1. DL manuals
  2. Suzuki
  3. Motorcycle
  4. GSX-R1000 2007
  5. Service Manual

Suzuki GSX-R1000 2007 Service Manual

Summary of GSX-R1000 2007

  • Page 1

    9 9 5 0 0 - 3 9 3 1 0 - 0 1 e gsx-r1000 pdf processed with cutepdf evaluation edition www.Cutepdf.Com.

  • 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: General Information

    General information 1-1 1 general information contents warning/caution/note........................................................................ 1- 2 general precautions ......................................................................... 1- 2 suzuki gsx-r1000k7 (’07-model).....................

  • Page 4: 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. # indicat...

  • Page 5

    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 6: Serial Number Location

    1-4 general information suzuki gsx-r1000k7 (’07-model) • difference between illustration and actual motorcycle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) is stamped on the right side of the steering head pipe. The engi...

  • Page 7

    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 8

    1-6 general information front fork oil use fork oil l01 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 clog ...

  • Page 9: 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 10: Information Labels

    1-8 general information information labels a: attached *1: this label is attached on the left side of rear fender. *2: this label is attached on the upper side of rear fender. Gsx-r1000 gsx-r1000uf noise label a (for e-03, 24, 33) information label a (for e-03, 28, 33) vacuum hose routing label a (f...

  • Page 11: Specifications

    General information 1-9 specifications dimensions and dry mass overall length .......................................................................... 2 045 mm (80.5 in) overall width ........................................................................... 720 mm (28.3 in) overall height .........

  • Page 12

    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 13: Periodic Maintenance

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

  • Page 14

    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 15

    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 16: 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 • lift and support the fuel tank. ( 5-3) • remove the air cleaner box cover . • remove the air cleaner element. • inspect th...

  • Page 17

    Periodic maintenance 2-5 spark plug spark plug and ignition coil/plug cap removal • lift and support the fuel tank. ( 5-3) • remove the air cleaner box. ( 5-14) • disconnect all lead wire couplers from the ignition coil/plug caps. • remove the ignition coils/plug caps. • remove the spark plugs. \ 09...

  • Page 18

    2-6 periodic maintenance spark plug gap • measure the spark plug gap " with a wire gauge. • if it is not within the specification, replace the spark plug. Spark plug gap: standard: 0.8 – 0.9 mm (0.031 – 0.035 in) electrode’s condition • check the condition of the electrode. • if it is extremely worn...

  • Page 19

    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 . • remove the pair control solenoid valve . • remove the spark plugs. ( 2-5) • loosen the throttle bod...

  • Page 20

    2-8 periodic maintenance • turn the crankshaft to bring the “top” line on the starter clutch to the index mark and also to bring the notches $ 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 % (in. And ex. Of no....

  • Page 21: 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. ( 3-16) • remove the tappet and shim by fingers or magnetic hand. • check the figures printed on the shim. These...

  • Page 22

    2-10 periodic maintenance (intake side) 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...

  • Page 23

    Periodic maintenance 2-11 (exhaust side) 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....

  • Page 24

    2-12 periodic maintenance engine oil and oil filter engine oil replacement • place an oil pan below the engine, and drain oil by removing the oil drain plug and filler cap . • tighten the drain plug to the specified torque, and pour fresh oil through the oil filler. The engine will hold about 3.0 l ...

  • Page 25

    Periodic maintenance 2-13 oil filter replacement • drain the engine oil as described in the engine oil replace- ment procedure. • remove the right under cowling. ( 8-5) • remove the oil filter with the special tool. \ 09915-40610: oil filter wrench • apply engine oil lightly to the gasket of the new...

  • Page 26

    2-14 periodic maintenance • remove the right under cowling. ( 8-5) • check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play ( 6-9) and tighten them. Fuel line • inspect the fuel feed hose for damage and fuel leakage. If any defects are found, the fuel feed hose must be repl...

  • Page 27

    Periodic maintenance 2-15 throttle cable play • adjust the throttle cable play " as follows. • loosen the lock-nut of the throttle pulling cable . • turn the adjuster in or out until the throttle cable play (at the throttle grip) " is between 2.0 – 4.0 mm (0.08 – 0.16 in). • tighten the lock-nut whi...

  • Page 28

    2-16 periodic maintenance clutch clutch fluid level • keep the motorcycle upright and place the handlebars straight. • check the clutch fluid level by observing the lower line on the clutch fluid reservoir. • if the level is found to be lower than the lower line, replenish with brake fluid that meet...

  • Page 29

    Periodic maintenance 2-17 bleeding air from the clutch fluid circuit the clutch fluid circuit may be purged of air in the following man- ner. • keep the motorcycle upright and place the handlebars straight. • fill up the clutch master cylinder reservoir to the upper line. Place the reservoir cap to ...

  • Page 30

    2-18 periodic maintenance cooling system engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the upper and lower lines on the engine coolant reservoir. " upper line # lower line • if the level is below the lower line, lift and support the fuel tank...

  • Page 31

    Periodic maintenance 2-19 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 32

    2-20 periodic maintenance radiator hoses • remove the under cowlings. ( 8-5) • lift and support the fuel tank. ( 5-3) • remove the sprocket cover bolts. • check the radiator hoses for crack, damage or engine coolant leakage. • if any defect is found, replace the radiator hose with new one..

  • Page 33

    Periodic maintenance 2-21 drive chain visually check the drive chain for the possible defects listed below. (support the motorcycle by a jack or a wooden block, turn the rear wheel slowly by hand with the transmission shifted to neutral.) * loose pins * excessive wear * damaged rollers * improper ch...

  • Page 34

    2-22 periodic maintenance adjusting • loosen or tighten both chain adjuster bolts until there is 20 – 30 mm (0.8 – 1.2 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The chain adjuster position relative to the reference marks " on both sides of the swingarm m...

  • Page 35

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

  • Page 36

    2-24 periodic maintenance brake pads front brake the extent of brake pad wear can be checked by observing the grooved limit line " on the pads. When the wear exceeds the grooved limit line, replace the pads with the new ones. ( 8-66) rear brake the extent of brake pad wear can be checked by observin...

  • Page 37

    Periodic maintenance 2-25 brake pedal height • loosen the lock-nut . • turn the push rod until the brake pedal height becomes 65 – 75 mm (2.6 – 3.0 in) " below the top of the footrest. • tighten the lock-nut securely. " rear brake master cylinder rod lock-nut: 18 n·m (1.8 kgf-m, 13.0 ib-ft) brake pe...

  • Page 38

    2-26 periodic maintenance front brake (caliper side) • fill the master cylinder reservoir to the upper level. Place the reservoir cap to prevent dirt from entering. • attach a hose to the brake caliper air bleeder valve and insert the free end of the hose into a receptacle. • squeeze and release the...

  • Page 39

    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 40

    2-28 periodic maintenance steering the steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtighten steering pre- vents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Suppo...

  • Page 41

    Periodic maintenance 2-29 exhaust pipe bolt and muffler bolt • tighten the exhaust pipe bolts, muffler mounting bolts and muffler connecting bolts to the specified torque. • ho2 sensor removal and installation ( 4-113) tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 mi...

  • Page 42

    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 43

    Periodic maintenance 2-31.

  • Page 44: 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 45: 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 46: Sds Check

    2-34 periodic maintenance sds check using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the cond...

  • Page 47

    Periodic maintenance 2-35 data at 3 000 r/min under no load data at the time of racing approx. 3 000 r/min check the manifold absolute pressure. Xx kpa check the engine coolant temperature. Xx ˚c pair control solenoid valve on off in accordance with the throttle valve opens closes secondary throttle...

  • Page 48

    2-36 periodic maintenance data of intake negative pressure during idling (100 °c) data of manifold absolute pressure operation at the time of starting check the manifold absolute pressure. Xx kpa check the engine coolant temperature. Approx. 100 ˚c check the manifold absolute pressure. Xx kpa.

  • Page 49

    Periodic maintenance 2-37 example of trouble three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same co...

  • Page 50: 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 51

    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 52

    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 53

    3-4 engine oil cooler • remove the oil cooler hose bolts. • remove the oil cooler . Radiator • remove the regulator/rectifier bracket. • disconnect the water/air bleed hose and radiator inlet hose . • disconnect the reservoir inlet hose . • disconnect the cooling fan lead wire coupler . Be careful n...

  • Page 54

    Engine 3-5 • remove the radiator mounting bolts. • remove the radiator . • remove the horn . • remove the front engine cover . Muffler, chamber and exhaust pipe • remove the excv cables along with the bracket . • disconnect the ho2 sensor coupler lead wire. ( 6-13) • remove the mufflers, muffler cha...

  • Page 55

    3-6 engine electric parts and pair hose • disconnect the oil pressure switch lead wire . • disconnect the starter motor lead wire . • disconnect the ground lead wire . • disconnect the ckp sensor lead wire coupler . • disconnect the ect sensor lead wire coupler . • disconnect the gp switch lead wire...

  • Page 56

    Engine 3-7 • remove the ignition coils/plug caps. • disconnect the pair hoses . Engine sprocket and gearshift lever • disengage the gearshift lever from the gearshift shaft. • remove the engine sprocket cover . • remove the clutch push rod . • remove the speed sensor rotor . • remove the engine spro...

  • Page 57

    3-8 engine • loosen the rear axle nut . • loosen the chain adjuster lock-nuts (lh and rh). • loosen the chain adjusters . (lh and rh) • push the rear wheel forward and make sure that the drive chain has enough slack. • disengage the drive chain from the rear sprocket. • remove the engine sprocket . ...

  • Page 58

    Engine 3-9 • loosen the engine mounting pinch bolts and . • remove the engine mounting bolts # and %. • remove the engine mounting nut . • remove the engine mounting thrust adjuster lock-nut with the special tool. • loosen the engine mounting thrust adjuster fully. \ 09940-14980: engine mounting thr...

  • Page 59

    3-10 engine • remove the engine mounting nut . • loosen the engine mounting thrust adjuster lock-nut with the special tool. • loosen the engine mounting thrust adjuster . \ 09940-14980: engine mounting thrust adjuster socket wrench note: do not remove the engine mounting bolts at this stage. • remov...

  • Page 60

    Engine 3-11 • gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft. • install all engine mounting bolts, spacers and tighten them temporarily. ( 3-12) • tighten the engine mounting thrust adjusters to the specified torque. " engine mounting thrust adju...

  • Page 61

    3-12 engine b lh c rh " length item n·m kgf-m lb-ft item mm in "#$% 55 5.5 40.0 bolt "$ 45 1.77 75 7.5 54.0 #% 55 2.17 23 2.3 16.5 &( 215 8.46 23 2.3 16.5 spacer 30.5 1.20 45 4.5 32.5 adjuster 40 1.57.

  • Page 62

    Engine 3-13 • install the engine sprocket and the washer. • apply a small quantity of thread lock to the driveshaft thread portion. H 99000-32110: thread lock super “1322” or equivalent • tighten the engine sprocket nut to the specified torque. " engine sprocket nut: 115 n·m (11.5 kgf-m, 83.0 lb-ft)...

  • Page 63

    3-14 engine • install the exhaust pipes, muffler chamber and mufflers. ( 6-16) • connect the excv cables and install the bracket . " excv cable bracket nut: 11 n·m (1.1 kgf-m, 8.0 lb-ft) • fit the new o-rings to the union of the oil cooler pipes. • apply thread lock to the bolts, install the oil coo...

  • Page 64: Engine Disassembly

    Engine 3-15 engine disassembly • remove all the spark plugs. ( 2-5) • remove the engine coolant reservoir bracket. Starter motor • remove the starter motor . Cylinder head cover • remove the cylinder head cover and its gaskets. • remove the dowel pins and o-rings. Identify the position of each remov...

  • Page 65

    3-16 engine camshaft • remove the valve timing inspection cap . • turn the crankshaft to bring the line " on the starter clutch to the index mark # of the valve timing inspection hole and also to bring the cams to the position as shown below. • remove the cam chain tension adjuster cap bolt , washer...

  • Page 66

    Engine 3-17 • remove the cam chain guide no.2 . • remove the intake camshaft journal holder . • remove the exhaust camshaft journal holder . • remove the intake camshaft . • remove the exhaust camshaft ". • remove the dowel pins. Cylinder head • remove the bypass hose . • remove the thermostat cover...

  • Page 67

    3-18 engine • remove the cylinder head gasket and dowel pins. Clutch • remove the clutch cover . • remove the gasket and dowel pins. • 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 b...

  • Page 68

    Engine 3-19 • remove the pressure plate . • remove the clutch drive plates and driven plates . • remove the clutch push piece , bearing and the thrust washer . • remove the spring washer and its seat . • remove the clutch push rod ". Note: if it is difficult to pull out the push rod ", use a magneti...

  • Page 69

    3-20 engine • hold the clutch sleeve hub with the special tool. \ 09920-53740: clutch sleeve hub holder • remove the clutch sleeve hub #. • remove the conical spring washer $, washer % and spring washer seat & from the clutch sleeve hub. • remove the spring washers ' and clutch lifter driven cam (. ...

  • Page 70

    3-20 engine • hold the clutch sleeve hub with the special tool. 09920-53740: clutch sleeve hub holder • remove the clutch sleeve hub . • remove the conical spring washer , washer and spring washer seat from the clutch sleeve hub. • remove the spring washers and clutch lifter driven cam . • remove th...

  • Page 71

    Engine 3-21 • remove the thrust washer . • remove the oil pump drive gear from the primary driven gear assembly . Oil pump • remove the snap ring . • remove the oil pump driven gear . Note: do not drop the snap ring into the crankcase. • remove the pin and washer . • remove the oil pump . Note: do n...

  • Page 72

    3-22 engine starter idle gear • remove the starter idle gear cover . • remove the dowel pins and gasket . • remove the spring washer , washer and starter idle gear no.1 . • remove the shaft , bearing and thrust washer . • remove the starter clutch cover ..

  • Page 73

    Engine 3-23 • remove the dowel pins and gasket . • remove the spring washer , starter idle gear no.2 and shaft . Starter clutch • hold the starter clutch with the special tool. 09920-34830: starter clutch holder • remove the starter clutch bolt and washer. • remove the starter clutch assembly and wa...

  • Page 74

    3-24 engine generator cover • remove the generator cover . • remove the dowel pins and gasket . Generator rotor • hold the generator rotor with the special tool. 09930-44520: rotor holder • remove the generator rotor bolt. • install a bolt " of suitable size to the left end of crankshaft. Suitable b...

  • Page 75

    Engine 3-25 water pump • remove the water inlet cover . • remove the water pump . Water pump servicing ( 7-13) gear position switch • remove the gear position switch . Crankcase breather (pcv) cover • remove the crankcase breather cover . • remove the gasket ..

  • Page 76

    3-26 engine oil filter • remove the oil filter with the special tool. 09915-40610: oil filter wrench oil pan • remove the oil pan . • remove the gasket . • remove the oil pipe . Oil pressure switch • remove the oil pressure switch . Oil strainer • remove the oil strainer and o-ring. Lower crankcase ...

  • Page 77

    Engine 3-27 transmission • remove the countershaft assembly and driveshaft assem- bly . • remove the o-rings and dowel pins. • remove the c-rings and bearing pins . Middle crankcase • remove the crankcase bolts (m6). • remove the crankcase bolts (m6). • remove the crankcase bolts (m8). • remove the ...

  • Page 78

    3-28 engine crankshaft • remove the o-ring . • loosen the bearing cap bolts by using 10 mm, 12 point socket wrench, and tap the bearing cap bolts lightly with plastic ham- mer to remove the bearing cap. • remove the crankshaft and thrust washers . Piston and conrod • push the conrod to cylinder head...

  • Page 79: Engine Components Inspection

    Engine 3-29 engine components inspection and service cylinder head cover • clean and check the gasket grooves " and pair reed valve gasket mating surfaces of cylinder head cover. • if it is damaged, replace the cylinder head cover with a new one. Cmp sensor removal • remove the cmp sensor from the c...

  • Page 80

    3-30 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. Installation • install the pair reed valves and pair reed valve covers. • apply thread lock to the bolts and tighten to the specifie...

  • Page 81

    Engine 3-31 camshaft journal wear • determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • use the plastigauge to read the clearance at the widest portion, which is specified as follows: camshaft journal oil clearance: s...

  • Page 82

    3-32 engine • if the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • replace the camshaft or the cylinder head depending upon which one exceeds the specification. Camshaft journal ho...

  • Page 83

    Engine 3-33 cam chain tensioner inspection • check the contacting surface of the cam chain tensioner. • if it is worn or damaged, replace it with a new one. Cam chain guide inspection • check the contacting surfaces of the cam chain guides no.1 and no.2. • if they are worn or damaged, replace them w...

  • Page 84

    3-34 engine • remove the oil seal and spring seat . • remove the other valves in the same manner as described previously. 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...

  • Page 85

    Engine 3-35 valve head radial runout • place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. • if it measures more than the service limit, replace the valve. Valve head radial runout: service limit: 0.03 mm (0.001 in) 09900-20607: dial gauge (1/100 mm...

  • Page 86

    3-36 engine valve stem wear • if the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. • if the stem is within the limit, then replace the guide. • after replacing valve or guide, be sure to recheck the deflec- tion. Valve stem o.D.: standard (in) : 4.475 – 4.49...

  • Page 87

    Engine 3-37 • cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c (212 – 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 and attachment . 09916-43211: val...

  • Page 88

    3-38 engine • if the seat width measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter. Valve seat width : 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 seats for...

  • Page 89

    Engine 3-39 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 90

    3-40 engine • put on the valve spring retainer , and using the special tools, press down the spring, fit the cotter halves 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 09916-84...

  • Page 91

    Engine 3-41 • apply grease to the o-rings. 99000-25010: suzuki super grease “a” or equivalent • install the intake pipes with “up” mark faces to the top side. Water bypass union • remove the water bypass union . • apply bond to the thread part of water bypass union and tighten it to the specified to...

  • Page 92

    3-42 engine • measure the claw width of drive plates with a vernier calipers. • replace the drive plates found to have worn down to the limit. Drive plate claw width: service limit: 13.05 mm (0.5138 in) 09900-20102: vernier calipers clutch driven plate inspection note: wipe off engine oil from the c...

  • Page 93

    Engine 3-43 clutch sleeve hub/primary driven gear assembly • inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one. Clutch lifter clutch lifter drive cam and driven cam inspec- tion • inspect...

  • Page 94

    3-44 engine • check the height of clutch lifter adjusting pin screws at three positions using the thickness gauges. • if the measurement is out of the specification, adjust the height in the following procedures. Note: each clutch lifter adjusting pin screw height should be as close as possible. • l...

  • Page 95

    Engine 3-45 starter clutch inspection • install the starter driven gear onto the starter clutch . • turn the starter driven gear by hand. • inspect the starter clutch for a smooth movement. • check that the gear turns only in one direction. • if a large resistance is felt for rotation, inspect the s...

  • Page 96

    3-46 engine water pump 7-13 gearshift system gearshift shaft/gearshift arm disassembly • remove the following parts from the gearshift shaft/gearshift arm. Washer gearshift cam drive plate snap ring plate return spring gearshift shaft return spring gearshift shaft/gearshift arm inspection • inspect ...

  • Page 97

    Engine 3-47 oil pressure regulator removal • remove the oil pressure regulator case from the oil pan. • remove the oil pressure regulator . Inspection • inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • if the piston does not operate, replace the oil p...

  • Page 98

    3-48 engine transmission disassembly disassemble the countershaft and driveshaft. Pay attention to the following points: • remove the 6th drive gear snap ring from its groove and slide it towards the 3rd/4th drive gears . • slide the 6th and 2nd drive gears toward the 3rd/4th drive gears , then remo...

  • Page 99

    Engine 3-49 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 100

    3-50 engine transmission parts location countershaft driveshaft.

  • Page 101

    Engine 3-51 cylinder crankcase servicing ( 3-55) 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 102

    3-52 engine piston and piston ring piston diameter • using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) " from the piston skirt end. • if the measurement is less than the limit, replace the piston. Piston diameter: service limit: 73.280 mm (2.8850 in) at 10 mm (0.39 in) from t...

  • Page 103

    Engine 3-53 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 ring-...

  • Page 104

    3-54 engine piston ring free end gap and piston ring end gap • measure the piston ring free end gap using the vernier cali- pers. • next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. • if any of the measurements exceeds the service lim...

  • Page 105

    Engine 3-55 crankcase gearshift fork and gearshift cam removal • remove the gearshift cam bearing retainer screws and gearshift fork shaft retainer from the lower crankcase. • remove the gearshift fork shafts and gearshift forks from the lower crankcase. • remove the gearshift cam and its bearing . ...

  • Page 106

    3-56 engine gearshift fork thickness • measure the gearshift fork thickness using the vernier cali- pers. Shift fork thickness: standard: 4.8 – 4.9 mm (0.189 – 0.193 in) \ 09900-20102: vernier calipers gearshift cam bearing and gearshift shaft bearing bearing inspection • inspect the gearshift cam b...

  • Page 107

    Engine 3-57 • remove the oil seal . • remove the gearshift shaft bearing with the special tool. \ 09921-20240: bearing remover set (15 mm) installation • install the bearings with the special tool. \ 09913-70210: bearing installer set ( ¬20) ( ¬22) ( ¬32) note: the stamped mark side of the gearshift...

  • Page 108

    3-58 engine • install the gearshift forks and their shafts as shown. For 3rd/4th drive gears for 5th driven gear for 6th driven gear • apply a small quantity of thread lock to the bearing retainer screws . • tighten the bearing retainer screws and gearshift fork shaft retainer bolt to the specified ...

  • Page 109

    Engine 3-59 oil jet removal • remove the piston cooling oil jets from the upper crank- case. • remove the oil jet (for transmission) from the lower crank- case. • remove the oil jet (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • check the oil jets for clogging. • ...

  • Page 110

    3-60 engine installation • fit new o-ring to each piston cooling oil jet and apply engine oil to them. • install each piston cooling oil jet with the bolt. Note: apply a small quantity of thread lock to the bolts and tighten them to the specified torque. H 99000-32110: thread lock super “1322” or eq...

  • Page 111

    Engine 3-61 • remove the water jacket plugs . • remove the oil gallery plugs (for lower crankcase side). Installation • apply engine coolant to the o-rings of the water jacket plugs . • apply thread lock to the oil gallery plug . H 99000-32110: thread lock super “1322” or equivalent note: it is not ...

  • Page 112

    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. P molybdenum oil solution • set the dam...

  • Page 113

    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) service...

  • Page 114

    3-64 engine installation • when fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part " first and press the other end. Crankshaft and conrod crankshaft runout • support the crankshaft with v-blocks as shown, with the two end journals resting ...

  • Page 115

    Engine 3-65 conrod big end side clearance • inspect the conrod side clearance by using a thickness gauge. • if the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width. • if the width exceed the limit, replace conrod or crankshaft. Conrod big en...

  • Page 116

    3-66 engine *1: the number faces the intake side. • remove the bearing caps and measure the width of the com- pressed plastigauge using the envelope scale. This measure- ment should be taken at the widest part of the compressed plastigauge. Conrod big end oil clearance: standard: 0.032 – 0.056 mm (0...

  • Page 117

    Engine 3-67 crank pin o.D. \ 09900-20202: micrometer (25 – 50 mm) bearing thickness code o.D. Specification 1 34.992 – 35.000 mm (1.3776 – 1.3780 in) 2 34.984 – 34.992 mm (1.3773 – 1.3776 in) 3 34.976 – 34.984 mm (1.3770 – 1.3773 in) color (part no.) thickness green (12164-41g01-0a0) 1.480 – 1.484 m...

  • Page 118

    3-68 engine crankshaft journal bearing inspection • inspect each bearing of upper and middle crankcases for any damage. Selection • place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown. \ 09900-22301: plastigauge • mate the middle crankcase with the upper crank...

  • Page 119

    Engine 3-69 • 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. Crankshaft journal oil clearance: standard: 0.010 – 0.028 mm (0.0004 – 0.0011 in) service lim...

  • Page 120

    3-70 engine crankshaft journal o.D. Specification \ 09900-20202: micrometer (25 – 50 mm) bearing thickness specification note: upper and middle crankshaft journal bearings are the same. Installation • when fitting the crankshaft journal bearings to the upper and middle crankcases, be sure to fix the...

  • Page 121

    Engine 3-71 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. -: left-side thrust bearing 3: right-side thrust bearing note: pull the cra...

  • Page 122

    3-72 engine 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. " color code note: right-side thrust bearing has the same specification as the green (12228-48b00-0e0...

  • Page 123: Engine Reassembly

    Engine 3-73 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 124

    3-74 engine • be sure to bring the concave side of 1st ring to the top when fitting it to the piston. • 2nd ring has letters “t” marked on the side. Be sure to bring the marked side ring to the top when fitting it to the piston. • position the gaps of the three ring as shown. Before inserting each p...

  • Page 125

    Engine 3-75 • apply a small quantity of molybdenum oil solution to the sliding surface of the pistons and cylinder walls. P molybdenum oil solution note: be sure to install the pistons in the cylinders from which they were removed in disassembly, referring to the cylinder numbers, “1” through “4”, s...

  • Page 126

    3-76 engine crankshaft • position the no.2 and no.3 conrod big ends on the same side, and the no.1 and no.4 conrod big ends on the opposite side of no.2 and no.3. • set the crankshaft to the conrods and upper crankcase. • apply a molybdenum oil solution to the crank pin and bearing surface. P molybd...

  • Page 127

    Engine 3-77 • apply a molybdenum oil solution to each crankshaft journal and bearing lightly. P molybdenum oil solution • insert the right and left-thrust bearings with oil groove # fac- ing the crank web. Note: right-thrust bearing has green painting. Balancer shaft • install the thrust washers , a...

  • Page 128

    3-78 engine • apply bond to the mating surface of the middle crankcase. D 99000-31140: suzuki bond “1207b” or equivalent note: use of bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * spread on surfaces thinly to form an even layer, and assemble the cra...

  • Page 129

    Engine 3-79 • tighten the other crankcase bolts a little at a time to equalize the pressure. " crankcase bolt: (m6) initial: 6 n·m (0.6 kgf-m, 4.5 lb-ft) final : 11 n·m (1.1 kgf-m, 8.0 lb-ft) (m8) initial : 15 n·m (1.5 kgf-m, 11.0 lb-ft) final : 26 n·m (2.6 kgf-m, 19.0 lb-ft) note: fit a new gasket ...

  • Page 130

    3-80 engine transmission • install the bearing pins and the c-rings on the middle crankcase. • install the countershaft assembly to the middle crankcase. Note: align the c-ring with the groove of bearing and the bearing pin with the indent on the bearing. • install the driveshaft assembly to the mid...

  • Page 131

    Engine 3-81 • apply bond to the mating surface of the lower crankcase. D 99000-31140: suzuki bond “1207b” or equivalent note: use of bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * apply to both mating surfaces of crankcases at hatched parts. * spread...

  • Page 132

    3-82 engine • tighten the crankcase bolts a little at a time to equalize the pressure. Note: * fit the new copper washers to the crankcase bolts #. * fit the new gasket washers to the crankcase bolts $. " crankcase bolt: (m6) initial: 6 n·m (0.6 kgf-m, 4.5 lb-ft) final : 11 n·m (1.1 kgf-m, 8.0 lb-ft...

  • Page 133

    Engine 3-83 oil pipe • apply grease to the o-rings. • press in the oil pipe to the crankcase. X 99000-25010: suzuki super grease “a” or equivalent oil pressure switch • apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. D 99000-31140: suzuki...

  • Page 134

    3-84 engine oil filter • install 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 . • install the breather cover . " breather cover bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) gear position...

  • Page 135

    Engine 3-85 water pump • apply grease to the o-ring. X 99000-25010: suzuki super grease “a” or equivalent • 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) note: pass the gear position switch lead wire under the water pump rib ...

  • Page 136

    3-86 engine • install the generator rotor onto the crankshaft. • hold the generator rotor with the special tool and tighten its bolt to the specified torque. \ 09930-44520: rotor holder " generator rotor bolt: 120 n·m (12.0 kgf-m, 87.0 lb-ft) generator cover • apply bond lightly to the mating surfac...

  • Page 137

    Engine 3-87 • install the ckp sensor . • apply bond lightly to the groove of signal generator lead wire grommet. D 99000-31140: suzuki bond “1207b” or equivalent cam chain drive sprocket • install the cam chain drive sprocket onto the crankshaft. Note: when installing the cam chain drive sprocket, a...

  • Page 138

    3-88 engine starter clutch • install the washer . • install the starter clutch assembly onto the crankshaft. Note: when installing the starter clutch assembly, align the wide spline teeth " and #. • install the starter clutch bolt with the washer. • hold the starter clutch with the special tool and ...

  • Page 139

    Engine 3-89 • install the starter clutch cover and tighten the bolts. Note: * fit a new gasket washer to the bolt $. " starter clutch cover bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the starter idle gear no.1 shaft , thrust washer , bearing , starter idle gear no.1 , washer , and spring washer ....

  • Page 140

    3-90 engine gearshift system • install the gearshift cam stopper , its bolt , washer and return spring . Note: apply a small quantity of thread lock to the gearshift cam stop- per bolt and tighten it to the specified torque. H 99000-32110: thread lock super “1322” or equivalent " gearshift cam stopp...

  • Page 141

    Engine 3-91 • install the washer and snap ring . Oil pump • install the o-ring to the oil pump and apply grease to it. Note: set the oil pump shaft end " to the water pump shaft. X 99000-25010: suzuki super grease “a” or equivalent • install the oil pump with the oil pump mounting bolts and then tig...

  • Page 142

    3-92 engine • install the oil pump drive gear to the primary driven gear assembly . • install the primary driven gear assembly . Note: * if it is difficult to install the primary driven gear, rotate the crankshaft. * be sure to engage the oil pump driven gear with the drive gear and the primary driv...

  • Page 143

    Engine 3-93 • install the clutch sleeve hub assembly onto the countershaft. • install the washer " and spring washer #. Note: * before installing the washer ", 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 144

    3-94 engine • install the clutch push rod & into the countershaft. • install the clutch push piece ', bearing ( and thrust washer ) to the countershaft. Note: thrust washer ) is located between the pressure plate and bearing (. • insert the clutch drive plates and driven plates one by one into the c...

  • Page 145

    Engine 3-95 *1: direction of outside *2: paint drive plate: b no. 2 drive plate.......1 pc. [no paint/friction piece: 48 pcs/i.D. 111 mm (4.4 in)] c no. 1 drive plate.......8 pcs. [purple paint/friction piece: 36 pcs/i.D. 111 mm (4.4 in)] d no. 3 drive plate.......1 pc. [no paint/friction piece: 36 ...

  • Page 146

    3-96 engine • install the clutch springs and bolts. • hold the clutch housing with the special tool. \ 09920-53740: clutch sleeve hub holder • tighten the clutch spring set bolts to the specified torque. " clutch spring set bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) note: tighten the clutch spring set bolt...

  • Page 147

    Engine 3-97 • install the clutch cover and tighten its bolts to the specified torque. " clutch cover bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) note: * fit the clamp to the bolt ". * fit new gasket washers to the bolts #. Cylinder head • install dowel pins and new cylinder head gasket to the cyl- inder. • ...

  • Page 148

    3-98 engine • tighten the cylinder head bolts to the specified torque. " cylinder head bolt (m6): 10 n·m (1.0 kgf-m, 7.0 lb-ft) • fit the gasket and tighten the ect sensor. " ect sensor: 18 n·m (1.8 kgf-m, 13.0 lb-ft) • install the thermostat . Note: the jiggle valve " of thermostat faces upside. • ...

  • Page 149

    Engine 3-99 camshaft • turn the crankshaft clockwise with the box wrench and align the line " on the starter clutch with the index mark # of valve timing inspection hole while keeping the cam chain pulled upward. • the camshafts are identified by the embossed letters. • before replacing the camshaft...

  • Page 150

    3-100 engine • pull the cam chain lightly. • the exhaust camshaft sprocket has an arrow marked “1” $. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • engage the cam chain with the exhaust camshaft sprocket. • bind the cam chain and sprocket with...

  • Page 151

    Engine 3-101 • install the dowel pins. • install the camshaft journal holders, intake and exhaust, and cam chain guide. • have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers. Note: * damage to head or camshaft j...

  • Page 152

    3-102 engine cam chain tension adjuster • retract the push rod by pushing the stopper . • fit a new gasket . • install the cam chain tension adjuster with “up” mark faced to the top side. " cam chain tension adjuster mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the spring . • install the g...

  • Page 153

    Engine 3-103 10 n·m (1.0 kgf-m, 7.0 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft).

  • Page 154

    3-104 engine • tighten the valve timing inspection plug to the specified torque. " valve timing inspection plug: 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 dowel pins. •...

  • Page 155

    Engine 3-105 starter motor • apply grease to the o-ring. X 99000-25010: suzuki super grease “a” or equivalent • install the starter motor . " starter motor mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) engine coolant reservoir bracket • install the engine coolant reservoir bracket . • install all the...

  • Page 156: Fi System Diagnosis

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

  • Page 157: Fi System Diagnosis

    4-2 fi system diagnosis contents fi system diagnosis “c40” (p0505 or p0506 and p0507) isc valve circuit malfunction..................................................................................... 4-79 “c41” (p0230-h/l) fp relay circuit malfunction .................. 4-83 “c41” (p2505) ecm/pcm p...

  • Page 158: 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 159

    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 160

    Fi system diagnosis 4-5 • when disconnecting and connecting the ecm, make sure to turn off the ignition switch , 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 re...

  • Page 161

    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 162

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

  • Page 163

    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 164

    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 the t...

  • Page 165: Fi System Technical Features

    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 166

    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 167

    4-12 fi system diagnosis fi system parts location intake air temperature sensor (iats) throttle position sensor (tps) secondary throttle position sensor (stps) secondary throttle valve actuator (stva) exhaust control valve actuator (excva) fuel pump relay (fp relay) fuel pump (fp) crankshaft positio...

  • Page 168

    Fi system diagnosis 4-13 tip-over sensor (tos) atmospheric pressure sensor (aps) engine coolant temperature sensor (ects) camshaft position sensor (cmps) gear position switch (gp switch) speed sensor cooling fan relay cooling fan primary fuel injector secondary fuel injector idle speed control valve...

  • Page 169

    4-14 fi system diagnosis fi system wiring diagram 10 a 10 a 30 a 10 a speedometer camshaft position sensor (cmps) crankshaft position sensor (ckps) throttle position sensor (tps) intake air pressure sensor (iaps) atmospheric pressure sensor (aps) driving mode switch intake air temperature sensor (ia...

  • Page 170: Ecm Terminal

    Fi system diagnosis 4-15 ecm terminal terminal no. Circuit terminal no. Circuit excva power (mo+) * iap sensor signal (iaps) speed sensor signal + ap sensor signal (aps) stva signal (stva 2a) , ckp sensor signal (ckps–) stva signal (stva 1a) - gear position switch signal (gp) — . Serial data for spe...

  • Page 171

    4-16 fi system diagnosis terminal no. Circuit terminal no. Circuit isc valve signal (isc 2a) p pair control solenoid (pair) = isc valve signal (isc 1b) q secondary injector #4 (#42) > isc valve signal (isc 1a) r secondary injector #3 (#32) ? Fuel pump relay (fp relay) s secondary injector #2 (#22) b...

  • Page 172: 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 indicator light). To check the function of the individual fi system...

  • Page 173

    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 174

    Fi system diagnosis 4-19 code malfunction part remarks c00 c11 c12 c13 c14 c15 c21 c22 c23 c24 c25 c26 c27 c28 c29 c31 c32 c33 c34 c35 c36 c37 c38 c39 c40 c41 c42 c44 c46 c49 c60 c62 c91 c93 none camshaft position sensor (cmps) crankshaft position sensor (ckps) intake air pressure sensor (iaps) thro...

  • Page 175

    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 176

    Fi system diagnosis 4-21 tps adjustment 1. Connect the special tool (mode select switch) to the dealer mode coupler at the wiring harness. 2. If the throttle position sensor adjustment is necessary, loosen the screw and turn the throttle position sensor and bring the line to the middle. 3. Then, tig...

  • Page 177: Fail-Safe Function

    4-22 fi system diagnosis 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

    Fi system diagnosis 4-23 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

    4-24 fi system diagnosis 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

    Fi system diagnosis 4-25 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

    4-26 fi system diagnosis self-diagnostic procedures note: * do not disconnect the couplers from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized information in...

  • Page 182

    Fi system diagnosis 4-27 use of sds diagnostic procedures * do not disconnect the couplers from ecm, battery cable from battery, ecm ground wire from the engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized informatio...

  • Page 183

    4-28 fi system diagnosis 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 . • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase the...

  • Page 184

    Fi system diagnosis 4-29 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

    4-30 fi system diagnosis 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

    Fi system diagnosis 4-31 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

    4-32 fi system diagnosis 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 connection p1654 h sensor voltage is higher tha...

  • Page 188

    Fi system diagnosis 4-33 * : immobilizer system equipped model only. (e-02, 19, 24) dtc no. Detected item detected failure condition check for c41 (p0230) fp relay no voltage is applied to the fuel pump, although fuel pump relay is turned on, or voltage is applied to fuel pump although fuel pump rel...

  • Page 189

    4-34 fi system diagnosis dtc no. Detected item detected failure condition check for c46 excv actuator excva position sensor produces fol- lowing voltage. 0.1 v sensor voltage in other than the above range, c46 (p1675) is indicated. When no actuator control signal is supplied from the ecm, communica-...

  • Page 190

    Fi system diagnosis 4-35 dtc no. Detected item detected failure condition check for c93 steering damper solenoid valve steering damper control current does not flow to the solenoid valve. With ig turned on, ecm detects a fail- ure of internal circuit element. Sole- noid current does not converge to ...

  • Page 191

    4-36 fi system diagnosis “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. ( 3-29) 5) conn...

  • Page 192

    Fi system diagnosis 4-37 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. ( 4-28) yes ...

  • Page 193

    4-38 fi system diagnosis “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 c...

  • Page 194

    Fi system diagnosis 4-39 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 v tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing the...

  • Page 195

    4-40 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 196

    Fi system diagnosis 4-41 4) disconnect the iap sensor coupler. 5) turn the ignition switch on. 6) insert the needle pointed probes to the lead wire coupler. 7) measure the voltage at the r wire and ground. 8) if ok, then measure the voltage at the r wire and b/br wire. Iap sensor input voltage: 4.5 ...

  • Page 197

    4-42 fi system diagnosis 6) disconnect the ecm coupler. 7) check the continuity between g/b wire and terminal *. 8) if ok, then check the continuity between b/br wire and ter- minal :. Iaps lead wire continuity: continuity (?) \ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe...

  • Page 198

    Fi system diagnosis 4-43 7) disconnect the ecm coupler. 8) check the continuity between r wire and terminal . 9) also, check the continuity between g/b wire and terminal *. Iaps lead wire continuity: continuity (?) \ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set = teste...

  • Page 199

    4-44 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 (check that total - voltage is 4.5 – 5.0 v) and connect terminal to the ground - terminal and term...

  • Page 200

    Fi system diagnosis 4-45 “c14” (p0120-h/l) tp sensor circuit malfunction inspection step 1 (when indicating c14:) 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 measure the tp sensor input voltage. 4) ...

  • Page 201

    4-46 fi system diagnosis tp sensor input voltage: 4.5 – 5.5 v ( r – ground) ( r – b/br) \ 09900-25008: multi-circuit tester set w 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. ( 5-3) 3) chec...

  • Page 202

    Fi system diagnosis 4-47 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 check the tp sensor lead wire continuity. 4) disconnect the tp sensor coupler. 5) check the con...

  • Page 203

    4-48 fi system diagnosis step 2 1) connect the special tool between tp sensor and its coupler. 2) turn the ignition switch on. 3) measure the tp sensor output voltage at the terminals (between p/b and b/br) by turning the throttle grip. Tp sensor output voltage throttle valve is closed: approx. 1.1 ...

  • Page 204

    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 205

    4-50 fi system diagnosis ect sensor voltage: 4.5 – 5.5 v ( b/bl – ground) ( b/bl – b/br) \ 09900-25008: multi-circuit tester set w tester knob indication: voltage () is the voltage ok? Step 1 (when indicating p0115-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) che...

  • Page 206

    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 betw...

  • Page 207

    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 v tester knob indication: resistance (Ω)...

  • Page 208

    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 209

    4-54 fi system diagnosis 5) measure the voltage between dg wire terminal and ground. 6) if ok, then measure the voltage between dg wire terminal and b/br wire terminal . Iat sensor input voltage: 4.5 – 5.5 v ( dg – ground) ( dg – b/br) \ 09900-25008: multi-circuit tester set w tester knob indication...

  • Page 210

    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 211

    4-56 fi system diagnosis step 2 1) turn the ignition switch off. 2) measure the iat sensor resistance. Iat sensor resistance: approx. 2.58 kΩ at 20 °c (68 °f) (terminal – terminal) \ 09900-25008: multi-circuit tester set v tester knob indication: resistance (Ω) is the resistance ok? Iat sensor speci...

  • Page 212

    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. ( 8-8) 3) check the ap sensor coupler for loose or poor contacts. If ok, then measure the ap sensor input voltage. Detected con...

  • Page 213

    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 and b/br wire . Ap sensor input voltage: 4.5 – 5.5 v ( r – ground) ( r – b/br) \ 09900-25008: multi-circuit ...

  • Page 214

    Fi system diagnosis 4-59 6) disconnect the ecm coupler. 7) check the continuity between g/y wire and terminal +. 8) if ok, then check the continuity between b/br wire and ter- minal :. Aps lead wire continuity: continuity (?) \ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe ...

  • Page 215

    4-60 fi system diagnosis 7) disconnect the ecm coupler. 8) check the continuity between r wire and terminal . 9) if ok, then check the continuity between g/y wire and ter- minal +. Aps lead wire continuity: continuity (?) \ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set ...

  • Page 216

    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 (check that total voltage is 4.5 – 5.0 v) and connect terminal to the ground terminal and terminal to the vcc terminal . 3) check the...

  • Page 217

    4-62 fi system diagnosis “c23” (p1651-h/l) to sensor circuit malfunction inspection step 1 (when indicating c23:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the to sensor coupler for loose or poor contacts. If ok, then measure the to sensor resistance. 4) dis...

  • Page 218

    Fi system diagnosis 4-63 5) measure the resistance between terminal and terminal . To sensor resistance: 16.5 – 22.3 kΩ (terminal – terminal ) \ 09900-25008: multi-circuit tester set v tester knob indication: resistance (Ω) is the resistance ok? Step 1 (when indicating p1651-h:) 1) turn the ignition...

  • Page 219

    4-64 fi system diagnosis step 1 (when indicating p1651-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 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 con...

  • Page 220

    Fi system diagnosis 4-65 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 at the wire side coupler between b and b/br wires. To sensor voltage (normal): 0.4 – 1.4 v ( b – b/br...

  • Page 221

    4-66 fi system diagnosis “c28” (p1655) stv actuator circuit malfunction inspection step 1 1) lift and support the fuel tank. ( 5-3) 2) remove the air cleaner cover. ( 2-4) 3) check the stva lead wire coupler for loose or poor con- tacts. 4) turn the ignition switch on to check the stv operation. (st...

  • Page 222

    Fi system diagnosis 4-67 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 b wire and p wire ) and (betwee...

  • Page 223

    4-68 fi system diagnosis 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” . 4) click each button . At this time, if an operation sound is heard from the stva, the...

  • Page 224

    Fi system diagnosis 4-69 “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 225

    4-70 fi system diagnosis stp sensor input voltage: 4.5 – 5.5 v ( r – ground) ( r – b/br) \ 09900-25008: multi-circuit tester set w tester knob indication: voltage () is the voltage ok? Step 1 (when indicating p1654-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) che...

  • Page 226

    Fi system diagnosis 4-71 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 227

    4-72 fi system diagnosis step 2 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 228

    Fi system diagnosis 4-73 “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 jac...

  • Page 229

    4-74 fi system diagnosis is the voltage ok? 10)after repairing the trouble, clear the dtc using sds tool. ( 4-28) 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 connectio...

  • Page 230

    Fi system diagnosis 4-75 “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 primary injector coupler for loose or poor con- tacts. If ok, then ...

  • Page 231

    4-76 fi system diagnosis 5) if ok, then check the continuity between each terminal and ground. Primary injector continuity: ∞ Ω (infinity) \ 09900-25008: multi-circuit tester set v tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing the trouble, clear the ...

  • Page 232

    Fi system diagnosis 4-77 “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 secondary injector coupler for loose or poor contacts. If ok, th...

  • Page 233

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

  • Page 234

    Fi system diagnosis 4-79 “c40” (p0505 or p0506 and p0507) isc valve circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the air cleaner box. ( 5-14) 3) check the isc valve coupler for loose or poor contacts. If ok, then check the isc valve lead wire continuity. Detected ...

  • Page 235

    4-80 fi system diagnosis 4) disconnect the isc valve coupler and ecm couplers. 5) check the continuity between terminals (y) and >, termi- nals (bl) and =, terminals (br) and (g) and j. Isc valve continuity: continuity (?) \ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set...

  • Page 236

    Fi system diagnosis 4-81 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” . 5) check that the “spec” is idle speed 1 ...

  • Page 237

    4-82 fi system diagnosis check 3 1) click the button and increase the “spec” to 1 500 rpm slowly. 2) check that the “desired idle speed” is nearly equal to the “spec” . Also, check that the number of steps in the isc valve position increases check 4 1) increase the “spec” to 1 900 rpm. 2) check that...

  • Page 238

    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) remove the front seat. ( 8-8) 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. ( 5-7) detected condition possi...

  • Page 239

    4-84 fi system diagnosis is the fp relay ok? Step 1 (when indicating p0230-h:) 1) turn the ignition switch off. 2) remove the front seat. ( 8-8) 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 ...

  • Page 240

    Fi system diagnosis 4-85 step 1 (when indicating p0230-l:) 1) turn the ignition switch off. 2) remove the front seat. ( 8-8) 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 using sds to...

  • Page 241

    4-86 fi system diagnosis “c41” (p2505) ecm/pcm power input signal malfunction inspection step 1 (when indicating c41:) 1) turn the ignition switch off. 2) remove the front seat. ( 8-8) 3) check the ecm couplers for loose or poor contacts. If ok, then measure the ecm input voltage. Detected condition...

  • Page 242

    Fi system diagnosis 4-87 4) disconnect the ecm couplers. 5) measure the voltage between terminal and ground. Ecm input voltage: battery voltage \ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set w tester knob indication: voltage () is the voltage ok? “c42” (p01650) ig swit...

  • Page 243

    4-88 fi system diagnosis “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction inspection step 1 (when indicating c44/p0130:) 1) turn the ignition switch off. 2) remove the left under cowling. ( 8-5) 3) check the ho2 sensor coupler for loose or poor contacts. If ok, then check the ho2 sensor lea...

  • Page 244

    Fi system diagnosis 4-89 7) disconnect the ecm coupler. 8) check the continuity between w/g wire and terminal 9. 9) also, check the continuity between b/br wire and terminal :. Ho2s lead wire continuity: continuity (?) \ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set = t...

  • Page 245

    4-90 fi system diagnosis is the voltage ok? 6) after repairing the trouble, clear the dtc using sds tool. ( 4-28) step 1 (when indicating c44/p0135:) 1) turn the ignition switch off. 2) remove the left under cowling. ( 8-5) 3) check the ho2 sensor coupler for loose or poor contacts. If ok, then meas...

  • Page 246

    Fi system diagnosis 4-91 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

    4-92 fi system diagnosis “c46” (p1657-h/l or p1658) excv actuator circuit malfunction inspection step 1 (when indicating c46:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the excva position sensor coupler and excva motor coupler for loose or poor contacts. Det...

  • Page 248

    Fi system diagnosis 4-93 4) turn the ignition switch on. 5) check the operation of the excva . (excva operating order: full close → full open → 30% open) is the operation ok? Step 1 (when indicating p1657-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the exc...

  • Page 249

    4-94 fi system diagnosis step 1 (when indicating p1657-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 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 pos...

  • Page 250

    Fi system diagnosis 4-95 step 1 (when indicating p1658:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the excva motor coupler for loose or poor con- tacts. Is the contacting ok? 4) after repairing the trouble, clear the dtc using sds tool. ( 4-28) step 2 1) tur...

  • Page 251

    4-96 fi system diagnosis step 3 1) turn the ignition switch off. 2) check the continuity between y wire and ground. Excva position sensor continuity: ∞ Ω (infinity) 3) if ok, then measure the excva position sensor resistance. 4) connect the excva position sensor coupler. 5) set the excva to adjustme...

  • Page 252

    Fi system diagnosis 4-97 step 4 1) turn the ignition switch off. 2) connect the position sensor coupler . 3) measure the excva position sensor output voltage at excv fully closed position and fully opened position. 4) insert the needle pointed probes to the back side of the excva position sensor cou...

  • Page 253

    4-98 fi system diagnosis step 5 1) if the excva position sensor output voltage is 0.5 v and less at excv fully closed position, adjust the output voltage to the specified value by turning out the no.1 cable adjuster . 2) repeat the above procedure (step 4) until the output voltage becomes specified ...

  • Page 254

    Fi system diagnosis 4-99 step 6 1) turn the ignition switch off. 2) disconnect the excva motor coupler . 3) apply 12 v to the terminals and check the operation of excva. 4) then, switch the wires supplied 12 v and check the operation of excva. (check the operation of excva in both way.) is the opera...

  • Page 255

    4-100 fi system diagnosis 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” . 4) click each button . At this time, if an operation sound is heard from the excva, the fu...

  • Page 256

    Fi system diagnosis 4-101 “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 solenoid...

  • Page 257

    4-102 fi system diagnosis 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 w tester knob indication: voltage () is the voltage ok? 3) after repairing the trouble, cle...

  • Page 258

    Fi system diagnosis 4-103 “c60” (p0480) cooling fan relay circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the front seat. ( 8-8) 3) check the cooling fan relay coupler for loose or poor contacts. If ok, then inspection the cooling fan relay. ( 7-7) is the cooling fan...

  • Page 259

    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” . 4) click the “operate” . At this time, if an operation sound is heard from the ...

  • Page 260

    Fi system diagnosis 4-105 6) click the “off” to check the cooling fan relay and cooling fan motor operation. Note: this inspection should be begun from when the engine coolant temperature is below 50 °c (122 °f). Check that the cooling fan relay operates for a few seconds as the engine coolant tempe...

  • Page 261

    4-106 fi system diagnosis “c91” (p0500) vehicle speed sensor circuit malfunction inspection 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the speed sensor coupler for loose or poor con- tacts. If ok, remove the speed sensor. ( 9-33) 4) connect 12 v battery, 10 k...

  • Page 262

    Fi system diagnosis 4-107 5) under this condition, if a suitable screwdriver touching the pick-up surface of the speed sensor is moved, the tester reading voltage changes (0 v → 12 v or 12 v → 0 v). If the tester reading voltage does not change, replace the speed- ometer sensor with a new one. . Is ...

  • Page 263

    4-108 fi system diagnosis “c93” (p1769) steering damper solenoid valve circuit malfunction inspection step 1 1) turn the ignition switch off. 2) check the steering damper solenoid valve coupler for loose or poor contacts. If ok, then measure the steering damper solenoid valve resistance. Detected co...

  • Page 264

    Fi system diagnosis 4-109 3) disconnect the steering damper solenoid valve coupler. 4) measure the steering damper solenoid valve resistance. Steering damper solenoid valve resistance: approx 12.5 Ω at 20 °c (68 °f) \ 09900-25008: multi-circuit tester set v tester knob indication: resistance (Ω) is ...

  • Page 265

    4-110 fi system diagnosis active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) raise the front wheel off the ground. 3) turn the ignition switch on. 4) click “steering damper solenoid operating control” . 5) click each button on/off while turn...

  • Page 266: Sensors

    Fi system diagnosis 4-111 sensors cmp sensor inspection the camshaft position sensor is installed on the cylinder head cover. ( 4-36) cmp sensor removal and installation • remove the cmp sensor. ( 3-29) • install the cmp sensor in the reverse order of removal. Ckp sensor inspection the crankshaft po...

  • Page 267

    4-112 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-ft...

  • Page 268

    Fi system diagnosis 4-113 stp sensor inspection the secondary throttle position sensor is installed at the right side of the no.4 throttle body. ( 4-69) stp sensor removal and installation • remove the stp sensor. ( 5-17) • install the stp sensor in the reverse order of removal. Stp sensor adjustmen...

  • Page 269

    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 270: 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 271: Fuel System

    Fuel system and throttle body 5-3 fuel system fuel tank lift-up • remove the seats. ( 8-8 and -9) • remove the fuel tank side covers. ( 8-8) • take out the fuel tank prop stay . • remove the fuel tank bolt. • lift and support the fuel tank with the fuel tank prop stay..

  • Page 272

    5-4 fuel system and throttle body fuel tank removal • lift and support the fuel tank. ( 5-3) • disconnect the fuel pump lead wire coupler . • disconnect the fuel tank drain hose and fuel tank breather hose (except for e-33). • place a rag under the fuel feed hose and disconnect the fuel feed hose fr...

  • Page 273

    Fuel system and throttle body 5-5 fuel pressure inspection • lift and support the fuel tank. ( 5-3) • place a rag under the fuel feed hose . • remove the fuel feed hose. • install the special tools between the fuel tank and fuel delivery pipe. \ 09940-40211: fuel pressure gauge adaptor 09940-40220: ...

  • Page 274

    5-6 fuel system and throttle body fuel pump inspection turn the ignition switch on and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor. If the fuel ...

  • Page 275

    Fuel system and throttle body 5-7 • connect proper lead wires 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 terminal if t...

  • Page 276

    5-8 fuel system and throttle body fuel pump and fuel filter removal construction fuel level gauge fuel pump case " fuel filter cartridge fuel mesh filter item n·m kgf-m lb-ft fuel outlet joint o-ring " 10 1.0 7.0 o-ring o-ring fuel pump " fuel pump mounting bolt.

  • Page 277

    Fuel system and throttle body 5-9 removal • remove the fuel tank. ( 5-4) • remove the fuel pump assembly by removing its mounting bolts diagonally. # • disconnect the lead wires (r and b). • remove the fuel level gauge . • remove the fuel filter cartridge . • remove the fuel outlet joint . • remove ...

  • Page 278

    5-10 fuel system and throttle body • remove the o-ring . • remove the nut . • remove the fuel pump plate . • remove the fuel mesh filter . • remove the fuel pump from the case. Fuel mesh filter inspection and cleaning if the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoot...

  • Page 279

    Fuel system and throttle body 5-11 fuel pump and fuel mesh filter installation install the fuel pump and fuel mesh filter in the reverse order of removal. Pay attention to the following points: • replace the o-rings with new ones. • apply thin coat of engine oil to the o-ring . • set the fuel outlet...

  • Page 280

    5-12 fuel system and throttle body • install a new o-ring and apply grease to it. X 99000-25010: suzuki super grease “a” or equivalent # • install the clamp to the bolt . • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque...

  • Page 281: Throttle Body

    Fuel system and throttle body 5-13 throttle body construction only for e-33 tp sensor cushion seal stp sensor isc valve stva evap purge control solenoid valve " fuel delivery pipe " vacuum hose item n·m kgf-m lb-ft fuel delivery pipe joint " fuel delivery pipe mounting screw " 3.5 0.35 2.5 o-ring # ...

  • Page 282

    5-14 fuel system and throttle body air cleaner box removal • lift and support the fuel tank. ( 5-3) • disconnect the pair hose , iat sensor lead wire coupler and iap sensor . • loosen the throttle body clamp screw (rh). • disconnect the pcv hose and isc valve hose . • loosen the throttle body clamp ...

  • Page 283

    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 disconnect the fuel feed hose from the fuel pump. • disconnect the stva lead wire coupler , stp sensor lead wire...

  • Page 284

    5-16 fuel system and throttle body • remove the fasteners on the main frame. (lh and rh) • loosen the throttle body clamp screws at the intake pipe side. • remove the throttle body assembly. Throttle body disassembly • disconnect the fuel feed hose . • disconnect the respective vacuum hoses from eac...

  • Page 285

    Fuel system and throttle body 5-17 • remove the fuel pipe from the primary injectors. • disassemble the fuel delivery pipe assembly. • remove the isc valve hoses . • remove the isc valve . • remove the tp sensor and stp sensor " with the special tool. \ 09930-11950: torx wrench note: prior to disass...

  • Page 286

    5-18 fuel system and throttle body never remove the secondary throttle valves $ and throttle valves %. * these adjusting screws ( &, ', (, )) are fac- tory-adjusted at the time of delivery and do not turn or remove them. * do not separate the throttle body..

  • Page 287

    Fuel system and throttle body 5-19 throttle body cleaning # • clean passageways (except for main bore) with a spray-type carburetor cleaner and blow dry with compressed air. Inspection • check following items for any damage or clogging. * o-rings * throttle valves * secondary throttle valves * vacuu...

  • Page 288

    5-20 fuel system and throttle body throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • with the secondary throttle valves fully opened, install the stp sensor and tighten the stp sensor mounting screw to the specified ...

  • Page 289

    Fuel system and throttle body 5-21 • apply thin coat of engine oil to the new o-rings and cush- ion seals . • assemble the fuel delivery pipes as shown. • install each fuel injector by pushing it straight to the delivery pipe. • install the fuel delivery pipe assembly to the throttle body. • tighten...

  • Page 290

    5-22 fuel system and throttle body 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 291

    Fuel system and throttle body 5-23 stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor output voltage and adjust the stp sensor position as follows: • disconnect the stva lead wire coupler. • remove the air cleaner box cover. ( 2-4) • insert the needle pointed probes ...

  • Page 292

    5-24 fuel system and throttle body 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. ( 5-16...

  • Page 293

    Fuel system and throttle body 5-25 isc valve removal • remove the air cleaner box. ( 5-14) • disconnect the isc valve coupler . • remove the isc valve . Isc valve inspection • inspect the isc valve for wear, damage or carbon deposition. • replace it with a new one if necessary. Note: the isc valve c...

  • Page 294

    5-26 fuel system and throttle body isc valve pre-set when removing or replacing the isc valve, set the isc valve in the following procedures: 1) turn the ignition switch on position. 2) set up the sds tool. ( 4-27) 3) click “active control”. 4) click “isc learned value reset” . 5) click “reset” butt...

  • Page 295

    Fuel system and throttle body 5-27 throttle valve synchronization use of sds tool check and adjust the throttle valve synchronization among four cylinders. Step 1 • lift and support the fuel tank. ( 5-3) • disconnect the respective vacuum hoses from each vac- uum nipple. • disconnect the iap sensor ...

  • Page 296

    5-28 fuel system and throttle body • click “active control”. • click “isc air volume control” . • click “on” to fix the isc air volume of four cylinders. Note: when making this synchronization, be sure that the water tem- perature is within 70 – 100 °c (158 – 212 °f). " engine speed: approx. 1 150 r...

  • Page 297

    Fuel system and throttle body 5-29 • repeat the procedures of step 2. • disconnect the vacuum tester and install the removed parts. • after completing the throttle valve synchronization, clear the dtc and reset the isc learned value using sds tool. ( 4-28 and 5-26) use of mode select switch the foll...

  • Page 298: Exhaust System

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

  • Page 299: 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 in the exhaust pipe. Excva is mounted inside of the right ...

  • Page 300

    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 301: Excv (Exhaust Control Valve)

    6-4 exhaust system excva (exhaust control valve actuator) and excv (exhaust control valve) excva removal • turn the ignition switch off. • lift and support the fuel tank. ( 5-3) • remove the right under cowling. ( 8-5) • connect the special tool (mode select switch) to the dealer mode coupler. ( 4-2...

  • Page 302

    Exhaust system 6-5 • disconnect the no.2 cable and then no.1 cable from the pulley. • remove the excva. • 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...

  • Page 303

    6-6 exhaust system excva installation • install the excva pulley to the shaft. Note: align the shaft’s line " and cable slots # as shown. • hold the excva pulley with an adjustable wrench, and then tighten the excva pulley mounting bolt to the specified torque. " excva pulley mounting bolt: 5 n·m (0...

  • Page 304

    Exhaust system 6-7 • turn the adjuster in or out until the thread length $ becomes the measured value before disconnecting the no.1 cable . • tighten the lock-nut . • turn the adjuster in or out until the thread length % becomes the measured value before disconnecting the no.2 cable . • tighten the ...

  • Page 305

    6-8 exhaust system • connect the excv cables (no.1 and no.2) temporarily to the excv pulley. • make the no. 1 cable (21h0cl) straight and turn the no. 1 cable adjuster in or out until the inner cable length " becomes 44 – 45 mm (1.73 – 1.77 in). • after adjusting the inner cable length ", tighten th...

  • Page 306

    Exhaust system 6-9 44 – 45 mm (1.73 – 1.77 in) 60 – 61 mm (2.36 – 2.40 in) no.1 no.2 no.1 no.2 11 – 12 mm (0.43 – 0.47 in) 5 n·m (0.5 kgf-m, 3.5 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 wrenc...

  • Page 307

    6-10 exhaust system excva adjustment 1st step: • set the excva to adjustment position. ( 6-4) 2nd step: • turn the mode select switch off. • turn the ignition switch on to check the excva operation. • turn the mode select switch on. • if c46 is not indicated on the lcd (display), the adjustment is c...

  • Page 308

    Exhaust system 6-11 • turn the ignition switch on. • measure the excva position sensor output voltage at fully closed position. Position sensor output voltage: excv is fully closed: 0.45 output voltage 1.4 v ( y – b/br) \ 09900-25008: multi circuit tester set 09900-25009: needle pointed probe set w ...

  • Page 309

    6-12 exhaust system if the measured voltage is more than specification, adjust the no.2 cable adjuster as follows: • set the excva to adjustment position. ( 6-4) • turn out the no.2 cable adjuster . • repeat the previous procedure until the output voltage comes within the specified value. • after ad...

  • Page 310

    Exhaust system 6-13 • remove the no.1 muffler joint cover . • separate the muffler and muffler joint . • remove the gasket and o-rings from the muffler. • remove the under cowlings. ( 8-5) • disconnect the ho2 sensor lead wire coupler . • loosen the muffler chamber connecting bolt . • remove the muf...

  • Page 311

    6-14 exhaust system • remove the excv cable bracket nut. • disconnect the excv cables from the excv pulley. • remove the side cowlings. ( 8-6) • move the radiator and oil cooler forward. • disconnect one of the oil cooler hose from the oil cooler. • remove the exhaust pipe bolts. • remove the exhaus...

  • Page 312

    Exhaust system 6-15 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 assembly. • decarbonize the excv if necessary. * do not attempt to disassemble the excv. * the excv is available only as the e...

  • Page 313

    6-16 exhaust system muffler, muffler chamber and excv/exhaust pipe installation install the excv/exhaust pipe, muffler chamber and mufflers in the reverse order of removal. Pay attention to the following points: • tighten each bolt/nut to the specified torque. Replace the gaskets, connectors and o-r...

  • Page 314

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

  • Page 315: 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 316: 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 and connect the tester to the filler. # • give a p...

  • Page 317: 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. ( 2-18) • remove the radiator assembly. ( 3-4) • remove the cooling fan from the radiator. Radiator cap inspection • fit the cap to the radiator cap tester . •...

  • Page 318

    Cooling and lubrication system 7-5 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 properly. ( 10-20) • pour engine coolant. ( 2-18) • bleed air from the cooling circuit. ( 2-19) • install t...

  • Page 319: Cooling Fan

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

  • Page 320: Ect Sensor

    Cooling and lubrication system 7-7 cooling fan relay inspection cooling fan relay is located under the front seat. • remove the front seat. ( 8-8) • remove the cooling fan relay . First check the insulation between " and # terminals with tester. Then apply 12 v to $ and % terminals, to $ and to %, a...

  • Page 321

    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) intake air t...

  • Page 322: Thermostat

    Cooling and lubrication system 7-9 thermostat removal • remove the right under cowling. ( 8-5) • lift and support the fuel tank. ( 5-3) • place a rag under the thermostat cover. • remove the thermostat cover . • remove the thermostat . Inspection inspect the thermostat pellet for signs of cracking. ...

  • Page 323

    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 ": standard: 8.0 mm and over at 95 °c (0.31 in and over at 20...

  • Page 324: 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 325

    7-12 cooling and lubrication system • remove the water pump cover and clamp . • holding the impeller with water pump pliers, remove the impeller securing bolt. • remove the mechanical seal ring and rubber seal from the impeller. • remove the impeller shaft and washer . • remove the mechanical seal w...

  • Page 326

    Cooling and lubrication system 7-13 • remove the oil seal ". Note: if there is no abnormal condition, the oil seal removal is not nec- essary. Inspection mechanical seal • visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. • replace the mechanical...

  • Page 327

    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 grease to the oil seal lip. X 99000-25010: suzuk...

  • Page 328

    Cooling and lubrication system 7-15 • install the rubber seal 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 # of mechanical seal ring faces the rub- ber seal. • install the washer and seal wash...

  • Page 329

    7-16 cooling and lubrication system • install the water pump. Note: set the water pump shaft end ' to the oil pump shaft ( 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) note: pass the gear position switch lead wir...

  • Page 330: Lubrication System

    Cooling and lubrication system 7-17 lubrication system oil pressure 2-33 oil filter 2-13 oil pressure regulator 3-47 oil strainer 3-47 oil jet 3-59 oil pump 3-44 oil pressure switch 9-34 oil cooler removal • remove the under cowlings. ( 8-5) • drain the engine oil. ( 2-12) • remove the oil cooler. (...

  • Page 331

    7-18 cooling and lubrication system inspection and cleaning • road dirt or trash stuck to the fins must be removed. • use of compressed air is recommended for this cleaning. • fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. Installation • install...

  • Page 332: Sub-Gallery

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

  • Page 333

    7-20 cooling and lubrication system engine lubrication system main gallery to sub- gallery to sub- gallery.

  • Page 334

    Cooling and lubrication system 7-21 to transmission sub-gallery main gallery view of a a.

  • Page 335: Chassis

    Chassis 8-1 8 chassis contents exterior parts ...................................................................................... 8- 3 fastener removal and installation..................................... 8- 3 lower bracket cover ................................................................. ...

  • Page 336: Chassis

    Chassis contents 8-2 chassis rear suspension ................................................................................... 8-55 construction .................................................................................. 8-55 removal ............................................................

  • Page 337: Exterior Parts

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

  • Page 338

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

  • Page 339

    Chassis 8-5 lower bracket cover removal • remove the lower bracket cover by removing the bolts. Installation • install the lower bracket cover in the reverse order of removal. Under cowling removal • remove the fasteners and bolts. • remove the under cowlings . (lh/rh) • remove the under cowling . (...

  • Page 340

    8-6 chassis side cowling removal note: the left and right side cowlings are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. • remove the under cowling. ( 8-5) • remove the body cowling cover fasteners and . • bend the body cowling cove...

  • Page 341

    Chassis 8-7 screen removal • remove the screws. • remove the combination meter . (9-29) • disconnect the turnsignal lead wire couplers. • remove the rear view mirrors/turn signals . • remove the screen . Installation • install the screen in the reverse order of removal. • refer to the rear view mirr...

  • Page 342

    8-8 chassis air intake pipe removal • remove the body cowling. ( 8-7) • remove the side cowling (-s) . (8-6) • remove the air intake pipe (-s) . (lh/rh) installation • install the air intake pipe (-s) in the reverse order of removal. Cowling brace removal • remove the body cowling. ( 8-7) • remove t...

  • Page 343

    Chassis 8-9 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 344: Front Wheel

    8-10 chassis front wheel construction brake disc front axle " collar front wheel item n·m kgf-m lb-ft dust seal " front axle bolt " 100 10.0 72.5 bearing # brake disc bolt # 23 23.0 16.5 spacer.

  • Page 345

    Chassis 8-11 removal • remove the brake calipers. (lh and rh) • loosen two axle pinch bolts on the right front fork leg. • remove the front axle bolt . • loosen two axle pinch bolts on the left front fork leg. • raise the front wheel off the ground and support the motorcy- cle with a jack or a woode...

  • Page 346

    8-12 chassis inspection and disassembly • remove the brake discs. (lh and rh) tire inspection ( 2-27 and 8-93) brake disc inspection ( 8-71) • remove the dust seals on both sides with the special tool. 09913-50121: oil seal remover axle shaft • using a dial gauge, check the axle shaft for runout and...

  • Page 347

    Chassis 8-13 • remove the wheel bearings with the special tool. 09921-20240: bearing remover set • remove the spacer . The removed bearings must be replaced with new ones..

  • Page 348

    8-14 chassis reassembly and installation pay attention to the following points: wheel bearing • apply grease to the wheel bearings. 99000-25010: suzuki super grease “a” or equivalent 100 n·m (10.0 kgf-m, 72.5 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) 39 n·m (3.9 kgf-m, 28.0 lb-ft) 23 n·m (2.3 kgf-m, 16....

  • Page 349

    Chassis 8-15 • install the wheel bearings with the special tools as follows. 09924-84510: bearing installer set spacer " clearance # directional arrow mark • install the dust seal with the special tool. 09913-70210: bearing installer set • apply grease to the dust seal lip. 99000-25010: suzuki super...

  • Page 350

    8-16 chassis • install the collar to the right side of wheel. Wheel • install the front wheel with the front axle and hand-tighten the front axle bolt temporarily. Brake caliper • install the brake calipers (lh and rh). • tighten the brake caliper mounting bolts to the specified torque. " front brak...

  • Page 351

    Chassis 8-17 • move the front fork up and down 4 or 5 times. • 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 352: Front Fork

    8-18 chassis front fork construction o-ring oil seal spring retainer oil seal stopper ring spacer dust seal washer inner tube " spring " front fork cap bolt item n·m kgf-m lb-ft adjuster rod # lock-nut " 23 2.3 16.5 inner rod/damper rod (cartridge) $ front axle pinch bolt # 15 1.5 11.0 outer tube da...

  • Page 353

    Chassis 8-19 removal and disassembly note: * the left and right front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. * when the brake caliper is removed, care must be used so as not to cause stress to the brake hose. (hang t...

  • Page 354

    8-20 chassis • 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 tools " and #. • remove the front fork cap bolt , adjuster rod , spring retainer , spacer , washer and spring . • invert the front for...

  • Page 355

    Chassis 8-21 • remove the inner rod/damper rod (cartridge) . • slide the outer tube to remove it from the inner tube. Note: be careful not to damage the “anti-friction” metals. • remove the dust seal and oil seal stopper ring . • remove the oil seal with the special tool. 09913-50121: oil seal remov...

  • Page 356

    8-22 chassis 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 scratches. • if any defects are found, replace them with the new ones. Fork spring • measure the fork spring free length...

  • Page 357

    Chassis 8-23 reassembly reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: oil seal and dust seal • install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. Dust seal oil seal stopper ring oil seal oil seal r...

  • Page 358

    8-24 chassis 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 09940-30221: front fork assembling tool " dampe...

  • Page 359

    Chassis 8-25 • refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until no more bubbles come out from the oil. • keep the front fork vertically and wait 5 – 6 minutes. Note: * always keep oil level over the cartridge top end, ...

  • Page 360

    8-26 chassis front fork cap bolt • pull up the inner rod with the special tool ". • compress the spring with the special tool # and then insert the special tool $ between the lock-nut and the spacer. 09940-52841: inner rod holder " 09940-94930: front fork spacer holder # 09940-94922: stopper plate $...

  • Page 361

    Chassis 8-27 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 " at 7.0 mm (0.276 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts to...

  • Page 362

    8-28 chassis front suspension setting after installing the front fork, adjust the spring pre-load and three kinds of damping force as follows. Spring pre-load adjustment there are five grooved lines on the side of the spring adjuster. Position 0 provides the maximum spring pre-load and position 5 pr...

  • Page 363: Steering Damper

    Chassis 8-29 steering damper construction steering damper convex curve side of the washer faces down side. " dust seal item n·m kgf-m lb-ft steering stem head nut " damper rod bolt "# 23 2.3 16.5 # damper rod nut 90 9.0 65.0

  • Page 364

    8-30 chassis removal • turn the ignition switch off. • disconnect the steering damper solenoid coupler . • remove the lower bracket cover. ( 8-5) • remove the nut by holding the nut . • remove the bolt . • remove the steering damper. Inspection • inspect the steering damper body, bearing and oil sea...

  • Page 365

    Chassis 8-31 installation install the steering damper in the reverse order of removal. Pay attention to the following points: • apply grease to the bearings and dust seals. 99000-25010: suzuki super grease “a” or equivalent • install the steering damper and tighten the bolt and nut . " steering damp...

  • Page 366: Steering

    8-32 chassis steering construction steering stem upper bracket steering stem lower bracket " handlebars " steering stem head nut item n·m kgf-m lb-ft steering stem nut # steering stem lock-nut " 90 9.0 65.0 dust seal cover $ front fork upper clamp bolt # 90 9.0 65.0 dust seal handlebar clamp bolt $ ...

  • Page 367

    Chassis 8-33 removal • remove the under cowlings. ( 8-5) • support the motorcycle with a jack or a wooden block. • remove the front wheel. ( 8-11) • remove the front forks. ( 8-19) • remove the steering damper. ( 8-30) • remove the steering stem head nut and washer . • remove the steering stem upper...

  • Page 368

    8-34 chassis • remove the dust seal cover , dust seal , steering stem upper bearing inner race and bearing . Inspection and disassembly inspect the removed parts for the following abnormalities. * handlebar distortion * race wear and brinelling * bearing wear or damage * abnormal noise of bearing if...

  • Page 369

    Chassis 8-35 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 370

    8-36 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 371

    Chassis 8-37 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. ( 8-30) • check to make sure that the cables and wir...

  • Page 372: Handlebars

    8-38 chassis handlebars construction removal • remove the front brake master cylinder . • remove the right handle switch . • remove the handle balancer . • remove the throttle grip . Left handle grip handlebar (rh) throttle grip handlebar (lh) " left handle switch " handlebar clamp bolt item n·m kgf...

  • Page 373

    Chassis 8-39 • remove the clutch master cylinder . (8-89) • remove the left handle switch . • remove the handle balancer . • loosen the handlebar clamp bolts and front fork upper clamp bolts. (lh and rh) • remove the steering stem head nut . • remove the steering stem upper bracket along with the ig...

  • Page 374

    8-40 chassis installation install the handlebars in the reverse order of removal. Pay atten- tion to the following points: • install the handlebars temporarily. • install the steering stem upper bracket, washer and head nut. ( 8-36) • insert the protrusion " of the handlebars into the hole # of the ...

  • Page 375

    Chassis 8-41 • apply grease onto the right handlebar before installing the throttle grip. 99000-25010: suzuki super grease “a” or equivalent • apply grease to the throttle cables and cable drum. 99000-25010: suzuki super grease “a” or equivalent • when remounting the right and left handle switches, ...

  • Page 376: Rear Wheel

    8-42 chassis rear wheel construction rear axle wheel damper brake disc sprocket mounting drum collar sprocket " dust seal " brake disc bolt item n·m kgf-m lb-ft rear wheel # rear sprocket nut " 35 3.5 25.5 spacer $ rear axle nut # 60 6.0 43.5 bearing $ 100 10.0 72.5.

  • Page 377

    Chassis 8-43 removal • loosen the axle nut . • 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 disengaging the drive chain. • remove the collar . • remove the brake disc . • rem...

  • Page 378

    8-44 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 8-93) wheel inspection ( 8-93) rear axle • using the dial gauge, check the rear a...

  • Page 379

    Chassis 8-45 sprocket • inspect the sprocket teeth for wear. • if they are worn as shown, replace the two sprockets and drive chain as a set. " normal wear # excessive wear bearings • inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place. ...

  • Page 380

    8-46 chassis reassembly and installation reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: lh rh (b) (c) (d) (e) (a) 100 n·m (10.0 kgf-m, 72.5 lb-ft) 33 n·m (3.3 kgf-m, 24.0 lb-ft) 60 n·m (6.0 kgf-m, 43.5 lb-ft) 7.5 n·m (0.7...

  • Page 381

    Chassis 8-47 bearings • apply grease to the bearings before installing them. 99000-25010: suzuki super grease “a” or equivalent • install a new bearing to the sprocket mounting drum with the special tool. 09924-84510: bearing installer set • first install the right wheel bearing, then install the le...

  • Page 382

    8-48 chassis wheel damper • to install the wheel dampers, apply a special tire lubricant or neutral soapy liquid to the damper surface. Dust seals • install new dust seal with the special tool. 09913-70210: bearing installer set • apply grease to the dust seal lip before assembling rear wheel. 99000...

  • Page 383

    Chassis 8-49 • tighten the sprocket mounting nuts to the specified torque. " rear sprocket nut: 60 n·m (6.0 kgf-m, 43.5 lb-ft) note: stamped mark " on the sprocket should face outside. • install the collar . Brake disc • apply thread lock to the disc bolts and tighten them to the specified torque. N...

  • Page 384: Rear Shock Absorber

    8-50 chassis rear shock absorber construction left right rear shock absorber " rear shock absorber mount- ing bolt/nut " item n·m kgf-m lb-ft rear shock absorber bracket # rear shock absorber bracket nut " 50 5.0 36.0 # 115 11.5 83.0

  • Page 385

    Chassis 8-51 removal • remove the mufflers and muffler chamber. ( 6-12) • support the motorcycle with a jack to relieve load on the rear shock absorber. • remove the muffler chamber brackets . • remove the rear shock absorber upper and lower mounting bolts and nuts. • take out the rear shock absorbe...

  • Page 386

    8-52 chassis rear shock absorber disposal gas pressure release the rear cushion damper unit contains high-pressure nitrogen gas. Make sure to observe the following precautions. Mark the drill center at the location " using a center punch. Wrap the rear cushion unit with a vinyl bag and fix it on a v...

  • Page 387

    Chassis 8-53 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 nuts. " rear shock absorber mounting nut: 50 n·m (5.0 kgf-m, 36.0 lb-...

  • Page 388

    8-54 chassis compression damping force (high speed) fully turn the compression damping force (high speed) adjuster clockwise. From that position (stiffest), turn it out to the stan- dard setting position. Std position: 3 turns out from stiffest position compression damping force (low speed) fully tu...

  • Page 389: Rear Suspension

    Chassis 8-55 rear suspension construction rear shock absorber " swingarm pivot boss (lh) rear cushion rod " rear shock absorber mounting bolt/nut " rear cushion lever item n·m kgf-m lb-ft spacer # rear cushion lever bolt/nut " 50 5.0 36.0 bearing $ rear cushion rod bolt/nut #$ 98 9.8 71.0 chain case...

  • Page 390

    8-56 chassis removal • cut the drive chain. ( 8-97) note: it is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • remove the rear wheel. ( 8-43) • remove the brake hose guide . • remove the brake caliper from the swingarm. • remove the rear shock absorber. ( 8-51) • r...

  • Page 391

    Chassis 8-57 • remove the rear fender (lower) . • remove the chain case . • remove the chain buffer . Swingarm pivot boss removal and installation • remove the swingarm. ( 8-56) • remove the swingarm pivot boss nut . Note: remove the swingarm pivot boss when only replacing it. • remove the swingarm ...

  • Page 392

    8-58 chassis inspection and disassembly spacer • remove the spacers from swingarm. • remove the spacers from the cushion lever and cushion rod. • inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones. Swingarm bearing • insert the spacer into ...

  • Page 393

    Chassis 8-59 cushion lever 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. • remove the cushion lever bearings with the special tool. 09921-20240: bearing remover set ( 20 mm) ( 17 mm)...

  • Page 394

    8-60 chassis chain buffer • inspect the chain buffer for wear and damage. • if any defects are found, replace the chain buffer with a new one. Plate • inspect the plate for damage and excessive bend..

  • Page 395

    Chassis 8-61 reassembly reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: 115 n·m (11.5 kgf-m, 83.0 lb-ft) 100 n·m (10.0 kgf-m, 72.5 lb-ft) apply suzuki super grease “a” or equiva- lent one to the bearings, washers and dust seals. 50 n·m ...

  • Page 396

    8-62 chassis swingarm bearing • install the center spacer. • press the bearings into the swingarm pivot with the special tool and suitable size socket wrench. 09941-34513: steering race installer note: when installing the bearing, stamped mark on the bearing must face outside. Cushion lever bearing ...

  • Page 397

    Chassis 8-63 • install the chain case chain buffer and rear fender . Installation install the swingarm in the reverse order of disassembly and removal, and pay attention to the following points: swingarm pivot thrust clearance adjustment adjust swingarm pivot thrust clearance in the following proced...

  • Page 398

    8-64 chassis cushion lever, cushion rod and rear shock absorber • install the cushion lever and washers. • install the cushion rod and washers. • tighten each nut to the specified torque. " cushion lever mounting nut: 98 n·m (9.8 kgf-m, 71.0 lb-ft) cushion rod mounting nut (front side): 98 n·m (9.8 ...

  • Page 399: Front Brake

    Chassis 8-65 front brake construction front brake lever front brake hose " dust boot " master cylinder mounting bolt item n·m kgf-m lb-ft piston set # brake hose union bolt " 10 1.0 7.0 piston seal $ caliper mounting bolt # 23 2.3 16.5 dust seal % caliper air bleeder valve $ 39 3.9 28.0 brake calipe...

  • Page 400

    8-66 chassis brake pad replacement • loosen the pad mounting pins . • remove the brake caliper by removing the caliper mounting bolts . • remove the pad mounting pins , 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. (h...

  • Page 401

    Chassis 8-67 • install the spring to the caliper, bring its wider side of pawl " facing top. • install the new brake pads. • install the brake caliper. • tighten each bolt to the specified torque. " pad mounting pin : 16 n·m (1.6 kgf-m, 11.5 lb-ft) front brake caliper mounting bolt : 39 n·m (3.9 kgf...

  • Page 402

    8-68 chassis caliper removal note: * the left and right front brake calipers are installed symmetri- cally and therefore the removal procedure for one side is the same as that for the other side. * place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. • remove th...

  • Page 403

    Chassis 8-69 • place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air. • remove the dust seals and piston seals . Caliper inspection brake caliper • inspect the brake caliper cylinder wall for nicks, scratches or other damage. Brake caliper pi...

  • Page 404

    8-70 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 pisto...

  • Page 405

    Chassis 8-71 • temporarily tighten the air bleeder valve . • tighten each bolt to the specified torque. " front brake caliper housing bolt : 22 n·m (2.2 kgf-m, 16.0 lb-ft) 09930-11920: torx bit jt40h 09930-11940: bit holder caliper installation install the caliper in the reverse order of removal. Pa...

  • Page 406

    8-72 chassis master cylinder removal and disassembly • drain the brake fluid. ( 8-67) • disconnect the front brake light switch lead wires . • place a rag underneath the union bolt on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose. • remove ...

  • Page 407

    Chassis 8-73 • remove the dust boot push rod and snap ring ". • remove the following parts. Secondary cup piston primary cup return spring return spring guide air bleeder valve • remove the dust rubber and snap ring . • remove the connector and o-ring . Master cylinder inspection • inspect the maste...

  • Page 408

    8-74 chassis • 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: specificatio...

  • Page 409

    Chassis 8-75 • apply suzuki silicone grease to the brake lever pivot bolt. 99000-25100: suzuki silicone grease or equivalent " brake lever pivot bolt: 1.0 n·m (0.1 kgf-m, 0.7 lb-ft) brake lever lock-nut: 6.0 n·m (0.6 kgf-m, 4.5 lb-ft) • align the convex part " of brake light switch with the hole # o...

  • Page 410: Rear Brake

    8-76 chassis rear brake construction brake pedal " caliper air bleeder valve " piston/cup set # brake hose union bolt item n·m kgf-m lb-ft reservoir hose $ brake caliper mounting bolt " 7.5 0.75 5.5 brake hose % brake master cylinder mounting bolt # 23 2.3 16.5 brake pad & brake master cylinder rod ...

  • Page 411

    Chassis 8-77 brake pad replacement • remove the pad mounting pin . • remove the caliper mounting bolt . • 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: 16 n·m (1.6 kgf-m, 11.5 lb-...

  • Page 412

    8-78 chassis brake fluid replacement • remove the brake fluid reservoir mounting bolt . • place a rag underneath the brake fluid reservoir to catch any split brake fluid. Remove the brake fluid reservoir cap . • replace the brake fluid in the same manner as the front brake. ( 8-67) specification and...

  • Page 413

    Chassis 8-79 • remove the brake pad spring. • remove the caliper air bleeder valve . • remove the spacer and rubber boot 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 and piston seal . Avoid ...

  • Page 414

    8-80 chassis 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 415

    Chassis 8-81 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 pisto...

  • Page 416

    8-82 chassis 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 : 23 n·m (2.3 kgf-m, 16.5 lb-ft) brake caliper mounting bolt : 18 n·m (1.8 kgf-m, 13.0 lb-ft) brake calip...

  • Page 417

    Chassis 8-83 master cylinder disassembly • remove the reservoir cap, insulator , diaphragm and reservoir tank . • remove the connector by removing the screw. • remove the o-ring . • pull out the dust boot , then remove the snap ring . 09900-06108: snap ring pliers • remove the push rod , piston/prim...

  • Page 418

    8-84 chassis master cylinder reassembly reassemble the master cylinder in the reverse order of disas- sembly. Pay attention to the following points: specification and classification: dot 4 • apply suzuki silicone grease to the push rod end. 99000-25100: suzuki silicone grease or equivalent master cy...

  • Page 419

    Chassis 8-85 clutch release cylinder and master cylinder construction diaphragm spring " push rod clutch release cylinder item n·m kgf-m lb-ft dust boot " clutch master cylinder mounting bolt " 10 1.0 7.0 piston/cup set # clutch hose union bolt # 23 2.3 16.5 clutch hose $ air bleeder valve $ 6.0 0.6...

  • Page 420

    8-86 chassis clutch fluid replacement • place the motorcycle on a level surface and keep the handle- bars straight. • remove the clutch master cylinder reservoir cap and dia- phragm. • suck up the old clutch fluid as much as possible from the res- ervoir. • fill the reservoir with new clutch fluid. ...

  • Page 421

    Chassis 8-87 clutch release cylinder removal and disassembly • drain the clutch fluid. ( 8-86) • disconnect the clutch hose by removing the union bolt . Note: place a rag underneath the union bolt on the release cylinder to catch any spilled brake fluid. • remove the clutch release cylinder . • plac...

  • Page 422

    8-88 chassis clutch release cylinder reassembly and remounting reassemble the clutch release cylinder in the reverse order of disassembly and by taking the following steps: specification and classification: dot 4 piston piston cup spring air bleeder valve bleeder cap clutch release cylinder body • a...

  • Page 423

    Chassis 8-89 clutch master cylinder removal and disassembly • drain clutch fluid. ( 8-86) • disconnect the clutch lever position switch lead wires. • place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt and disconnect the clutch ho...

  • Page 424

    8-90 chassis • remove the dust boot and push rod . • remove the snap ring . 09900-06108: snap ring pliers • remove the piston/cup set. " secondary cup piston primary cup spring clutch master cylinder inspection • inspect the piston surface for any scratches or other damage. • inspect the primary cup...

  • Page 425

    Chassis 8-91 clutch master cylinder reassembly and remounting reassemble the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: specification and classification: dot 4 • apply brake fluid to the piston/cup set and install them to the clutch master...

  • Page 426

    8-92 chassis • apply suzuki silicone grease to the bushing and clutch lever pivot bolt. 99000-25100: suzuki silicone grease or equivalent " clutch lever pivot bolt: 1.0 n·m (0.1 kgf-m, 0.7 lb-ft) clutch lever lock-nut: 6.0 n·m (0.6 kgf-m, 4.5 lb-ft) • align the convex part " of clutch switch with th...

  • Page 427: Tire and Wheel

    Chassis 8-93 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 428

    8-94 chassis valve inspection • inspect the valve after the tire is removed from the rim. • replace the valve with a new one if the seal " 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 429

    Chassis 8-95 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 " on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the tim...

  • Page 430

    8-96 chassis • in this condition, check the “rim line” # 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 431: Drive Chain

    Chassis 8-97 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 • set...

  • Page 432

    8-98 chassis • place the drive chain link being disjointed on the holder part of the tool. • turn in both the adjuster bolt and pressure bolt “a” so that each of their end hole fits over the chain joint pin properly. • tighten the pressure bolt “a” with the bar. • turn in the pressure bolt “b” with ...

  • Page 433

    Chassis 8-99 • apply grease on the recessed portion of the joint plate holder and set the joint plate . Note: when positioning the joint plate on the tool, its stamp mark must face the joint plate holder side. • set the drive chain on the tool as illustrated and turn in the adjuster bolt to secure t...

  • Page 434

    8-100 chassis • stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “a” with the bar until the pin end diameter becomes the specified dimension. Pin end diameter specification % • adjust the drive chain, after connecting it. ( 2-22) did 5.50 – 5.80 mm (0.217 – 0.228 in) * after...

  • Page 435: Electrical System

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

  • Page 436: Electrical System

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

  • Page 437: 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 438

    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 439

    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 sure t...

  • Page 440

    9-6 electrical system location of electrical components excva (6-10) iap sensor (4-40) stv actuator (4-66) stp sensor (4-69) tp sensor (4-45) iat sensor (4-53) driving mode switch to sensor (4-62) pair control solenoid valve (11-6) cmp sensor (4-36) ignition coil isc valve (4-79) evap system purge c...

  • Page 441

    Electrical system 9-7 steering damper solenoid valve (4-108) secondary fuel injector (4-77) primary fuel injector (4-75) fuel pump fuel level gauge regulator/rectifier horn battery cooling fan relay (7-7) fuel pump relay (5-7) ap sensor (4-57) mode select switch coupler ecm starter relay/main fuse g...

  • Page 442: 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 re...

  • Page 443

    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/rectifier...

  • Page 444

    9-10 electrical system regulated voltage • remove the front seat. ( 8-8) • 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 spec...

  • Page 445

    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 speci...

  • Page 446

    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 447

    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 1 1)...

  • Page 448

    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 and measure the brush length ". If any damages are found, replace the br...

  • Page 449

    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 450

    9-16 electrical system • install the starter motor to the engine. • tighten the starter motor mounting bolts and lead wire bolt. ( 10-16) starter motor mounting bolt: 6 n·m (0.6 kgf-m, 4.5 lb-ft) starter motor lead wire bolt: 5 n·m (0.5 kgf-m, 3.5 lb-ft) starter relay inspection • remove the front s...

  • Page 451

    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 452

    9-18 electrical system gear position sensor • lift and support the fuel tank. ( 5-3) • disconnect the gear position switch coupler and check the continuity between bl and b/w with the transmission in “neu- tral”. 09900-25008: multi-circuit tester set tester knob indication: continuity test () • conn...

  • Page 453

    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 turn signal/side-stand relay . Side-stand relay inspection first check the insulation between % and & terminals with the tester. Then ap...

  • Page 454: 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 13 500 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 455

    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 456

    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 457

    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 igniti...

  • Page 458

    9-24 electrical system step 5 1) inspect the ignition coil/plug caps. ( 9-25) is the ignition coil/plug cap ok? Step 6 1) measure the crankshaft position sensor peak voltage and its resistance. ( 9-27) note: the crankshaft position sensor peak voltage inspection is applicable only with the multi cir...

  • Page 459

    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 ea...

  • Page 460

    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 the ignition switch on. • crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil pri...

  • Page 461

    Electrical system 9-27 ckp sensor peak voltage note: be sure that all couplers are connected properly and the battery used is in fully-charged condition. • lift and support the fuel tank. ( 5-3) • disconnect the ckp sensor lead wire coupler and connect the multi-circuit tester with the peak volt ada...

  • Page 462: Combination Meter

    9-28 electrical system 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 463

    Electrical system 9-29 removal and disassembly • remove the screw . • with the hooked parts behind the combination meter pulled from the cowling brace, disconnect the combination meter lead wire coupler. • remove the combination meter. • disassemble the combination meter as follows. When disconnecti...

  • Page 464

    9-30 electrical system inspection led (light emitting diode) check that the led lights [fi light, fuel level indicator light, engine revolution indicator lamp and immobilizer indicator light (for e-02, 19, 24)] immediately after turning the ignition switch on. Also, other led lights (neutral indicat...

  • Page 465

    Electrical system 9-31 engine coolant temperature meter and indicator ect sensor inspection ( 7-7 to -8) • lift and support the fuel tank. ( 5-3) • disconnect the ect sensor coupler . • connect the variable resistor " between the terminals. • disconnect the oil pressure switch lead wire from the oil...

  • Page 466

    9-32 electrical system 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: resi...

  • Page 467

    Electrical system 9-33 speedometer if the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. Speed sensor • lift and support the fuel tank....

  • Page 468

    9-34 electrical system oil pressure indicator note: before inspecting the oil pressure switch, check if the engine oil level is correct. ( 2-12) • remove the right under cowling. ( 8-5) • disconnect the oil pressure switch lead wire from the oil pres- sure switch. • turn the ignition switch on. • ch...

  • Page 469: Lamps

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

  • Page 470

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

  • Page 471: 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 472: Switch

    9-38 electrical system switch ignition switch removal • remove the air cleaner box. ( 5-14) • disconnect the ignition switch lead wire coupler (green) . • disconnect the immobilizer lead wire coupler (black) . (for e-02, 19, 24) • remove the cable guide . • remove the steering upper bracket. ( 8-33)...

  • Page 473

    Electrical system 9-39 driving mode switch description engine power characteristics can be changed in 3 modes by operating the driving mode switch to meet various riding condi- tions and rider’s preference. Operation driving mode is preset at a-mode when the ignition switch and engine stop switch ar...

  • Page 474

    9-40 electrical system inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “data monitor”. 4) make sure each of “driving mode selection” on the monitor is indicated “open”. 5) push each of driving mode switch and (up an...

  • Page 475

    Electrical system 9-41 switch 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 th...

  • Page 476: Battery

    9-42 electrical system battery specifications upper cover breather terminal cathode plates safety valve stopper anode plates filter separator (fiberglass plate) initial charging filling electrolyte • remove the aluminum tape sealing the battery electrolyte filler holes ". Note: when filling electrol...

  • Page 477

    Electrical system 9-43 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 478

    9-44 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 479: Servicing Information

    Servicing information 10-1 10 servicing information contents troubleshooting ................................................................................ 10- 3 fi system malfunction code and defective condition..................................................................... 10- 3 engine ......

  • Page 480: Servicing Information

    Servicing information contents 10-2 servicing information rear view mirror installation ............................................... 10-37 rear combination light installation .................................. 10-38 rear combination light cushion/fastener installation................................

  • Page 481: Troubleshooting

    Servicing information 10-3 troubleshooting fi system malfunction code and defective condition ( 4-30 to -35) 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...

  • Page 482

    10-4 servicing information 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 483

    Servicing information 10-5 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 484

    10-6 servicing information 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 485

    Servicing information 10-7 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 p...

  • Page 486

    10-8 servicing information 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 487

    Servicing information 10-9 radiator (cooling system) complaint symptom and possible causes remedy transmission jumps out of gear. 1. Worn shifting gears on driveshaft or countershaft 2. Distorted or worn gearshift forks 3. Weakened stopper spring on gearshift stopper 4. Worn gearshift cam plate repl...

  • Page 488

    10-10 servicing information 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 5. Defective steering damper solenoid adjust. Replace. Replace. Adjust. Rep...

  • Page 489

    Servicing information 10-11 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 490

    10-12 servicing information electrical complaint symptom and possible causes remedy no sparking or poor sparking 1. Defective ignition coils 2. Defective spark plugs 3. Defective ckp sensor 4. Defective ecm 5. Defective to sensor 6. Open-circuited wiring connections replace. Replace. Replace. Replac...

  • Page 491

    Servicing information 10-13 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 492

    10-14 servicing information wiring harness, cable and hose routing wiring harness routing pair control solenoid valve clamp fixed clamp fixed clamp clamp clamp ecm clamp fixed clamp fixed clamp fixed clamp secondary fuel injector primary fuel injector regulator/rectifier fixed clamp fixed clamp ecm ...

  • Page 493

    Servicing information 10-15 ecm cushion clamp clamp backside of the headlight guide fixed clamp clamp guide clutch hose side-stand switch ho2 sensor lead wire.

  • Page 494

    10-16 servicing information grommet 120 n.M 12.0 kgf-m 87 lb-ft make slack to the gear position switch lead wire at this point. Gear position sensor 6.5 n.M (0.65 kgf-m, 4.7 lb-ft) oil pressure switch 14 n.M 1.4 kgf-m 10.0 lb-ft 10 n.M 1.0 kgf-m 7.0 lb-ft 1.5 n.M (0.15 kgf-m, 1.0 lb-ft) 5 n.M (0.5 k...

  • Page 495

    Servicing information 10-17 throttle cable routing throttle cable no.1 brake hose throttle cable no.2 *1 pass the throttle cables along the air cleaner box. 0 mm (0 in) 0 mm (0 in) *1.

  • Page 496

    10-18 servicing information throttle body hose routing fuel feed hose evap purge hose (e-33 only) pcv (breather) hose evap system purge control solenoid valve (e-33 only) isc valve hose evap system purge control solenoid valve hose evap surge hose (e-33 only) " to iap sensor evap canister (e-33 only...

  • Page 497

    Servicing information 10-19 fuel tank drain hose routing fuel feed hose pass the breather hose and drain hose through over the wiring harness. Breather hose (except for e-33) bend the hose clamp at the white painted mark on the breather hose . Drain hose set the breather hose and drain hose to the l...

  • Page 498

    10-20 servicing information cooling system hose routing the ends of the clamp should face..... 6 n·m (0.6 kgf-m, 4.5 lb-ft) the clamp screw head should face..... 12 n·m (1.2 kgf-m, 8.5 lb-ft) marking (white) : backward. “a” marking (green) : right side. : right side. “a” “b” : left side. “a” : backw...

  • Page 499

    Servicing information 10-21 front brake hose routing clamp ends should face downward. The green paint is right side and face upside. Clamp ends should face backward. Brake hose guide. After the brake hose union has contacted the stopper, tighten the union bolt. 23 n·m (2.3 kgf-m, 16.5 lb-ft) clamp t...

  • Page 500

    10-22 servicing information rear brake hose routing clamp ends should face backward. 23 n·m (2.3 kgf-m, 16.5 lb-ft) clamp ends should face inside. 33 n·m (3.3 kgf-m, 24.0 lb-ft) white paint faces outside. 7.5 n·m (0.75 kgf-m, 5.5 lb-ft) after the brake hose union has contacted the stopper, tighten t...

  • Page 501

    Servicing information 10-23 clutch hose routing 1 clutch hose guide. 6 n·m (0.6 kgf-m, 4.3 lb-ft) stopper: after the clutch hose union has con- tacted the stopper, tighten the union bolt. 23 n·m (2.3 kgf-m, 16.5 lb-ft) grommet: install the grommet of the clutch hose to the clutch. 10 n·m (1.0 kgf-m,...

  • Page 502

    10-24 servicing information pair (air supply) system hose routing 0˚ *1 0˚ approx. 45˚ approx. 25˚ *1 *1 pair control solenoid valve air cleaner box pair reed valve *1 to air cleaner box.

  • Page 503

    Servicing information 10-25 fuel tank installation fuel tank cover apply adhesive agent. Velcro fastening view from bottom. Frame cover cushion align the fuel tank cushion with the dent mark . Fuel tank cushion dent mark “a” “a” “a” “a” “a” “b” “c” “a” “b” “c”.

  • Page 504

    10-26 servicing information fuel tank lower side cover cushion rubber/ fastener installation air intake cover cushion rubber installation note: clean the adhesive surface before adhering the cushion rubber. Cushion protective tape cushion align the velcro fastening to the aligned mark. Clean an adhe...

  • Page 505

    Servicing information 10-27 body cowling cushion rubber installation note: clean the adhesive surface before adhering the cushion rubber. Under cowling heat shield installation note: clean an adhesive surface before adhering the heat shield. Heat shield (rh) clean the adhesive surface before adherin...

  • Page 506

    10-28 servicing information fuel tank heat shield and fuel tank bracket cushion installation fuel tank cover cushion/velcro fastening installation the ends of the clamp should face forward. Fuel tank cover cushion velcro fastening.

  • Page 507

    Servicing information 10-29 cowling installation “b” “a1” to “a” to “a1” “a” to “b” to radiator heat shield.

  • Page 508

    10-30 servicing information frame cover installation seat lock cable routing.

  • Page 509

    Servicing information 10-31 front fender installation 1 reflex reflector 1.8 n·m (0.18 kgf-m, 1.3 lb-ft) 4.5 n·m (0.45 kgf-m, 3.25 lb-ft) (for e-03, 24, 28, 33) (a) (b) 1 (a) (b).

  • Page 510

    10-32 servicing information rear fender installation rear fender (front) rear fender (lower) rear fender cover (front) swingarm rear fender (rear).

  • Page 511

    Servicing information 10-33 side-stand installation 50 n·m (5.0 kgf-m, 36.0 lb-ft) 95 n·m (9.5 kgf-m, 68.5 lb-ft) 40 n·m (4.0 kgf-m, 29.0 lb-ft) x apply grease to sliding surface. (b) (c) (a) (a) (c) (b).

  • Page 512

    10-34 servicing information gearshift pedal installation * when adjusting the footrest position to the backside, the optional gearshift rod must be used. “a” “std” footrest top position a: 195.65 mm (7.70 in) b adjust the thread of each rod end b to equal length. “b” “lower” footrest top position b:...

  • Page 513

    Servicing information 10-35 front footrest installation 39 n·m (3.9 kgf-m, 28.0 lb-ft) 18 n·m (1.8 kgf-m, 13.0 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) align the cutaway when installing. 10 n·m (1.0 kgf-m, 9.0 lb-ft) (d) (c) (b) (a) (b) (b) (c) (d) (a) “a” (a) (d) (b) “a” (c).

  • Page 514

    10-36 servicing information pillion footrest installation footrest x apply grease to sliding surface..

  • Page 515

    Servicing information 10-37 rear view mirror installation body cowling mirror cover cowling brace mirror body cushion 10 n·m (1.0 kgf-m, 7.0 lb-ft) turn signal lead wire locate the turn signal lead wire coupler between the mirror cover and mirror body . Turn signal lead wire coupler “a” (a) (a) “a”.

  • Page 516

    10-38 servicing information rear combination light installation 5 n·m (0.5 kgf-m, 3.5 lb-ft) 2.75 n·m (0.275 kgf-m, 2.0 lb-ft) 2.75 n·m (0.275 kgf-m, 2.0 lb-ft) (a) (b) (b) (c) (a) (b) (c).

  • Page 517

    Servicing information 10-39 rear combination light cushion/fastener installation rear combination light a lign the corner of cushions and fasteners with the root of the rib. 30 mm (1.18 in) 40 mm (1.58 in) 4 mm (0.16 in) or more 33 mm (1.30 in) 25 mm (0.98 in) cushion fastener.

  • Page 518

    10-40 servicing information regulator/rectifier installation note: to remove or install the regulator/rectifier easily, hold its bolt head with an open-end wrench. 1 regulator/rectifier 3 clamp 2 bracket 4 radiator 1 4 2 1 3 2.

  • Page 519

    Servicing information 10-41 special tools 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) 09900-20530 cylinder gauge set 09900-20602 dia...

  • Page 520

    10-42 servicing information 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 (for high pressure) 09916-10911 valve lapper set ...

  • Page 521

    Servicing information 10-43 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 09924-84510 bearing installer set 09924-84521 bearing installer set 09925-18011 steering bearing i...

  • Page 522

    10-44 servicing information note: when order the special tool, please confirm whether it is available or not. 09940-40211 fuel pressure gauge adaptor 09940-40220 fuel pressure gauge hose attachment 09940-52841 front fork inner rod holder 09940-52861 front fork oil seal installer 09940-92720 spring s...

  • Page 523: Tightening Torque

    Servicing information 10-45 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 25 2.5 18.0 muffler chamber bracket bolt 25 2.5 18.0 muffler chamber mounting bolt 23 2.3 16.5 muffler joint nut 25 2.5 18.0 speed sensor ...

  • Page 524

    10-46 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 crankshaft journal bolt (m: 9) (initial) 18 1.8 13.0 (final) 50° oil gallery plug (m: 6) 10 1....

  • Page 525

    Servicing information 10-47 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 23 2.3 16.5 front fork inner rod...

  • Page 526

    10-48 servicing information tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter " (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m lb-ft n·m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0...

  • Page 527: Service Data

    Servicing information 10-49 service data valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 24 (0.94) — valve clearance (when cold) in. 0.08 – 0.18 (0.003 – 0.007) — ex. 0.18 – 0.28 (0.007 – 0.011) — valve guide to valve stem ...

  • Page 528

    10-50 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 0.035 –...

  • Page 529

    Servicing information 10-51 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 530

    10-52 servicing information clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio item standard limit drive plate thickness no. 1, 2 and 3 2.72 – 2.88 (0.107 – 0.113) 2.42 (0.095) drive plate claw width no. 1, 2 and 3 13.85 – 13.96 (0.5453 – 0.5496) 13.05 (0.5138) driven plate d...

  • Page 531

    Servicing information 10-53 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 532

    10-54 servicing information fi sensors item specification note ckp sensor resistance 142 – 194 Ω ckp sensor peak voltage 0.5 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.6 v at idle speed tp sensor input voltage 4.5 – 5.5 v tp sensor output voltag...

  • Page 533

    Servicing information 10-55 throttle body electrical unit: mm (in) item specification bore size 44 mm (1.73 in) i.D. No. 21g1 (for e-33), 21g0 (for the others) idle r/min 1 150 ± 100 r/min throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specification note firing order 1.2.4.3 spark plug type ...

  • Page 534

    10-56 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 ← brake light/taillight led ← turn signal light 21 × 4 ← license plate light 5 ← combination meter light led ← turn signal indica...

  • Page 535

    Servicing information 10-57 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 6.00 — wheel axle runout front — 0.25 (0.010) rear — 0.25 (0.010) item standard limit cold inflation tire pressure (solo riding) front...

  • Page 536

    10-58 servicing information suspension unit: mm (in) item standard limit front fork stroke 125 (4.92) — front fork spring free length 238.5 (9.39) 233 (9.17) front fork oil level (without spring, outer tube fully compressed) 124 (4.88) — front fork oil type suzuki fork oil l01 or an equivalent fork ...

  • Page 537

    Servicing information 10-59 fuel + oil item specification note fuel type 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 corro- sion inhibitor is...

  • Page 538: Emission Control Information

    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 539: Emission Control Systems

    11-2 emission control information emission control systems fuel injection system gsx-r1000 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With...

  • Page 540

    Emission control information 11-3 crankcase emission control system the engine is equipped with a pcv system to prevent discharging crankcase emissions into the atomo- sphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combus- tion chamber through the ...

  • Page 541

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

  • Page 542

    Emission control information 11-5 ho2 sensor inspection ( 4-88) ho2 sensor removal and installation ( 4-113) 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 ino...

  • Page 543: 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 for secure connection. Pair reed valve • lift and support the fuel tank. ( 5-3) • remove the pair reed valve cover. ( 3-2...

  • Page 544

    Emission control information 11-7 • connect the 12 v battery to the pair control solenoid valve terminals and check the air flow. • if air does not flow out, the solenoid valve is in normal condi- tion. • check the resistance between the terminals of the pair con- trol solenoid valve. Resistance: 18...

  • Page 545

    11-8 emission control information pair (air supply) system diagram pair (air supply) system hose routing ( 10-24) pair control solenoid valve *1 from air cleaner pair reed valve *2 to #1 and #2 cylinders " fresh air *3 to #3 and #4 cylinders # exhaust gas *1 *1 *2 *3 *1.

  • Page 546

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

  • Page 547

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

  • Page 548

    Prepared by january, 2007 part no. 99500-39310-01e printed in japan 556.

  • Page 549

    Printed in japan k7.