37 4 N m (27 3 lb.ft.).
Do not let the liquid gasket enter the pump during application or assembly.
11. Put 7M7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body (3). The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install the tachometer drive on cover (1).END BY:a. install fuel transfer pump