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Suzuki DT225: Removing fuel injectors

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  • Suzuki DT225: Removing fuel injectors

    I have a '94 Suzuki DT225, and I need to remove the fuel injectors to have them cleaned. I've never done this before, and can use some advice on how to remove & reinstall them. I know the Delivery Pipe (fuel manifold, shown as #7) has to be removed, first. Is there anything special that needs to be done to pull the injectors? I've included the schematic, below.

    Thanks for your help!
    -Mike
    Attached Files

  • #2
    You need to move the oil tank out of the way...don't undoo the oil lines or you will have to purge/prime the oil system. just push it out and back and hold with a bungee cord...remove the 4 bolts that hold the rail to the engine, 2 or 3 are easy one is slightly difficult due to position/clearance...a ratcheting dogbone makes it easier. I think there is a grounding strap also. Gently pull the rail back towards you. The injectors will come out with the rail...it is a very loose fit at the injector tip into the block...the part into the rail is just a big o-ring. The injector connector is a little awkward because the release clip is small and your fingers will be covered in oily/slippery fuel.. Mark the injector connections for position..they don't have too much wiggle room but better safe than sorry.less than 2 hours easy if your medium handy

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    • #3
      Originally posted by seaox230c View Post
      You need to move the oil tank out of the way...don't undoo the oil lines or you will have to purge/prime the oil system. just push it out and back and hold with a bungee cord...remove the 4 bolts that hold the rail to the engine, 2 or 3 are easy one is slightly difficult due to position/clearance...a ratcheting dogbone makes it easier. I think there is a grounding strap also. Gently pull the rail back towards you. The injectors will come out with the rail...it is a very loose fit at the injector tip into the block...the part into the rail is just a big o-ring. The injector connector is a little awkward because the release clip is small and your fingers will be covered in oily/slippery fuel.. Mark the injector connections for position..they don't have too much wiggle room but better safe than sorry.less than 2 hours easy if your medium handy
      Excellent. Thanks.
      Is it obvious what the injector connector looks-like, and will it be intuitive for me to know which way to move it, once the injectors are exposed?

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      • #4
        Yes...more info...when you get the injector out...keep the spacer that goes over the tip where it mounts into the block...When i sent my injectors in I got all new o-rings but the spacer they gave me wad thicker than stock so I reused my original ones but used their replacement o-rings...They tested them before and after and gave me a readout and replaced the filter screen in the inlet of each injector ...i think it cost me 125...in NY so anywhere else its probably cheaper

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