09100-10306 Suzuki BOLT (10X150)

Troubleshooting The Fuel Injection Nozzles On The Engine
Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all surfaces and threads are clean.Only personnel that have the proper training should disassemble the fuel injection nozzles. Only personnel that have the proper training should perform repairs to the fuel injection nozzle.Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly.Refer to Specifications, "Fuel Injection Nozzles" for additional information. The engine is difficult to start or the engine runs rough.
Probable Cause
The fuel injection nozzle does not seal correctly in the cylinder head.Make sure that the gaskets, the insert and the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head.
There is debris on the mating surface of the cylinder head with the gaskets or the insert. Make sure that extra gaskets were removed from the threaded recess in the cylinder head for the fuel injection nozzle.Remove any extra gaskets or debris.
The connections of the high pressure fuel line leak.Tighten the fittings of the high pressure fuel line.
The fuel injection nozzle does not operate correctly.Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.
The incorrect fuel injection nozzle is installed.Make sure that all fuel injection nozzles are the correct replacement parts for the engine. Refer to the Parts Manual for the correct replacement part. The engine exhaust has too much black smoke.
Probable Cause
Extra gaskets were not removed from the threaded recess in the cylinder head for the fuel injection nozzle. There is debris on the mating surface of the cylinder head with the gaskets or the insert.Remove any extra gaskets or debris.
The fuel injection nozzle does not operate correctly.Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.
The incorrect fuel injection nozzle is installed.Make sure that all fuel injection nozzles are the correct replacement parts for the engine. Refer to the Parts Manual for the correct replacement part. The engine has lost power and the engine uses too much fuel.
Probable Cause
The fuel injection nozzle does not seal in the cylinder head.Make sure that the gaskets, the insert and the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head.
Extra gaskets were not removed from the threaded recess in the cylinder head for the fuel injection nozzle. There is debris on the sealing surface for the fuel injection nozzle.Remove any extra gaskets or debris.
The connections of the high pressure fuel line leak.Tighten the fittings of the high pressure fuel line.
The fuel injection nozzle does not operate correctly.Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.Test the fuel injection nozzle on a nozzle tester.
The incorrect fuel injection nozzle is installed.Make sure that all fuel injection nozzles have the correct code for the engine.
A connection of the fuel return line leaks.Inspect all connections of the low pressure fuel line for tightening to the correct torque. The engine is misfiring, running rough, or running poorly.
Probable Cause
The fuel injection nozzle does not seal in the cylinder head.Make sure that the gaskets, the insert and the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head.
Extra gaskets were not removed from the threaded recess in the cylinder head for the fuel injection nozzle. There is debris on the sealing surface for the fuel injection nozzle.Remove any extra gaskets or debris.
The connections of the high pressure fuel line leak.Tighten the fittings of the high pressure fuel line.
The fuel injection nozzle does not operate correctly.Make sure that the components of the fuel injection nozzle are tightened to the correct torques. Make sure that the gaskets and the insert are positioned correctly. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.Test the fuel injection nozzle on a nozzle tester.
The incorrect fuel injection nozzle is installed.Make sure that all fuel injection nozzles have the correct code for the engine.
A restriction exists in the high pressure fuel line.Inspect all high pressure fuel lines for damage.
A seat washer that is not the correct thickness is installed.The correct seat washer is 2.0 mm (0.08 inch) thick.Troubleshooting Fuel Injection Nozzles on a Nozzle Tester
Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all surfaces and threads are clean.Only personnel that have the proper training should disassemble the fuel injection nozzles. Only personnel that have the proper training should perform repairs to the fuel injection nozzles. Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly.Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.Back leakage
Fuel leaks through the threaded connection of the body and the nozzle nut.Make sure that the threads are clean. Tighten the body to the correct torque.
Debris or damage exists on the orifices.Visually inspect the components of the valve for carbon pitting, for scoring, or for other damage. Clean the surface