Suzuki Intruder 1978 - Engine Removal

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2. L if t off body cover. Remove spring and
diaphragm assembly .
3. R emo ve f ilt er fr om body A.
4. Remove body A. gasket. body B, diaphragm and
gasket. Note the
position of the gasket in re-
lation to body B.
5. Once removed, the grommets cannot be rein-
stalled - Be sure to have replac ements on hand
before r emov ing th em. Remove grom mets and
check valves from body B.
Cleaning
Clean th e body castings A and B, the cap and the
bottom body with a mild solvent. Cl ean fi lt er or re-
place if necessary.
Do not clean rubber diaphragms with
solvent . Damage to diaphragms will occur.
Be
sure fuel line and impulse line fittings
are clear of a ny obstructions.
Reassembly
1. Install lower gasket and diaphrag m on b ottom
body. (See Figure 3- 22)
2. Install check va lves using new grommets in
body B. Po sition body B on bottom body.
3.
Install gasket and body A onto body B. Be sure
alignment tabs on gasket, body A. and body B
are indexed dur i ng assembly .
4. Install filte r into body A.
5. Install diaphragm assembly onto body A. Be
sure al ignment tabs on body A and dia phragm
are indexed during assembly.
6. Install spring into diaphragm assembly.
7. Install cap onto diaphragm assembly. Be sure
al ign ment tabs on cap, diaphragm assembly,
body A. gasket. and body B are indexed
properly.
8. Install e ight retain ing screws and t ig hten in a
cris scross patt ern.
Installation
1. Connect i mpul se line to fr ont f i tt in g.
2. Install fuel inlet line and fuel outlet lines.
Arrows on top of body cover indicate direct i on
of fuel flow . (See Figure 3-22.)
3. Install two fuel pump mounting nuts.
4. Replace air intake silencer to carburetor.
While installing the air intake silencer,
check that:
1. The cover is securely fastened to silencer
body and properly sealed.
2. The rubber seal between silencer body and
carburetor fits securely during installation.
3. Intake hose must be directed rearward.
Failure to comply with the above steps will
cause engine failure. Install the short spring on
the bottom and the long spring on the top.
Engine Removal
1. Unplug the harness from the rear of the head-
light. Open the cl amps securing th e ha rness to
the hood. Remove the harness fro m the ho od.
2. Disconnect the hood l anyard from th e engine
shroud. Remove the
hinge pins from the
hinges. Remove the hood.
3. Remove the
retainer pins and remove the drive
belt guard. (See Figure 3-23.) Remove the drive
belt.
1. Drive Belt Guard
2. Drive Belt
Figure 3-23
ENGINE REMOVAL 3-41