99011-95547-03A Suzuki DT75/85 OWNERS MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 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.
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.
If necessary, remove the boost pressure sensor. Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install".
Illustration 1 g01247416
Typical example
Disconnect plastic tube assemblies (3), (5) and (6) from fuel filter base (1). Note: If the tube assemblies have quick fit connections, ensure that the connections are clean before the tube assemblies are plugged.
Remove tube assembly (4), if equipped.
Use Tooling (A) in order to remove fuel filter (7). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace".
Remove bolts (2) from fuel filter base (1). Remove the fuel filter base from the cylinder head. Note: Do not attempt to disassemble the fuel filter base.Installation Procedure
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.
Ensure that the fuel filter base is clean and free from damage. If necessary, replace the complete fuel filter base assembly.
Illustration 2 g01247416
Typical example
Position fuel filter base (1) onto the cylinder head. Install bolts (2). Tighten the bolts to a torque of 22 N m (16 lb ft).
Install a new fuel filter (7) to fuel filter base (1). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
If necessary, install the boost pressure sensor. Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install".
Install tube assembly (4), if equipped. Tighten the nuts to a torque of 9 N m (80 lb in).
Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Contaminated fuel will cause serious damage to the engine.
Connect plastic tube assemblies (3), (5) and (6) to fuel filter base (1). Note: If the tube assemblies have quick fit connections, ensure that the connections are clean before the tube assemblies are connected.
Turn the fuel supply to the ON position.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime".