11390-98J00 Suzuki JET, PISTON COOLING

Table 1
Required Tools
Tool Part Number Part Description Qty
A 360-8376 Capping Kit 1
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 System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Illustration 1 g06143255
Thoroughly clean the area around fuel manifold (6) and relief valve (5).
Remove banjo bolt (1) from banjo connection (3). Remove sealing washer (2) (not shown) and sealing washer (4) (not shown). Use Tooling (A) to cap the banjo connection and plug relief valve (4). Position the assembly of the banjo connection away from fuel manifold (6) and the relief valve.
Use a suitable socket to remove relief valve (5) from fuel manifold (6). Use Tooling (A) to cap the relief valve and plug the fuel manifold.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 System Operation, Testing and Adjusting, "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: Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage.Note: Do not install a relief valve that has not been plugged. All plugs and caps must be left in place until the fuel lines are about to be installed.
Illustration 2 g06143255
Remove the cap from the port in fuel manifold (6).
Immediately clean the threads in fuel manifold (6) for relief valve (5). Ensure that the thread is clean and free from debris. Ensure that the thread in the fuel manifold is free from damage.
Immediately cap the open port in fuel manifold (6) with a new cap after cleaning and inspection.
Remove the cap from the threaded end of relief valve (5). Lubricate the thread of the pressure relief valve with clean fuel.
Remove the cap from the port of fuel manifold (6). Use a suitable socket to install the relief valve (5) into fuel manifold hand tight.
Tighten relief valve (5) to a snug torque of 30 N m (266 lb in). Rotate the fuel pressure relief valve in a clockwise direction for an additional 24 degrees to achieve the final torque.
Remove plug from relief valve (5) and cap from banjo connection (3).
Install a new sealing washer (2) (not shown) onto banjo bolt (1). Install the banjo bolt and the remaining new sealing washer (4) (not shown) to banjo connection (3).
Position banjo connection (3) onto relief valve (5). Tighten the banjo bolt to a torque of 15 N m (133 lb in).
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.