Chapter Thirteen Oil Injection System This chapter provides removal, inspection and installation instructions for all oil injection components. Air bleeding instructions are also provided. Refer to Chapter Three for an explanation on system operation and all oil injection system troubleshooting procedures. Many of the warning system components are connected directly to the oil injection system. Warning system components related to the oil injection system include: 1. Oil level sensor. 2. Oil flow sensor. 3. CDIunit Refer to Chapter Seven for removal, inspection and installation of all warning system components. Tables 1 and 2 are located at the end of this chapter. They provide tightening torque specifications and oil reservoir capacities. Oil Reservoir Removal/Installation The oil reservoir (Figure 1) is located on the front port side of the powerhead on all models. To prevent contamination of the oil injection system, clean all debris or contaminates from the reservoir and oil lines prior to removing them from the engine. To assist with oil line routing and connections, refer to Figures 2-4. 1. Disconnect both battery cables from the battery. 2. Trace the oil line from its connection on the bottom of the oil reservoir to the oil filter or oil flow sensor. Using needlenose pliers, squeeze the clamp ends to open the oil line clamp and carefully slide the clamp from the oil line fitting (inlet side). Place a shop towel under the filter or sensor to capture any spilled oil.
OIL INJECTION SYSTEM 443 OIL INJECTION SYSTEM (DT8, DT9.9 AND DT40) Oil fill cap OH Ievei sensor Oii iine check valve Oii fiiter Oii pump Carburetor 13 3. Using a pair of locking pliers, carefully pinch the oil line closed approximately 4.0 mm (1.0 inch) from the oil filter or oil flow sensor. Carefully slide the oil line from the oil filter or oil flow sensor. Plug the fitting to prevent leakage and contamination. 4. Direct the disconnected hose into a clean container suitable for holding oil. Remove the oil fill cap. Release the locking pliers and allow all oil to drain from the reservoir. Release the clamp and slip the oil line from the oil line fitting on the bottom of the reservoir. 5. Refer to Chapter Seven and remove the oil level sensor from the oil reservoir. Remove the bolts, washers and grommets that retain the oil reservoir to the engine. Remove all fasteners and lift the oil reservoir from the engine 6. Thoroughly clean the oil reservoir in a suitable solvent. Dry the reservoir with compressed air. Check all oil line clamps for corrosion, damage or weak tension. Replace them as needed. 7. Inspect the oil reservoir for cracked or worn surfaces. Replace the reservoir if any defects are noted. 8. Install the oil line and clamp onto the fitting at the bottom of the reservoir. Place the reservoir onto the powerhead and install all mounting fasteners and securely tighten them. Refer to Chapter Seven to install the oil level sensor into the reservoir 9. Slide the oil line onto the oil filter or oil flow sensor fitting. Do not install the clamp at this time. Refer to Chapter Four to fill the oil reservoir with oil. 10. Using needlenose pliers, pinch the oil line (near the oil filter or oil flow sensor fitting) closed. Carefully slide the hose from the fitting. Slide the clamp over the removed line. Place a shop towel under the disconnected line to capture any spilled oil. Slowly release the pliers un-
444 CHAPTER THIRTEEN OIL INJECTION SYSTEM (1992-1994 DT25, DT30, DT55/DT65) Oil fill cap Oil ievei sensor Oil reservoir Oii pump OH line clieck valve Carburetor Carburetor Carburetor ^ Reed vaive
OIL INJECTION SYSTEM 445 OIL INJECTION SYSTEM (1995-1999 DT55 AND DT65) Oil fiil cap #3 carburetor 13 Oil pump Oii iine check vaive til oil just begins to flow from the disconnected lines. Pinch the line shut and slip it onto the fitting on the oil filter or oil flow sensor. Slide the clamp into position over the line and fitting. 11, Clean the terminals and connect the cables to the battery. Refer to Bleeding the System to bleed all air from the oil lines before returning the engine to service. Air Bubbler Removal/Installation Do not remove the air bubbler unless replacement is necessary. Age and operation in a warm environment tends to cause the component to become brittle. The removal process may result in breakage of the bubbler. Always mark all oil line routing connections (Figure 5) prior to removing them. Work in a clean environment to help prevent contamination of the oil injection system. 1. Disconnect both battery cables from the battery. 2. Clean the bubbler and crankcase prior to removing any components. Mark the oil lines at the inlet and outlet side of the valve. Carefully open and slide both oil line clamps away from the fittings on the air bubbler 3. Using locking pliers, carefully pinch the oil line closed at a point approximately 4.0 mm (1 in.) from both air
446 CHAPTER THIRTEEN Air-oll mixture Oil (froin oil pump) To oil reservoir Outlet oil line inlet oil iine pump Oil filter Carburetor Reed valve bubbler fittings. Slip the oil lines from the air bubbler fittings. 4. Mark the oil line fittings relative to the cylinder block. This step is important to ensure correct oil line routing during assembly. 5. Using pliers, carefully twist the bubbler and pull it from the crankcase. Clean the passage leading to the crankcase. 6. Lubricate the replacement bubbler with Suzuki CCI outboard oil and carefully place the bubbler into the crankcase opening. Gently twist the bubbler and push it into the opening and align the bubbler with the fitting as noted in Step 4. Seat the bubbler against the cylinder block. 7. Noting that the inlet oil line fitting is closer to the cylinder block, slide the inlet and outlet oil lines onto the bubbler fittings. Slide the clamps fiilly onto the fittings and release the locking pliers from the oil lines. 8. Repeat Steps 2-7 for the remaining bubblers on the engine. 9. Clean the terminals and connect the cables to the battery. Refer to Bleeding the System to bleed all air from the oil lines before returning the engine to service. Oil Filter Removal/InstaUation An oil filter is used on Models DT8, DT9.9 and DTI5. All other models utilize a filter within the oil flow sensor. Refer to Oil Flow Sensor for service procedures on such models. Always note all oil line routing and connection points (Figure 5) prior to removing them. Work in a clean environment to help prevent contamination of the oil injection system.
OIL INJECTION SYSTEM 447 OIL PUMP AND DRIVEN GEAR (DT8, DT9.9 AND DTI 5) 1. Boit 2. Long boit 3. Sleeve 4. Air bleed fitting 5. Gasket 6. Adapter 7. Gasket 8. Driven gear 9. Oii iine fitting 10. Oii iine fitting 1. Disconnect both battery cables from the battery. 2. Mark the oil lines at the inlet and outlet side of the filter. Carefully open and slide both oil line clamps away from the fittings on the oil filter. 3. Using locking type pliers, carefully pinch the oil line closed at a point approximately 4.0 mm (1 in.) from both of the oil filter fittings. Slip the oil lines from the oil filter fittings. 4. Inspect the oil filter for debris or contaminants. Clean and inspect the oil reservoir and all oil lines if debris or contaminants are present. Inspect the oil line clamps for corrosion, damage or lost spring tension. 5. Note the arrow (Figure 6), then slide the reservoir side oil line onto the inlet side fitting of the oil filter. Release the locking pliers from the oil line (oil reservoir side). As soon as oil begins to exit the outlet side oil filter fitting, slide the oil pump side oil line onto the outlet side fitting. 6. Release the locking pliers from the oil pump side of the filter fitting. Place the oil line clamps over the oil lines and fittings. 7. Place the oil filter in its normal position. Ensure that the oil lines do not contact any moving components on the engine. 8. Clean the terminals and connect the cables to the battery. Refer to Bleeding the System to bleed all air from the oil lines before returning the engine to service. Oil Pump and Driven Gear Removal/Installation Never install an oil pump (Figure 7) that is not designated for that engine. The oil pump is precisely matched to deliver the proper amount of oil to the engine. Using an improper oil pump can result in insufficient or excessive oil delivery. Parts or repair instructions are not provided for the oil pump. Replace the complete unit if faulty. Mark all hoses prior to removal to ensure correct connections during assembly. Note the size and location of plastic tie clamps and replace them if removed. Refer to Figures 8-12 as necessary during pump removal and installation. 1. Disconnect both cables from the battery. 2. Carefully pry the linkage connector from the pump lever. Do not loosen the jam nuts on the linkage as you may disturb the link rod length. 13
448 CHAPTER THIRTEEN OIL PUMP AND DRIVEN GEAR (DT25 AND DT30) 11 16 1. Linkage connector 2. Jam nut 3. Link rod 4. Jam nut 5. Linkage connector 6. Mounting bolt 7. Mounting boit 8. Washer 9. Oii pump 10. Iniet fitting 11. Outlet fittings 12. Oil iine ciamp 13. O-ring 14. Adapter 15. Gasket 16. Driven gear 17. Linkage assembly
OIL INJECTION SYSTEM 449 OIL PUMP AND DRIVEN GEAR (DT40) 17 11 15 16 13 1. Linkage connector 2. Jam nut 3. Link rod 4. Jam nut 5. Linkage connector 6. Mounting boit 7. Washer 8. Mounting boit 9. Oii pump 10. inietoii iine fitting 11. Outietoii iine fitting 12. Oii iine clamps 13. O-ring 14. Adapter 15. Gasket 16. Driven gear 17. Oii pump iinkage assembiy
450 CHAPTER THIRTEEN OIL PUMP AND DRIVEN GEAR COMPONENTS (1992-1994 DT55 AND DT65) 1. Linkage connector 2. Jam nut 3. Link rod 4. Mounting boit 5. Jam nut 6. Linkage connector 7. Screw 8. Seaiing washer 9. Banjo fitting 10. Oii iine clamp 11. Infet oii line fitting 12. Bleed bolt/screw 13. O-ring 14. Adapter 15. Driven gear 16. Gasket 17. Oil pump linkage assembiy
OIL INJECTION SYSTEM 451 OIL PUMP AND DRIVEN GEAR (1995-1999 DT55 AND DT65) 15 13 1. Linkage connector 2. Jam nut 3. Link rod 4. Jam nut 5. Linkage connector 6. Mounting boit 7. Mounting bolt 8. Oil iine fitting 9. Oii iine fitting 10. Oii pump 11. O-ring 12. Adapter 13. Driven gear 14. Gasket
452 CHAPTER THIRTEEN 3. Remove the clamp and hose from the inlet side of the oil pump and quickly plug the hose. 4. Loosen the oil line clamps and slide them away from the oil pump outlet fittings. Carefully pull the hoses from the outlet fittings. Plug the hoses. a. On DT55 and DT65 (1992-1994 models), mark the orientation of the outlet fittings relative to the oil pump prior to removing them. b. Remove the screws (7, Figure 11), then carefiilly pull the bayonet fittings and sealing washer (Figure 13) from the oil pump. 5. Remove the two retaining bolts and carefully pull the oil pump from the cylinder block. Use care if you must pry the oil pump from the adapter to avoid damaging any surfaces. Remove and discard the O-ring or gasket. 6. Work carefully to avoid damaging any surfaces and carefully pry the adapter from the cylinder block (Figure 14). 7. Remove the gasket from the cylinder block or adapter block. Discard the gasket. 8. Using needlenose pliers, slightly rotate the driven gear and carefully pull it from the cylinder block. 9. Inspect the driven gear for the presence of debris, worn surfaces and damaged or missing gear teeth. Disassemble the powerhead and replace the drive and driven gear if debris or defective surfaces are noted. 10. Install a new O-ring onto the oil pump. Lubricate the O-ring and driven gear surfaces with Suzuki CCI outboard oil. Using needlenose pliers, carefully guide the driven gear into the cylinder block. 11. Install a new gasket(s) on the oil pump adapter and place it over the driven gear shaft. Seat the adapter onto its mounting pad on the cylinder block. 12. Position the oil pump on the powerhead. Carefully insert the oil pump drive shaft into the drive gear slot. Rotate the oil pump until the oil pump drive shaft aligns with the slot in the driven gear. The oil pump will move inward when the slot and gear shaft align. Never force the pump into position. 13. Rotate the pump until the retaining bolts align with the holes in the adapter and cylinder block. Install and securely tighten the retaining bolts (see Table 1). 14. Attach the linkage connector to the pump lever. Slide all disconnected inlet and outlet lines over the fittings. Slide all oil line clamps over the lines and fittings. a. On DT55 and DT65 (1992-1994 models), install the bayonet fittings with new sealing washers to the oil pump outlet fittings (Figure 13). b. Align the fittings with the markings made prior to removal. Securely tighten the screws (7, Figure 11). 15. Operate the throttle and shiflt linkage to ensure that the hoses do not contact any moving components. Correct the hose routing as required. 16. Clean the terminals and connect the cables to the battery. Refer to Bleeding the System (to bleed all air from the oil lines before returning the engine to service. CAUTION Use caution when installing oil line check valves. The engine will suffer serious powerhead damage if a check valve is installed in the wrong direction. The arrow on the check valve must point toward the oil discharge fitting at the intake manifold or fuel line. Oil Line Check Valves Removal/Installation Bear in mind that whatever condition caused failure of one of the check valves could have affected the other
OIL INJECTION SYSTEM 453 OIL From -*-[n oil pump y/ Smaller diameter fitting j Larger diameter fitting cm- OIL To bubbler, carburetor, fuel fiiter or intake fitting valves. It is wise to replace all check valves if any are faulty. Refer to Chapter Three for testing this component. 1. Disconnect both battery cables from the battery, 2. Clean the external surfaces of the oil line check valves and oil lines prior to disconnecting them. Carefully open and slide both oil line clamps away from the fittings on the valve. 3. Using locking pliers, carefully pinch the oil line closed at a point approximately 4.0 mm (1 in.) from both check valve fittings. Slip the oil lines from the oil line check valve fittings. Note which oil lines connect to the smaller and larger diameter fittings (Figure 15). 4. Inspect the check valve for the presence of debris. Clean and inspect the oil reservoir and all oil lines if debris is present. Inspect the oil line clamps for corrosion, damage or lost spring tension. 5. Note the smaller diameter fitting (Figure 15) and slide the oil line (connected to the oil pump) onto the smaller diameter fitting of the oil line check valve. Note the larger diameter fitting (Figure 15) and slide the larger diameter oil line onto the valve. Release the locking pliers and position the clamps over the lines and fittings. 6. Place the oil filter in its normal position. Ensure the oil lines will not contact any moving components on the engine. 7. Clean the terminals and connect the cables to the battery. Refer to Bleeding the System to bleed all air from the oil lines before returning the engine to service. Oil Lines and Hoses Removal/Installation Work in a clean environment. A small amount of debris can cause the oil injection system to fail. Note the size and location of all plastic tie clamps. Mark all hose routing and connections prior to removal to ensure correct routing during assembly. Only remove the hoses necessary to replace the faulty component. This will reduce oil spillage, the chance of incorrect connections and the time needed to bleed air from the system. Inspect all hoses and oil lines for cuts or abrasions and replace them if defects are noted. Replace any hose or oil lines that feel hard or brittle. Replace hoses or oil lines that feel too soft of spongy. Clear oil lines are used in several locations within the system. Inspect these hoses and replace any that are dark or cloudy in appearance. To reduce the time required to bleed air from the system, prefill long oil lines and hoses with Suzuki CCI outboard oil prior to installing them. A pump type oil can works well when filling hoses and oil lines. OIL FLOW SENSOR REMOVAL, INSPECTION AND INSTALLATION This section provides removal, inspection and installation instructions for the oil flow sensor (Figure 16). Clean and inspect the filter (inside the sensor) anytime the sensor is removed or at the intervals specified in Chapter Four. Refer to Figures 3 and 4 as necessary during this procedure. 1. Disconnect both battery cables from the battery. 2. Trace the oil lines from the oil reservoir fitting on the bottom of the reservoir to the oil flow sensor. Disconnect the wire harness from the oil flow sensor. Disconnect the sensor from the main engine wire harness. 3. Clean the oil lines and oil flow sensor prior to disconnecting the oil lines. Using a feu-tip marker, mark the oil lines at the inlet and outlet side of the sensor. Carefully open and slide both oil line clamps away from the fittings on the sensor. 13
454 CHAPTER THIRTEEN Obstruction O-ring O-rinc From oil tank 0-rlng To oii pump ON-^OFF Diaphragm 4. Using locking pliers, carefully pinch the oil line closed at a point approximately 4.0 mm (1 in.) from both sensor oil line fittings. Slip the oil lines from the fittings and lift the sensor from the engine. 5. Mark the mating surfaces of the cover and the sensor body. Remove the screw (Figure 17) and lift the cover from the sensor. Remove and discard the 0-rings from the top cover. Carefully lift the filter and spring (Figure 17) from the sensor body. 6. Using a suitable solvent, clean the filter (Figure 18) and the sensor body. Dry all components with compressed air. Avoid aiming the air directly at the components. 7. Clean and inspect the oil reservoir and oil lines if debris is present in the filter. Carefully install the spring and filter into the sensor body. 8. Install new 0-rings onto the sensor cover and position it onto the sensor body. Align the marks made prior to disassembly. Securely tighten the screws that retain the cover to the body. 9. Noting that the inlet oil line fitting is integrated into the cover, slide the inlet and outlet oil lines onto the oil flow sensor fittings. Slide the clamps fully onto the fittings and release the locking pliers from the oil lines. 10. Position the oil flow sensor into its nonnal position below the level of the oil reservoir. Ensure that all hoses and oil lines will not contact any moving components. 11. Clean the terminals and connect the cables to the battery. Refer to Bleeding the System to bleed all air from the oil lines before retuming the engine to service. BLEEDING THE SYSTEM Bleed air from the system if air is noted in the clear oil lines and if any components, lines or fittings have been disturbed. 1. Place the engine in the upright position. Place a container under the oil pump. Ensure adequate oil is present in the oil reservoir.