Evaporative Emission System Tester Setup: Assembly

WARNING: Failure to use the specified gas and to take proper precautions may result in death, serious injury or fire.

Be sure to use only nitrogen gas for this inspection. If any other gas is used, the gasoline in the fuel system may ignite and explode.
Handle compressed nitrogen correctly. Contact your local supplier of compressed gases for the procedures to follow and precautions to observe to correctly handle compressed nitrogen.

CAUTION: Failure to take proper precautions when using compressed gas can cause damage to the cylinder valve, pressure regulator, or tester.

Do not remove the valve cover cap until the cylinder is securely attached to the EVAP cart. If the valve cover cap is removed and the tank falls down, the valve may be damaged.
Do not try to detach the black vinyl cover from the pressure regulator and turn the valve inside. If the original setting of the pressure regulator on the tester is disturbed, the tester will not operate correctly unless it is re-calibrated. If it is absolutely necessary to adjust the pressure regulator, refer to OUTPUT PRESSURE CALIBRATION .

NOTE:

Nitrogen gas tank is not attached to this tester. Obtain the nitrogen gas tank from your local supplier of compressed gas. We recommend the tank with 125 cubic feet capacity for the nitrogen gas tank.
If the nitrogen gas tank pressure is lower than 100 psi, it is required to ask your local supplier of compressed gas to replenish the nitrogen gas to the tank.

Unpack the tester from its shipping carton.
Bring the tester (1) up through the EVAP cart's handlebar, and place it on the two tabs (2) located on the bracket on the EVAP cart.
NOTE: Rotate the tester slightly to one side so that the remote cable clears the handlebar.

Fig 1: Identifying Tester And Tabs
Courtesy of SUZUKI OF AMERICA CORP.
Install handlebar brackets (1) on the right and left side and the remote switch cord wrap (2) to the tester (3) by using the hexagon screws (4).

Fig 2: Identifying Handlebar Brackets On Right And Left Side And Remote Switch Cord Wrap To Tester
Courtesy of SUZUKI OF AMERICA CORP.
Attach the nitrogen tank (3) securely to the EVAP cart (1) by using the tank fixing bands (2) that should be attached to the EVAP cart (1).

Fig 3: Attaching Nitrogen Tank To EVAP Cart
Courtesy of SUZUKI OF AMERICA CORP.
Remove valve cover cap from the nitrogen tank.
Install the pressure regulator (1) to the nitrogen tank.
Tighten the nut (2) with wrench.
NOTE: No sealant is required.

Fig 4: Identifying Pressure Regulator And Nut
Courtesy of SUZUKI OF AMERICA CORP.
Install the 90° adapter (1) onto the nitrogen inlet (2) on the left side of the tester.

Fig 5: Identifying Adapter Onto Nitrogen Inlet On Left Side Of Tester
Courtesy of SUZUKI OF AMERICA CORP.
Connect regulator to tester hose (1) to pressure regulator (2) and 90° adapter (3).
NOTE: Connection should be finger-tightened.

Fig 6: Identifying Tester Hose And Pressure Regulator
Courtesy of SUZUKI OF AMERICA CORP.
Fill the tester with two bottles of smoke producing fluid according to the following procedures.
WARNING: There is a risk of personal injury and damage to the tester if smoke-producing fluid not approved by the manufacturer is used in the tester. Use only manufacturer-specified smoke-producing fluid in the tester.
1. Remove the refill plug (1) located on the right side of the tester.
  
  Fig 7: Identifying Refill Plug
  Courtesy of SUZUKI OF AMERICA CORP.
2. Cut the end off the plastic tip on top of each smoke producing fluid bottle.
3. With the tester in an upright position, empty the contents of two smoke producing fluid bottles into the refill port.
  Filling amount of smoke producing fluid
  
  0.95 liters (32/33 US/Imp.oz)
4. Secure the plug back into the refill port.
5. Record your name and the date of the fluid change.
Upon completion of all jobs, calibrate evaporative emissions system tester referring to the following.