99011-95549-03A Suzuki DT75/85 OWNERS MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
B 276-1216 Injector Pipe Nut Tool 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.
Note: The following procedure should be adopted in order to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed. If the electronic unit injectors or the fuel manifold have been removed, refer to Disassembly and Assembly, "Electronic Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for more information.
Illustration 1 g01254886
Typical example
Remove the caps from the port in fuel injection pump (5) and from the appropriate port in fuel manifold (4). Remove the caps from the new fuel injection line (6).
Loosely connect the nuts at both ends of fuel injection line (6), to fuel manifold (4) and to fuel injection pump (5). Ensure that the ends of the fuel injection line are correctly seated in the fuel injection pump and in the fuel manifold.
Use Tooling (B) to tighten the nuts on fuel injection line (6) to a torque of 30 N m (22 lb ft).
Install bolt (7) to clip (8). Tighten bolt (7) to a torque of 22 N m (16 lb ft). Ensure that fuel injection line does not contact any other engine component.
Install the electronic control module. Refer to Disassembly and Assembly, "Electronic Control Module - Remove and Install".
If necessary, install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".
Illustration 2 g01457387
Typical example
Illustration 3 g01271377
Typical example
The valve mechanism cover is not shown for clarity.
Install a new seal (1) to electronic unit injector (2) and to valve mechanism cover base (13). Note: Ensure that the flange on the seal is flush with the valve mechanism cover base.
Remove the caps from the new fuel injection line (3). Note: Ensure that a dust seal is installed to the fuel injection line. Install the fuel injection line for number one cylinder first. Install the fuel injection lines in numerical order.
Remove the caps from electronic unit injector (2) and from the appropriate port in fuel manifold (4).
Loosely connect the nuts at both ends of fuel injection line (3), to electronic unit injector (2) and to the appropriate port in fuel manifold (4). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.
Use Tooling (B) to tighten the nuts on fuel injection line (3) to a torque of 30 N m (22 lb ft). Ensure that the dust seal is seated correctly against seal (1).
Follow Step 7 through Step 11 in order to install the remaining fuel injection lines. Note: Ensure that fuel injection lines do not contact any other engine component.
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Remove the air from the fuel system. Refer to Operations and Maintenance Manual, "Fuel System - Prime".