99011-95544-03A Suzuki DT75/85 OWNERS MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
B 298-5564 T40 Torx Socket 1
D 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter 1
E 276-1216 Injector Pipe Nut Tool 1
F 247-5377 Torque Wrench 1
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 to install the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Illustration 1 g01772353
Typical calibration code
If a replacement electronic unit injector is installed, the correct trim file for the injector must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Trim File" for more information. The code that is required to obtain the trim file for the injector is at Position (X).Note: Record Code (X) before the electronic unit injector is installed.
Use Tooling (D) to remove any fuel from the cylinder.Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Illustration 2 g01769574
Typical example
On installing an original electronic unit injector, install a new O-ring seal (16) and sealing washer (15) to electronic unit injector (12).Ensure that O-ring seal (16) and sealing washer (15) on a new electronic unit injector are not damaged and in place.Note: Do not lubricate the O-ring seal.
Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the old sealing washer has been removed from the cylinder head.
Illustration 3 g01769513
The rocker shaft is not shown for clarity.
Position clamp (14) between the rocker arm and the valve springs. Align electronic unit injector (12) to the bore for the electronic unit injector in the cylinder head. Install the clamp to the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.
Install a new torx screw (13) to clamp (14). Tighten the torx screw finger tight.
Remove the cap from electronic unit injector (12). Install a new seal (9) to electronic unit injector (12) and to the valve mechanism cover base. Ensure that the flange on the seal is flush with the valve mechanism cover base.
Remove the plugs from the new fuel injection line. Loosely install the fuel injection line. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install".Note: Ensure that the ends of the fuel injection line are seated in the electronic unit injector and the fuel manifold. Tighten the nuts finger tight.
Use Tooling (B) to tighten torx screw (13) to a torque of 27 N m (239 lb in).Note: Tooling (B) must be used to ensure no damage to the rocker arms.
Tighten the clamps and the fuel injection lines. Use Tooling (E) to tighten the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for more information.
Illustration 4 g01772534
Typical example
Illustration 5 g01774093
Typical example
The electronic unit injector is not shown for clarity.