99011-87D49-03A Suzuki DT150/200/225 OWNERS MANUAL

4. Disconnect wires (1) from the starting motor and wire (2) from the frame of the machine. 5. For power shift machine: a) Disconnect oil supply line (4) from the torque divider.b) Disconnect vent line (5) from the torque divider.c) Disconnect oil supply line (6) for the transmission.d) Disconnect line (3) from the sequence relief valve. 6. For direct drive machine: a) Disconnect the actuating linkage (7) for the flywheel clutch.b) Disconnect oil line (8).c) Disconnect oil supply line (9) at the flywheel clutch. 7. Disconnect oil lines (10), (11) and (12) from the hydraulic oil pump. 8. Remove hydraulic oil pump (15) from the flywheel housing.9. Disconnect clip (13) from the flywheel housing and move the battery cable out of the way of the engine.10. Disconnect two oil lines (14) from the transmission oil filter.11. Disconnect the main fuel line from the fuel filter base.
Make a final inspection to make sure oil lines, hoses, wires and clips are clear of the engine and other components.
12. Remove four rear mounting bolts (16) at the rear of the engine. 13. Remove two front mounting bolts (17) at the engine front support.14. Fasten a hoist to the engine. Remove the engine from the machine. Weight of the engine is 3000 lb. (1360 kg).15. Remove the shims from under the rear engine mounts on the main frame. Put identification on the shims for correct installation.Install Engine
This procedure was done on an earlier machine without a cab and air conditioning and heating. 1. Put shims (2) in position on the frame for the engine rear mounts. 2. Fasten a hoist to the engine. Put engine (1) in position over the frame. Lower the engine until it makes contact with the frame. Make sure the engine is over the dowels in the frame for the engine rear mounts.3. Install the two front mounting bolts of the engine front support. Install the four rear mounting bolts at the rear of the engine. Tighten the bolts to a torque of 325 25 lb.ft. (440 35 N m).4. Connect the main fuel line to the fuel filter base. 5. Connect two oil lines (3) to the transmission oil filter. Put the clip and battery cable in position on the torque divider. Install the bolt that holds it.6. For the power shift machine: a) Connect the oil line to the sequence relief valve. b) Connect oil supply line (4) for the transmission.c) Connect vent line (6) to the torque divider.d) Connect oil supply line (5) for the torque divider. 7. Put hydraulic oil pump (7) in position in the flywheel housing.8. Connect the three oil lines to the hydraulic oil pump. 9. For the direct drive machine: a) Connect actuating linkage (8) for the flywheel clutch.b) Connect oil supply line (9) for the transmission.c) Connect oil supply line (10) for the flywheel clutch.10. Connect the ground wire to the frame of the machine.11. Connect the wire from the master switch on the starting motor.12. Turn the valve for the fuel supply to the "ON" position.13. Fill the hydraulic tank, transmission, torque divider or flywheel clutch with oil to the correct level. See MAINTENANCE GUIDE.end by: a) install air conditioner compressor (if so equipped)b) install indicator and guardc) install universal joint*d) install dash (if so equipped)*e) tilt cab forward (if so equipped)***These operations are in POWER TRAIN DISASSEMBLY AND ASSEMBLY section.**This operation is in OPERATOR'S STATION DISASSEMBLY AND ASSEMBLY section.