99011-95543-03A Suzuki DT75/85 OWNERS MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 298-5564 T40 Torx Socket 1
C 5F-4764 Pry Bar 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Start By:
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install". Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Note: Put identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g01772534
Typical example
Use Tooling (A) in order to rotate the crankshaft until rocker arms (1) for the appropriate cylinder are in the correct position in order to adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".
Follow Step 4.a through Step 4.d in order to gain access to the electronic unit injector.
Make a temporary mark on valve bridges (5) in order to show the location and orientation. Note: Identification will ensure that the valve bridges can be reinstalled in the original location and the original orientation.
Loosen nuts (3) for the appropriate cylinder. Unscrew adjusters (2) for the appropriate cylinder until pushrods (4) can be withdrawn from the balls of the adjusters.
Withdraw the cups of pushrods (4) from the balls of adjusters (2).
Remove valve bridges (5) from the cylinder head. If the valve bridges are equipped with shrouds (6), ensure that the shrouds are removed from the cylinder head. Note: Do not interchange the location or the orientation of used valve bridges.
Illustration 2 g01769493
Typical example
Loosen banjo bolt (8) on the fuel transfer pump sufficiently in order to allow the fuel to drain from tube assembly (7).
Illustration 3 g01769513
The rocker shaft is not shown for clarity.
Remove the fuel injection line and remove seal (9) from the appropriate electronic unit injector (12). Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove". Note: Cap all open ports immediately with new caps.
Use a deep socket to remove connections (11) from electronic unit injector (12).
Slide rocker arms (1) to one side in order to gain access to torx screw (13). Use Tooling (B) in order to remove the torx screw from clamp (14). Discard the torx screw. Note: Tooling (B) must be used to ensure no damage to the rocker arms.
Place a temporary identification mark on the original electronic unit injector. The electronic unit injector must be reinstalled in the original location in the cylinder head.
Illustra