99011-95546-03A Suzuki DT75/85 OWNERS MANUAL

Note: This procedure is for the removal of the engine oil pump on engines that are not equipped with a balancer. Refer to Disassembly and Assembly, "Balancer - Remove" for information on the removal of the engine oil pump for engines that are equipped with a balancer.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.
Illustration 1 g01255703
Typical example
Remove bolts (1) and suction pipe (2).
Remove the gasket from the suction pipe.
Remove bolts (5). Remove the assembly of the engine oil pump (3) from the cylinder block.
If necessary, remove pressure relief valve (4) from the housing of engine oil pump (3). Refer to Disassembly and Assembly, "Engine Oil Relief Valve - Remove and Install".
Illustration 2 g01470295
Typical example
If necessary, remove bolts (9) and front cover assembly (6). Remove outer rotor (7) from the housing of engine oil pump (3). Note: Do not remove dowels (8) and (10) from the housing of the engine oil pump unless the dowels are damaged.Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-7324 Indicator Bracket 1
7H-1942 Dial Indicator 1
3S-3268 Indicator Contact Point 1
7H-1940 Universal Attachment 1 Note: This procedure is for the installation of the engine oil pump on engines that are not equipped with a balancer. Refer to Disassembly and Assembly, "Balancer - Install" for information on the installation of the engine oil pump for engines that are equipped with a balancer.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
If any of the parts on the engine oil pump are worn or damaged, the entire pump must be replaced.
Ensure that all components of the engine oil pump are clean and free from wear or damage. Check the clearance between the outer rotor of the oil pump and the oil pump body. Check the clearance between the outer rotor and the inner rotor. Check the end play of the rotor. Refer to Systems Operation, Testing and Adjusting, "Engine Oil Pump - Inspect". Replace the complete assembly of the engine oil pump if any of the components are worn or damaged.
Illustration 3 g01470295
Typical example
If necessary, lubricate the internal components of the assembly of the engine oil pump with clean engine oil. Install outer rotor (7) and front cover (6) to the housing of engine oil pump (3). Install bolts (9). Tighten the bolts to a torque of 9.5 N m (84 lb in).
Illustration 4 g01255703
Typical example
If necessary, install pressure relief valve (4). Refer to Disassembly and Assembly, "Engine Oil Relief Valve - Remove and Install" for further information.
Ensure that dowel (8) and dowel (10) are correctly located in the housing of engine oil pump (3). Position the assembly of the engine oil pump onto the cylinder block. Note: Ensure that the dowels in the housing of the engine oil pump are aligned with the holes in the cylinder block.
Install bolts (5). Tighten the bolts to a torque of 44 N m (32 lb ft).
Install suction pipe (2) and a new gasket to the assembly of the engine oil pump.
Install bolts (1). Tighten the bolts to a torque to 22 N m (16 lb ft).
Use Tooling (A) in order to check the backlash between the idler gear of the oil pump and the crankshaft gear. Refer to Specifications, "Gear Group - Front" for further information. End By:
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".