1. DL manuals
  2. Suzuki
  3. Motorcycle
  4. 2006 gsxr 600
  5. Service Manual

Suzuki 2006 gsxr 600 Service Manual

Summary of 2006 gsxr 600

  • Page 1

    Gsx-r750 9 9 5 0 0 - 3 7 1 3 0 - 0 1 e.

  • Page 2: Group Index

    Group index general information 1 periodic maintenance 2 engine 3 fi system diagnosis 4 fuel system and throttle body 5 exhaust system 6 cooling and lubrication system 7 chassis 8 electrical system 9 servicing information 10 emission control information 11 wiring diagram 12 foreword this manual cont...

  • Page 3: How To Use This Manual

    How to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. The section titles are listed in the group index. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on ...

  • Page 4

    Symbol listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Apply thread loc...

  • Page 5: Manual

    Abbreviations used in this manual a abdc : after bottom dead center ac : alternating current acl : air cleaner, air cleaner box api : american petroleum institute atdc : after top dead center atm pressure : atmospheric pressure : atmospheric pressure sensor (aps, ap sensor) a/f : air fuel mixture b ...

  • Page 6

    M mal-code : malfunction code (diagnostic code) max : maximum mil : malfunction indicator lamp (led) min : minimum n nox : nitrogen oxides o ohc : over head camshaft ops : oil pressure switch p pcv : positive crankcase ventilation (crankcase breather) r rh : right hand rom : read only memory s sae :...

  • Page 7

    Wire color b : black g : green p :pink bl : blue gr : gray r : red br : brown lbl : light blue w : white dg : dark green lg : light green y : yellow dgr : dark gray o : orange b/bl : black with blue tracer b/br : black with brown tracer b/g : black with green tracer b/lg : black with light green tra...

  • Page 8: General Information

    General information 1-1 1 general information contents warning/caution/note......................................................................... 1- 2 general precautions .......................................................................... 1- 2 suzuki gsx-r750k6 (’06-model)....................

  • Page 9: Warning/caution/note

    1-2 general information warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates...

  • Page 10

    General information 1-3 * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. * when removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * be sure to use s...

  • Page 11: Serial Number Location

    1-4 general information suzuki gsx-r750k6 (’06-model) • difference between illustrations and actual motorcycle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering head pipe. The en...

  • Page 12

    General information 1-5 fuel, oil and engine coolant recommendation fuel (for usa and canada) use only unleaded gasoline of at least 90 pump octane (r/2 + m/2). Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and cor...

  • Page 13

    1-6 general information front fork oil use fork oil ss-05 or an equivalent fork oil. Engine coolant use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. Water for mixing use distilled water only. Water other than distilled water can corrode and clo...

  • Page 14: Break-In Procedures

    General information 1-7 break-in procedures during manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performa...

  • Page 15: Information Labels

    1-8 general information information labels a: attached *1: rear fender (front) *2: chain case gsx-r750 gsx-r750uf 1 noise label a (for e-03, 24, 33) 2 information label a (for e-03, 28, 33) 3 vacuum hose routing label a (for e-33) 4 fuel caution label a (for e-02, 24) 5 fuel information label a a 6 ...

  • Page 16: Specifications

    General information 1-9 specifications dimensions and dry mass overall length .......................................................................... 2 040 mm (80.3 in) overall width ........................................................................... 715 mm (28.1 in) overall height .........

  • Page 17

    1-10 general information chassis front suspension .................................................................... Inverted telescopic, coil spring, oil damped rear suspension ..................................................................... Link type, coil spring, oil damped front fork stro...

  • Page 18: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance contents periodic maintenance schedule .................................................... 2- 2 periodic maintenance chart..................................................... 2- 2 lubrication points ......................................................

  • Page 19

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your conve...

  • Page 20

    Periodic maintenance 2-3 lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Note: * before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or g...

  • Page 21: Maintenance And Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner • remove the front seat. ( 8-7) • lift and support the fuel tank. ( 5-3) • remove the air cleaner element by removing the ...

  • Page 22

    Periodic maintenance 2-5 spark plug spark plug and ignition coil/plug cap removal • remove the front seat. ( 8-7) • lift and support the fuel tank. ( 5-3) • remove the air cleaner box. ( 5-14) • disconnect all lead wire couplers from ignition coil/plug caps. • remove the ignition coils/plug caps....

  • Page 23

    2-6 periodic maintenance spark plug gap • measure the spark plug gap with a thickness gauge. • adjust the spark plug gap if necessary.  spark plug gap: standard: 0.7 – 0.8 mm (0.028 – 0.031 in)  09900-20803: thickness gauge electrode’s condition • check the condition of the electrode. • if it is e...

  • Page 24

    Periodic maintenance 2-7 valve clearance • remove the right under cowling. ( 8-5) • lift and support the fuel tank. ( 5-3) • remove the air cleaner box. ( 5-14) • disconnect the cmp sensor coupler 1. • remove the pair control solenoid valve 2. • remove the spark plugs. ( 2-5) • loosen the thrott...

  • Page 25

    2-8 periodic maintenance • turn the crankshaft to bring the line a on the ckp sensor rotor to the rib b behind the clutch cover and also to bring the notches a on the left ends of both camshafts (ex. And in.) to the positions as shown. • in this condition, read the valve clearance at the valves b (i...

  • Page 26: 170

    Periodic maintenance 2-9 valve clearance adjustment the clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • remove the intake or exhaust camshafts. ( 3-14) • remove the tappet and shim by fingers or magnetic hand. • check the figures printed on the shim. Thes...

  • Page 27

    2-10 periodic maintenance measured v al ve clearance (mm) suffix no . 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 present shim size (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 0.00 – 0.04 1.20 1...

  • Page 28

    Periodic maintenance 2-11 ho w t o use this char t : i. Measure v alv e clear ance . “engine is cold” ii. Measure present shim siz e . Iii. Match clear ance in v er tical column with present shim siz e in hor iz ontal column. Example v alv e clear ance is 0.33 mm present shim siz e 1.70 mm shim siz ...

  • Page 29

    2-12 periodic maintenance engine oil and oil filter engine oil replacement • remove the under cowlings. ( 8-5) • keep the motorcycle upright. • place an oil pan below the engine, and drain oil by removing the oil drain plug 1 and filler cap 2. • tighten the drain plug 1 to the specified torque, and...

  • Page 30

    Periodic maintenance 2-13 oil filter replacement • drain the engine oil as described in the engine oil replace- ment procedure. • remove the oil filter 1 with the special tool.  09915-40610: oil filter wrench • apply engine oil lightly to the gasket of the new oil filter before installation. • inst...

  • Page 31

    2-14 periodic maintenance • remove the under cowlings. ( 8-5) • check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. Fuel line • inspect the fuel feed hose 1 for damage and fuel leakage. If any defects are found, the fuel feed hose must be repl...

  • Page 32

    Periodic maintenance 2-15 throttle valve synchronization • inspect the throttle valve synchronization periodically. ( 5-26) evaporative emission control system (e-33 only) • inspect the evaporative emission control system periodically. Pair (air supply) system • inspect the pair (air supply) system...

  • Page 33

    2-16 periodic maintenance clutch • lift and support the fuel tank with its prop stay. ( 5-3) • turn in the adjuster 1 all the way into the clutch lever assem- bly. • loosen the lock-nut 2 and turn the clutch cable adjuster 3 to obtain proper cable play. • remove the clutch release adjuster cap. • l...

  • Page 34

    Periodic maintenance 2-17 cooling system engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. A full line b lower line • if the level is below the lower line, remove the right under cowling (...

  • Page 35

    2-18 periodic maintenance air bleeding the cooling circuit • add engine coolant up to the radiator inlet. • support the motorcycle upright. • slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • add engine coolant up to the radiator inlet. • start up the en...

  • Page 36

    Periodic maintenance 2-19 radiator hoses • remove the under cowlings. ( 8-5) • lift and support the fuel tank. ( 5-3) • check the radiator hoses for crack, damage or engine coolant leakage. • if any defect is found, replace the radiator hose with new one..

  • Page 37

    2-20 periodic maintenance drive chain visually check the drive chain for the possible defects listed below. (support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to neutral.) * loose pins * excessive wear * damaged rollers * improper c...

  • Page 38

    Periodic maintenance 2-21 • count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.  drive chain 20-pitch length: service limit: 319.4 mm (12.57 in) adjusting • loosen or tighten both chain a...

  • Page 39

    2-22 periodic maintenance cleaning and lubricating • clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. • after washing and drying the chain, oil it with a heavyweight motor oil. Do not use trichloroethylene, gasoline or any similar solven...

  • Page 40

    Periodic maintenance 2-23 brake brake fluid level check • keep the motorcycle upright and place the handlebars straight. • check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs. • when the level is below the lower limit line, replenish with brake ...

  • Page 41

    2-24 periodic maintenance brake pads front brake the extent of brake pad wear can be checked by observing the grooved limit line a on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. ( 8-65) rear brake the extent of brake pad wear can be checked by observin...

  • Page 42

    Periodic maintenance 2-25 brake light switch • adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. Air bleeding from brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large pr...

  • Page 43

    2-26 periodic maintenance front brake (master cylinder side) • bleed air from the master cylinder in the same manner as front brake (caliper side).  air bleeder valve: 6.0 n·m (0.6 kgf-m, 4.3 ib-ft) note: if air is trapped in the master cylinder, bleed air from the master cylinder first. Rear brake...

  • Page 44

    Periodic maintenance 2-27 tires tire tread condition operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specificatio...

  • Page 45

    2-28 periodic maintenance front fork • inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( 8-18) rear suspension • inspect the rear shock absorbers for oil leakage and check that there is no play in the ...

  • Page 46

    Periodic maintenance 2-29 exhaust pipe bolt and nut • tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque. Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. 1 gasket 2 exhaust pipe connecter item n·m kgf-m l...

  • Page 47

    2-30 periodic maintenance chassis bolts and nuts check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-31 for the loca- tions of the following nuts and bolts on the motorcycle.) tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 mi...

  • Page 48

    Periodic maintenance 2-31.

  • Page 49: Compression Pressure Check

    2-32 periodic maintenance compression pressure check the compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should ...

  • Page 50: Oil Pressure Check

    Periodic maintenance 2-33 oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specification if the oil pressure is lower or higher than the specification, the following causes may be considered. Low oil pr...

  • Page 51: Sds Check

    2-34 periodic maintenance sds check using sds, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be co...

  • Page 52

    Periodic maintenance 2-35 data at 3 000 r/min under no load data at the time of racing 3 000 r/min check the manifold absolute pressure. Xxx mmhg throttle: quick wide open throttle: slowly open secondary throttle valve opens closes in according with the engine r/min..

  • Page 53

    2-36 periodic maintenance data of intake negative pressure during idling (100 °c) data of secondary throttle valve operation at the time of starting check the manifold absolute pressure. Approx. Xxx mmhg closes fully in approx. Xx sec..

  • Page 54: Engine

    Engine 3-1 engine contents 3 engine components removable with engine in place .......... 3- 2 engine removal and installation................................................. 3- 3 engine removal .............................................................................. 3- 3 engine installation ....

  • Page 55

    3-2 engine engine components removable with engine in place the parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. Engine center engine right side engine left side item remova...

  • Page 56

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • remove the under cowlings. ( 8-5) •...

  • Page 57

    3-4 engine radiator • disconnect the by-pass hose 1 and radiator inlet hose 2. • disconnect the oil cooler outlet hose 3. • disconnect the cooling fan coupler 4. • remove the radiator mounting bolts. • remove the radiator 5. Be careful not to bent the radiator fins..

  • Page 58

    Engine 3-5 exhaust pipe and muffler • remove the excv cables along with the bracket 1. • loosen the muffler connecting bolt. • remove the ho2 sensor 2 (for e-02, 19). ( 4-107) • remove the exhaust pipe bolts. • remove the exhaust pipe. • remove the exhaust pipe gaskets. • remove the radiator mounti...

  • Page 59

    3-6 engine • disconnect the following couplers. 3 gp switch lead wire 4 ckp sensor lead wire 5 ground lead wire 6 starter motor lead wire 7 speed sensor lead wire 8 ect sensor • disconnect the ignition coil/plug cap lead wire couplers. • disconnect the cmp sensor lead wire coupler 9 and regula- tor/...

  • Page 60

    Engine 3-7 engine sprocket and gearshift lever • disengage the gearshift lever 1. • remove the engine sprocket cover 2. • remove the clutch push rod 3. • remove the speed sensor rotor 4. • remove the engine sprocket nut 5 and the washer 6. • remove the cotter pin. (for e-03, 28, 33) • loosen the rea...

  • Page 61

    3-8 engine • remove the engine sprocket 0. Engine mounting • support the engine using an engine jack. • remove the engine mounting bolt a. • loosen the engine mounting pinch bolt 1. • remove the engine mounting bolt b..

  • Page 62

    Engine 3-9 • remove the engine mounting nut 2. • remove the engine mounting thrust adjuster lock-nut 3 with the special tool. • loosen the engine mounting thrust adjuster 4 fully.  09940-14980: engine mounting thrust adjuster socket wrench • remove the engine mounting nut 5. • loosen the engine mou...

  • Page 63

    3-10 engine engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: note: be careful not to damage the frame and engine when installing the engine. • before installing the engine, install the spacers 1. • gradually raise the rear side of ...

  • Page 64

    Engine 3-11 a lh b rh length item n·m kgf-m lb-ft item mm in ab 55 5.5 40.0 bolt a 45 1.77 1 23 2.3 16.5 b 55 2.17 34 23 2.3 16.5 c 215 8.46 56 45 4.5 32.5 d 205 8.07 78 75 7.5 54.0 spacer 2 30.5 1.20 adjuster 34 40 1.57.

  • Page 65

    3-12 engine • install the engine sprocket and the washer. • apply a small quantity of thread lock to the driveshaft thread portion.  99000-32050: thread lock “1342” • tighten the engine sprocket nut to the specified torque.  engine sprocket nut: 115 n·m (11.5 kgf-m, 83.0 lb-ft) • install the speed...

  • Page 66

    Engine 3-13 • tighten the muffler mounting bolts, exhaust pipe bolts and muffler connecting bolt to the specified torque.  muffler mounting bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) muffler connecting bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) exhaust pipe bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • install the ho...

  • Page 67: Engine Disassembly

    3-14 engine engine disassembly • remove the spark plugs. ( 2-5) starter motor • remove the starter motor 1. Cylinder head cover • remove the cylinder head cover 1 and its gaskets. • remove the pair reed valves 2 with their gaskets. Camshaft • remove the valve timing inspection cap 1. Identify the p...

  • Page 68

    Engine 3-15 • turn the crankshaft to bring the line a on the ckp sensor rotor to the rib b behind the clutch cover and also to bring the cams to the position as shown. • remove the cam chain tension adjuster 2. • remove the cam chain guide no. 2 3. • remove the camshaft journal holders 4. • remove t...

  • Page 69

    3-16 engine cylinder head • remove the thermostat cover 1. • remove the thermostat 2 and thermostat conector 3. Thermostat inspection ( 7-9) • remove the ect sensor 4. Ect sensor inspection ( 7-7) • remove the cylinder head bolts (m6) 5. • remove the o-rings 6. • remove the cylinder head bolts and...

  • Page 70

    Engine 3-17 • hold the clutch housing with the special tool.  09920-53740: clutch sleeve hub holder • remove the clutch springs. Note: loosen the clutch spring set bolts little by little and diagonally. • remove the pressure plate 3. • remove the clutch drive plates 4 and driven plates 5. • remove ...

  • Page 71

    3-18 engine • hold the clutch sleeve hub with the special tool.  09920-53740: clutch sleeve hub holder • remove the clutch sleeve hub nut. • remove the washers c, d and e from the clutch sleeve hub. • remove the wave spring washers f and clutch lifter driven cam g. • remove the clutch lifter drive ...

  • Page 72

    Engine 3-19 oil pump drive sprocket • remove the spacer 1. • remove the oil pump drive sprocket 2 and chain 3. • remove the thrust washer 4. Gearshift system • with the snap ring 1 and washer removed, remove the gear- shift shaft assembly 2. • remove the gearshift cam plate bolt 3 and gearshift cam ...

  • Page 73

    3-20 engine • remove the shaft 4, bearing 5 and thrust washer 6. • remove the generator cover. • remove the dowel pins and gasket. • remove the starter idle gear no. 2 7 and shaft 8. Cam chain/cam chain tensioner/cam chain guide • while holding the generator rotor with the special tool, remove the c...

  • Page 74

    Engine 3-21 generator rotor and starter driven gear • hold the generator rotor with the special tool.  09930-44520: rotor holder • remove the generator rotor bolt. • install a bolt a of suitable size to the left end of crankshaft. Suitable bolt a [m12, length: 28 – 38 mm (1.1 – 1.5 in)] • remove th...

  • Page 75

    3-22 engine gear position switch • remove the gear position switch 1. Crankcase breather (pcv) cover • remove the crankcase breather cover 1. • remove the gasket 2. Oil pressure switch • remove the oil pressure switch 1. Oil filter • remove the oil filter with the special tool.  09915-40610: oil fi...

  • Page 76

    Engine 3-23 oil cooler • remove the oil cooler 1. Oil pan • remove the plate 1 and oil pan. • remove the gasket. Oil pressure regulator • remove the oil pressure regulator 1. Oil strainer • remove the oil strainer 2. Oil pump • remove the oil pump 1. • remove the dowel pins and o-ring 2. Lower crank...

  • Page 77

    3-24 engine • remove the upper crankcase bolts. • remove the lower crankcase bolts (m8). • remove the crankshaft journal bolts (m9). • remove the lower crankcase assembly. • remove the dowel pins and o-ring 2. Balancer shaft • remove the balancer shaft 1 and oil seal 2. Countershaft • remove the dow...

  • Page 78

    Engine 3-25 • remove the c-ring 6 and bearing pin 7. Crankshaft • loosen the conrod bearing cap bolts by using a 10 mm, 12-point socket wrench, and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap. • remove the crankshaft and thrust bearings 1. Piston and conrod • pu...

  • Page 79

    3-26 engine • separate the piston and conrod by driving out the piston pin. Note: scribe the cylinder number on the piston head..

  • Page 80: And Service

    Engine 3-27 engine components inspection and service cylinder head cover • clean and check the gasket grooves a and pair reed valve gasket mating surfaces b of cylinder head cover. • if it is damaged, replace the cylinder head cover with a new one. Cmp sensor removal • remove the cmp sensor 1 from t...

  • Page 81

    3-28 engine inspection • inspect the reed valve for the carbon deposit. • if the carbon deposit is found in the reed valve, replace the pair reed valve with a new one. Crankcase breather reed valve removal • remove the crankcase breather reed valve 1 from the crank- case breather cover. Inspection •...

  • Page 82

    Engine 3-29 camshaft camshaft identification the exhaust camshaft can be distinguished from that of the intake by the embossed letters “ex” (for exhaust) as against let- ters “in” (for intake). Cam wear • check the camshaft for wear or damage. • measure the cam height h with a micrometer.  cam heig...

  • Page 83

    3-30 engine note: do not rotate the camshaft with the plastigauge in place. • remove the camshaft holders, and read the width of the com- pressed plastigauge with envelope scale. • this measurement should be taken at the widest part. • if the camshaft journal oil clearance measured exceeds the limit...

  • Page 84

    Engine 3-31 cam chain tension adjuster inspection • holding the cam chain tension adjuster as shown, compress the plunger by turning the adjuster body until the outer circlip a fits the groove b. Note: * wipe off engine oil from the plunger head and thumb so that they may not to be slippery. * if it...

  • Page 85

    3-32 engine cam chain guide inspection • check the contacting surfaces of the cam chain guide no. 1 and no. 2. • if they are worn or damaged, replace them with the new ones. Cylinder head and valve valve and valve spring disassembly • remove the tappet 1 and shim 2 by fingers or magnetic hand. • ins...

  • Page 86

    Engine 3-33 cylinder head distortion • decarbonize the combustion chambers. • check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • if the largest reading at any position of the straightedge e...

  • Page 87

    3-34 engine valve stem deflection • lift the valve about 10 mm from the valve seat. • measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • if the deflection measured exceeds the limit, then determine whether the valve or the gu...

  • Page 88

    Engine 3-35 • cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 °c – 150 °c (212 °f – 302 °f) with a hot plate. • apply engine oil to the valve guide hole. • drive the valve guide into the hole using the valve guide installer 1 and attachment 2.  09916...

  • Page 89

    3-36 engine • if the seat width w measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter.  valve seat width w: standard: 0.9 – 1.1 mm (0.035 – 0.043 in) if the valve seat is out of specification, re-cut the seat. Valve seat servicing • the valve seat...

  • Page 90

    Engine 3-37 valve spring the force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • check the valve spring for proper strength by measuring its free length and also ...

  • Page 91

    3-38 engine • put on the valve spring retainer 2, and using the special tool 3, press down the spring, fit the cotter halves 4 to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.  09916-14510: valve lifter 09916-14530: valve lifter attachment 09...

  • Page 92

    Engine 3-39 • apply suzuki super grease “a” to the o-rings.  99000-25010: suzuki super grease “a” (or equivalent grease) • install the intake pipes. • apply thread lock to the bolts.  99000-32050: thread lock “1342” clutch clutch drive plate inspection note: * wipe off engine oil from the clutch d...

  • Page 93

    3-40 engine clutch spring inspection • measure the free length of each coil spring with a vernier cali- pers, and compare the length with the specified limit. • replace all the springs if any spring is not within the limit.  clutch spring free length: service limit: 53.2 mm (2.094 in)  09900-20102...

  • Page 94

    Engine 3-41 clutch lifter pin adjustment note: when adjusting the clutch lifter, it is not necessary to install the clutch onto the countershaft. • assemble the following parts into the primary driven gear assembly. ( 3-90 to -93) * clutch sleeve hub * spring washer seat, spring washer * clutch dri...

  • Page 95

    3-42 engine wave spring washer inspection • measure the free height h of each wave spring washer with a vernier calipers. • if each wave spring washer height h is not within the speci- fied limit, replace it with a new one.  09900-20102: vernier calipers  wave spring washer height h service limit:...

  • Page 96

    Engine 3-43 disassembly • with holding the rotor with the special tool remove the starter clutch bolts.  09930-44520: rotor holder • remove the one way clutch 1 and guide 2 from the rotor. Reassembly • when fitting the one way clutch 1 to the guide 2, position flange side a of one way clutch to the...

  • Page 97

    3-44 engine generator inspection ( 9-10) reassembly • when installing the generator stator set bolts, tighten them to the specified torque.  generator stator set bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) note: be sure to install the grommet 1 to the generator cover. Water pump 7-11 gearshift system gea...

  • Page 98

    Engine 3-45 • install the following parts to the gearshift shaft/gearshift arm as shown in the illustration. 1 washer 5 plate return spring 2 snap ring 6 washer 3 gearshift shaft return spring 7 screw 4 gearshift cam drive plate oil pressure regulator • inspect the operation of the oil pressure regu...

  • Page 99

    3-46 engine transmission driveshaft removal ( 3-52) disassembly disassemble the countershaft and driveshaft. Pay attention to the following points: • remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2. • slide the 6th 3 and 2nd 4 drive gears toward ...

  • Page 100

    Engine 3-47 reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: note: * rotate the bearings by hand to inspect for smooth rotation. Replace the bearings if there is anything unusual. * before installing the gears, apply engi...

  • Page 101

    3-48 engine transmission parts location 1 countershaft 2 driveshaft.

  • Page 102

    Engine 3-49 cylinder crankcase servicing ( 3-52) cylinder distortion • check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • if the largest reading at any position of the straightedge exceeds...

  • Page 103

    3-50 engine piston and piston ring piston diameter • using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) a from the piston skirt end. • if the measurement is less than the limit, replace the piston.  piston diameter: service limit: 69.88 mm (2.7512 in) at 15 mm (0.6 in) from t...

  • Page 104

    Engine 3-51 piston ring-to-groove clearance • measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • if any of the clearances exceeds the limit, replace both the piston and piston rings.  09900-20803: thickness gauge 09900-20205: micrometer (0 – 25 mm)  piston rin...

  • Page 105

    3-52 engine crankcase driveshaft and gearshift cam removal • remove the screws. • remove the gearshift fork shaft 1, gearshift cam 2 and gearshift forks 3. • remove the spacer 4. • remove the driveshaft left bearing dust seal 5. • remove the driveshaft left bearing case bolts. • by using suitable si...

  • Page 106

    Engine 3-53 • remove the driveshaft assembly 8. Gearshift fork-to-groove clearance • using a thickness gauge, check the gearshift fork clearance in the groove of its gear. • the clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action.  shi...

  • Page 107

    3-54 engine bearing and dust seal inspection • inspect the gearshift cam bearing 1 for abnormal noise and smooth rotation. • replace the bearings if there is anything unusual. • inspect the gearshift cam bearing 2, gearshift shaft bearings 3 (lh) and 4 (rh) for abnormal noise and smooth rotation whi...

  • Page 108

    Engine 3-55 • inspect the driveshaft left bearing dust seal for wear and dam- age. • replace the dust seal if there is anything unusual. Removal • remove the gearshift cam bearing with the special tools.  09923-74511: bearing remover 09930-30104: sliding shaft • remove the oil seal. (lh only) • rem...

  • Page 109

    3-56 engine • remove the driveshaft left bearing dust seal from the retainer using the special tool.  09913-50121: oil seal remover installation • install the bearings with the special tool.  09913-70210: bearing installer set (132) (2, 3 20) note: the stamped mark side of the gearshift shaft be...

  • Page 110

    Engine 3-57 • install the driveshaft left bearing dust seal with the special tool.  09913-70210: bearing installer set (62) • put the driveshaft assembly 1 into the lower crankcase. • install the driveshaft right bearing assembly 2. • apply thread lock to the bolts and tighten them to the specifie...

  • Page 111

    3-58 engine • apply thread lock to the bolts and tighten them to the specified torque.  99000-32050: thread lock “1342”  driveshaft left bearing case bolt: 12 n·m (1.2 kgf-m, 8.7 lb-ft) • apply suzuki super grease “a” to the dust seal lip and o-ring. • apply thread lock to the bolts and tighten th...

  • Page 112

    Engine 3-59 • remove the oil jet 2 (for transmission) from the lower crank- case. • remove the oil jet 3 (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • check the oil jets for clogging. • if they are clogged, clean their oil passage with a proper wire and compresse...

  • Page 113

    3-60 engine • install the oil jet (for transmission). • apply engine oil to the o-ring. • install the oil jet (for cam chain tension adjuster). Plug removal • remove the oil gallery plugs 1 and 2. • remove the oil gallery plugs 3 and 4. • remove the water jacket plugs 5 and 6. Use new o-ring to prev...

  • Page 114

    Engine 3-61 installation • apply thread lock to the oil gallery plug 2.  99000-32050: thread lock “1342” note: * it is not required to apply thread lock when installing the other removed oil gallery plugs. * after tightening the plug 2, make sure that the plug end is flush with the cover mating sur...

  • Page 115

    3-62 engine balancer shaft disassembly • remove the balancer gear along with the dampers from the balancer shaft. Inspection • inspect the damper for wear and damage, replace it if any defects are found. Reassembly • apply molybdenum oil solution to each part.  molybdenum oil solution • set the dam...

  • Page 116

    Engine 3-63 • remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge.  balancer shaft journal oil clearance: standard: 0.028 – 0.052 mm (0.0011 – 0.0020 in) servi...

  • Page 117

    3-64 engine installation • when fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part a first and press the other end. Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell..

  • Page 118

    Engine 3-65 crankshaft and conrod crankshaft runout • support the crankshaft with v-blocks as shown, with the two end journals resting on the blocks. • set up the dial gauge, as shown. • rotate the crankshaft slowly to read the runout. • replace the crankshaft if the runout is greater than the limit...

  • Page 119

    3-66 engine conrod-big end bearing inspection • inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. Conrod-big end bearing selection • place the plastigauge axially along the crank pin, avoiding the oil hole, as shown. ...

  • Page 120

    Engine 3-67 • check the corresponding conrod i.D. Code number (“1” or “2”) a. • check the corresponding crank pin o.D. Code number (“1”, “2” or “3”) b.  bearing selection table  conrod i.D. Crank pin o.D. B code 1 2 3 conrod i.D a 1 green black brown 2 black brown yellow code i.D. Specification 1 ...

  • Page 121

    3-68 engine  crank pin o.D.  09900-20202: micrometer (25 – 50 mm)  bearing thickness code o.D. Specification 1 32.992 – 33.000 mm (1.2989 – 1.2992 in) 2 32.984 – 32.992 mm (1.2986 – 1.2989 in) 3 32.976 – 32.984 mm (1.2983 – 1.2986 in) color c (part no.) thickness yellow (12164-30g00-0d0) 1.492 – ...

  • Page 122

    Engine 3-69 crankshaft journal bearing inspection • inspect each bearing of upper and lower crankcases for any damage. Selection • place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown.  09900-22301: plastigauge • mate the lower crankcase with the upper crankca...

  • Page 123

    3-70 engine • check the corresponding crankcase journal i.D. Code number a, “a”, “b” or “c” which is stamped on the rear of upper crankcase. • check the corresponding crankshaft journal o.D. Code num- ber b, “a”, “b” or “c” which is stamped on the crankshaft.  bearing selection table  crankcase i....

  • Page 124

    Engine 3-71  crankshaft journal o.D. Specification  09900-20202: micrometer (25 – 50 mm)  bearing thickness specification note: upper and lower crankshaft journal bearings are the same. Installation • when fitting the crankshaft journal bearings to the upper and middle crankcases, be sure to fix ...

  • Page 125

    3-72 engine crankshaft thrust bearing • with the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. L: left-side thrust bearing r: right-side thrust bearing note: pull the cra...

  • Page 126

    Engine 3-73  thrust bearing selection table • after selecting a left-side thrust bearing, insert it and again perform the thrust clearance measurement to make sure it falls within the standard range. A color code note: right-side thrust bearing has the same specification as the green (12228-17e00-0...

  • Page 127: Engine Reassembly

    3-74 engine engine reassembly • reassemble the engine in the reverse order of disassembly. • the following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. • be sure to install the following item...

  • Page 128

    Engine 3-75 • 1st ring 4 and 2nd ring 3 have letters “ir” and “r” marked on one side. Be sure to bring the marked side upward when fitting them to the piston. • position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located. C 2nd rin...

  • Page 129

    3-76 engine • install the pistons and conrods into the cylinders from upside. Note: when installing the pistons, the indent c of each piston head must be brought to the exhaust side. • check that i.D. Code d on each conrod faces intake side. • apply a molybdenum oil solution to each crank pin bearin...

  • Page 130

    Engine 3-77 • set the crankshaft to the conrods and upper crankcase. • apply engine oil to the crank pin and bearing surface. • when fitting the conrod cap, make sure that i.D. Code a on each conrod faces intake side. • apply engine oil to the bearing cap bolts. • tighten the conrod bearing cap bolt...

  • Page 131

    3-78 engine • insert the right and left thrust bearings with oil groove b fac- ing the crank web. Note: right thrust bearing has green painting. Balancer shaft • install the thrust washers 1, 2 and oil seal 3. • apply a molybdenum oil solution to each balancer shaft journal and bearing lightly.  mo...

  • Page 132

    Engine 3-79 • turn the bearing to fit the bearing dowel pin in the position a. • install the dowel pin and oil seal 3. • install the gearshift shaft and fork 4, bushing 5 and retainer 6..

  • Page 133

    3-80 engine crankcase • clean the mating surfaces of the crankcases. • install the dowel pins. • install the dowel pins, o-ring 1 and cap 2. • apply suzuki bond to the mating surface of the lower crankcase.  99000-31110: suzuki bond “1215” (or equivalent bond) note: use of suzuki bond is as follows...

  • Page 134

    Engine 3-81 • tighten the crankshaft journal bolts (m9) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure in the following two steps.  crankshaft journal bolt: (m9) initial : 18 n·m (1.8 kgf-m, 13.0 lb-ft) final : 50° • tighten the ...

  • Page 135

    3-82 engine • install the clutch push rod oil seal retainer 1. • apply thread lock to the bolts.  99000-32110: thread lock super “1322” (or equivalent thread lock) oil pump • install new o-ring. • apply suzuki super grease “a” to the o-ring.  99000-25010: suzuki super grease “a” (or equivalent gre...

  • Page 136

    Engine 3-83 oil pan • install new gasket. • install the plate 1 and oil pan. Note: * fit the clamp to the bolt a. * fit new gasket washer to the bolt b. • tighten the oil pan bolts diagonally to the specified torque.  oil pan bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) oil pressure switch • apply suzuki bo...

  • Page 137

    3-84 engine oil filter • install the oil filter with the special tool. ( 2-13)  09915-40610: oil filter wrench  oil filter: 20 n·m (2.0 kgf-m, 14.5 lb-ft) crankcase breather cover • install a new gasket 1. • install the crankcase breather cover 2.  crankcase breather cover bolt: 10 n·m (1.0 kgf-...

  • Page 138

    Engine 3-85 water pump • apply suzuki super grease “a” to the o-ring.  99000-25010: suzuki super grease “a” (or equivalent grease) • install the water pump. Note: set the water pump shaft end a to the oil pump shaft b as shown. • tighten the water pump mounting bolts to the specified torque.  wate...

  • Page 139

    3-86 engine generator rotor and starter driven gear • degrease the tapered portion a of generator rotor and also the crankshaft b. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. • install the generator rotor onto the crankshaft. • install ...

  • Page 140

    Engine 3-87 • while holding the generator rotor with the special tool, tighten the ckp sensor rotor/cam chain drive sprocket bolt.  09930-44520: rotor holder  ckp sensor rotor/cam chain drive sprocket bolt: 54 n·m (5.4 kgf-m, 39.0 lb-ft) starter idle gear • install the starter idle gear no. 2 1 an...

  • Page 141

    3-88 engine • install the starter idle gear no. 1 shaft 5, thrust washer 6, bearing 7, starter idle gear no. 1 8, washer 9, and spring washer 0. • apply suzuki super grease “a” to the o-ring.  99000-25010: suzuki super grease “a” (or equivalent grease) • install the starter idle gear cover and tigh...

  • Page 142

    Engine 3-89 • install the gearshift cam stopper plate 5. Note: align the gearshift cam pin b with the gearshift cam stopper plate hole c. • apply a small quantity of thread lock to the gearshift cam stopper plate bolt and tighten it to the specified torque.  99000-32050: thread lock “1342”  gearsh...

  • Page 143

    3-90 engine • install the oil pump drive sprocket 1 to the countershaft. Note: teeth a on the sprocket must face the clutch side. • pass the chain between the oil pump drive and driven sprock- ets. Clutch • install the primary driven gear assembly 1. Note: * before assembling the clutch, adjust the ...

  • Page 144

    Engine 3-91 • install the clutch sleeve hub assembly onto the countershaft. • install the washer 9 and spring washer 0. Note: * before installing the washer 9, visually inspect the washer surface for wear and damage. If necessary, replace it with a new one. * the conical curve side of spring washer ...

  • Page 145

    3-92 engine • install the clutch push rod c into the countershaft. • install the clutch push piece d, bearing e and thrust washer f to the countershaft. Note: thrust washer f is located between the pressure plate and bearing e. • insert the clutch drive plates and driven plates one by one into the c...

  • Page 146

    Engine 3-93 *1: direction of outside *2: paint drive plate: a no. 2 drive plate .......1 pc. [black paint/i.D. 111 mm (4.4 in)] b no. 1 drive plate .......7 pcs. [purple paint/i.D. 111 mm (4.4 in)] c no. 3 drive plate .......1 pc. [nil/i.D. 118 mm (4.6 in)] note: no.3 drive plate can be distinguishe...

  • Page 147

    3-94 engine clutch cover • apply suzuki bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.  99000-31140: suzuki bond “1207b” • install new gasket 1 and dowel pin. • apply suzuki bond lightly to the ckp sensor gromet.  99000-31140: suzuki bond “...

  • Page 148

    Engine 3-95 • place the cylinder head on the cylinder. Note: when installing the cylinder head, keep the cam chain taut. • tighten the cylinder head bolts (m10) in the following four-step. Step 1: • tighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagona...

  • Page 149

    3-96 engine • apply engine coolant to the o-ring. • install the thermostat conector 3.  thermostat conector bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the thermostat 4. Note: the jiggle valve a of thermostat faces upside. • install the thermostat cover 5.  thermostat cover bolt: 10 n·m (1.0 kgf...

  • Page 150

    Engine 3-97 the camshafts are identified by the embossed letters. • before replacing the camshafts on cylinder head, apply molybdenum oil solution to their journals and cam faces. • apply a molybdenum oil solution to the camshaft jour- nal holders.  molybdenum oil solution note: before installing t...

  • Page 151

    3-98 engine • install the dowel pins. • install o-rings 3 to the camshaft journal holders. • install the camshaft journal holders. Note: * each camshaft journal holder is identified with an embossed letter. “a”: no.1 and no.2 cylinders “b”: no.3 and no.4 cylinders * check that embossed letter on eac...

  • Page 152

    Engine 3-99 • tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque.  camshaft journal holder bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • remove the clamps. Cam chain tension adjuster • holding the cam chain tension adjuster as shown, compress the plunger by ...

  • Page 153

    3-100 engine • fit a new gasket 1. • install the cam chain tension adjuster.  cam chain tension adjuster mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • turn the crankshaft approx. 180° counterclockwise to make the push rod come out from the adjuster against the cam chain, via chain tensioner. Note:...

  • Page 154

    Engine 3-101 10 n·m (1.0 kgf-m, 7.0 lb-ft).

  • Page 155

    3-102 engine • tighten the valve timing inspection cap 2 to the specified torque.  valve timing inspection cap: 11 n·m (1.1 kgf-m, 8.0 lb-ft) cylinder head cover • pour engine oil in each oil pocket in the cylinder head. Note: be sure to check the valve clearance. ( 2-7) • install the pair reed va...

  • Page 156

    Engine 3-103 • tighten the head cover bolts to the specified torque.  head cover bolt: 14 n·m (1.4 kgf-m, 10.0 lb-ft) starter motor • apply suzuki super grease “a” to the o-ring.  99000-25010: suzuki super grease “a” (or equivalent grease) • install the starter motor 1.  starter motor mounting bo...

  • Page 157: Fi System Diagnosis

    Fi system diagnosis 4-1 4 contents fi system diagnosis precautions in servicing ................................................................... 4- 3 electrical parts ............................................................................ 4- 3 fuse...............................................

  • Page 158: Fi System Diagnosis

    4-2 fi system diagnosis contents fi system diagnosis “c31” (p0705) gp switch circuit malfunction........................ 4-75 “c32” (p0201), “c33” (p0202), “c34” (p0203) or “c35” (p0204) primary fuel injector circuit malfunction ....................... 4-77 “c36” (p1764), “c37” (p1765), “c38” (p1766...

  • Page 159: Precautions In Servicing

    Fi system diagnosis 4-3 precautions in servicing when handling the component parts or servicing the fi system, observe the following points for the safety of the system. Electrical parts connector/coupler • when connecting a connector, be sure to push it in until a click is felt. • with a lock type ...

  • Page 160

    4-4 fi system diagnosis • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female...

  • Page 161

    Fi system diagnosis 4-5 • when disconnecting and connecting the ecm, make sure to turn off the ignition switch 1, or electronic parts may get damaged. • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi system instantly when r...

  • Page 162

    4-6 fi system diagnosis electrical circuit inspection procedure while there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check possible causes for the open circuits are as...

  • Page 163

    Fi system diagnosis 4-7 continuity check • measure resistance across coupler b (between a and c in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals a and c. 1 ecm • disconnect the coupler b and measure resistance between couplers a and b. If ...

  • Page 164

    4-8 fi system diagnosis short circuit check (wire harness to ground) • disconnect the negative cable from the battery. • disconnect the connectors/couplers at both ends of the circuit to be checked. Note: if the circuit to be checked branches to other parts as shown, disconnect all connectors/couple...

  • Page 165

    Fi system diagnosis 4-9 using the multi-circuit tester • use the suzuki multi-circuit tester set (09900-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Using the tester • incorrectly connecting the + and - probes may cause the inside of t...

  • Page 166

    4-10 fi system diagnosis fi system technical features injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. Thes...

  • Page 167

    Fi system diagnosis 4-11 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description atmospheric pressure sensor signal when atmospheric pressure is low,...

  • Page 168

    4-12 fi system diagnosis fi system parts location a throttle position sensor (tps) b secondary throttle position sensor (stps) c secondary throttle valve actuator (stva) d intake air pressure sensor (iaps) e exhaust control valve actuator (excva) f ho2 sensor (for e-02, 19) g crankshaft position sen...

  • Page 169

    Fi system diagnosis 4-13 j cooling fan relay k cooling fan l intake air temperature sensor (iats) m pair control solenoid valve n camshaft position sensor (cmps) o ignition coil (ig coil) p secondary fuel injector q primary fuel injector r engine coolant temperature sensor (ects) s speed sensor t at...

  • Page 170

    4-14 fi system diagnosis fi system wiring diagram 10 a 10 a 30 a 15 a speedometer camshaft position sensor (cmps) cr ankshaft position sensor (ckps) throttle position sensor (tps) intak e air pressure sensor (iaps) atmospher ic pressure sensor (aps) engine coolant temper ature sensor (ects) intak e ...

  • Page 171: Ecm Terminal

    Fi system diagnosis 4-15 ecm terminal terminal no. Circuit terminal no. Circuit 1 stva signal (stva. 2a) h stva signal (stva. 2b) 2 stva signal (stva. 1a) i stva signal (stva. 1b) 3 excva power (mo–) j stp sensor signal (stp) 4 excva power (mo+) k ignition switch signal [for e-03, 28, 33] 5 excva po...

  • Page 172

    4-16 fi system diagnosis terminal no. Circuit terminal no. Circuit y — l — z — m — [ — n — \ tachometer o — ] fuel pump relay (fp relay) p — ^ immobilizer communication [for e-02, 19, 24] q immobilizer communication [for e-02, 19, 24] a ho2 sensor heater (oxh) [for e-02, 19] r mode select switch b s...

  • Page 173: Self-Diagnosis Function

    Fi system diagnosis 4-17 self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi light). To check the function of the individual fi system devices, ...

  • Page 174

    4-18 fi system diagnosis dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive signal from the devices....

  • Page 175

    Fi system diagnosis 4-19 in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The malfunction code is indicated in three digits. I...

  • Page 176

    4-20 fi system diagnosis tps adjustment 1. Adjust the engine rpm to 1 200 r/min. ( 2-14) 2. Connect the special tool (mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, remove the aircleaner box and lift up the throttle ...

  • Page 177: Fail-Safe Function

    Fi system diagnosis 4-21 fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. Item fail-safe mode starting ability running ability cmp sensor when camshaft positi...

  • Page 178

    4-22 fi system diagnosis the engine can start and can run even if the above signal is not received from each sensor. But, the engine running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is nec- essary to bring the motorcycle to the workshop for co...

  • Page 179: Fi System Troubleshooting

    Fi system diagnosis 4-23 fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for prope...

  • Page 180

    4-24 fi system diagnosis note: the above form is a standard sample. The form should be modified according to conditions and characteris- tics of each market. Visual inspection • prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea- son for visual ...

  • Page 181

    Fi system diagnosis 4-25 self-diagnostic procedures note: * do not disconnect couplers from the ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection w...

  • Page 182

    4-26 fi system diagnosis use of sds diagnostic procedures * don’t disconnect couplers from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will era...

  • Page 183

    Fi system diagnosis 4-27 use of sds diagnosis reset proce- dure • after repairing the trouble, turn off the ignition switch and turn on again. • click the dtc inspection button 1. • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase th...

  • Page 184

    4-28 fi system diagnosis show data when trouble (displaing data at the time of dtc) ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “show data when trouble”. Therefore, it is ...

  • Page 185

    Fi system diagnosis 4-29 malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c11 cmp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Cmp sensor wiring and mechan- ical pa...

  • Page 186

    4-30 fi system diagnosis dtc no. Detected item detected failure condition check for c21 iat sensor the sensor voltage should be the fol- lowing. 0.15 v sensor voltage in other than the above range, c21 (p0110) is indicated. Iat sensor, lead wire/coupler connection p0110 h sensor voltage is higher th...

  • Page 187

    Fi system diagnosis 4-31 * : immobilizer system is equipped model only. Dtc no. Detected item detected failure condition check for c29 stp sensor the sensor should produce following voltage. 0.15 v sensor voltage in other than the above range, c29 (p1654) is indicated. Stp sensor, lead wire/coupler ...

  • Page 188

    4-32 fi system diagnosis dtc no. Detected item detected failure condition check for c44 ho2 sensor (for e-02, 19) ho2 sensor output voltage is not input to ecm during engine operation and running condition. (sensor voltage in other than the above value, c44 (p0130) is indicated. Ho2 sensor circuit o...

  • Page 189

    Fi system diagnosis 4-33 “c11” (p0340) cmp sensor circuit malfunction inspection 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) remove the air cleaner box. ( 5-14) 4) check the cmp sensor coupler for loose or poor contacts. If ok, remove the cmp sensor. ( 3-26) 5) c...

  • Page 190

    4-34 fi system diagnosis 6) under this condition, if a suitable screwdriver touching the pick-up surface of the cmp sensor is moved, the tester read- ing voltage changes (0.8 v and less ↔ 4.3 v and more). . Is the voltage ok? 7) after repairing the trouble, clear the dtc using sds tool. ( 4-27) yes...

  • Page 191

    Fi system diagnosis 4-35 “c12” (p0335) ckp sensor circuit malfunction inspection step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the ckp sensor coupler for loose or poor contacts. If ok, then measure the ckp sensor resistance. 4) disconnect the ckp sensor ...

  • Page 192

    4-36 fi system diagnosis 5) if ok, then check the continuity between each terminal and ground.  ckp sensor continuity: ∞Ω (infinity) (b – ground) (g – ground)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing th...

  • Page 193

    Fi system diagnosis 4-37 . Is the voltage ok? 3) after repairing the trouble, clear the dtc using sds tool. ( 4-27) yes • g/w or o/bi wire open or shorted to ground. • loose or poor contacts on the ckp sensor cou- pler or ecm coupler (terminal d or u). • if wire and connection are ok, intermittent ...

  • Page 194

    4-38 fi system diagnosis “c13” (p0105-h/l) iap sensor circuit malfunction inspection step 1 (when indicating c13:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the iap sensor coupler for loose or poor contacts. If ok, then measure the iap sensor input voltage....

  • Page 195

    Fi system diagnosis 4-39 4) disconnect the iap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the r wire and ground. 7) if ok, then measure the voltage at the r wire a and b/br wire b.  iap sensor input voltage: 4.5 – 5.5 v (+ r – - ground) (+ r – - b/br)  09900-25008: m...

  • Page 196

    4-40 fi system diagnosis 6) disconnect the ecm coupler. 7) check the continuity between g/b wire c and terminal 9. 8) if ok, then check the continuity between b/br wire b and ter- minal s.  iaps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed...

  • Page 197

    Fi system diagnosis 4-41 7) disconnect the ecm coupler. 8) check the continuity between r wire a and terminal a. 9) also, check the continuity between g/b wire c and terminal 9.  iaps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set ...

  • Page 198

    4-42 fi system diagnosis step 3 1) turn the ignition switch off. 2) remove the iap sensor. 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. Arrange 3 new 1.5 v batteries in series 1 (check that total voltage is 4.5 – 5.0 v) and connect - terminal to the ground terminal 2 and + ...

  • Page 199

    Fi system diagnosis 4-43 output voltage (vcc voltage 4.5 – 5.0 v, ambient temp. 20 – 30 °c, 68 – 86 °f) altitude (reference) atmospheric pressure output voltage (ft) (m) (mmhg) kpa (v) 0 2 000 0 610 760 707 100 94 3.1 – 3.6 2 001 5 000 611 1 524 707 634 94 85 2.8 – 3.4 5 001 8 000 1 525 2 438 634 56...

  • Page 200

    4-44 fi system diagnosis “c14” (p0120-h/l) tp sensor circuit malfunction inspection step 1 (when indicating c14:) 1) turn the ignition switch to off. 2) lift and support the fuel tank. ( 5-3) 3) check the tp sensor coupler for loose or poor contacts. If ok, then measure the tp sensor input voltage....

  • Page 201

    Fi system diagnosis 4-45  tp sensor input voltage: 4.5 – 5.5 v (+ r – - ground) (+ r – - b/br)  09900-25008: multi-circuit tester set  tester knob indication: voltage () is the voltage ok? Step 1 (when indicating p0120-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-...

  • Page 202

    4-46 fi system diagnosis is the continuity ok? 9) after repairing the trouble, clear the dtc using sds tool. ( 4-27) step 1 (when indicating p0120-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the tp sensor coupler for loose or poor contacts. If ok, then c...

  • Page 203

    Fi system diagnosis 4-47 step 2 1) turn the ignition switch off. 2) disconnect the tp sensor coupler. 3) install the test harness to the tp sensor. 4) check the continuity between terminal a and ground.  tp sensor continuity: ∞Ω (infinity) (terminal a – ground) 5) if ok, then measure the tp sensor ...

  • Page 204

    4-48 fi system diagnosis step 3 1) connect the tp sensor coupler 1 to the test harness. 2) turn the ignition switch on. 3) measure the tp sensor output voltage at the coupler (between + p/b and - b/br) by turning the throttle grip.  tp sensor output voltage throttle valve is closed: approx. 1.1 v t...

  • Page 205

    Fi system diagnosis 4-49 “c15” (p0115-h/l) ect sensor circuit malfunction inspection step 1 (when indicating c15:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the ect sensor coupler for loose or poor contacts. If ok, then measure the ect sensor voltage at the...

  • Page 206

    4-50 fi system diagnosis step 1 (when indicating p0115-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) disconnect the ect sensor coupler and ecm coupl...

  • Page 207

    Fi system diagnosis 4-51 step 1 (when indicating p0115-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the ect sensor coupler for loose or poor contacts. If ok, then measure the output voltage. 4) disconnect the ect sensor coupler. 5) check the continuity bet...

  • Page 208

    4-52 fi system diagnosis step 2 1) turn the ignition switch off. 2) disconnect the ect sensor coupler. 3) measure the ect sensor resistance.  ect sensor resistance: approx. 2.45 k Ω at 20 °c (68 °f) (terminal – terminal)  09900-25008: multi-circuit tester set  tester knob indication: resistance (...

  • Page 209

    Fi system diagnosis 4-53 “c21” (p0110-h/l) iat sensor circuit malfunction inspection step 1 (when indicating c21:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the iat sensor coupler for loose or poor contacts. If ok, then measure the iat sensor voltage at the...

  • Page 210

    4-54 fi system diagnosis step 1 (when indicating p0110-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler and ecm coupl...

  • Page 211

    Fi system diagnosis 4-55 step 1 (when indicating p0110-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler. 5) check the...

  • Page 212

    4-56 fi system diagnosis step 2 1) turn the ignition switch off. 2) measure the iat sensor resistance.  iat sensor resistance: approx. 2.45 kΩ at 20 °c (68 °f) (terminal – terminal)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) is the resistance ok?  iat sensor s...

  • Page 213

    Fi system diagnosis 4-57 “c22” (p1450-h/l) ap sensor circuit malfunction inspection step 1 (when indicating c22:) 1) turn the ignition switch off. 2) remove the front seat. ( 8-7) 3) check the ap sensor coupler for loose or poor contacts. If ok, then measure the ap sensor input voltage. Detected co...

  • Page 214

    4-58 fi system diagnosis 4) disconnect the ap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the r wire and ground. 7) if ok, then measure the voltage at the r wire a and b/br wire b.  ap sensor input voltage: 4.5 – 5.5 v (+ r – - ground) (+ r – - b/br)  09900-25008: mul...

  • Page 215

    Fi system diagnosis 4-59 6) disconnect the ecm coupler. 7) check the continuity between g/y wire c and terminal p. 8) if ok, then check the continuity between b/br wire b and ter- minal s.  aps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed ...

  • Page 216

    4-60 fi system diagnosis 7) disconnect the ecm coupler. 8) check the continuity between r wire a and terminal a. 9) if ok, then check the continuity between g/y wire c and ter- minal p.  aps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed pro...

  • Page 217

    Fi system diagnosis 4-61 step 3 1) remove the ap sensor. 2) connect the vacuum pump gauge to the vacuum port of the ap sensor. Arrange 3 new 1.5 v batteries in series 1 (check that total voltage is 4.5 – 5.0 v) and connect - terminal to the ground terminal 2 and + terminal to the vcc terminal 3. 3) ...

  • Page 218

    4-62 fi system diagnosis output voltage (vcc voltage 4.5 – 5.0 v, ambient temp. 20 – 30 °c, 68 – 86 °f) altitude (reference) atmospheric pressure output voltage (ft) (m) (mmhg) kpa (v) 0 2 000 0 610 760 707 100 94 3.1 – 3.6 2 001 5 000 611 1 524 707 634 94 85 2.8 – 3.4 5 001 8 000 1 524 2 438 634 56...

  • Page 219

    Fi system diagnosis 4-63 “c23” (p1651-h/l) to sensor circuit malfunction inspection step 1 (when indicating c23:) 1) turn the ignition switch off. 2) remove the frame cover. ( 8-8) 3) check the to sensor coupler for loose or poor contacts. If ok, then measure the to sensor resistance. 4) disconnect...

  • Page 220

    4-64 fi system diagnosis step 1 (when indicating p1651-h:) 1) turn the ignition switch off. 2) remove the frame cover. ( 8-8) 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity...

  • Page 221

    Fi system diagnosis 4-65 step 1 (when indicating p1651-l:) 1) turn the ignition switch off. 2) remove the frame cover. ( 8-8) 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity...

  • Page 222

    4-66 fi system diagnosis step 2 1) connect the to sensor coupler and ecm coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage between b and b/br wires.  to sensor voltage (normal): 0.4 – 1.4 v (+ b – - b/br) also, measure the ...

  • Page 223

    Fi system diagnosis 4-67 “c28” (p1655) stv actuator circuit malfunction inspection step 1 1) lift and support the fuel tank. ( 5-3) 2) remove the air cleaner box. ( 5-14) 3) check the stva lead wire coupler for loose or poor contacts. 4) turn the ignition switch on to check the stv operation. (stv...

  • Page 224

    4-68 fi system diagnosis step 2 1) turn the ignition switch off. 2) disconnect the stva lead wire coupler. 3) check the continuity between each terminal and ground.  stva continuity: ∞Ω (infinity) (terminal – ground) 4) if ok, then measure the stva resistance (between terminal a and terminal b) and...

  • Page 225

    Fi system diagnosis 4-69 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “secondary throttle operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from the stva, t...

  • Page 226

    4-70 fi system diagnosis “c29” (p1654-h/l) stp sensor circuit malfunction inspection step 1 (when indicating c29:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the stp sensor coupler for loose or poor contacts. If ok, then measure the stp sensor input voltage....

  • Page 227

    Fi system diagnosis 4-71 step 1 (when indicating p1654-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the stp sensor coupler. 5) check the...

  • Page 228

    4-72 fi system diagnosis step 1 (when indicating p1654-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the stp sensor coupler. 5) check the...

  • Page 229

    Fi system diagnosis 4-73 step 2 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) disconnect the stp sensor coupler. 4) check the continuity between each terminal and ground.  stp sensor continuity: ∞Ω (infinity) (terminal – ground) 5) if ok, then measure the stp sensor...

  • Page 230

    4-74 fi system diagnosis step 3 1) turn the ignition switch off. 2) connect the stp sensor coupler. 3) insert the needle pointed probes to the stp sensor coupler. 4) disconnect the stva lead wire coupler. 5) turn the ignition switch on. 6) measure the stp sensor output voltage at the coupler (betwee...

  • Page 231

    Fi system diagnosis 4-75 “c31” (p0705) gp switch circuit malfunction inspection step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the gp switch coupler for loose or poor contacts. If ok, then measure the gp switch voltage. 4) support the motorcycle with a ja...

  • Page 232

    4-76 fi system diagnosis is the voltage ok? 10)after repairing the trouble, clear the dtc using sds tool. ( 4-27) yes • p wire open or shorted to ground • if wire and connection are ok, intermittent trou- ble or faulty ecm. • recheck each terminal and wire harness for open circuit and poor connecti...

  • Page 233

    Fi system diagnosis 4-77 “c32” (p0201), “c33” (p0202), “c34” (p0203) or “c35” (p0204) primary fuel injector circuit malfunction inspection step 1 1) turn the ignition switch off. 2) lift and support the fuel tank ( 5-3) 3) check the injector coupler for loose or poor contacts. If ok, then measure t...

  • Page 234

    4-78 fi system diagnosis 5) if ok, then check the continuity between each terminal and ground.  injector continuity: ∞Ω (infinity)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing the trouble, clear the dtc usi...

  • Page 235

    Fi system diagnosis 4-79 is the voltage ok? 3) after repairing the trouble, clear the dtc using sds tool. ( 4-27) yes • gr/w wire open or shorted to ground, or poor h connection (#1 cylinder side) • gr/b wire open or shorted to ground, or poor g connection (#2 cylinder side) • gr/y wire open or sho...

  • Page 236

    4-80 fi system diagnosis “c36” (p1764), “c37” (p1765), “c38” (p1766) or “c39” (p1767) secondary fuel injector circuit malfunction inspection step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the injector coupler for loose or poor contacts. If ok, then measur...

  • Page 237

    Fi system diagnosis 4-81 5) if ok, then check the continuity between each terminal and ground.  injector continuity: ∞Ω (infinity)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing the trouble, clear the dtc usi...

  • Page 238

    4-82 fi system diagnosis is the voltage ok? 3) after repairing the trouble, clear the dtc using sds tool. ( 4-27) yes • lg wire open or shorted to ground, or poor x connection (#1 cylinder side) • lg/w wire open or shorted to ground, or poor w connection (#2 cylinder side) • lg/g wire open or short...

  • Page 239

    Fi system diagnosis 4-83 “c41” (p0230-h/l) fp relay circuit malfunction inspection step 1 (when indicating c41:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. ( 5-7) detected cond...

  • Page 240

    4-84 fi system diagnosis is the fp relay ok? 4) after repairing the trouble, clear the dtc using sds tool. ( 4-27) step 1 (when indicating p0230-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the fp relay coupler for loose or poor contacts. If ok, then chec...

  • Page 241

    Fi system diagnosis 4-85 step 1 (when indicating p0230-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. ( 5-7) is the fp relay ok? 4) after repairing the trouble, clear the dtc u...

  • Page 242

    4-86 fi system diagnosis “c42” (p01650) ig switch circuit malfunction inspection * refer to the ignition switch inspection for details. ( 9-39) detected condition possible cause ignition switch signal is not input to the ecm. • ignition system circuit open or short • ecm malfunction when the id agr...

  • Page 243

    Fi system diagnosis 4-87 “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19) inspection step 1 (when indicating c44/p0130:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the ho2 sensor for loose or poor contacts. If ok, then check the ho2 s...

  • Page 244

    4-88 fi system diagnosis 7) disconnect the ecm coupler. 8) check the continuity between w/g wire a and terminal b. 9) also, check the continuity between b/br wire b and terminal s.  ho2s lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed probe s...

  • Page 245

    Fi system diagnosis 4-89 is the voltage ok? 6) after repairing the trouble, clear the dtc using sds tool. ( 4-27) step 1 (when indicating c44/p0135:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the ho2 sensor for loose or poor contacts. If ok, then measure t...

  • Page 246

    4-90 fi system diagnosis step 2 (when indicating c44/p0135:) 1) connect the ho2 sensor coupler. 2) insert the needle pointed probe to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between w (o/w) wire and ground. 4) if the tester voltage indicates the battery ...

  • Page 247

    Fi system diagnosis 4-91 “c46” (p1657-h/l or p1658) excv actuator circuit malfunction inspection step 1 (when indicating c46:) 1) turn the ignition switch off. 2) remove the frame cover. ( 5-8) 3) check the excva lead wire couplers for loose or poor con- tacts. 4) turn the ignition switch on. 5) ch...

  • Page 248

    4-92 fi system diagnosis step 1 (when indicating p1657-h:) 1) turn the ignition switch off. 2) remove the frame cover. ( 5-8) 3) check the excva position sensor coupler for loose or poor contacts. If ok, then check the excva position sensor lead wire conti- nuity. 4) disconnect the excva position s...

  • Page 249

    Fi system diagnosis 4-93 step 1 (when indicating p1657-l:) 1) turn the ignition switch off. 2) remove the frame cover. ( 5-8) 3) check the excva position sensor coupler for loose or poor contacts. If ok, then check the excva position sensor lead wire conti- nuity. 4) disconnect the excva position s...

  • Page 250

    4-94 fi system diagnosis step 1 (when indicating p1658:) 1) turn the ignition switch off. 2) remove the frame cover. ( 5-8) 3) check the excva motor coupler for loose or poor contacts. Is the contacting ok? 4) after repairing the trouble, clear the dtc using sds tool. ( 4-27) step 2 1) turn the ig...

  • Page 251

    Fi system diagnosis 4-95 step 3 1) turn the ignition switch off. 2) check the continuity between y wire and ground.  position sensor continuity: ∞Ω (infinity) 3) if ok, then measure the position sensor resistance. 4) connect the position sensor coupler. 5) set the excva to adjustment position. ( 6...

  • Page 252

    4-96 fi system diagnosis step 4 1) turn the ignition switch off. 2) connect the position sensor coupler. 3) measure the position sensor output voltage at fully close posi- tion and fully open position. 4) insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler. (...

  • Page 253

    Fi system diagnosis 4-97 step 5 1) if the position sensor output voltage is 0.5 v and less at fully close position, adjust the output voltage to specified by turn- ing out the no. 1 cable adjuster 1. 2) repeat the above procedure (step 4) until the out put voltage becomes specified value. (if c46/p1...

  • Page 254

    4-98 fi system diagnosis step 6 1) turn the ignition switch off. 2) disconnect the motor lead wire coupler of the excva. 3) apply 12 v to the terminal and check the operation of excva. 4) then, swap the wires supplied 12 v and check the operation of excva. (check the operation of excva both way.) is...

  • Page 255

    Fi system diagnosis 4-99 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “exhaust valve operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from the excva, the f...

  • Page 256

    4-100 fi system diagnosis “c49” (p1656) pair control solenoid valve circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the air cleaner box. ( 5-14) 3) check the pair control solenoid valve coupler for loose or poor contacts. If ok, then measure the pair control solenoi...

  • Page 257

    Fi system diagnosis 4-101 step 2 1) turn the ignition switch on. 2) measure the voltage between o/w wire and ground.  pair valve voltage: battery voltage (+ o/w – - ground)  09900-25008: multi-circuit tester set  tester knob indication: voltage () is the voltage ok? 3) after repairing the troubl...

  • Page 258

    4-102 fi system diagnosis 4) click each button 2. At this time, if an operation sound is heard from the pair control solenoid valve, the function is normal..

  • Page 259

    Fi system diagnosis 4-103 “c60” (p0480) cooling fan relay circuit malfunction inspection step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the cooling fan relay coupler for loose or poor contacts. If ok, then inspection the cooling fan relay. ( 7-7) is the ...

  • Page 260

    4-104 fi system diagnosis active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) start the engine and run it idling condition. 3) click “cooling fan relay control” 1. 4) click the operate button 2. At this time, if an operation sound is heard fr...

  • Page 261: Sensors

    Fi system diagnosis 4-105 sensors cmp sensor inspection the camshaft position sensor is installed on the cylinder head cover. ( 4-33) cmp sensor removal and installation • remove the cmp sensor. ( 3-26) • install the cmp sensor in the reverse order of removal.  cmp sensor: 10 n·m (1.0 kgf-m, 7.0 ...

  • Page 262

    4-106 fi system diagnosis ect sensor inspection the engine coolant temperature sensor is installed at the cylin- der head. ( 4-49) ect sensor removal and installation • remove the ect sensor. ( 7-7) • install the ect sensor in the reverse order of removal.  ect sensor: 18 n·m (1.8 kgf-m, 13.0 lb-...

  • Page 263

    Fi system diagnosis 4-107 stp sensor adjustment • adjust the stp sensor. ( 5-22) ho2 sensor inspection (for e-02, 19) the heated oxygen sensor is installed to the exhaust pipe. ( 4-87) ho2 sensor removal and installation • remove the right under cowling. ( 8-5) • lift and support the fuel tank. (...

  • Page 264

    Fuel system and throttle body 5-1 5 fuel system and throttle body contents fuel delivery system.......................................................................... 5- 2 fuel system............................................................................................. 5- 3 fuel tank lift-...

  • Page 265: Fuel Delivery System

    5-2 fuel system and throttle body fuel delivery system the fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the f...

  • Page 266: Fuel System

    Fuel system and throttle body 5-3 fuel system fuel tank lift-up • remove the seats. ( 8-7 and -8) • take out the fuel tank prop stay 1. • remove the fuel tank bolt. • lift and support the fuel tank with the fuel tank prop stay..

  • Page 267

    5-4 fuel system and throttle body fuel tank removal • lift and support the fuel tank. ( above) • disconnect the fuel pump lead wire coupler 1. • disconnect the fuel tank breather hose 2 and fuel tank drain hose 3. • place a rag under the fuel feed hose 4 and disconnect the fuel feed hose. • remove ...

  • Page 268

    Fuel system and throttle body 5-5 • install the special tools between the fuel tank and fuel delivery pipe.  09940-40211: fuel pressure gauge adaptor 09940-40220: fuel pressure gauge hose attachment 09915-77331: oil pressure gauge 09915-74521: oil pressure gauge hose turn the ignition switch on and...

  • Page 269

    5-6 fuel system and throttle body fuel discharge amount inspection • lift and support the fuel tank. ( 5-3) • turn the ignition switch off. • disconnect the battery - lead wire. • place a rag under the fuel feed hose and disconnect the fuel feed hose 1 from the fuel pump. • connect a proper fuel ho...

  • Page 270

    Fuel system and throttle body 5-7 • connect a proper lead wire to the fuel pump lead wire coupler (fuel pump side) and apply 12 v to the fuel pump (between y/r wire and b/w wire) for 10 seconds and measure the amount of fuel discharged. Battery + terminal (y/r terminal) battery - terminal (b/w termi...

  • Page 271

    5-8 fuel system and throttle body fuel pump and fuel filter removal construction 1 fuel level gauge 5 holder 2 fuel pump case/fuel filter cartridge 6 fuel mesh filter item n·m kgf-m lb-ft 3 fuel pump 7 o-ring a 10 1.0 7.0 4 rubber cushion a fuel pump mounting bolt.

  • Page 272

    Fuel system and throttle body 5-9 removal • remove the fuel tank. ( 5-4) • remove the fuel pump assembly 1 by removing its mounting bolts diagonally. • remove the nuts. • remove the lead wire 1, screws and fuel level gauge 2. • remove the screw. • remove the fuel pump 3 from the fuel pump plate 4. ...

  • Page 273

    5-10 fuel system and throttle body • remove the fuel mesh filter 7. • remove the fuel pump 8 from the fuel pump case/fuel filter cartridge 9. Fuel mesh filter inspection and cleaning if the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may re...

  • Page 274

    Fuel system and throttle body 5-11 • be sure to connect the wires to the proper terminals. A (bl) ........ + terminal for fuel pump b (r)......... + terminal for fuel level gauge • install a new o-ring and apply suzuki super grease “a” to it.  99000-25010: suzuki super grease “a” (or equivalent gre...

  • Page 275

    5-12 fuel system and throttle body • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers.  fuel pump mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) note: apply a small quantity of the thread...

  • Page 276: Throttle Body

    Fuel system and throttle body 5-13 throttle body construction only for e-33 1 tp sensor 8 fast idle adjusting screw 2 stp sensor 9 throttle stop screw 3 stva 0 vacuum hose 4 fuel delivery pipe a fuel delivery pipe mounting screw item n·m kgf-m lb-ft 5 o-ring b stp sensor mounting screw a 5.0 0.5 3.7...

  • Page 277

    5-14 fuel system and throttle body air cleaner box removal and instal- lation removal • lift and support the fuel tank. ( 5-3) • disconnect the fuel pump relay 1, cooling fan relay 2 and iat sensor lead wire coupler 3. • disconnect the pcv hose 4. • remove the air cleaner mounting bolt 5. • disconn...

  • Page 278

    Fuel system and throttle body 5-15 throttle body removal • remove the air cleaner box. ( 5-14) • disconnect the throttle cables from their drum. • place a rag under the fuel feed hose and remove the fuel feed hose. • disconnect the stva lead wire coupler 1, stp sensor lead wire coupler 2 tp sensor ...

  • Page 279

    5-16 fuel system and throttle body • remove the throttle body assembly. Throttle body disassembly • disconnect the respective vacuum hoses 1 from each throttle body. • remove the iap sensor 2 • remove the fuel delivery pipe assembly 3. • remove the cushion seal 4 from the throttle body. • remove the...

  • Page 280

    Fuel system and throttle body 5-17 • remove the tp sensor and stp sensor with the special tool.  09930-11950: torx wrench note: prior to disassembly, mark the each sensor’s original position with a paint or scribe for accurate reinstallation. Never remove the stva 7 from the throttle body. Never re...

  • Page 281

    5-18 fuel system and throttle body throttle body cleaning • clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. Inspection check following items for any damage or clogging. * o-ring * throttle valve * secondary throttle valve * vacuum hose some carburetor cle...

  • Page 282

    Fuel system and throttle body 5-19 throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • with the stv fully open, install the stp sensor 1 and tighten the stp sensor mounting screw to the specified torque. Note: * apply ...

  • Page 283

    5-20 fuel system and throttle body • install the fuel injector 5 by pushing it straight to the delivery pipe 6. Note: align the boss e of the injector with the groove f of the delivery pipe. • install the fuel delivery pipe assembly 7 to the throttle body assembly. Tighten the fuel delivery pipe mou...

  • Page 284

    Fuel system and throttle body 5-21 throttle body installation installation is in the reverse order of removal. Pay attention to the following points: • connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead w...

  • Page 285

    5-22 fuel system and throttle body stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor output voltage and adjust the stp sensor position as follows: • remove the air cleaner box . ( 5-14) • loosen the throttle body clamp screws at the intake pipe side. • lift up the ...

  • Page 286

    Fuel system and throttle body 5-23 fuel injector removal • remove the air cleaner box. ( 5-14) • with battery negative cable disconnected, disconnect the injector couplers. • remove the fuel delivery pipe assemblies. ( 5-16) • remove the primary and secondary fuel injectors #1, #2, #3 and #4. ( 5...

  • Page 287

    5-24 fuel system and throttle body fast idle the fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warm...

  • Page 288

    Fuel system and throttle body 5-25 • calculate the voltage difference between tp sensor output voltage at idle and tp sensor output voltage with the stv full opened. Example: tp sensor output voltage with the stv fully open minus tp sensor output voltage at idle is 0.030 v stv fully open 1.155 v idl...

  • Page 289

    5-26 fuel system and throttle body throttle valve synchronization check and adjust the throttle valve synchronization among four cylinders. Step 1 • lift and support the fuel tank. ( 5-3) • start up the engine and run it in idling condition for warming up. • stop the warmed-up engine. • disconnect ...

  • Page 290

    Fuel system and throttle body 5-27 step 3 • turn in all the idle air screws to the complete close position. • check for difference of vacuum between #1 and #2. • equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower. Similarly p...

  • Page 291: Exhaust System

    Exhaust system 6-1 4 6 exhaust system contents exhaust system..................................................................................... 6- 2 exhaust control system ........................................................... 6- 2 operation .....................................................

  • Page 292: Exhaust System

    6-2 exhaust system exhaust system exhaust control system the exhaust control system (excs) consists of the exhaust control valve (excv), exhaust control valve actuator (excva) and exhaust control valve cables (excv cables). Excv is installed the exhaust pipes. Excva is mounted on the right side of t...

  • Page 293

    Exhaust system 6-3 operation the excs is operated by the signal supplied from the ecm. The open/close operation of the excv is performed by the excva which is controlled by the ecm by changing the current direction of the actuator motor. The position sensor (incorporated in the excva) detects the ex...

  • Page 294: (Exhaust Control Valve)

    6-4 exhaust system excva (exhaust control valve actuator) and excv (exhaust control valve) excva removal • turn the ignition switch off. • remove the frame cover. ( 8-8) • connect the special tool (mode select switch) to the dealer mode coupler. ( 4-18) • after turning the special tool’s switch on...

  • Page 295

    Exhaust system 6-5 • hold the excva pulley with an adjustable wrench, and loosen the pulley mounting bolt. • remove the excva pulley from the excva body. Excva pulley inspection • inspect the excva pulley groove for wear and damage. • if any defects are found, replace the excva pulley with a new one...

  • Page 296

    6-6 exhaust system • tighten the excva mounting bolts to the specified torque.  excva mounting bolt: 6.0 n·m (0.6 kgf-m, 4.5 lb-ft) • turn in the two cable adjusters fully. • connect the no.1 cable 1 (01h0cl) and no.2 cable 2 (01h0op) to the excva pulley. No.1 cable: 01h0cl no.2 cable: 01h0op • aft...

  • Page 297

    Exhaust system 6-7 excv cable replacement • lift and support the fuel tank. ( 5-3) • check the excva to adjustment position. ( 6-4) • disconnect the excv cables from the excva pulley. ( 6-4) • measure the thread length a before disconnecting the no.1 cable. • disconnect the excv cables 1 and 2 fr...

  • Page 298

    6-8 exhaust system • connect the no.1 cable 1 and no.2 cable 2 to the excva pulley. • loosen the lock-nut 9 and turn the no.2 cable adjuster 0 in or out until the thread length d becomes 11.0 – 12.0 mm (0.43 – 0.47 in). • tighten the lock-nut 9. Excva adjustment 1st step: • set the excva to adjustme...

  • Page 299

    Exhaust system 6-9 • to set the excv to fully close position, apply 12 v to a and b terminals. Battery + terminal–– a (pink lead wire) terminal battery - terminal–– b (gray lead wire) terminal • turn the ignition switch on. • measure the position sensor output voltage at fully close posi- tion.  po...

  • Page 300

    6-10 exhaust system measure the position sensor output voltage at fully open posi- tion.  position sensor output voltage excv is fully open: 3.7 output voltage 4.5 (v) (+ yellow – - b/br) if the measured voltage is more than specification, adjust the no.2 cable adjuster as follows: • set the excva ...

  • Page 301

    Exhaust system 6-11 • loosen the exhaust pipe connector bolt 5. • remove the muffler mounting bolts 6. • loosen the exhaust pipe bolts 7. • remove the muffler body a. • remove the exhaust pipe bolts 7. • remove the exhaust pipe b. Note: when an exhaust pipe separates, not to throw or drop, have by h...

  • Page 302

    6-12 exhaust system excv inspection • turn the excv by hand and check that it moves smoothly. • if it does not move smoothly, replace the excv together with the exhaust pipe. • decarbonize the excv if necessary. Excv/exhaust pipe, muffler installation install the exhaust pipe and muffler in the reve...

  • Page 303

    Exhaust system 6-13 • tighten the radiator mounting bolts to the specified torque.  radiator mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the excv cables. ( 6-7).

  • Page 304

    6-14 exhaust system 10 n·m (1.0 kgf-m, 7.0 lb-ft) ! * when adjusting the no. 1 and no. 2 cables, the cable slots of excva pulley must be located to adjustment position. * do not use the adjustable wrench to turn excva pul- ley so as not to cause damage to the internal gear of excva. 23 n·m (2.3 kgf-...

  • Page 305

    Cooling and lubrication system 7-1 7 cooling and lubrication system contents engine coolant ..................................................................................... 7- 2 cooling circuit ..................................................................................... 7- 3 cooling ci...

  • Page 306: Engine Coolant

    7-2 cooling and lubrication system engine coolant at the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the c...

  • Page 307: Cooling Circuit

    Cooling and lubrication system 7-3 cooling circuit cooling circuit inspection before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • remove the right under cowling. ( 8-5) • remove the radiator cap 1 and connect the tester 2 to the filler. • give ...

  • Page 308: Radiator And Water Hoses

    7-4 cooling and lubrication system radiator and water hoses radiator removal • remove the under cowlings. ( 8-5) • drain the engine coolant. ( 2-17) • remove the radiator assembly. ( 3-4) • remove the reservoir tank 1, cooling fan 2 from the radia- tor. Radiator cap inspection • fit the cap 1 to ...

  • Page 309

    Cooling and lubrication system 7-5 fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. Radiator installation • install the cooling fan.  cooling fan mounting bolt: 8 n·m (0.8 kgf-m, 6.0 lb-ft) • install the radiator. • route the radiator hoses prope...

  • Page 310: Cooling Fan

    7-6 cooling and lubrication system cooling fan removal ( 7-4) inspection • remove the right under cowling. ( 8-5) • disconnect the cooling fan coupler 1. • test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • the voltmeter is for making sure that th...

  • Page 311: Ect Sensor

    Cooling and lubrication system 7-7 cooling fan relay inspection cooling fan relay is located on the air cleaner box (left side one). • lift and support the fuel tank. ( 8-3) • remove the cooling fan relay 1. First check the insulation between a and b terminals with tester. Then apply 12 v to c and ...

  • Page 312

    7-8 cooling and lubrication system • if the ect sensor ohmic value does not change in the propor- tion indicated, replace it with a new one.  temperature sensor specification  cooling fan operating temperature: standard (off →on): approx. 105 °c (221 °f) (on →off): approx. 100 °c (212 °f) note: as...

  • Page 313: Thermostat

    Cooling and lubrication system 7-9 thermostat removal • drain engine coolant. ( 2-17) • lift and support the fuel tank. ( 5-3) • place a rag under the thermostat cover. • remove the thermostat cover 1. • remove the thermostat 2. Inspection inspect the thermostat pellet for signs of cracking. Test ...

  • Page 314

    7-10 cooling and lubrication system • keep on heating the water to raise its temperature. • just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in).  thermostat valve lift a standard: 8.0 mm and over at 95 °c (0.31 in and over at 2...

  • Page 315: Water Pump

    Cooling and lubrication system 7-11 water pump removal and disassembly note: before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and o-ring. If engine coolant is leaking, v...

  • Page 316

    7-12 cooling and lubrication system • remove the mechanical seal ring 4 and rubber seal 5 from the impeller. • remove the impeller shaft 6 and washer 7. • remove the mechanical seal with the special tool.  09921-20240: bearing remover set (12 mm) note: if there is no abnormal condition, the mechani...

  • Page 317

    Cooling and lubrication system 7-13 inspection mechanical seal • visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. • replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. Oil seal • visually ins...

  • Page 318

    7-14 cooling and lubrication system reassembly and installation • install the oil seal with the special tool.  09913-70210: bearing installer set (22) note: the stamped mark on the oil seal faces mechanical seal side. • apply a small quantity of the suzuki super grease “a” to the oil seal lip.  9...

  • Page 319

    Cooling and lubrication system 7-15 • install the rubber seal 1 into the impeller. • after wiping off the oily or greasy matter from the mechanical seal ring, install it into the impeller. Note: the paint marked side b of mechanical seal ring faces the rub- ber seal. • install the washer 2 and seal ...

  • Page 320

    7-16 cooling and lubrication system • install the water pump. Note: set the water pump shaft end f to the oil pump shaft g as shown. • tighten the water pump mounting bolts to the specified torque.  water pump mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • connect the water hoses. ( 10-24) • pour ...

  • Page 321: Lubrication System

    Cooling and lubrication system 7-17 lubrication system oil cooler inspection inspect the oil cooler and oil cooler water hoses for engine oil leakage and engine coolant leakage. Replace any defective parts if necessary. Removal • remove the under cowlings. ( 8-5) • drain engine oil. ( 2-12) • drai...

  • Page 322

    7-18 cooling and lubrication system oil pressure 2-33 oil filter 2-13 oil pressure regulator 3-44 oil strainer 3-44 oil jet 3-58 oil pump 3-41 oil pressure switch 9-34.

  • Page 323: Sub Gallery #2

    Cooling and lubrication system 7-19 engine lubrication system chart intake camshaft cam drive chain cam chain tension adjuster #1 piston cooling oil jet #1 piston and cylinder wall #1 crank pin bearing #1 crankshaft journal bearing orifice generator & starter clutch #2 crankshaft journal bearing #3 ...

  • Page 324

    7-20 cooling and lubrication system engine lubrication system.

  • Page 325

    Cooling and lubrication system 7-21.

  • Page 326: Chassis

    Chassis 8-1 8 chassis contents exterior parts ...................................................................................... 8- 3 fastener removal and installation..................................... 8- 3 body cowling cover and lower bracket cover ............. 8- 5 inner under cowling........

  • Page 327: Chassis

    Chassis contents 8-2 chassis removal ............................................................................................. 8-49 inspection ......................................................................................... 8-51 rear shock absorber scrapping procedure .....................

  • Page 328: Exterior Parts

    Chassis 8-3 exterior parts fastener removal and installation fastener (type a) removal • depress the head of fastener center piece 1. • pull out the fastener a. Installation • let the center piece stick out toward the head so that the pawls 2 close. • insert the fastener into the installation hole. ...

  • Page 329

    8-4 chassis installation • insert the fastener into the installation hole. Note: to prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. • push in the head of center piece..

  • Page 330

    Chassis 8-5 body cowling cover and lower bracket cover removal • remove the body cowling cover 1 by removing the screws and fasteners. • remove the lower bracket cover 2 by removing the bolts. Installation • install the lower bracket cover and body cowling cover in the reverse order of removal. Inne...

  • Page 331

    8-6 chassis screen removal • remove the screen 1 by removing the screws. Installation • install two nuts (middle ones) as shown. • install the window screen. Body cowling removal • remove the left and right under cowlings. ( 8-5) • remove the screen. ( above) • remove the combination meter. ( 9-2...

  • Page 332

    Chassis 8-7 air intake pipe removal • remove the body cowling. ( 8-6) • remove the fasteners. • remove the air intake pipes 1. (lh/rh) installation • install the air intake pipes in the reverse order of removal. Cowling brace removal • remove the body cowling. ( 8-6) • remove the cowling brace 1. ...

  • Page 333

    8-8 chassis rear seat/seat tail cover removal • remove the rear seat (seat tail cover) using the ignition key. Installation • insert the seat hook to the guide and push down the seat (seat tail cover) firmly until the seat (seat tail cover) snaps into the locked position. Frame cover removal • remov...

  • Page 334: Front Wheel

    Chassis 8-9 front wheel construction 1 brake disc 6 front axle 2 collar 7 front wheel item n·m kgf-m lb-ft 3 dust seal a front axle bolt a 100 10.0 72.5 4 bearing b brake disc bolt b 23 2.3 16.5 5 spacer.

  • Page 335

    8-10 chassis removal and disassembly • remove the brake calipers. • loosen two axle pinch bolts 1 on the right front fork leg. • remove the front axle bolt 2. • remove the under cowling. ( 8-5) • raise the front wheel off the ground and support the motorcy- cle with a jack or a wooden block. • loos...

  • Page 336

    Chassis 8-11 • remove the brake discs, left and right. • remove the dust seals on both sides with the special tool.  09913-50121: oil seal remover • remove the wheel bearings with the special tool.  09921-20240: bearing remover set • remove the spacer 5. The removed dust seals must be replaced wit...

  • Page 337

    8-12 chassis inspection tire inspection ( 8-85) brake disc inspection ( 8-70) axle shaft • using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.  09900-20607: dial gauge (1/100) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm)  axle shaf...

  • Page 338

    Chassis 8-13 reassembly and installation reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply suzuki super grease “a” to the wheel bearings.  99000-25010: suzuki super grease “a” (or equivalent grease) 2...

  • Page 339

    8-14 chassis • install the wheel bearings with the special tools as follows.  09924-84510: bearing installer set • install the dust seal with the special tool.  09913-70210: bearing installer set • apply suzuki super grease “a” to the dust seal lip.  99000-25010: suzuki super grease “a” (or equiv...

  • Page 340

    Chassis 8-15 • install the collar 1 in the right side. Wheel • install the front wheel with the front axle and hand-tighten the front axle bolt temporarily. Brake caliper • tighten the brake caliper mounting bolts to the specified torque.  front brake caliper mounting bolt: 35 n·m (3.5 kgf-m, 25.5 ...

  • Page 341

    8-16 chassis • tighten two axle pinch bolts on the left front fork leg to the specified torque.  front axle pinch bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft).

  • Page 342: Front Fork

    Chassis 8-17 front fork construction 1 adjuster rod 9 oil seal stopper ring 2 spring retainer 0 dust seal 3 spacer a inner tube 4 spring a front fork cap bolt item n·m kgf-m lb-ft 5 inner rod/damper rod (cartridge) b lock-nut a 35 3.5 25.5 6 outer tube c front axle pinch bolt b 20 2.0 14.5 7 oil sea...

  • Page 343

    8-18 chassis removal and disassembly • remove the under cowling cover and the lower bracket cover. ( 8-5) • remove the front wheel. ( 8-10) • disconnect the brake hose from the brake hose guides at the front fender. • remove the front fender. • loosen the front fork upper clamp bolts 1, left and r...

  • Page 344

    Chassis 8-19 • remove the front fork cap bolt from the inner rod by loosening the lock nut. • compress the fork spring with the special tool and remove the special tool. • remove the front fork cap bolt 5, adjuster rod 6, spring retainer 7, spacer 8 and spring 9. • invert the front fork and stroke t...

  • Page 345

    8-20 chassis • remove the damper rod bolt with the special tool and a hexa- gon wrench.  09940-30221: front fork assembling tool • remove the inner rod/damper rod (cartridge) b. • slide the outer tube to remove it from the inner tube. Note: be careful not to damage the “anti-friction” metals. • rem...

  • Page 346

    Chassis 8-21 • remove the oil seal e with the special tool.  09913-50121: oil seal remover • remove the oil seal retainer f. Inspection inner and outer tubes • inspect the inner tube outer surface and outer tube inner sur- face for scratches. • inspect the “anti-friction” metal surfaces for scratch...

  • Page 347

    8-22 chassis damper rod • move the inner rod by hand to examine it for smoothness. • if any defects are found, replace inner rod/damper rod (car- tridge) with a new one. Reassembly reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: oil seal and dust...

  • Page 348

    Chassis 8-23 damper rod bolt • insert the inner rod/damper rod (cartridge) into the inner tube. • apply thread lock to the damper rod bolt and tighten it to the specified torque with the special tool.  99000-32110: thread lock super “1322” (or equivalent thread lock)  09940-30221: front fork assem...

  • Page 349

    8-24 chassis • move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.  09940-52841: inner rod holder note: refill front fork oil up to the top of the outer tube so that bubbles are visible while bleeding air. • refill specified front fork oil...

  • Page 350

    Chassis 8-25 • insert the adjuster rod to the front fork cap bolt. • apply fork oil to the o-ring. • be sure to check or adjust the height d of the rebound damp- ing force adjuster as follows. H: 1.5 mm (0.05 in) • slowly turn the cap bolt completely by hand until the end of the cap bolt seats on th...

  • Page 351

    8-26 chassis installation install the front fork in the reverse order of removal. Pay atten- tion to the following points: • set the upper surface of the outer tube height a at 5.0 mm (0.196 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts 1 ...

  • Page 352

    Chassis 8-27 suspension setting after installing the front fork, adjust the spring pre-load and damping force as follows. Spring pre-load adjustment turn the damping force adjuster 1 counterclockwise fully. It is at softest position and turn it out to standard setting position.  std position: 7 tur...

  • Page 353: Steering Damper

    8-28 chassis steering damper construction 1 steering damper 4 convex curve side of the washer faces down side. 2 dust seal item n·m kgf-m lb-ft 3 steering stem head nut a damper rod bolt ab 23 2.3 16.5 b damper rod nut 3 90 9.0 65.0

  • Page 354

    Chassis 8-29 removal • remove the lower bracket cover. ( 8-5) • remove the nut 1 by holding the nut 2. • remove the bolt 3 and remove the steering damper. Inspection • inspect the steering damper body, bearing and oil seal for damage and oil leaking. • move the steering damper rod by hand to inspec...

  • Page 355: Steering

    8-30 chassis steering construction 1 steering stem upper bracket 8 steering stem lower bracket 2 handlebars a steering stem head nut item n·m kgf-m lb-ft 3 handlebar balancer b steering stem lock-nut a 90 9.0 65.0 4 steering stem nut c front fork upper clamp bolt b 80 8.0 58.0 5 dust seal cover d ha...

  • Page 356

    Chassis 8-31 removal • remove the under cowling. ( 8-5) • support the motorcycle with a jack or a wooden block. • remove the front wheel. ( 8-10) • remove the front forks. ( 8-18) • remove the steering damper. ( 8-29) • remove the steering stem head nut 1 and washer 2. • remove the steering stem...

  • Page 357

    8-32 chassis • remove the dust seal cover 1, dust seal 2, steering stem upper bearing inner race 3 and bearing 4. Inspection and disassembly inspect the removed parts for the following abnormalities. * handlebars distortion * race wear and brinelling * bearing wear or damage * abnormal noise of bear...

  • Page 358

    Chassis 8-33 reassembly reassemble the steering stem in the reverse order of disassem- bly. Pay attention to the following points: outer race • press in the upper and lower bearing outer races with the special tools.  09941-34513: steering outer race installer set 09913-70210: bearing installer set...

  • Page 359

    8-34 chassis • turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will be seated properly. • loosen the stem nut by 1/4 – 1/2 turn. Note: this adjustment will vary from motorcycle to motorcycle. Note: when installing the washer, align...

  • Page 360

    Chassis 8-35 steering tension adjustment check the steering movement in the following procedure. • by supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). • remove the steering damper. ( 8-29) • check to make sure that the cables and wi...

  • Page 361: Handlebars

    8-36 chassis handlebars construction removal • remove the brake master cylinder 1. • remove the right handle switch 2. • remove the handle balancer 3. • remove the right handle throttle grip 4. Fw d fwd 1 left handle grip 5 handlebar (rh) 2 right handle throttle grip 6 handlebar (lh) 3 right handle ...

  • Page 362

    Chassis 8-37 • remove the left handle switch 5 and disconnect the clutch lever switch lead wire. • remove the handle balancer 6. • remove the left handle grip 7. • disconnect the clutch cable 8. • remove the clutch lever holder 9. • loosen the handlebar clamp bolts and front fork upper clamp bolts. ...

  • Page 363

    8-38 chassis • insert the protrusion a of the handlebars into the hole b of the steering stem upper bracket. • tighten the front fork upper clamp bolts 1 and handlebar clamp bolts 2 to the specified torque.  front fork upper clamp bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) handlebar clamp bolt: 23 n·m (2...

  • Page 364

    Chassis 8-39 • apply the suzuki super grease “a” to the throttle cables and cable drum.  99000-25010: suzuki super grease “a” (or equivalent grease) • when remounting the right and left handle switches, engage the stopper with the handlebar hole. After installing the steering, the following adjustm...

  • Page 365: Rear Wheel

    8-40 chassis rear wheel construction 1* 1 rear axle 0 sprocket mounting drum 2 brake disc a sprocket 3 collar b bearing 4 dust seal c dust seal 5 rear wheel d collar 6 spacer a brake disc bolt item n·m kgf-m lb-ft 7 bearing b rear sprocket nut a 35 3.5 25.5 8 cushion c rear axle nut b 93 9.3 67.5 9 ...

  • Page 366

    Chassis 8-41 removal • remove the cotter pin. (for e-03, 28, 33) • loosen the axle nut 1. • remove the under cowling. ( 8-5) • raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the axle nut and draw out the rear axle. • remove the rear wheel by d...

  • Page 367

    8-42 chassis • remove the dust seal with the special tool.  09913-50121: oil seal remover • remove the dust seal with the special tool.  09913-50121: oil seal remover inspection and disassembly tire inspection ( 2-27 and 8-85) wheel inspection ( 8-85) rear axle • using a dial gauge, check the re...

  • Page 368

    Chassis 8-43 sprocket • inspect the sprocket teeth for wear. • if they are worn as shown, replace the two sprockets and drive chain as a set. A normal wear b excessive wear bearings • inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place. ...

  • Page 369

    8-44 chassis reassembly and installation reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: left right 100 n·m (10.0 kgf-m, 72.5 lb-ft) e-02, 19, 24 e-03, 28, 33 93 n·m (9.3 kgf-m, 67.5 lb-ft) 35 n·m (3.5 kgf-m, 25.5 lb-ft) 1...

  • Page 370

    Chassis 8-45 bearings • apply suzuki super grease “a” to the bearings before installing.  99000-25010: suzuki super grease “a” (or equivalent grease) • install the new bearing to the sprocket mounting drum with the special tool.  09913-70210: bearing installer set • first install the right wheel b...

  • Page 371

    8-46 chassis wheel damper • to install the wheel dampers, apply a special tire lubricant or neutral soapy liquid to the damper surface. Dust seals • install the new dust seal with the special tool.  09913-70210: bearing installer set • apply suzuki super grease “a” to the dust seal lip before assem...

  • Page 372

    Chassis 8-47 brake disc • apply thread lock to the disc bolts and tighten them to the specified torque. Note: make sure that the brake disc is clean and free of any greasy matter.  99000-32130: thread lock super “1360”  brake disc bolt: 35 n·m (3.5 kgf-m, 25.5 lb-ft) • install the collar 1. Rear a...

  • Page 373: Rear Shock Absorber

    8-48 chassis rear shock absorber construction 1 rear shock absorber a rear shock absorber mount- ing bolt/nut item n·m kgf-m lb-ft 2 rear shock absorber bracket b rear shock absorber bracket nut a 50 5.0 36.0 b 115 11.5 83.0

  • Page 374

    Chassis 8-49 removal • remove the front seat. ( 8-5) • remove the fuel tank. ( 5-4) • disconnect the ho2 sensor lead wire coupler. ( 4-107) • remove the under cowling. ( 8-5) • remove the exhaust muffler. ( 6-10) • loosen the axle nut. • support the motorcycle with a jack relieve no load on the...

  • Page 375

    8-50 chassis • remove the brake fluid reservoir mounting bolt. • loosen the rear shock absorber bracket. • remove the rear shock absorber upper and lower mounting bolts and nuts. • remove the rear shock absorber..

  • Page 376

    Chassis 8-51 inspection inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one. Rear shock absorber scrapping procedure rear shock absorber gas release • remove the valve cap 1. Do not attempt to disassemble the rea...

  • Page 377

    8-52 chassis • press the valve with a screwdriver to bleed out the nitrogen gas. Installation remount the rear shock absorber in the reverse order of removal. Pay attention to the following points: • install the rear shock absorber and tighten the rear shock absorber upper/lower mounting bolts and n...

  • Page 378

    Chassis 8-53 suspension setting after installing the rear suspension, adjust the spring pre-load and damping force as follows. Spring pre-load adjustment the set length 176.4 mm (6.94 in) provides the maximum spring pre-load. The set length 186.4 mm (7.34 in) provides the minimum spring pre-load.  ...

  • Page 379: Rear Suspension

    8-54 chassis rear suspension construction 1 rear shock absorber 0 plate 2 rear cushion rod a rear shock absorber mounting bolt/nut 3 rear cushion lever item n·m kgf-m lb-ft 4 spacer b rear cushion lever bolt/nut a 50 5.0 36.0 5 bearing c rear cushion rod bolt/nut b 98 9.8 71.0 6 chain cover d swinga...

  • Page 380

    Chassis 8-55 removal • cut the drive chain. ( 8-89 and -90) note: it is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • remove the rear shock absorber. ( 8-49 and -50) • remove the cushion lever mounting bolt/nut 1. • remove the cushion lever 2. • remove the cushi...

  • Page 381

    8-56 chassis • remove the plate 0. Inspection swingarm pivot shaft • using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit.  swingarm pivot shaft runout: service limit: 0.3 mm (0.01 in)  09900-20607: dial gauge (1/100 mm, 10 mm) 09900-20701: magnetic stand...

  • Page 382

    Chassis 8-57 swingarm • inspect the swingarm for damage. If any damages are found, replace the swingarm with a new one. Cushion rod • inspect the cushion rod for damage and distortion. • if any defects are found, replace the cushion rod with a new one. Cushion lever • inspect the cushion lever for d...

  • Page 383

    8-58 chassis swingarm bearing • insert the spacer into bearing and check the play when mov- ing the spacer up and down. • if excessive play is noted, replace the bearing with a new one. Cushion rod bearing • insert the spacer into bearing and check the play when mov- ing the spacer up and down. • if...

  • Page 384

    Chassis 8-59 disassembly swingarm bearing • draw out the swingarm pivot bearings with the special tool.  09921-20240: bearing remover set ( 28 mm) • remove the center spacer. Cushion rod bearing • draw out the cushion rod bearings with the special tool.  09921-20240: bearing remover set cushion le...

  • Page 385

    8-60 chassis reassembly and installation reassemble and install the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: left right 115 n·m (11.5 kgf-m, 83.0 lb-ft) 50 n·m (5.0 kgf-m, 36.0 lb-ft) 50 n·m (5.0 kgf-m, 36.0 lb-ft) 78 n·m (7.8 kgf-m, 56.5 lb-ft...

  • Page 386

    Chassis 8-61 swingarm bearing • install the center spacer. • press the bearings into the swingarm pivot with the special tool.  09941-34513: steering race installer note: when installing the bearing, stamped mark on the bearing must face outside. Cushion rod bearing • press the bearings into the cu...

  • Page 387

    8-62 chassis • remount the plate 1. • remount the chain cases 2 chain buffer 3 and rear fender (lower) 4. Swingarm pivot thrust clearance adjustment adjust swingarm pivot thrust clearance in the following procedure. • insert the swingarm pivot shaft and tighten to the specified torque.  09944-28320...

  • Page 388

    Chassis 8-63 shock absorber, cushion lever and cushion rod mounting bolt/nut • install the cushion lever. • tighten the cushion lever mounting nut 1 to the specified torque.  cushion lever mounting nut: 98 n·m (9.8 kgf-m, 71.0 lb-ft) • install the cushion rod. • tighten the cushion rod mounting nut...

  • Page 389: Front Brake

    8-64 chassis front brake construction 1 brake lever a master cylinder mounting bolt 2 dust boot b brake hose union bolt item n·m kgf-m lb-ft 3 piston set c caliper mounting bolt a 10 1.0 7.0 4 piston seal d caliper air bleeder valve b 23 2.3 16.5 5 dust seal e caliper housing bolt c 35 3.5 25.5 6 br...

  • Page 390

    Chassis 8-65 brake pad replacement • loosen the pad mounting pins 1. • remove the brake caliper by removing the caliper mounting bolts 2. • remove the pad mounting pins 1, brake pads and spring. Note: * when the brake caliper is removed, care must be used so as not to cause stress to the brake hose....

  • Page 391

    8-66 chassis • install the spring to the caliper, bring its wider side of pawl a facing top. • install the new brake pads. • install the brake caliper. • tighten each bolt to the specified torque.  pad mounting pin 1: 15 n·m (1.5 kgf-m, 11.0 lb-ft) front brake caliper mounting bolt 2: 35 n·m (3.5 k...

  • Page 392

    Chassis 8-67 caliper removal • remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta- cle. Note: place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. • remove the brake pads and spring. ( 8-65) calip...

  • Page 393

    8-68 chassis • remove the dust seals 4 and piston seals 5. Caliper inspection brake caliper • inspect the brake caliper cylinder wall for nicks, scratches or other damage. Brake caliper piston • inspect the brake caliper piston surface for any scratches or other damage. Caliper reassembly reassemble...

  • Page 394

    Chassis 8-69 piston seal • install the piston seals as shown in the illustration. O-ring • install the new o-ring 1 and reassemble caliper halves. • temporarily tighten the air bleeder valve 2. • tighten each bolt to the specified torque.  front brake caliper housing bolt 3: 22 n·m (2.2 kgf-m, 16.0...

  • Page 395

    8-70 chassis brake disc inspection • visually check the brake disc for damage or cracks. • measure the thickness with a micrometer. • replace the disc if the thickness is less than the service limit or if damage is found.  front disc thickness: service limit: 5.0 mm (0.20 in)  09900-20205: microme...

  • Page 396

    Chassis 8-71 master cylinder removal and disassembly • drain the brake fluid. ( 8-66) • disconnect the front brake light switch lead wires 1. • place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose. • rem...

  • Page 397

    8-72 chassis • remove the dust boot 9 push rod 0 and snap ring a. • remove the following parts. B secondary cup c piston d primary cup e return spring f return spring guide g air bleeder valve • remove the dust rubber h and snap ring i. • remove the connector j and o-ring k. Master cylinder inspecti...

  • Page 398

    Chassis 8-73 • inspect the piston surface for any scratches or other damage. • inspect the primary cup, secondary cup and dust seal for wear or damage. Master cylinder reassembly reassemble the master cylinder in the reverse order of disas- sembly. Pay attention to the following points:  specificat...

  • Page 399

    8-74 chassis • apply suzuki silicone grease to the brake lever pivot bolt.  99000-25100: suzuki silicone grease  brake lever pivot bolt: 1 n·m (0.1 kgf-m, 0.7 lb-ft) brake lever lock-nut: 6 n·m (0.6 kgf-m, 4.5 lb-ft) • align the convex part a of brake light switch with the hole b of master cylinde...

  • Page 400: Rear Brake

    Chassis 8-75 rear brake construction 1 brake pedal a caliper air bleeder valve 2 piston/cup set b brake hose union bolt item n·m kgf-m lb-ft 3 reservoir hose c brake caliper mounting bolt a 7.5 0.75 5.5 4 brake hose d brake master cylinder mounting bolt b 23 2.3 16.5 5 brake pad e brake master cylin...

  • Page 401

    8-76 chassis brake pad replacement • remove the pad mounting pin 1. • remove the caliper mounting bolt 2. • remove the brake pads with the rear caliper pivoted up. • clean up the caliper especially around the caliper piston. • install the new brake pads.  pad mounting pin: 15 n·m (1.5 kgf-m, 11.0 l...

  • Page 402

    Chassis 8-77 brake fluid replacement • remove the brake fluid reservoir mounting bolt 1. • place a rag underneath the brake fluid reservoir to catch any split brake fluid. Remove the brake fluid reservoir cap 2. • replace the brake fluid in the same manner as the front brake. ( 8-66)  specificatio...

  • Page 403

    8-78 chassis • remove the brake pad spring. • remove the caliper air bleeder valve 4. • remove the spacer 5 and rubber boot 6 from the caliper. • place a rag over the piston to prevent it from popping out and then force out the pistons using compressed air. • remove the dust seal 7 and piston seal 8...

  • Page 404

    Chassis 8-79 caliper inspection brake caliper and brake caliper piston • inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. • inspect the brake caliper piston surface for any scratches and other damage. If any da...

  • Page 405

    8-80 chassis caliper reassembly reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves.  specification and classification: dot 4 pis...

  • Page 406

    Chassis 8-81 caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • tighten each bolt to the specified torque.  brake hose union bolt 1: 23 n·m (2.3 kgf-m, 16.5 lb-ft) brake caliper mounting bolt 2: 17 n·m (1.7 kgf-m, 12.5 lb-ft) brake cal...

  • Page 407

    8-82 chassis • remove the reservoir cap 7, insulator 8, diaphragm 9 and reservoir tank 0. • remove the snap ring a with the special tool.  09900-06108: snap ring pliers • remove the connector b. • remove the o-ring c. • pull out the dust boot d, then remove the snap ring e.  09900-06108: snap ring...

  • Page 408

    Chassis 8-83 master cylinder inspection cylinder, piston and cup set • inspect the cylinder bore wall for any scratches or other dam- age. • inspect the cup set and each rubber part for damage. Master cylinder reassembly reassemble the master cylinder in the reverse order of disas- sembly. Pay atten...

  • Page 409

    8-84 chassis master cylinder installation install the master cylinder in the reverse order of removal. Pay attention to the following points: • apply thread lock to the master cylinder mounting bolts.  99000-32110: thread lock super “1322” (or equivalent thread lock) • tighten each bolt to the spec...

  • Page 410: Tire And Wheel

    Chassis 8-85 tire and wheel tire removal the most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. For o...

  • Page 411

    8-86 chassis valve inspection • inspect the valve after the tire is removed from the rim. • replace the valve with a new one if the seal a rubber is peel- ing or has damage. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the se...

  • Page 412

    Chassis 8-87 tire installation • apply tire lubricant to the tire bead. • when installing the tire onto the wheel, observe the following points. • when installing the tire, the arrow a on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the tim...

  • Page 413

    8-88 chassis • in this condition, check the “rim line” b cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire comp...

  • Page 414: Drive Chain

    Chassis 8-89 drive chain use the special tool in the following procedures, to cut and rejoin the drive chain.  09922-22711: drive chain cutting and joining tool set note: when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Drive chain cutting • s...

  • Page 415

    8-90 chassis • place the drive chain link being disjointed on the holder part 8 of the tool. • turn in both the adjuster bolt 6 and pressure bolt “a” 3 so that each of their end hole fits over the chain joint pin properly. • tighten the pressure bolt “a” 3 with the bar. • turn in the pressure bolt “...

  • Page 416

    Chassis 8-91 • apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0. Note: when positioning the joint plate 0 on the tool, its stamp mark must face the joint plate holder 3 side. • set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 to...

  • Page 417

    8-92 chassis • stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “a” 3 with the bar until the pin end diameter becomes the specified dimension.  pin end diameter specification d • adjust the drive chain, after connecting it. ( 2-20) rk 5.45 – 5.85 mm (0.215 – 0.230 in) * af...

  • Page 418: Electrical System

    Electrical system 9-1 9 electrical system contents cautions in servicing ......................................................................... 9- 3 connector ........................................................................................ 9- 3 coupler........................................

  • Page 419: Electrical System

    Electrical system contents 9-2 electrical system turn signal/side-stand relay .................................................. 9-37 starter relay ................................................................................. 9-37 fuel pump relay ....................................................

  • Page 420: Cautions In Servicing

    Electrical system 9-3 cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock when dis- connecting, an...

  • Page 421

    9-4 electrical system semi-conductor equipped part • be careful not to drop the part with a semi-conductor built in such as a ecm. • when inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. Battery • the mf battery used in this mot...

  • Page 422

    Electrical system 9-5 using the multi-circuit tester • properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make su...

  • Page 423

    9-6 electrical system location of electrical components 1 fuel pump relay ( 5-7) 2 iat sensor ( 4-53) 3 cooling fan relay ( 7-7) 4 pair control solenoid valve ( 11-7) 5 cmp sensor ( 4-33) 6 ignition coil (no.1, 2, 3, 4) 7 horn 8 fuel level gauge 9 fuel pump ( 5-8) 0 regulator/rectifier a oil p...

  • Page 424

    Electrical system 9-7 1 battery 2 ap sensor ( 4-57) 3 mode selection switch coupler ( 4-18) 4 fuse box 5 ecm (engine control module) 6 secondary fuel injector ( 4-80) 7 primary fuel injector ( 4-77) 8 ect sensor ( 4-49) 9 stv actuator ( 4-67) 0 stp sensor ( 4-70) a tp sensor ( 4-44) b iap se...

  • Page 425: Charging System

    9-8 electrical system charging system troubleshooting battery runs down quickly step 1 1) check accessories which use excessive amounts of electricity. Are accessories being installed? Step 2 1) check the battery for current leaks. ( 9-9) is the battery for current leaks ok? Step 3 1) measure the r...

  • Page 426

    Electrical system 9-9 step 5 1) measure the generator no-load performance. ( 9-11) is the generator no-load performance ok? Step 6 1) inspect the regulator/rectifier. ( 9-11) is the regulator/rectifier ok? Step 7 1) inspect wirings. Is the wirings ok? Battery overcharges • faulty regulator/rectifi...

  • Page 427

    9-10 electrical system regulated voltage • remove the front seat. ( 8-7) • start the engine and keep it running at 5 000 r/min with the dimmer switch turned hi position. • measure the dc voltage between the + and - battery termi- nals using the multi-circuit tester. If the voltage is not within the...

  • Page 428

    Electrical system 9-11 generator no-load performance • lift and support the fuel tank. ( 5-3) • disconnect the generator coupler. • start the engine and keep it running at 5 000 r/min. • using the multi-circuit tester, measure the voltage between three lead wires. If the tester reads under the spec...

  • Page 429

    9-12 electrical system starter system and side-stand/ignition interlock system troubleshooting make sure that the fuses are not blown and the battery is fully-charged before diagnosing. Starter motor will not run step 1 1) shift the transmission to neutral. 2) pull the clutch lever, turn on the igni...

  • Page 430

    Electrical system 9-13 step 3 1) measure the starter relay voltage at the starter relay connectors (between y/g + and b/y -) when the starter button is pushed. Is a voltage ok? Step 4 1) check the starter relay. ( 9-16) is the starter relay ok? Starter motor runs but does not crank the engine step ...

  • Page 431

    9-14 electrical system starter motor disassembly • disassemble the starter motor as shown in the illustration. Starter motor inspection carbon brush inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. ...

  • Page 432

    Electrical system 9-15 armature coil inspection check for continuity between each segment and between each segment and the armature shaft using the multi-circuit tester. If there is no continuity between the segments or there is conti- nuity between the segments and shaft, replace the armature with ...

  • Page 433

    9-16 electrical system • tighten the starter motor lead wire mounting bolt to the speci- fied torque.  lead wire mounting bolt: 6 n·m (0.6 kgf-m, 4.5 lb-ft) starter relay inspection • remove the front seat. ( 8-7) • disconnect the battery - lead wire from the battery. • remove the frame cover. ( ...

  • Page 434

    Electrical system 9-17 side stand/ignition interlock system parts inspection check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Side-s...

  • Page 435

    9-18 electrical system gear position switch • remove the front seat. • disconnect the battery - lead wire from the battery. • lift and support the fuel tank. ( 5-3) • disconnect the gear position switch coupler and check the continuity between blue and black/white with the transmis- sion in “neutra...

  • Page 436

    Electrical system 9-19 turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • remove the front seat.( 8-7) • disconnect the battery - lead wire from the battery. • remove the frame cover. ( 8-8) • remove the turn signal/sid...

  • Page 437: Ignition System

    9-20 electrical system ignition system note: the fuel cut-off circuit is incorporated in this ecm in order to prevent over-running of engine. When engine speed reaches 14 500 r/min, this circuit cuts off fuel at the fuel injector. But under no load, the clutch lever is pulled or the gear position is...

  • Page 438

    Electrical system 9-21 immobilizer (except for e-03, 28, 33) description the immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key id agrees with ecm id by means of radio communication through the immobilizer antenna. When the id agreement is ...

  • Page 439

    9-22 electrical system operation when the ignition switch is turned on with the engine stop switch in on, the immobi-antenna and ecm are powered on. The ecm transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key id and ecm id. With the signal rec...

  • Page 440

    Electrical system 9-23 troubleshooting no spark or poor spark note: check that the transmission is in neutral and the engine stop switch is in the “run” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) check the ignition...

  • Page 441

    9-24 electrical system step 5 1) inspect the ignition coil/plug caps. ( 9-26) is the ignition coil/plug cap ok? Step 6 1) measure the ckp sensor peak voltage and its resistance. ( 9-27 to -28) note: the ckp sensor peak voltage inspection is applicable only with the multi circuit tester and peak vo...

  • Page 442

    Electrical system 9-25 inspection ignition coil primary peak voltage • remove the air cleaner box. ( 5-14) • disconnect all the ignition coil/plug cap lead wire couplers before removing the ignition coil/plug caps. • remove all of the ignition coil/plug caps. • connect the new four spark plugs to e...

  • Page 443

    9-26 electrical system note: use the special tool, to prevent the rubber of the water proof coupler from damage. • shift the transmission into neutral and turn ignition switch “on”. • crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil prima...

  • Page 444

    Electrical system 9-27 ckp sensor peak voltage • remove the front seat. ( 8-7) note: be sure that all couplers are connected properly and the battery used is in fully-charged condition. • disconnect the both couplers 1. • connect the multi-circuit tester with peak volt adaptor as fol- lows. • measu...

  • Page 445

    9-28 electrical system if the peak voltage is lower than the standard range, check the peak voltage at the ckp sensor lead wire coupler. • remove the front seat. ( 8-7) • lift and support the fuel tank. ( 5-3) • disconnect the ckp sensor lead wire coupler and connect the multi-circuit tester with ...

  • Page 446: Combination Meter

    Electrical system 9-29 combination meter description this combination meter mainly consists of the stepping motor, lcd (liquid crystal display) and led (light emitting diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition. T...

  • Page 447

    9-30 electrical system removal and disassembly • remove the screw 1. • with the hooked parts 2 of the combination meter pulled from the headlight housing, disconnect the combination meter lead wire coupler. • remove the combination meter. • disassemble the combination meter as follows. When disconne...

  • Page 448

    Electrical system 9-31 inspection led (light emitting diode) check that the led lights [fi light, fuel level indicator light, engine rpm indicator light and immobilizer indi- cator light (for e-02, 19, 24)] immediately after turning the ignition switch on. Also, other led lights (neutral indicator l...

  • Page 449

    9-32 electrical system engine coolant temperature meter and indicator ect sensor inspection ( 7-7) • remove the front seat.( 8-7) • lift and support the fuel tank. ( 5-3) • disconnect the ect sensor coupler 1. • connect the variable resistor a between the terminals. • disconnect the oil pressure ...

  • Page 450

    Electrical system 9-33 fuel level gauge inspection • remove the fuel pump assembly. ( 5-9) • measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one.  09900-25008: multi-circuit tester set  tester knob indication:...

  • Page 451

    9-34 electrical system speedometer if the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. Speed sensor • remove the front seat.( ...

  • Page 452: Lamps

    Electrical system 9-35 lamps headlight, brake light/taillight, license plate light and turn signal light headlight 12 v 55 w h7 1 12 v 65 w h9 2 position light 3 12 v 5 w × 2 brake light/taillight: led licence plate light 4 12 v 5 w turn signal light 5 12 v 21 w × 4 if you have touched and the bulb ...

  • Page 453

    9-36 electrical system headlight beam adjustment • adjust the headlight beam. Note: * use a screw driver + for adjuster a and b. * to adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. A: horizontal adjuster b: vertical adjuster to adjust the beam horizontally: • ...

  • Page 454: Relays

    Electrical system 9-37 relays turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Inspection before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not i...

  • Page 455

    9-38 electrical system ignition switch removal • remove the air cleaner box. ( 5-14) • disconnect the ignition switch lead wire coupler (green) 1. • disconnect the immobilizer lead wire coupler (black) 2. (for e-02, 19, 24) • remove the cable guide 3. • remove the ignition switch mounting bolts wit...

  • Page 456

    Electrical system 9-39 switches inspection color position ignition switch (for e-02, 19, 24) hazard switch inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Note: before inspecting the oil pressure switch, check if ...

  • Page 457: Battery

    9-40 electrical system battery specifications 1 upper cover breather 5 terminal 2 cathode plates 6 safety valve 3 stopper 7 anode plates 4 filter 8 separator (fiberglass plate) initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes a. Note: whe...

  • Page 458

    Electrical system 9-41 note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers ...

  • Page 459

    9-42 electrical system servicing visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powder...

  • Page 460: Servicing Information

    Servicing information 10-1 10 servicing information contents troubleshooting ............................................................................... 10- 2 fi system malfunction code and defective condition...... 10- 2 engine ......................................................................

  • Page 461: Troubleshooting

    10-2 servicing information troubleshooting fi system malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c11 cmp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Cmp senso...

  • Page 462

    Servicing information 10-3 dtc no. Detected item detected failure condition check for c21 iat sensor the sensor voltage should be the fol- lowing. 0.15 v sensor voltage in other than the above range, c21 (p0110) is indicated. Iat sensor, lead wire/coupler connection p0110 h sensor voltage is higher ...

  • Page 463

    10-4 servicing information * : immobilizer system is equipped model only. Dtc no. Detected item detected failure condition check for c29 stp sensor the sensor should produce following voltage. 0.15 v sensor voltage in other than the above range, c29 (p1654) is indicated. Stp sensor, lead wire/couple...

  • Page 464

    Servicing information 10-5 dtc no. Detected item detected failure condition check for c44 ho2 sensor (for e-02, 19) ho2 sensor output voltage is not input to ecm during engine operation and running condition. (sensor voltage in other than the above value, c44 (p0130) is indicated. Ho2 sensor circuit...

  • Page 465

    10-6 servicing information engine complaint symptom and possible causes remedy engine will not start or is hard to start. Compression too low 1. Valve clearance out of adjustment 2. Worn valve guides or poor seating of valves 3. Mistiming valves 4. Excessively worn piston rings 5. Worn-down cylinder...

  • Page 466

    Servicing information 10-7 complaint symptom and possible causes remedy engine idles poorly. 1. Valve clearance out of adjustment 2. Poor seating of valves 3. Defective valve guides 4. Worn down camshafts 5. Too wide spark plug gaps 6. Defective ignition coil/plug caps 7. Defective ckp sensor 8. Def...

  • Page 467

    10-8 servicing information complaint symptom and possible causes remedy noisy engine excessive valve chatter 1. Too large tappet clearance 2. Weakened or broken valve springs 3. Worn tappet or cam surface 4. Worn and burnt camshaft journal noise seems to come from piston 1. Worn down pistons or cyli...

  • Page 468

    Servicing information 10-9 complaint symptom and possible causes remedy engine runs poorly in high speed range. Defective engine internal/electrical parts 1. Weakened valve springs 2. Worn camshafts 3. Valve timing out of adjustment 4. Too narrow spark plug gaps 5. Ignition not advanced sufficiently...

  • Page 469

    10-10 servicing information complaint symptom and possible causes remedy engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance 2. Weakened valve springs 3. Valve timing out of adjustment 4. Worn piston rings or cylinders 5. Poor seating of valves 6. Fouled spark ...

  • Page 470

    Servicing information 10-11 complaint symptom and possible causes remedy engine overheats defective engine internal parts 1. Heavy carbon deposit on piston crowns 2. Not enough oil in the engine 3. Defective oil pump or clogged oil circuit 4. Sucking air from intake pipes 5. Use incorrect engine oil...

  • Page 471

    10-12 servicing information radiator (cooling system) complaint symptom and possible causes remedy engine overheats 1. Not enough engine coolant 2. Radiator core clogged with dirt or scale 3. Faulty cooling fan 4. Defective cooling fan relay, or open- or short- circuited 5. Defective ecm 6. Defectiv...

  • Page 472

    Servicing information 10-13 chassis complaint symptom and possible causes remedy heavy steering 1. Overtightened steering stem nut 2. Broken bearing in steering stem 3. Distorted steering stem 4. Not enough pressure in tires adjust. Replace. Replace. Adjust. Wobbly handlebars 1. Loss of balance betw...

  • Page 473

    10-14 servicing information brakes complaint symptom and possible causes remedy insufficient brake power 1. Leakage of brake fluid from hydraulic system 2. Worn pads 3. Oil adhesion of engaging surface of pads/shoe 4. Worn disc 5. Air in hydraulic system 6. Not enough brake fluid in the reservoir re...

  • Page 474

    Servicing information 10-15 electrical complaint symptom and possible causes remedy no sparking or poor sparking 1. Defective ignition coils 2. Defective spark plugs 3. Defective cmp sensor 4. Defective ckp sensor 5. Defective ecm 6. Defective to sensor 7. Open-circuited wiring connections replace. ...

  • Page 475

    10-16 servicing information battery complaint symptom and possible causes remedy “sulfation”, acidic white powdery sub- stance or spots on surface of cell plates 1. Cracked battery case 2. Battery has been left in a run-down condition for a long time. Replace the battery. Replace the battery. Batter...

  • Page 476

    Servicing information 10-17 wiring harness, cable and hose routing wiring harness routing *5 *3 *4 *2 clamp wiring harness brake light switch ho2 sensor (e-02, 19) wiring harness starter motor lead wire clamp *2 *1 1 integrated clamp 8 protector 2 cooling fan relay *1 to ect sensor 3 fuel pump relay...

  • Page 477

    10-18 servicing information *2 clamp position light (lh) wiring harness turn signal light (rh) *3 6 n·m (0.6 kgf-m, 4.5 lb-ft) wiring harness battery - lead wire *4 *1 clamp guide iginition switch handlebar switch (rh) 1 rear combination light 8 brake light switch 2 excva 9 horn 3 ap sensor 0 regula...

  • Page 478

    Servicing information 10-19 *1 10 n·m (1.0 kgf-m, 7.0 lb-ft) 6 n·m (0.6 kgf-m, 4.5 lb-ft) 5 n·m (0.5 kgf-m, 3.5 lb-ft) 11 n·m (1.1 kgf-m, 8.0 lb-ft) 7 n·m (0.7 kgf-m, 5.0 lb-ft) 14 n·m (1.4 kgf-m, 10 lb-ft) 1 battery - lead wire *1 fix the clamp in parallel with the cover surface. 2 white tape.

  • Page 479

    10-20 servicing information ho2 sensor harness routing (for e-02, 19) *1 *2 *3 48 n·m (4.8 kgf-m, 34.5 lb-ft) *4 1 ho2 sensor *2 clamp the ho2 sensor lead wire so as not to over- lap the oil inspection window. 2 clutch cable 3 oil pan *3 pass the ho2 sensor lead wire through between the frame and en...

  • Page 480

    Servicing information 10-21 cable routing *1 *2 0 mm *3 0 mm 0 mm 1 clutch cable *1 clutch cable must be clamped on the grommet. 2 throttle cable no.1 *2 pass the throttle cables above the clutch cable. 3 throttle cable no.2 *3 pass the throttle cable no.2 outer from no.1..

  • Page 481

    10-22 servicing information fuel tank hose routing *2 *1 *3 1 fuel tank water drain hose *1 pass the fuel tank drain hose and breather hose through behind the pcv hose. 2 fuel tank breather hose *2 set the fuel tank drain hose and breather hose with lengthwise backward. 3 pcv (breather) hose *3 whit...

  • Page 482

    Servicing information 10-23 cooling system hose routing 1 reservoir tank overflow hose *1 clamp should face downward. 2 reservoir tank inlet hose *2 clamp should face right side. 3 oil cooler outlet hose *3 yellow marking 4 clearance *4 white marking 5 radiator inlet hose *5 clamp should face backwa...

  • Page 483

    10-24 servicing information front brake hose routing *1 *2 *5 1 – 2 mm (0.04 – 0.08 in) 42˚ *3 *4 *3 *6 *7 *3 42˚ 14˚ *4 1 brake hose guide *4 clamp the brake hose firmly. *1 clamp should face downward. *5 after positioning the clamp with stopper, tighten the clamp bolt. *2 clamp should face backwar...

  • Page 484

    Servicing information 10-25 rear brake hose routing *1 *2 28˚ 28˚ *4 28˚ 23 n.M 2.3 kgf-m 16.5 lb-ft *6 *5 23 n.M 2.3 kgf-m 16.5 lb-ft *3 *3 1 rear brake hose *2 pass the reservoir hose above the brake hose. 2 brake fluid reservoir hose *3 position the brake union with the stopper before tightening....

  • Page 485

    10-26 servicing information fuel tank installation cowling installation *1 *1 *1 1 velcro fastening 4 fuel tank side cushion 2 frame cover cushion *1 apply adhesive agent. (equivalent to aronalpha 201) 3 fuel tank front cover.

  • Page 486

    Servicing information 10-27 frame cover installation intake cover (rh) air intake pipe (rh) side cowling (lh) to head light under cowling cover (rh) side cowling (rh) to frame to oil pan under cowling (rh) heat shield heat shield body cowling under cowling (lh) under cowling cover (lh) wind screen c...

  • Page 487

    10-28 servicing information seat lock cable routing rear fender installation.

  • Page 488

    Servicing information 10-29 1 seat rail 4 rear fender (rear) 2 rear fender (front) 5 rear fender (lower) 3 rear fender cover (front) 6 swingarm.

  • Page 489

    10-30 servicing information side-stand installation under cowling cushion rubber/heat shield installation 40 n·m (4.0 kgf-m, 29.0 lb-ft) 50 n·m (5.0 kgf-m, 36.0 lb-ft) 50 n·m (5.0 kgf-m, 36.0 lb-ft) 1 side-stand spring no.1 2 side-stand spring no.2 max. 3 mm (0.12 in) 2 mm (0.08 in) 1 under cowling ...

  • Page 490

    Servicing information 10-31 front footrest installation 18 n.M (1.8 kgf-m, 13.0 lb-ft) *1 10 n.M (1.0 kgf-m, 7.0 lb-ft) 46 n.M (4.6 kgf-m, 33.5 lb-ft) 18 n.M (1.8 kgf-m, 13.0 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) *2 23 n·m (2.3 kgf-m, 16.5 lb-ft) *2 1 footrest 7 front footrest no. 2 bracket (rh) 2 b...

  • Page 491

    10-32 servicing information rear view mirror installation *1 1 body cowling 5 turn signal lead wire coupler 2 cowling brace 6 mirror cover 3 cushion 7 mirror body 4 turn signal lead wire *1 locate the turn signal lead wire coupler 5 between the mirror cover 6 and mirror body 7..

  • Page 492

    Servicing information 10-33 special tools 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-18740 hexagon socket (24 mm) 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20203 micrometer (50 – 75 mm) 09900-20205 micrometer (0 – 25 mm) 09900-20508 cylin...

  • Page 493

    10-34 servicing information 09910-20115 conrod stopper 09913-10750 adapter 09913-50121 oil seal remover 09913-70210 bearing installer set 09915-40610 oil filter wrench 09915-64512 compression gauge set 09915-74521 oil pressure gauge hose 09915-74540 oil pressure gauge attachment 09915-77331 meter (f...

  • Page 494

    Servicing information 10-35 09917-47011 vacuum pump gauge 09919-28610 sleeve protector 09920-34830 starter clutch holder 09920-53740 clutch sleeve hub holder 09921-20210 bearing remover 09921-20240 bearing remover set 09922-22711 drive chain cutting and joining tool 09923-74511 bearing remover 09924...

  • Page 495

    10-36 servicing information note: when order the special tool, please confirm whether it is available or not. 09940-14940 swingarm pivot thrust adjuster socket wrench 09940-14990 engine mounting thrust adjuster socket wrench 09940-30221 front fork assem- bling tool 09940-40211 fuel pressure gauge ad...

  • Page 496: Tightening Torque

    Servicing information 10-37 tightening torque engine item n·m kgf-m lb-ft exhaust pipe bolt 23 2.3 16.5 muffler connecting bolt 23 2.3 16.5 muffler mounting bolt 23 2.3 16.5 speed sensor rotor bolt 25 2.5 18.0 speed sensor bolt 4.5 0.45 3.0 engine sprocket nut 115 11.5 83.0 engine mounting bolt (cyl...

  • Page 497

    10-38 servicing information fi system and intake air system cooling system item n·m kgf-m lb-ft crankcase bolt (m: 6) (initial) 6 0.6 4.5 (final) 11 1.1 8.0 (m: 8) (initial) 15 1.5 11.0 (final) 26 2.6 19.0 crankcase bolt (inner hexagon) (m: 8) (initial) 15 1.5 11.0 (final) 22 2.2 16.0 crankshaft jou...

  • Page 498

    Servicing information 10-39 chassis item n·m kgf-m lb-ft steering stem head nut 90 9.0 65.0 steering stem lock-nut 80 8.0 58.0 steering damper bolt and nut 23 2.3 16.5 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 23 2.3 16.5 front fork cap bolt 35 3.5 25.5 front fork inner rod...

  • Page 499

    10-40 servicing information tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: item n·m kgf-m lb-ft seat rail bolt 50 5.0 36.0 rear view mirror nut 10 1.0 7.0 bolt diameter a (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m lb-ft n·m...

  • Page 500: Service Data

    Servicing information 10-41 service data valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 29.0 (1.14) — ex. 23.0 (0.91) — valve clearance (when cold) in. 0.08 – 0.18 (0.0031 – 0.0071) — ex. 0.18 – 0.28 (0.0071 – 0.0110) — valve guide to val...

  • Page 501

    10-42 servicing information cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm², 185 – 242 psi) 1 000 kpa (10 kgf/cm 2 , 142 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , 28 psi) piston to cylinder clearance 0.030 –...

  • Page 502

    Servicing information 10-43 conrod + crankshaft unit: mm (in) balancer unit: mm (in) oil pump item standard limit conrod small end i.D. 15.010 – 15.018 (0.5909 – 0.5913) 15.040 (0.5921) conrod big end side clearance 0.10 – 0.20 (0.004 – 0.008) 0.30 (0.012) conrod big end width 19.95 – 20.00 (0.7854 ...

  • Page 503

    10-44 servicing information clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio item standard limit clutch lever play 10 – 15 (0.4 – 0.6) — clutch release screw 1/2 turn back — drive plate thickness no. 1, 2 and 3 2.72 – 2.88 (0.107 – 0.113) 2.42 (0.095) drive plate claw width...

  • Page 504

    Servicing information 10-45 thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temper- ature approx. 82 °c (180 °f) — thermostat valve lift 8 mm (0.31 in) and over at 95 °c (203 °f) — ect sensor resistance 20...

  • Page 505

    10-46 servicing information fi sensors item specification note ckp sensor resistance 142 – 194 Ω ckp sensor peak voltage 0.28 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.7 v at idle speed tp sensor input voltage 4.5 – 5.5 v tp sensor resistance a...

  • Page 506

    Servicing information 10-47 throttle body electrical unit: mm (in) item specification bore size 42 mm i.D. No. 02h1 (for e-33), 02h0 (for the others) idle r/min 1 200 ± 100 r/min fast idle r/min 1 500 – 2 000 r/min (when cold engine) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specificati...

  • Page 507

    10-48 servicing information wattage unit: w brake + wheel unit: mm (in) item standard/specification e-03, 28, 33 others headlight hi 65 ← lo 55 ← position/parking light 5 × 2 ← brake light/taillight led ← turn signal light 21 × 4 ← license plate light 5 ← combination meter light led ← turn signal in...

  • Page 508

    Servicing information 10-49 tire item standard limit wheel rim runout axial — 2.0 (0.08) radial — 2.0 (0.08) wheel rim size front 17 m/c × mt 3.50 — rear 17 m/c × mt 5.50 — wheel axle runout front — 0.25 (0.010) rear — 0.25 (0.010) item standard limit cold inflation tire pressure (solo riding) front...

  • Page 509

    10-50 servicing information suspension unit: mm (in) fuel + oil item standard limit front fork stroke 120 (4.92) — front fork spring free length 264.8 (10.43) 259.5 (10.22) front fork oil level (without spring, outer tube fully compressed) 112 (4.41) — front fork oil type suzuki fork oil ss-05 or eq...

  • Page 510

    Emission control information 11-1 11 emission control information contents emission control systems ...............................................................11- 2 fuel injection system..................................................................11- 2 crankcase emission control system .......

  • Page 511: Emission Control Systems

    11-2 emission control information emission control systems fuel injection system gsx-r750 motocycles are equipped with a fuel injection system for emission level control. This fuel injec- tion system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With...

  • Page 512

    Emission control information 11-3 crankcase emission control system the engine is equipped with a pcv system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the pcv (breather) hose, air cleaner and throttle body. 1 pair control...

  • Page 513

    11-4 emission control information exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system, exhaust control system and three-way catalyst system. The fresh air is drawn into the exhaust port through the pair control solenoid valve and pair reed...

  • Page 514

    Emission control information 11-5 noise emission control system tampering with the noise control system prohibited: local law or federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or r...

  • Page 515: Inspection

    11-6 emission control information pair (air supply) system and emission control system inspection pair hoses • inspect the pair hoses for wear or damage. • inspect the pair hoses is securely connected. Pair reed valve • remove the cylinder head cover. ( 3-14) • remove the pair reed valve 1 with the...

  • Page 516

    Emission control information 11-7 pair control solenoid valve • remove the air cleaner box. ( 5-14) • disconnect the pair control solenoid valve lead wire coupler 1 and pair hoses. • remove the pair control solenoid valve 2. • check that air flows through the air inlet port to the air outlet port. ...

  • Page 517

    11-8 emission control information pair (air supply) system hose routing approx. 0˚ approx. 0˚ approx. 0˚ *2 *1 *1 1 pair control solenoid valve *1 white marking 2 pair reed valve *2 yellow marking (opposite side).

  • Page 518

    Emission control information 11-9 ho2 sensor inspection (for e-02, 19) the ho2 sensor coupler 1 is located under the fuel tank. • inspect the ho2 sensor and its circuit referring to flow table of the malfunction code c44 (p0130/p0135). • check the resistance between the terminals of the ho2 sen- sor...

  • Page 519

    12 wiring diagram e-02, 19, 24 wiring diagrams wire color, refer to section “wire color”. O/b o/w o/g w/b y/g o w/y o/b o/w b/r b/bl y/g o/r y/w g b/w o w/b o/g w/b o/w w/bl o/w b o/w y o/w g o/w w/g g b/w b/w w/r lg lg/w lg/g lg/bl b/y bl b/br o/bl bl/w bl/b bl/g w/bl b y gr/w gr/b gr/y gr/r w/g o/...

  • Page 520

    E-03, 28, 33 o/b o/w o/g w/b y/g o w/y o/b o/w b/r b/bl y/g o/r y/w g b/w o w/b o/g w/b o/w w/bl o/w b o/w y o/w g o/w w/g g b/w b/w w/r lg lg/w lg/g lg/bl b/y bl b/br bl/w bl/b bl/g w/bl b y gr/w gr/b gr/y gr/r w/g o/r y/g y/b y/bl bl/y b/w y/r gr o/bl b/br b/br dg g/y dgr p b o/y y/w b/lg g o/w r/...

  • Page 521

    Prepared by december, 2005 part no. 99500-37130-01e printed in japan 524.

  • Page 522

    Printed in japan k6.