09117-05001 Suzuki BOLT

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
Table 1
Troubleshooting Test Steps Values Results
1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head
A. Verify that the fuel injection nozzle is sealed correctly in the cylinder head.
Fuel Injection Nozzle
Result: 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.
Verify that the problem is resolved.
Result: The fuel injection nozzle is sealed correctly in the cylinder head.
Proceed to Test Step 2.
2. Check for Debris on the Mating Surface of the Cylinder Head with the Gaskets or the Insert
A. Check for debris on the mating surface of the cylinder head.
B. Make sure that extra gaskets were removed from the threaded recess in the cylinder head for the fuel injection nozzle.
Debris
Result: There is debris on the mounting surface of the cylinder head or extra gaskets were left in the cylinder head for the fuel injection nozzle.
Remove any extra gaskets or debris.
Verify that the problem is resolved.
Result: There is no debris on the mounting surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection nozzle.
Proceed to Test Step 3.
3. Check the Connections of the High Pressure Fuel Line
A. Check for a damaged or leaking high-pressure fuel line.
Fuel leak
Result: A high-pressure fuel line is leaking.
Repair or replace the high-pressure fuel line that is leaking.
Verify that the problem is resolved.
Result: A high-pressure fuel line is not leaking.
Proceed to Test Step 4.
4. Check that the Correct Fuel Nozzles are Installed
A. Verify that all fuel injection nozzles are the correct replacement parts for the engine.
Fuel Nozzle
Result: The correct fuel nozzles are not installed.
Install the correct fuel nozzles.
Refer to the Parts Manual for the correct replacement part.
Verify that the problem is resolved.
The Engine Exhaust has too Much Black Smoke
Probable Cause
Table 2
Troubleshooting Test Steps Values Results
1. Check for Debris on the Mating Surface of the Cylinder Head with the Gaskets or the Insert
A. Check for debris on the mating surface of the cylinder head.
B. Make sure that extra gaskets were removed from the threaded recess in the cylinder head for the fuel injection nozzle.
Debris
Result: There is debris on the mounting surface of the cylinder head or extra gaskets were left in the cylinder head for the fuel injection nozzle.
Remove any extra gaskets or debris.
Verify that the problem is resolved.
Result: There is no debris on the mounting surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection nozzle.
Proceed to Test Step 2.
2. Check for Correct Operation of the Fuel Nozzle
A. Make sure that the components of the fuel injection nozzle are tightened to the correct torques.
B. Make sure that the gaskets and the insert are positioned correctly.
C. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.
Fuel Nozzle
Result: The fuel nozzle is not operating properly.
Replace the fuel nozzle.
Verify that the problem is resolved.
Result: The fuel nozzle is operating properly.
Proceed to Test Step 3.
3. Check that the Correct Fuel Nozzles are Installed
A. Verify that all fuel injection nozzles are the correct replacement parts for the engine.
Fuel Nozzle
Result: The correct fuel nozzles are not installed.
Install the correct fuel nozzles.
Refer to the Parts Manual for the correct replacement part.
Verify that the problem is resolved.
The Engine has Lost Power and the Engine Uses too Much Fuel
Probable Cause
Table 3
Troubleshooting Test Steps Values Results
1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head
A. Verify that the fuel injection nozzle is sealed correctly in the cylinder head.
Fuel Injection Nozzle
Result: 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.
Verify that the problem is resolved.
Result: The fuel injection nozzle is sealed correctly in the cylinder head.
Proceed to Test Step 2.
2. Check for Debris on the Mating Surface of the Cylinder Head with the Gaskets or the Insert
A. Check for debris on the mating surface of the cylinder head.
B. Make sure that extra gaskets were removed from the threaded recess in the cylinder head for the fuel injection nozzle.
Debris
Result: There is debris on the mounting surface of the cylinder head or extra gaskets were left in the cylinder head for the fuel injection nozzle.
Remove any extra gaskets or debris.
Verify that the problem is resolved.
Result: There is no debris on the mounting surface of the cylinder head or extra gaskets left in the cylinder h