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Suzuki GSX-R1000 Service Manual

Other manuals for GSX-R1000: Service Manual, Service Manual, Service Manual

Summary of GSX-R1000

  • Page 2: Printed In Japan

    Printed in japan k5 no.7892 gsx-r1000_01e 99500-39270-01e 2005.1.19 cover_14 for ps printing (20mm) 1/1 9 9 5 0 0 - 3 9 2 7 0 - 0 1 e top bottom k5 gsx-r1000 gsx-r1000 tdp7.

  • Page 3: 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 4: How to Use This Manual

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

  • Page 5: Symbol

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

  • Page 6: Abbreviations Used In This

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

  • Page 7

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

  • Page 8: Wire Color

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

  • Page 9: General Information

    General information 1-1 1 general information contents warning/caution/note......................................................................... 1- 2 general precautions .......................................................................... 1- 2 suzuki gsx-r1000k5 (’05-model)...................

  • Page 10: Warning/caution/note

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

  • Page 11: Lent.

    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 12: Serial Number Location

    1-4 general information suzuki gsx-r1000k5 (’05-model) • difference between photograph and actual motorcycle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering head pipe. The engi...

  • Page 13: Fuel (For Usa and Canada)

    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 14: Front Fork Oil

    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 15: 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 16: 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 right side of rear fender. *3: this label is attached on the right side of seat rail. Gsx-r1000 gsx-r1000uf 1 noise label a (for e-03, 24, 33) 2 inform...

  • Page 17: Specifications

    General information 1-9 specifications dimensions and dry mass overall length .......................................................................... 2 030 mm (79.9 in) overall width ........................................................................... 710 mm (28.0 in) overall height .........

  • Page 18: Chassis

    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 19: Periodic Maintenance

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

  • Page 20: Periodic Maintenance Chart

    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 21: Lubrication Points

    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 22: Maintenance and Tune-Up

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

  • Page 23: Spark Plug

    Periodic maintenance 2-5 spark plug spark plug and ignition coil/plug cap removal • remove the front seat. ( 8-7) • lift and support the fuel tank. ( 5-3) • remove the air cleaner box. ( 5-13) • disconnect all lead wire couplers from ignition coil/plug caps. • remove the ignition coils/plug caps....

  • Page 24: Spark Plug Gap

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

  • Page 25: Valve Clearance

    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. ( 5-13) • disconnect the cmp sensor coupler 1. • remove the pair control solenoid valve 2. • remove the spark plugs. ( 2-5) • loosen the thrott...

  • Page 26

    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 a on the left ends of both camshafts (ex. And in.) to the positions as shown. • in this condition, read the valve clearance at the valves b (in. And ex. Of no....

  • Page 27: Valve Clearance Adjustment

    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. ( 3-15) • remove the tappet and shim by fingers or magnetic hand. • check the figures printed on the shim. Thes...

  • Page 28: (Intake Side)

    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 29: (Exhaust Side)

    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 30: Engine Oil and Oil Filter

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

  • Page 31: Oil Filter Replacement

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

  • Page 32: Fuel Line

    2-14 periodic maintenance • remove the two bolts and cover. • check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. Fuel line • inspect the fuel feed hose 1 for damage and fuel leakage. If any defects are found, the fuel feed hose must be replace...

  • Page 33: Evaporative Emission Control

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

  • Page 34: Clutch

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

  • Page 35: Cooling System

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

  • Page 36: Engine Side

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

  • Page 37: Radiator Hoses

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

  • Page 38: Drive Chain

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

  • Page 39: Adjusting

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

  • Page 40: Cleaning and Lubricating

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

  • Page 41: Brake

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

  • Page 42: Brake Pads

    2-24 periodic maintenance brake pads front brake the extent of brake pad wear can be checked by observing the grooved limit line a on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. ( 8-63) rear brake the extent of brake pad wear can be checked by observin...

  • Page 43: Brake Pedal Height

    Periodic maintenance 2-25 brake pedal height • loosen the lock-nut 1. • turn the push rod 2 until the brake pedal height becomes 55 – 65 mm (2.2 – 2.6 in) a below the top of the footrest. • tighten the lock-nut 1 securely.  rear brake master cylinder rod lock-nut: 18 n·m (1.8 kgf-m, 13.0 ib-ft)  b...

  • Page 44: Front Brake (Caliper Side)

    2-26 periodic maintenance front brake (caliper side) • fill the master cylinder reservoir to the top of the inspection window. Replace the reservoir cap to prevent dirt from enter- ing. • attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle. • squeeze and rele...

  • Page 45: Tires

    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 46: Front Fork

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

  • Page 47: Exhaust Pipe Bolt and Nut

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

  • Page 48: Chassis Bolts and Nuts

    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 49

    Periodic maintenance 2-31 sa mp le.

  • Page 50: 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 51: 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 52: Sds Check

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

  • Page 53: Data At The Time of Racing

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

  • Page 54

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

  • Page 55: Engine     3-1

    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 installatio...

  • Page 56: 3-2     Engine

    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 57: Engine     3-3

    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 58: 3-4     Engine

    3-4 engine • remove the throttle body assembly 2. ( 5-14) oil cooler • remove the oil cooler pipes. • remove the oil cooler 1. Radiator • disconnect the reservoir inlet hose 1 and radiator inlet hose 2. • disconnect the cooling fan coupler 3. Be careful not to bent the oil cooler fin. Sa mp le.

  • Page 59: Engine     3-5

    Engine 3-5 • remove the radiator mounting bolts. • remove the radiator 4. • remove the front engine cover 5. Exhaust pipe • remove the exhaust pipe bolts. • with the muffler connecting bolt loosened, remove the exhaust pipe 1. Be careful not to bent the radiator fin. Sa mp le.

  • Page 60: 3-6     Engine

    3-6 engine • remove the radiator mounting bracket 2. Electric parts and pair hose • disconnect the oil pressure switch lead wire 1. • disconnect the starter motor lead wire 2. • disconnect the ground lead wire 3. • disconnect the ckp sensor coupler 4. • disconnect the gp switch coupler 5. • disconne...

  • Page 61: Engine     3-7

    Engine 3-7 • disconnect the ignition coil/plug cap lead wire couplers and cmp sensor lead wire coupler. • remove the ignition coils/plug caps. • disconnect the pair hoses 8. Engine sprocket and gear shift lever • remove the gearshift lever 1. • remove the engine sprocket cover 2. • remove the clutch...

  • Page 62: 3-8     Engine

    3-8 engine • remove the speed sensor rotor 4. • remove the engine sprocket nut 5 and the washer 6. • remove the cotter pin. (for e-03, 28, 33) • loosen the rear axle nut 7. • loosen the chain adjuster lock-nuts. • loosen the chain adjusters 8. • push the rear wheel forward and make sure that the dri...

  • Page 63: Engine     3-9

    Engine 3-9 engine mounting • support the engine using an engine jack. • remove the engine mounting bolts a and c. • loosen the engine mounting pinch bolts 1 and 2. • remove the engine mounting bolts b and d. • remove the engine mounting nut 3. • remove the engine mounting thrust adjuster lock-nut 4 ...

  • Page 64: 3-10     Engine

    3-10 engine • remove the engine mounting nut 6. • loosen the engine mounting thrust adjuster lock-nut 7 with the special tool. • loosen the engine mounting thrust adjuster 8.  09940-14990: engine mounting thrust adjuster socket wrench note: do not remove the engine mounting bolts at this stage. • r...

  • Page 65: Engine     3-11

    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 adj...

  • Page 66: 3-12     Engine

    3-12 engine a left b right length item n·m kgf-m lb-ft item mm in abcd 55 5.5 40.0 bolt ac 45 1.77 58 75 7.5 54.0 bd 55 2.17 12 23 2.3 16.5 ef 215 8.46 69 23 2.3 16.5 spacer 34 30.5 1.20 70 45 4.5 32.5 adjuster 69 40 1.57 sa mp le.

  • Page 67: Engine     3-13

    Engine 3-13 • install the engine sprocket and the washer. • apply a small quantity of thread lock to the driveshaft thread portion.  99000-32050: thread lock “1342” • tighten the engine sprocket nut 1 to the specified torque.  engine sprocket nut: 115 n·m (11.5 kgf-m, 83.0 lb-ft) • install the spe...

  • Page 68: 3-14     Engine

    3-14 engine • install the radiator mounting bracket 1. • install the exhaust pipe 2.  muffler connecting bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft)  exhaust pipe bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • fit the new o-rings to the union of the oil cooler pipes. • apply thread lock to the bolts, install the...

  • Page 69: Engine     3-15

    Engine 3-15 engine disassembly • remove the spark plugs. ( 2-5) starter motor • remove the starter motor 1. Cylinder head cover • remove the cylinder head cover 1 and its gaskets. • remove the dowel pins and o-rings. Camshaft • remove the valve timing inspection cap 1. Identify the position of each...

  • Page 70: 3-16     Engine

    3-16 engine • turn the crankshaft to bring the line a on the starter clutch to the index mark b of the valve timing inspection hole and also to bring the cams to the position as shown. • remove the cam chain tension adjuster cap bolt 2 and spring. • remove the cam chain tension adjuster 3. • remove ...

  • Page 71: Engine     3-17

    Engine 3-17 cylinder head • remove the water hose 1. • remove the thermostat cover 2 and thermostat. Thermostat inspection ( 7-9) • remove the ect sensor 3. Ect sensor inspection ( 7-7) • remove the cylinder head bolts (m6) 4. • remove the cylinder head bolts and washers. Note: when loosening the ...

  • Page 72: 3-18     Engine

    3-18 engine • remove the pressure plate. • remove the clutch drive plates 1 and driven plates 2. • remove the clutch push piece 3, bearing 4 and the thrust washer 5. • remove the spring washer 6 and its seat 7. • remove the clutch push rod 8. Note: if it is difficult to pull out the push rod 8, use ...

  • Page 73: Engine     3-19

    Engine 3-19 • hold the clutch sleeve hub with the special tool.  09920-53740: clutch sleeve hub holder • remove the clutch sleeve hub nut. • remove the conical spring washer 9, washer 0 and clutch sleeve hub a. • remove the wave spring washers b and clutch lifter driven cam c. • remove the clutch l...

  • Page 74: 3-20     Engine

    3-20 engine • remove the thrust washer i. • remove the oil pump drive gear j from the primary driven gear assembly k. Oil pump • remove the snap ring 1. • remove the oil pump driven gear 2. Note: do not drop the snap ring 1 into the crankcase. • remove the pin 3 and washer 4. • remove the oil pump 5...

  • Page 75: Engine     3-21

    Engine 3-21 starter idle gear • remove the starter idle gear cover. • remove the dowel pins and gasket. • remove the spring washer 1, washer 2 and starter idle gear no. 1 3. • remove the shaft 4, bearing 5 and thrust washer 6. • remove the starter clutch cover. • remove the dowel pins and gasket. • ...

  • Page 76: 3-22     Engine

    3-22 engine 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 washer. Cam chain/cam chain tensioner/cam chain guide • remove the cam chain tensioner 1 and cam chai...

  • Page 77: Engine     3-23

    Engine 3-23 • install a bolt a of suitable size to the left end of crankshaft. Suitable bolt a [m12, length: 28 – 38 mm (1.1 – 1.5 in)] • remove the generator rotor with the special tool.  09930-34980: rotor remover water pump • remove the water hose 1 and water inlet cover 2. • remove the water pu...

  • Page 78: 3-24     Engine

    3-24 engine oil filter • remove the oil filter with the special tool. ( 2-13)  09915-40610: oil filter wrench oil pan • remove the oil pan 1. Oil pressure regulator • remove the oil pressure regulator 1. Oil pressure switch • remove the oil pressure switch 2. Oil strainer • remove the oil strainer...

  • Page 79: Engine     3-25

    Engine 3-25 transmission • remove the transmission 1 and o-rings. • remove the dowel pins 2. Middle crankcase • remove the crankcase bolts. • remove the crankcase bolts (m6). • remove the crankcase bolts (m8). • remove the crankshaft journal bolts (m9). Note: loosen the crankcase bolts diagonally wi...

  • Page 80: 3-26     Engine

    3-26 engine piston and conrod • push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase. • remove the piston pin circlip 1. • separate the piston and conrod by driving out the piston pin. Note: scribe the cylinder number on the piston head. Be careful not to d...

  • Page 81: Engine     3-27

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

  • Page 82: 3-28     Engine

    3-28 engine inspection • inspect the reed valve for the carbon deposit. • if the carbon deposit is found in the reed valve, replace the pair reed valve with a new one. Installation • install the pair reed valves and pair reed valve covers. • apply thread lock to the bolts and tighten to the specifie...

  • Page 83: Engine     3-29

    Engine 3-29 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 1 to read the clearance at the widest portion, which is specified as follows:  camshaft journal oil clearanc...

  • Page 84: 3-30     Engine

    3-30 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 ...

  • Page 85: Engine     3-31

    Engine 3-31 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. • if they are worn or damaged, replace them with the new on...

  • Page 86: 3-32     Engine

    3-32 engine • when compressing the valve spring, use a protector that is handcrafted from a 35-mm film cartridge as shown in the right illustration. For intake side for exhaust side a 7 mm (0.28 in) a 7 mm (0.28 in) b 46 mm (1.81 in) b 46 mm (1.81 in) c 24 mm (0.95 in) c 22 mm (0.87 in) • install th...

  • Page 87: Engine     3-33

    Engine 3-33 • remove the oil seal 8 and spring seat 9. • 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, takin...

  • Page 88: 3-34     Engine

    3-34 engine valve stem and valve face wear condition • visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one. Valve stem deflection • lift the valve about 10 mm (0.39 in) from the valve seat. • measure the valve stem deflecti...

  • Page 89: Engine     3-35

    Engine 3-35 valve guide servicing • using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side.  09916-53310: valve guide remover/installer note: * discard the removed valve guide subassemblies. * only oversized valve guides are available as replacement part...

  • Page 90: 3-36     Engine

    3-36 engine • after installing the valve guides, re-finish their guiding bores using the reamer. • clean and oil the guides after reaming.  09916-33210: valve guide reamer 09916-34542: reamer handle note: * be sure to cool down the cylinder head to ambient air temper- ature. * insert the reamer fro...

  • Page 91: Engine     3-37

    Engine 3-37 valve seat servicing • the valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to four different angles. The seat con- tact surface is cut at 45°.  09916-21111: valve seat cutter set 09916-20630: valve seat cutter (n-126) 09916-20640: solid pilot (n-100-4.5) note:...

  • Page 92: 3-38     Engine

    3-38 engine • if the valve seat is pitted or burned, use the 45° cutter to con- dition the seat some more. Note: cut only the minimum amount necessary from the seat to pre- vent the possibility of the valve stem becoming too close to the camshaft. Top narrowing cut • if the contact area w is too hig...

  • Page 93: Engine     3-39

    Engine 3-39 final seat cut • if the contact area w is too low or too narrow, use the 45° cut- ter to raise and widen the contact area. Note: after cutting the 15°, 30° and 60° angles, it is possible that the valve seat (45°) is too narrow. If so, re-cut the valve seat to the correct width. • after t...

  • Page 94: 3-40     Engine

    3-40 engine • clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • if any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Valve spring the force of the coil spring kee...

  • Page 95: Engine     3-41

    Engine 3-41 valve and valve spring reassembly • install the valve spring seat. • apply molybdenum oil solution to the oil seal 1, and press-fit it into position.  molybdenum oil solution • insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length ...

  • Page 96: 3-42     Engine

    3-42 engine • be sure that the rounded lip e of the cotter fits snugly into the groove f in the stem end. • install the other valves and springs in the same manner as described previously. 5 valve spring retainer 6 cotter • install the tappet shims and the tappets to their original posi- tions. Note...

  • Page 97: Engine     3-43

    Engine 3-43 water bypass union • remove the water bypass union 1. • apply suzuki bond to the thread part of water bypass union and tighten it to the specified torque.  99104-31140: suzuki bond “1207b” (usa) 99000-31140: suzuki bond “1207b” (others)  water bypass union: 12 n·m (1.2 kgf-m, 8.5 lb-ft...

  • Page 98: 3-44     Engine

    3-44 engine clutch driven plate inspection note: wipe off engine oil from the clutch driven plates with a clean rag. • measure each driven plate for distortion with a thickness gauge and surface plate. • replace driven plates which exceed the limit.  driven plate distortion (no. 1, no. 2 and no. 3)...

  • Page 99: Engine     3-45

    Engine 3-45 clutch lifter clutch lifter drive cam and driven cam inspec- tion • inspect the clutch lifter drive cam and driven cam for wear or damage. If any defects are found, replace the clutch lifter drive cam and driven cam as a set. Clutch lifter pin adjustment note: when adjusting the clutch l...

  • Page 100: 3-46     Engine

    3-46 engine • check the height h of clutch lifter adjusting pin screws at three positions using the thickness gauge. • if the measurement is out of the specification, adjust the height h as shown in the following specification.  clutch lifter adjusting pin screw height h standard: 0.2 – 0.4 mm (0.0...

  • Page 101: Engine     3-47

    Engine 3-47 starter clutch inspection • install the starter driven gear 1 onto the starter clutch 2. • 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 th...

  • Page 102: 3-48     Engine

    3-48 engine water pump 7-13 gearshift system gearshift shaft/gearshift arm disassembly • remove the following parts from the gearshift shaft/gearshift arm. 1 washer 4 gearshift cam drive plate 2 snap ring 5 plate return spring 3 gearshift shaft return spring gearshift shaft/gearshift arm inspection...

  • Page 103: Engine     3-49

    Engine 3-49 oil pressure regulator • 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 pressure regula- tor with a new one. Oil strainer • inspect the oil strainer body for damage. • clean the oil straine...

  • Page 104: 3-50     Engine

    3-50 engine transmission disassembly disassemble the countershaft and driveshaft. Pay attention to the following points: • remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2. • slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, t...

  • Page 105: Engine     3-51

    Engine 3-51 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 106: 3-52     Engine

    3-52 engine transmission parts location \ 1 countershaft 2 driveshaft sa mp le.

  • Page 107: Engine     3-53

    Engine 3-53 cylinder crankcase servicing ( 3-56) 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 108: 3-54     Engine

    3-54 engine piston and piston ring piston diameter • using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) a from the piston skirt end. • if the measurement is less than the limit, replace the piston.  piston diameter: service limit: 73.280 mm (2.8850 in) at 15 mm (0.6 in) from ...

  • Page 109: Engine     3-55

    Engine 3-55 piston ring-to-groove clearance • measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • if any of the clearances exceeds the limit, replace both the piston and piston rings.  09900-20803: thickness gauge 09900-20205: micrometer (0 – 25 mm)  piston rin...

  • Page 110: 3-56     Engine

    3-56 engine crankcase gearshift fork and gearshift cam removal • remove the gearshift cam bearing retainer screws 1 and gearshift fork shaft retainer 2 from the lower crankcase. • remove the gearshift fork shafts 3 and gearshift forks 4 from the lower crankcase. • remove the gearshift cam 5 and its ...

  • Page 111: Engine     3-57

    Engine 3-57 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...

  • Page 112: 3-58     Engine

    3-58 engine • remove the oil seal 1. • 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 (1, 220) (3 32) note: the stamped mark side of the gearshift s...

  • Page 113: Engine     3-59

    Engine 3-59 • install the gearshift forks and their shafts as shown. 6 for 3rd/4th drive gears 7 for 6th driven gear 8 for 5th driven gear • apply a small quantity of thread lock to the bearing retainer screws 9. • tighten the bearing retainer screws 9 and gearshift fork shaft retainer bolt 0 to the...

  • Page 114: 3-60     Engine

    3-60 engine oil jet removal • remove the piston cooling oil jets 1 from the upper crank- case. • remove the oil jet 2 (for transmission) from the lower crank- case. • remove the oil jet 3 (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • check the oil jets for cloggi...

  • Page 115: Engine     3-61

    Engine 3-61 installation • fit the new o-ring 1 to each piston cooling oil jet as shown 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.  99000-32050: thread lock “13...

  • Page 116: 3-62     Engine

    3-62 engine • remove the water jacket plugs 3. • remove the oil gallery plugs 4 (for lower crankcase side). Installation • apply engine coolant to the o-ring of the water jacket plug 1.  99000-99032-11x: suzuki coolant (except usa) • apply thread lock to the oil gallery plug 2.  99000-32050: threa...

  • Page 117: Engine     3-63

    Engine 3-63 balancer shaft disassembly • remove the balancer gear along with the dampers from the balancer shaft. Inspection • inspect the damper for wear and damage, replace it if any defects are found. Reassembly • apply molybdenum oil solution to each part.  molybdenum oil solution • set the dam...

  • Page 118: 3-64     Engine

    3-64 engine • remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge.  balancer shaft journal oil clearance: standard: 0.028 – 0.052 mm (0.0011 – 0.0020 in) servi...

  • Page 119: Engine     3-65

    Engine 3-65 installation • when fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part a first and press the other end. Crankshaft and conrod crankshaft runout • support the crankshaft with v-blocks as shown, with the two end journals resting ...

  • Page 120: 3-66     Engine

    3-66 engine 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 ...

  • Page 121: Engine     3-67

    Engine 3-67 *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 ...

  • Page 122: 3-68     Engine

    3-68 engine  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 (12164-41g00-0a0) 1.480 – 1.4...

  • Page 123: Engine     3-69

    Engine 3-69 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 • tighten the crankshaft journal bolts (m9) in a...

  • Page 124: 3-70     Engine

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

  • Page 125: Engine     3-71

    Engine 3-71  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...

  • Page 126: 3-72     Engine

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

  • Page 127: Engine     3-73

    Engine 3-73  thrust bearing selection table • after selecting a left-side thrust bearing, insert it and again perform the thrust clearance measurement to make sure it falls within the standard range. A color code note: right-side thrust bearing has the same specification as the green (12228-48b00-0...

  • Page 128: 3-74     Engine

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

  • Page 129: Engine     3-75

    Engine 3-75 • 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 130: 3-76     Engine

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

  • Page 131: Engine     3-77

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

  • Page 132: 3-78     Engine

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

  • Page 133: Engine     3-79

    Engine 3-79 • apply suzuki bond to the mating surface of the middle crankcase.  99104-31140: suzuki bond “1207b” (usa)  99000-31110: suzuki bond “1215” (others) note: use of suzuki bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * spread on surfaces t...

  • Page 134: 3-80     Engine

    3-80 engine • 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 135: Engine     3-81

    Engine 3-81 transmission • install the bearing pins 1 and the c-rings 2 on the middle crankcase. • install the countershaft assembly on 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 on the...

  • Page 136: 3-82     Engine

    3-82 engine • apply suzuki bond to the mating surface of the lower crankcase.  99104-31140: suzuki bond “1207b” (usa)  99000-31110: suzuki bond “1215” (others) note: use of suzuki bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * spread on surfaces th...

  • Page 137: Engine     3-83

    Engine 3-83 • tighten the crankcase bolts a little at a time to equalize the pressure. Note: * fit the new copper washers to the crankcase bolts b. * fit the new gasket washers to the crankcase bolts c.  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 138: 3-84     Engine

    3-84 engine oil pressure regulator • apply suzuki super grease “a” to the o-ring and press in the oil pressure regulator to the crankcase.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) oil pan • apply suzuki bond to the mating surface of the oil pan.  99...

  • Page 139: Engine     3-85

    Engine 3-85 oil filter • install the oil filter with the special tool. ( 2-13)  09915-40610: oil filter wrench  oil filter: 20 n·m (2.0 kgf-m, 14.5 lb-ft) crankcase breather cover • install a new gasket 1. • install the breather cover 2.  breather cover bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) gear p...

  • Page 140: 3-86     Engine

    3-86 engine water pump • apply suzuki super grease “a” to the o-ring.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • tighten the water pump mounting bolts 1 to the specified torque.  water pump mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) note: pass the...

  • Page 141: Engine     3-87

    Engine 3-87 • install the generator rotor onto the crankshaft. • install the rotor bolt with the washer. • 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...

  • Page 142: 3-88     Engine

    3-88 engine • apply suzuki bond lightly to the groove of signal generator lead wire grommet.  99104-31140: suzuki bond “1207b” (usa) 99000-31140: suzuki bond “1207b” (others) cam chain drive sprocket • install the cam chain drive sprocket onto the crankshaft. Note: when installing the cam chain dri...

  • Page 143: Engine     3-89

    Engine 3-89 • install the starter clutch bolt with the washer. • hold the starter clutch with the special tool and tighten its bolt to the specified torque.  09920-34830: starter clutch holder  starter clutch bolt: 55 n·m (5.5 kgf-m, 40.0 lb-ft) starter idle gear • install the starter idle gear no...

  • Page 144: 3-90     Engine

    3-90 engine • install the starter idle gear no. 1 shaft 6, thrust washer 7, bearing 8, starter idle gear no. 1 9, washer 0, and spring washer a. • install the dowel pins b and new gasket c. • install the starter idle gear cover and tighten its bolts to the specified torque.  starter idle gear cover...

  • Page 145: Engine     3-91

    Engine 3-91 • install the gearshift cam stopper plate 6. Note: align the gearshift cam pin b with the gearshift cam stopper plate hole c. • apply a small quantity of thread lock to the gearshift cam stopper plate bolt and tighten it to the specified torque.  99000-32050: thread lock “1342”  gearsh...

  • Page 146: 3-92     Engine

    3-92 engine oil pump • install the o-ring to the oil pump and apply suzuki super grease “a” to it. Note: set the oil pump shaft end a to the water pump shaft.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the oil pump with the oil pump mounting ...

  • Page 147: Engine     3-93

    Engine 3-93 • install the oil pump drive gear 1 to the primary driven gear assembly 2. • install the primary driven gear assembly 2. 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 ...

  • Page 148: 3-94     Engine

    3-94 engine • install the clutch sleeve hub assembly 9 onto the counter- shaft. • install the washer 0 and spring washer a. Note: * before installing the washer 0, visually inspect the washer surface for wear and damage. If necessary, replace it with a new one. * the conical curve side of spring was...

  • Page 149: Engine     3-95

    Engine 3-95 • install the clutch push rod d into the countershaft. • install the clutch push piece e, bearing f and thrust washer g to the countershaft. Note: thrust washer g is located between the pressure plate and bearing f. • insert the clutch drive plates and driven plates one by one into the c...

  • Page 150: 3-96     Engine

    3-96 engine *1: direction of outside *2: paint drive plate: a no. 2 drive plate....... 1 pc. [black paint/i.D. 111 mm (4.4 in)] b no. 1 drive plate....... 8 pcs. [purple paint/i.D. 111 mm (4.4 in)] c no. 3 drive plate....... 1 pc. [nil/i.D. 118 mm (4.6 in)] note: no.3 drive plate can be distinguishe...

  • Page 151: Engine     3-97

    Engine 3-97 • 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 bolts diagonally. * after mounting the eng...

  • Page 152: 3-98     Engine

    3-98 engine cylinder head • fit the dowel pins 1 and new cylinder head gasket 2 to the cylinder. • place the cylinder head on the cylinder. Note: when installing the cylinder head, keep the cam chain taut. • tighten the cylinder head bolts (m10) in the following four-step. Step 1: • tighten the cyli...

  • Page 153: Engine     3-99

    Engine 3-99 • fit the gasket 3 and tighten the ect sensor.  ect sensor: 18 n·m (1.8 kgf-m, 13.0 lb-ft) • install the thermostat 4. Note: the jiggle valve a of thermostat faces upside. • install the thermostat cover 5.  thermostat cover bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the water hose 6...

  • Page 154: 3-100     Engine

    3-100 engine camshaft • turn the crankshaft clockwise with the box wrench and align the line a on the starter clutch with the index mark b of valve timing inspection hole while keeping the cam chain pulled upward. • the camshafts are identified by the embossed letters. • before replacing the camshaf...

  • Page 155: Engine     3-101

    Engine 3-101 • pull the cam chain lightly. • the exhaust camshaft sprocket has an arrow marked “1” c. 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 156: 3-102     Engine

    3-102 engine • install the dowel pins 3. • 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...

  • Page 157: Engine     3-103

    Engine 3-103 cam chain tension adjuster • retract the push rod by pushing the stopper 1. • install a new gasket 2. • install the cam chain tension adjuster 3 and tighten its mounting bolts.  cam chain tension adjuster mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the spring 4. • install th...

  • Page 158: 3-104     Engine

    3-104 engine 10 n·m (1.0 kgf-m, 7.0 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) sa mp le.

  • Page 159: Engine     3-105

    Engine 3-105 • tighten the valve timing inspection plug 8 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 160: 3-106     Engine

    3-106 engine starter motor • apply suzuki super grease to the o-ring.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the starter motor 1.  starter motor mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the spark plugs. ( 2-6) sa mp le.

  • Page 161: Contents

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

  • Page 162: Contents

    4-2 fi system diagnosis contents fi system diagnosis “c31” (p0705) gp switch circuit malfunction ........................ 4-73 “c32” (p0201), “c33” (p0202), “c34” (p0203) or “c35” (p0204) primary fuel injector circuit malfunction ....................... 4-75 “c36” (p1764), “c37” (p1765), “c38” (p176...

  • Page 163: 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 164: Fuse

    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 165

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

  • Page 166: Procedure

    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 167: Continuity Check

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

  • Page 168

    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 169: Using The Tester

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

  • Page 170: 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 171: Injection Stop Control

    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 172: Fi System Parts Location

    4-12 fi system diagnosis fi system parts location a intake air temperature sensor (iats) b throttle position sensor (tps) c secondary throttle position sensor (stps) d secondary throttle valve actuator (stva) e exhaust control valve actuator (excva) f fuel pump relay (fp relay) g fuel pump (fp) h cr...

  • Page 173

    Fi system diagnosis 4-13 i tip-over sensor (tos) j atmospheric pressure sensor (aps) k intake air pressure sensor (iaps) l engine coolant temperature sensor (ects) m speed sensor n camshaft position sensor (cmps) o ignition coil (ig coil) p pair control solenoid valve q secondary fuel injector r pri...

  • Page 174: Fi System Wiring Diagram

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

  • Page 175: Ecm Terminal

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

  • Page 176

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

  • Page 177: Self-Diagnosis Function

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

  • Page 178: Dealer Mode

    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 179

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

  • Page 180: Tps Adjustment

    4-20 fi system diagnosis tps adjustment 1. Adjust the engine rpm to 1 150 r/min. ( 2-14) 2. Connect the special tool (mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, loosen the screw and turn the throttle position sen...

  • Page 181: Fail-Safe Function

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

  • Page 182

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

  • Page 183: Fi System Troubleshooting

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

  • Page 184: Visual Inspection

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

  • Page 185: Self-Diagnostic Procedures

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

  • Page 186

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

  • Page 187: Dure

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

  • Page 188: Show Data When Trouble

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

  • Page 189

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

  • Page 190

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

  • Page 191

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

  • Page 192

    4-32 fi system diagnosis dtc no. Detected item detected failure condition check for c46 exhaust con- trol valve 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 ...

  • Page 193: Inspection

    Fi system diagnosis 4-33 “c11” (p0340) cmp sensor circuit malfunction inspection step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) remove the air cleaner box. ( 5-13) 4) check the cmp sensor coupler for loose or poor contacts. If ok, then measure the cmp sensor r...

  • Page 194: Step 2

    4-34 fi system diagnosis step 2 1) crank the engine a few seconds with the starter motor, and measure the cmp sensor peak voltage at the coupler. 2) repeat the above test procedure a few times and measure the highest peak voltage.  cmp sensor peak voltage: 0.5 v and more (+ b/y – - brown) 1 peak vo...

  • Page 195: Inspection

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

  • Page 196: (Black – Ground)

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

  • Page 197: Inspection

    Fi system diagnosis 4-37 “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 198: (+ Red – - Ground)

    4-38 fi system diagnosis 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 red wire and ground. 8) if ok, then measure the voltage at the red wire and b/br wire.  iap sensor input voltage...

  • Page 199

    Fi system diagnosis 4-39 6) disconnect the ecm coupler. 7) check the continuity between g/b wire b and terminal 9. 8) if ok, then check the continuity between b/br wire c and ter- minal s.  iaps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed...

  • Page 200: Step 2

    4-40 fi system diagnosis 7) disconnect the ecm coupler. 8) check the continuity between red wire a and terminal a. 9) also, check the continuity between g/b wire b and terminal 9.  iaps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed probe se...

  • Page 201: Step 3

    Fi system diagnosis 4-41 step 3 1) turn the ignition switch off. 2) remove the iap sensor. 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. Arrange 3 new 1.5 v batteries in series 1 (check that total - voltage is 4.5 – 5.0 v) and connect - terminal to the ground - terminal 2 an...

  • Page 202: 30 °C, 68 – 86 °F)

    4-42 fi system diagnosis output voltage (vcc voltage 4.5 – 5.0 v, ambient temp. 20 – 30 °c, 68 – 86 °f) altitude (reference) atmospheric pressure output voltage (ft) (m) (mmhg) kpa (v) 0 2 000 0 610 760 707 100 94 3.1 – 3.6 2 001 5 000 611 1 524 707 634 94 85 2.8 – 3.4 5 001 8 000 1 525 2 438 634 56...

  • Page 203: Inspection

    Fi system diagnosis 4-43 “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 204

    4-44 fi system diagnosis step 1 (when indicating p0120-h:) 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 co...

  • Page 205

    Fi system diagnosis 4-45 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 co...

  • Page 206: Step 2

    4-46 fi system diagnosis step 2 1) turn the ignition switch off. 2) disconnect the tp sensor coupler and ecm coupler. 3) install the test harness to the tp sensor. 4) check the continuity between terminal a and ground.  tp sensor continuity: ∞Ω (infinity) (terminal a – ground) 5) if ok, then measur...

  • Page 207: Step 3

    Fi system diagnosis 4-47 step 3 1) connect the tp sensor coupler 1 to the test harness. 2) turn the ignition switch on. 3) measure the tp sensor output voltage at the coupler (between + p/b and - b/br) by turning the throttle grip.  tp sensor output voltage throttle valve is closed: approx. 1.1 v t...

  • Page 208: Inspection

    4-48 fi system diagnosis “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 209

    Fi system diagnosis 4-49 step 1 (when indicating p0115-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) disconnect the ect sensor coupler and ecm coupl...

  • Page 210: (+ B/bi – - Ground)

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

  • Page 211: Step 2

    Fi system diagnosis 4-51 step 2 1) turn the ignition switch off. 2) disconnect the ect sensor coupler. 3) measure the ect sensor resistance.  ect sensor resistance: approx. 2.45 k Ω at 20 °c (68 °f) (terminal – terminal)  09900-25008: multi-circuit tester set  tester knob indication: resistance (...

  • Page 212: Inspection

    4-52 fi system diagnosis “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 213

    Fi system diagnosis 4-53 step 1 (when indicating p0110-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler and ecm coupl...

  • Page 214: (+ Dg – - Ground)

    4-54 fi system diagnosis 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 215: Step 2

    Fi system diagnosis 4-55 step 2 1) turn the ignition switch off. 2) measure the iat sensor resistance.  iat sensor resistance: approx. 2.45 kΩ at 20 °c (68 °f) (terminal – terminal)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) is the resistance ok?  iat sensor s...

  • Page 216: Inspection

    4-56 fi system diagnosis “c22” (p1450-h/l) ap sensor circuit malfunction inspection step 1 (when indicating c22:) 1) turn the ignition switch off. 2) remove the front seat. ( 8-7) 3) check the ap sensor coupler for loose or poor contacts. If ok, then measure the ap sensor input voltage. Detected co...

  • Page 217: (+ Red – - Ground)

    Fi system diagnosis 4-57 4) disconnect the ap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the red wire and ground. 7) if ok, then measure the voltage at the red wire a and b/br wire b.  ap sensor input voltage: 4.5 – 5.5 v (+ red – - ground) (+ red – - b/br)  09900-25...

  • Page 218

    4-58 fi system diagnosis 6) disconnect the ecm coupler. 7) check the continuity between g/y wire c and terminal p. 8) if ok, then check the continuity between b/br wire b and ter- minal s.  aps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed ...

  • Page 219: Step 2

    Fi system diagnosis 4-59 7) disconnect the ecm coupler. 8) check the continuity between red wire a and terminal a. 9) if ok, then check the continuity between g/y wire c and ter- minal p.  aps lead wire continuity: continuity ()  09900-25008: multi-circuit tester set 09900-25009: needle pointed p...

  • Page 220: Step 3

    4-60 fi system diagnosis step 3 1) remove the ap sensor. 2) connect the vacuum pump gauge to the vacuum port of the ap sensor. Arrange 3 new 1.5 v batteries in series 1 (check that total voltage is 4.5 – 5.0 v) and connect - terminal to the ground terminal 2 and + terminal to the vcc terminal 3. 3) ...

  • Page 221: Inspection

    Fi system diagnosis 4-61 “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) di...

  • Page 222

    4-62 fi system diagnosis step 1 (when indicating p1651-h:) 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 co...

  • Page 223

    Fi system diagnosis 4-63 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 co...

  • Page 224: Step 2

    4-64 fi system diagnosis step 2 1) connect the to sensor coupler and ecm coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage at the wire side coupler between black and b/br wires.  to sensor voltage (normal): 0.4 – 1.4 v (+ b...

  • Page 225: Inspection

    Fi system diagnosis 4-65 “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 contacts. 4) turn the ignition switch on to check the stv operation. (st...

  • Page 226: Step 2

    4-66 fi system diagnosis step 2 1) turn the ignition switch off. 2) disconnect the stva lead wire coupler. 3) check the continuity between each terminal and ground.  stva continuity: ∞Ω (infinity) (terminal – ground) 4) if ok, then measure the stva resistance (between black wire a and pink wire b) ...

  • Page 227: Active Control Inspection

    Fi system diagnosis 4-67 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “secondary throttle operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from the stva, t...

  • Page 228: Inspection

    4-68 fi system diagnosis “c29” (p1654-h/l) stp sensor circuit malfunction inspection step 1 (when indicating c29:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the stp sensor coupler for loose or poor contacts. If ok, then measure the stp sensor input voltage....

  • Page 229

    Fi system diagnosis 4-69 step 1 (when indicating p1654-h:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the stp sensor coupler. 5) check the...

  • Page 230

    4-70 fi system diagnosis step 1 (when indicating p1654-l:) 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the stp sensor coupler. 5) check the...

  • Page 231: Step 2

    Fi system diagnosis 4-71 step 2 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) disconnect the stp sensor coupler. 4) check the continuity between each terminal and ground.  stp sensor continuity: ∞Ω (infinity) (terminal – ground) 5) if ok, then measure the stp sensor...

  • Page 232: Step 3

    4-72 fi system diagnosis step 3 1) turn the ignition switch off. 2) connect the stp sensor coupler. 3) insert the needle pointed probes to the stp sensor coupler. 4) disconnect the stva lead wire coupler. 5) turn the ignition switch on. 6) measure the stp sensor output voltage at the coupler (betwee...

  • Page 233: Inspection

    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 ja...

  • Page 234

    4-74 fi system diagnosis is the voltage ok? 10)after repairing the trouble, clear the dtc using sds tool. ( 4-27) yes • pink 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 conne...

  • Page 235: Inspection

    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 injector coupler for loose or poor contacts. If ok, then measure t...

  • Page 236: Step 2

    4-76 fi system diagnosis 5) if ok, then check the continuity between each terminal and ground.  stp sensor continuity: ∞Ω (infinity)  09900-25008: multi-circuit tester set  tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing the trouble, clear the dtc u...

  • Page 237: Inspection

    Fi system diagnosis 4-77 “c36” (p1764), “c37” (p1765), “c38” (p1766) or “c39” (p1767) second- ary fuel injector circuit malfunction inspection step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( 5-3) 3) check the injector coupler for loose or poor contacts. If ok, then meas...

  • Page 238: Step 2

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

  • Page 239: Inspection

    Fi system diagnosis 4-79 “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. ( 8-7) 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. ( 5-6) is the fp relay ok? De...

  • Page 240

    4-80 fi system diagnosis step 1 (when indicating p0230-h:) 1) turn the ignition switch off. 2) remove the front seat. ( 8-7) 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. ( 5-6) is the fp relay ok? 4) after repairing the trouble, clear the dtc using sds ...

  • Page 241: Inspection

    Fi system diagnosis 4-81 “c42” (p01650) ig switch circuit malfunction inspection * refer to the ignition switch inspection for details. ( 9-39) detected condition possible cause ignition switch signal is not input to the ecm. • ignition system circuit open or short • ecm malfunction when the id agr...

  • Page 242: Inspection

    4-82 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 lead wire coupler for loose or poor con- tacts. 4) turn the ignition switch on...

  • Page 243

    Fi system diagnosis 4-83 step 1 (when indicating p1657-h:) 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 po...

  • Page 244

    4-84 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 po...

  • Page 245: Step 2

    Fi system diagnosis 4-85 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 contacts. Is the contacting ok? 4) after repairing the trouble, clear the dtc using sds tool. ( 4-27) step 2 1) tur...

  • Page 246: Step 3

    4-86 fi system diagnosis step 3 1) turn the ignition switch off. 2) check the continuity between yellow wire and ground.  position sensor continuity: ∞Ω (infinity) 3) if ok, then measure the position sensor resistance. 4) connect the position sensor coupler. 5) set the excva to adjustment position....

  • Page 247: Step 4

    Fi system diagnosis 4-87 step 4 1) turn the ignition switch off. 2) connect the position sensor coupler. 3) measure the position sensor output voltage at fully close posi- tion and fully open position. 4) insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler. (...

  • Page 248: Step 5

    4-88 fi system diagnosis step 5 1) if the position sensor output voltage is 0.5 v and less at fully close position, adjust the output voltage to specified by turn- ing out the no. 1 cable adjuster 1. 2) repeat the above procedure (step 4) until the out put voltage becomes specified value. (if c46/p1...

  • Page 249: Step 6

    Fi system diagnosis 4-89 step 6 1) turn the ignition switch off. 2) disconnect the motor lead wire coupler of the excva. 3) apply 12 volts to the terminal and check the operation of excva. 4) then, swap the wires supplied 12 volts and check the opera- tion of excva. (check the operation of excva bot...

  • Page 250: Active Control Inspection

    4-90 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” 1. 4) click each button 2. At this time, if an operation sound is heard from the excva, the f...

  • Page 251: Inspection

    Fi system diagnosis 4-91 “c49” (p1656) pair control solenoid valve circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the air cleaner box. ( 5-13) 3) check the pair control solenoid valve coupler for loose or poor contacts. If ok, then measure the pair control solenoid...

  • Page 252: Step 2

    4-92 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  tester knob indication: voltage () is the voltage ok? 3) after repairing the trouble...

  • Page 253: Inspection

    Fi system diagnosis 4-93 “c60” (p0480) cooling fan relay circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the front seat. ( 8-7) 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 fa...

  • Page 254: Active Control Inspection

    4-94 fi system diagnosis active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) start the engine and run it idling condition. 3) click “cooling fan relay control” 1. 4) click the operate button 2. At this time, if an operation sound is heard fro...

  • Page 255: Sensors

    Fi system diagnosis 4-95 sensors cmp sensor inspection the camshaft position sensor is installed on the cylinder head cover. ( 4-33) cmp sensor removal and installation • remove the cmp sensor. ( 3-27) • install the cmp sensor in the reverse order of removal. Ckp sensor inspection the crankshaft p...

  • Page 256: Ect Sensor Inspection

    4-96 fi system diagnosis ect sensor inspection the engine coolant temperature sensor is installed at the cylin- der head. ( 4-48) 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-f...

  • Page 257: Stp Sensor Inspection

    Fi system diagnosis 4-97 stp sensor inspection stp sensor removal and installation the secondary throttle position sensor is installed at the right side of the no. 4 throttle body. • remove the stp sensor. ( 5-16) • install the stp sensor in the reverse order of removal. Stp sensor adjustment • adj...

  • Page 258: Contents

    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 lif...

  • Page 259: 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 260: Fuel System

    Fuel system and throttle body 5-3 fuel system fuel tank lift-up • remove the right and left fuel tank lower side covers. ( 8-7) • remove the fuel tank mounting bolts. . • lift and support the fuel tank with the fuel tank prop stay 2. Fuel tank removal • lift and support the fuel tank. ( above) • d...

  • Page 261: Fuel Tank Installation

    5-4 fuel system and throttle body fuel tank installation • installation is in the reverse order of removal. Fuel pressure inspection • lift and support the fuel tank. ( 5-3) • place a rag under the fuel feed hose and remove the fuel feed hose 1. • install the special tools between the fuel tank and...

  • Page 262: Fuel Pump Inspection

    Fuel system and throttle body 5-5 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 263:  Fuel Discharge Amount:

    5-6 fuel system and throttle body • connect a proper lead wire into the fuel pump lead wire cou- pler (fuel pump side) and apply 12 volts to the fuel pump (between y/r wire and b/w wire) for 10 seconds and mea- sure the amount of fuel discharged. Battery + terminal (yellow with red tracer) battery -...

  • Page 264: Construction

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

  • Page 265: Removal

    5-8 fuel system and throttle body removal • remove the fuel tank. ( 5-3) • remove the fuel pump assembly 1 by removing its mounting bolts diagonally. • remove the nuts. • remove the lead wire 1, screws and fuel level gauge 2. • remove the screw. • remove the fuel pump 3 from the fuel pump plate 4. ...

  • Page 266: Cleaning

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

  • Page 267: Fuel Leakage.

    5-10 fuel system and throttle body • be sure to connect the wires to the proper terminals. A ............... + terminal for fuel pump b ............... + terminal for fuel level gauge • install a new o-ring and apply suzuki super grease “a” to it.  99000-25030: suzuki super grease “a” (usa) 99000-2...

  • Page 268

    Fuel system and throttle body 5-11 • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers.  fuel pump mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) note: apply a small quantity of the thread...

  • Page 269: Throttle Body

    5-12 fuel system and throttle body throttle body construction only for e-33 1 tp sensor 8 cushion seal 2 stp sensor 9 fast idle adjusting screw 3 stva 0 throttle stop screw 4 fuel delivery pipe a vacuum hose item n·m kgf-m lb-ft 5 fuel delivery pipe joint a fuel delivery pipe mounting screw a 3.5 0....

  • Page 270: Air Cleaner Box Removal

    Fuel system and throttle body 5-13 air cleaner box removal • lift and support the fuel tank. ( 5-3) • disconnect the iat sensor lead wire coupler 1, pair hose 2 and pcv hose 3. • disconnect the iap sensor lead wire coupler 4 and vacuum hose 5. • loosen the throttle body clamp screws. • remove the a...

  • Page 271: Throttle Body Removal

    5-14 fuel system and throttle body throttle body removal • remove the air cleaner box. ( 5-13) • 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 1, stp sensor lead wi...

  • Page 272: Throttle Body Disassembly

    Fuel system and throttle body 5-15 • remove the throttle body assembly. Throttle body disassembly • disconnect the respective vacuum hoses 1 from each throt- tle body. • disconnect the fuel feed hose 2. • remove the fuel delivery pipe joint assembly 3 and plat 4. • remove the secondary fuel delivery...

  • Page 273: Throttle Valve D.

    5-16 fuel system and throttle body • remove the fuel injectors 7, secondary fuel delivery pipes 8 and primary fuel delivery pipes 9. • remove the fuel delivery pipe 0 and fuel delivery pipe joints a. • remove the tp sensor and stp sensor with the special tool.  09930-11950: torx wrench note: prior ...

  • Page 274: Throttle Body Cleaning

    Fuel system and throttle body 5-17 throttle body cleaning • clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. Inspection check following items for any damage or clogging. * o-ring * throttle valve * secondary throttle valve * vacuum hose the fast idle screw...

  • Page 275: Throttle Body Reassembly

    5-18 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 stv fully open, install the stp sensor 1 and tighten the stp sensor mounting screw to the specified torque. Note: * apply ...

  • Page 276: Ones.

    Fuel system and throttle body 5-19 • apply thin coat of the engine oil to the new o-ring 3 and cusion seal 4. • apply thin coat of the engine oil to the new o-rings 5. • install the joints. • install the fuel injector 6 by pushing it straight to the delivery pipe 7. Note: align the boss e of the inj...

  • Page 277

    5-20 fuel system and throttle body • assemble the fuel delivery pipes as shown. • install the primary fuel delivery pipe assembly 8 and second- ary fuel delivery pipe assembly 9 to the throttle body assem- bly. • tighten the fuel delivery pipe mounting screws to the speci- fied torque.  fuel delive...

  • Page 278: Throttle Body Installation

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

  • Page 279: Air Cleaner Box Installation

    5-22 fuel system and throttle body air cleaner box installation installation is in the reverse order of removal. Pay attention to the following points: • install the air cleaner box and tighten the throttle body clamp screws as shown in the illustration. Stp sensor adjustment if the stp sensor adjus...

  • Page 280: Fuel Injector Removal

    Fuel system and throttle body 5-23 fuel injector removal • remove the air cleaner box. ( 5-13) • with battery negative cable disconnected, disconnect the injector couplers. • remove the fuel delivery pipe assembly. ( 5-15) • remove the primary and secondary fuel injectors #1, #2, #3 and #4. ( 5-1...

  • Page 281: Fast Idle

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

  • Page 282: Stv Fully Open  1.152 V

    Fuel system and throttle body 5-25 • calculate the voltage difference between tp sensor output voltage at idle and tp sensor output voltage with the stv full opened. Example: tp sensor output voltage with the stv fully open minus tp sensor output voltage at idle is 0.027 v stv fully open 1.152 v idl...

  • Page 283: Use of Digital Vacuum Tester

    5-26 fuel system and throttle body throttle valve synchronization check and adjust the throttle valve synchronization among four cylinders. Use of digital vacuum tester step 1 • lift and support the fuel tank. ( 5-3) • start up the engine and run it in idling condition for warming up. • stop the wa...

  • Page 284: Step 3

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

  • Page 285

    5-28 fuel system and throttle body • connect a tachometer. • start up the engine and keep it running at 1 150 r/min by turn- ing throttle stop screw 3. • turn the air screw 4 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 5 in the tube to the center line 6....

  • Page 286

    Fuel system and throttle body 5-29 throttle position sensor (tps) setting after all adjustments are completed, check or adjust the tps setting condition. (refer to page 4-20 for tps setting procedure.) sa mp le.

  • Page 287: Exhaust System     6-1

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

  • Page 288: 6-2     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 between the exhaust pipes and muffler. Excva is mounted on...

  • Page 289: Exhaust System     6-3

    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 290: 6-4     Exhaust System

    6-4 exhaust system excva (exhaust control valve actuator) and excv (exhaust control valve) excva removal • turn the ignition switch off. • remove the front seat. • lift and support the fuel tank. ( 5-3) • connect the special tool (mode select switch) to the dealer mode coupler. ( 4-18) • after tur...

  • Page 291: Exhaust System     6-5

    Exhaust system 6-5 • remove the brake fluid reservoir tank mounting bolt 2 and front footrest bracket mounting bolts 3. • move the front footrest assembly. • hold the excva pulley with an adjustable wrench, and loosen the pulley mounting bolt. • disconnect the no. 2 cable 4 and then no. 1 cable 5 fr...

  • Page 292: 6-6     Exhaust System

    6-6 exhaust system excva installation • make the no. 1 cable straight and turn the no. 1 cable adjuster 1 in or out until the inner cable length a becomes 40 – 41 mm (1.57 – 1.61 in). • after adjusting the inner cable length a, tighten the lock-nut 2. No. 1 cable: 41g0cl • make the no.2 cable straig...

  • Page 293: Exhaust System     6-7

    Exhaust system 6-7 • hold the pulley with an adjustable wrench, and then tighten the pulley mounting bolt to the specified torque.  excva pulley mounting bolt: 5 n·m (0.5 kgf-m, 3.5 lb-ft) • after connecting the no. 2 cable 8, loosen the lock-nut 9 and turn the adjuster 0 in or out until 16.0 mm (0...

  • Page 294: 6-8     Exhaust System

    6-8 exhaust system excva inspection 4-82 excv cable replacement • disconnect the excv cables from the excva pulley. ( 6-4 to -5) • remove the cable guide. • disconnect the excv cables from the excv pulley. ( 6-14) note: the excv cables are identified by the plated chrome color and shape. No. 1 ca...

  • Page 295: Exhaust System     6-9

    Exhaust system 6-9 • make the no. 2 cable straight and turn in the cable adjuster 5 fully. • loosen the lock-nuts 6 and turn the no.2 cable adjuster 7 in or out until the inner cable length c becomes 62 – 63 mm (2.44 – 2.48 in). • after adjusting the inner cable length c, tighten the lock-nuts 6. • ...

  • Page 296: 6-10     Exhaust System

    6-10 exhaust system • after connecting the no. 2 cable 0, loosen the lock-nut a and turn the adjuster b in or out until 16 – 17 mm (0.63 – 0.67 in) of the thread length f on the cable adjuster cam be pro- vided and tighten the lock-nut a. • install the excva. ( 6-6 to -7) excva adjustment 1st step:...

  • Page 297: Exhaust System     6-11

    Exhaust system 6-11 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 correctly completed. In this case, it is unnecessary to pro- ceed to 3rd st...

  • Page 298: 6-12     Exhaust System

    6-12 exhaust system • turn the ignition switch on. • measure the position sensor output voltage at fully close posi- tion.  position sensor output voltage excv is fully close: 0.5 output voltage 1.3 v (+ yellow – - b/br)  09900-25008: multi circuit tester set 09900-25009: needle pointed probe set ...

  • Page 299: Exhaust System     6-13

    Exhaust system 6-13 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 1. • repeat the above procedure until the output voltage comes within the specified value.  position...

  • Page 300: 6-14     Exhaust System

    6-14 exhaust system • remove the excv cover 3 and disconnect the two cables from the excv pulley. 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 muffler body. • decarbonize the excv if necessary. Excv/muffl...

  • Page 301: Exhaust System     6-15

    Exhaust system 6-15 • install the cable guide. • install the front footrest assembly. ( 6-7) • install the excva. (refer to the excva installation pro- cedures.) ( 6-6 to -7) exhaust pipe removal 3-5 exhaust pipe installation 3-14 sa mp le.

  • Page 302: 6-16     Exhaust System

    6-16 exhaust system 23 n·m (2.3 kgf-m, 16.5 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) replace the gaskets with the new ones. 23 n·m (2.3 kgf-m,16.5 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) replace the exhaust pipe connector with a new one. 3 mm (0.12 in) 3 mm (0.12 in) no. 1 no. 2 40 – 41 mm (1.57 – 1.61 i...

  • Page 303: Contents

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

  • Page 304: 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 305: 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 under cowlings. ( 8-5) • remove the radiator cap 1 and connect the tester 2 to the filler. • give a pre...

  • Page 306: Radiator and Water Hoses

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

  • Page 307: Radiator Installation

    Cooling and lubrication system 7-5 • fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. Radiator installation • install the radiator. • route the radiator hoses. ( 10-24) • pour engine coolant. ( 2-17) • bleed air from the cooling circuit. ( 2-18...

  • Page 308: Cooling Fan

    7-6 cooling and lubrication system cooling fan removal • remove the under cowlings. ( 8-5) • drain the engine coolant. ( 2-17) • remove the radiator assembly. ( 3-5) • remove the cooling fan 1. Inspection • remove the under cowlings. ( 8-5) • disconnect the cooling fan coupler 1. • test the cool...

  • Page 309: Cooling Fan Relay Inspection

    Cooling and lubrication system 7-7 cooling fan relay inspection cooling fan relay is located in rear of the battery. • remove the front seat. ( 8-7) • remove the cooling fan relay 1. First check the insulation between a and b terminals with tester. Then apply 12 volts to c and d terminals, + to c a...

  • Page 310: Standard (Off

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

  • Page 311: Thermostat

    Cooling and lubrication system 7-9 thermostat removal • remove the front seat. ( 8-7) • lift and support the fuel tank. ( 5-3) • place a rag under the thermostat cover. • remove the thermostat cover 1. • remove the thermostat 2. Inspection inspect the thermostat pellet for signs of cracking. Test ...

  • Page 312: Standard:

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

  • Page 313: 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 314: New One.

    7-12 cooling and lubrication system • remove the water pump cover 5 and clamp 6. • remove the impeller securing bolt by holding the impeller with a water pump pliers. • remove the mechanical seal ring 7 and rubber seal 8 from the impeller. • remove the impeller shaft 9 and washer 0. • remove the mec...

  • Page 315: Inspection

    Cooling and lubrication system 7-13 • remove the oil seal using a suitable bar. 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. • rep...

  • Page 316: Reassembly and Installation

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

  • Page 317: Age.

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

  • Page 318

    7-16 cooling and lubrication system • install the water pump. Note: set the water pump shaft end f to the oil pump shaft g as shown. • tighten the water pump mounting bolts to the specified torque.  water pump mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) note: pass the gear position switch lead wir...

  • Page 319: Lubrication System

    Cooling and lubrication system 7-17 lubrication system oil pressure 2-33 oil filter 2-13 oil pressure regulator 3-49 oil strainer 3-49 oil jet 3-60 oil pump 3-46 oil pressure switch 9-34 oil cooler removal • remove the under cowlings. ( 8-5) • drain the engine oil. ( 2-12) • remove the oil ...

  • Page 320: Inspection and Cleaning

    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 321: 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 322: Engine Lubrication System

    7-20 cooling and lubrication system engine lubrication system main gallery to sub- o sub- galler gallery to sub- gallery sa mp le.

  • Page 323

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

  • Page 324: Chassis     8-1

    Chassis 8-1 8 chassis contents exterior parts ....................................................................................... 8- 3 fastener removal and installation...................................... 8- 3 screen ................................................................................

  • Page 325: Chassis

    Chassis contents 8-2 chassis inspection .......................................................................................... 8-49 rear shock absorber disposal ............................................... 8-50 installation.........................................................................

  • Page 326: Chassis     8-3

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

  • Page 327: 8-4     Chassis

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

  • Page 328: Chassis     8-5

    Chassis 8-5 screen removal • remove the screws. • remove the combination meter 1. ( 9-29) • disconnect the turnsignal lead wire couplers. • remove the rear view mirrors/turn signals 2. • remove the screen 3. Installation • install the screen in the reverse order of removal. • refer to the rear view...

  • Page 329: 8-6     Chassis

    8-6 chassis • remove the right under cowling. Note: “ ” indicates hook location. • remove the left under cowling. Note: “ ” indicates hook location. Installation • install the right and left under cowlings in the reverse order of removal. Body cowling removal • remove the screen. ( 8-5) • remove ...

  • Page 330: Chassis     8-7

    Chassis 8-7 air intake pipe removal • remove the body cowling. ( 8-6) • remove the fasteners. • remove the air intake pipes 1. Installation • install the right and left air intake pipes in the reverse order of removal. Cowling brace removal • remove the body cowling. ( 8-6) • remove the cowling br...

  • Page 331: 8-8     Chassis

    8-8 chassis rear seat and seat tail cover removal • remove the rear seat (seat tail cover) with the ignition key. Installation • hook the seat hook to the frame and push down the seat (seat tail cover) firmly until the seat (seat tail cover) snaps into the locked position. Frame cover removal • remo...

  • Page 332: Chassis     8-9

    Chassis 8-9 front wheel construction 1 brake disc 6 front axle 2 collar 7 front wheel item n·m kgf-m lb-ft 3 dust seal a front axle bolt a 100 10.0 72.5 4 bearing b brake disc bolt b 23 23.0 16.5 5 spacer sa mp le.

  • Page 333: 8-10     Chassis

    8-10 chassis removal • remove the brake calipers. • loosen two axle pinch bolts 1 on the right front fork leg. • remove the front axle bolt 2. • raise the front wheel off the ground and support the motorcy- cle with a jack or a wooden block. • loosen two axle pinch bolts 3 on the left front fork leg...

  • Page 334: Chassis     8-11

    Chassis 8-11 inspection and disassembly tire inspection ( 8-82) • remove the brake disc. Brake disc inspection ( 8-68) • 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 replace it if the...

  • Page 335: 8-12     Chassis

    8-12 chassis • remove the wheel bearings with the special tool.  09921-20240: bearing remover set the removed bearings should be replaced with new ones. Sa mp le.

  • Page 336: Chassis     8-13

    Chassis 8-13 reassembly and installation reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply suzuki super grease “a” to the wheel bearings.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuk...

  • Page 337: 8-14     Chassis

    8-14 chassis • install the wheel bearings with the special tools as follows.  09941-34513: bearing/steering race installer set 09924-84510: bearing installer set • install the dust seal with the special tool.  09913-70210: bearing installer set (52 mm) • apply suzuki super grease “a” to the dust s...

  • Page 338: Chassis     8-15

    Chassis 8-15 • install the collar 1 in the right side. Wheel • install the front wheel with the front axle and hand-tighten the front axle bolt temporarily. Brake caliper • tighten the brake caliper mounting bolts to the specified torque.  front brake caliper mounting bolt: 39 n·m (3.9 kgf-m, 28.0 ...

  • Page 339: 8-16     Chassis

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

  • Page 340: Chassis     8-17

    Chassis 8-17 front fork construction (usa) (others) 1 o-ring 0 oil seal 2 spring retainer a oil seal stopper ring 3 spacer b dust seal 4 washer c inner tube 5 spring a front fork cap bolt item n·m kgf-m lb-ft 6 adjuster rod b lock-nut a 23 2.3 16.5 7 inner rod/damper rod (cartridge) c front axle pin...

  • Page 341: 8-18     Chassis

    8-18 chassis removal and disassembly • remove the front wheel. ( 8-10) • disconnect the brake hose from the brake hose guides on the front fender. • remove the front fender. • loosen the front fork upper clamp bolts 1, left and right. • loosen the handlebar clamp bolts 2, left and right. Note: * sl...

  • Page 342: Chassis     8-19

    Chassis 8-19 • remove the front fork cap bolt from the inner rod by loosening the lock nut. • compress the fork spring with the special tool and remove the special tool. • remove the front fork cap bolt 5, adjuster rod 6, spring retainer 7, spacer 8, washer 9 and spring 0. • invert the front fork an...

  • Page 343: 8-20     Chassis

    8-20 chassis • remove the inner rod/damper rod (cartridge) b. • slide the outer tube to remove it from the inner tube. Note: be careful not to damage the “anti-friction” metals. • remove the dust seal c and oil seal stopper ring d. • remove the oil seal with the special tool.  09913-50121: oil seal...

  • Page 344: Chassis     8-21

    Chassis 8-21 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 345: 8-22     Chassis

    8-22 chassis 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. 1 dust seal 2 oil seal stopper ring 3 oil seal 4 oi...

  • Page 346: Chassis     8-23

    Chassis 8-23  09940-30221: front fork assembling tool  damper rod bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) fork oil • place the front fork vertically without spring. • compress it fully. • pour specified front fork oil up to the top level of the outer tube.  capacity (each leg): 510 ml (17.2/17.9 us/...

  • Page 347: 8-24     Chassis

    8-24 chassis front fork inner rod lock nut • adjust the height h of the inner rod threads by turning the lock-nut 1 as shown in illustration. H: 11 mm (0.43 in) fork spring • install the fork spring as shown in the illustration. • install the spring 1, washer 2, spacer 3 and spring retainer 4. Front...

  • Page 348: Chassis     8-25

    Chassis 8-25 • make sure that the height h of the inner rod threads is as fol- lows. H: 11 mm (0.43 in) • slowly turn the cap bolt completely by hand until the end of the cap bolt seats on the lock nut. • apply fork oil to the o-ring. • hold the cap bolt 2 and tighten the lock-nut 3 to the speci- fi...

  • Page 349: 8-26     Chassis

    8-26 chassis installation install the front fork in the reverse order of removal. Pay atten- tion to the following points: • set the upper surface of the outer tube height a at 4.0 mm (0.157 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts 1 ...

  • Page 350: Chassis     8-27

    Chassis 8-27 rebound damping force fully turn the damping force adjuster 1 clockwise. It is at stiffest position and turn it out to standard setting position. (for e-02, 19): 11 clicks out from stiffest position (for e-03, 24, 28, 33): 9 clicks out from stiffest position note: make sure to check the...

  • Page 351: 8-28     Chassis

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

  • Page 352: Chassis     8-29

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

  • Page 353: 8-30     Chassis

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

  • Page 354: Chassis     8-31

    Chassis 8-31 removal • remove the under cowling. ( 8-5 to -6) • support the motorcycle with a jack or a wooden block. • remove the front wheel. ( 8-10) • remove the front forks. ( 8-18) • remove the steering damper. ( 8-29) • remove the steering stem head nut and washer. • remove the steering st...

  • Page 355: 8-32     Chassis

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

  • Page 356: Chassis     8-33

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

  • Page 357: 8-34     Chassis

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

  • Page 358: Chassis     8-35

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

  • Page 359: 8-36     Chassis

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

  • Page 360: Chassis     8-37

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

  • Page 361: 8-38     Chassis

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

  • Page 362: Chassis     8-39

    Chassis 8-39 • apply the suzuki super grease “a” to the throttle cables and cable drum.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • when remounting the right and left handle switches, engage the stopper with the handlebar hole. After installing the st...

  • Page 363: 8-40     Chassis

    8-40 chassis rear wheel construction *1 1 rear axle 0 spacer *1 except for e-03, 28, 33 2 caliper bracket a sprocket mounting drum 3 brake disc b sprocket 4 collar c bearing 5 dust seal d dust seal 6 rear wheel e collar item n·m kgf-m lb-ft 7 spacer a brake disc bolt a 35 3.5 25.5 8 bearing b rear s...

  • Page 364: Chassis     8-41

    Chassis 8-41 removal • remove the cotter pin. (for e-03, 28, 33) • loosen the axle nut 1. • remove the under cowling. ( 8-5 to -6) • 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 whee...

  • Page 365: 8-42     Chassis

    8-42 chassis • remove the dust seal with the special tool.  09913-50121: oil seal remover • remove the dust seal with the special tool.  09913-50121: oil seal remover inspection and disassembly tire inspection ( 2-27 and 8-82) wheel inspection ( 8-82) rear axle • using a dial gauge, check the re...

  • Page 366: Chassis     8-43

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

  • Page 367: 8-44     Chassis

    8-44 chassis reassembly and installation reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: 25 n·m (2.5 kgf-m, 18.0 lb-ft) 35 n·m (3.5 kgf-m, 25.5 lb-ft) left right 100 n·m (10.0 kgf-m, 72.5 lb-ft) 93 n·m (9.3 kgf-m, 67.5 lb-...

  • Page 368: Chassis     8-45

    Chassis 8-45 bearings • apply suzuki super grease “a” to the bearings before installing.  99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the new bearing to the sprocket mounting drum with the special tool.  09924-84510: bearing installer set • fi...

  • Page 369: 8-46     Chassis

    8-46 chassis wheel damper • to install the wheel dampers, apply a special tire lubricant or neutral soapy liquid to the damper surface. Dust seals • install the new dust seal with the special tool.  09913-70210: bearing installer set (1 68) (2 52) • apply suzuki super grease “a” to the dust seal ...

  • Page 370: Chassis     8-47

    Chassis 8-47 • tighten the sprocket mounting nuts to the specified torque.  rear sprocket nut: 93 n·m (9.3 kgf-m, 67.5 lb-ft) note: stamped mark a on the sprocket should face outside. • install the collar 2. Brake disc • apply thread lock to the disc bolts and tighten them to the specified torque. ...

  • Page 371: 8-48     Chassis

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

  • Page 372: Chassis     8-49

    Chassis 8-49 removal • lift and support the fuel tank with the fuel tank prop stay. ( 5-3) • remove the regulator/rectifier 1. ( 10-40) • remove the under cowling. ( 8-5 to -6) • support the motorcycle with a jack relieve no load on the rear shock absorber. • remove the rear shock absorber upper ...

  • Page 373: 8-50     Chassis

    8-50 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 a using a center punch. Wrap the rear cushion unit with a vinyl bag and fix it on a v...

  • Page 374: Chassis     8-51

    Chassis 8-51 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 375: 8-52     Chassis

    8-52 chassis rear suspension construction 1 rear shock absorber a swingarm pivot boss (lh) 2 rear cushion rod a rear shock absorber mounting bolt/nut 3 rear cushion lever item n·m kgf-m lb-ft 4 spacer b rear cushion lever bolt/nut a 50 5.0 36.0 5 bearing c rear cushion rod bolt/nut b 78 7.8 56.5 6 c...

  • Page 376: Chassis     8-53

    Chassis 8-53 removal • cut the drive chain. ( 8-86) note: it is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • remove the rear wheel. ( 8-41) • remove the side-stand 1. Note: it is not necessary to remove the side-stand, unless when replacing the cushion lever. •...

  • Page 377: 8-54     Chassis

    8-54 chassis • hold the swingarm pivot shaft 5 and remove the swingarm pivot nut 6.  09944-28320: hexagon socket (19 mm) • draw out the swingarm pivot shaft. • remove the rear suspension assembly. • remove the cushion rods 7. • remove the rear fender (lower) 8. • remove the chain cases 9 and chain ...

  • Page 378: Chassis     8-55

    Chassis 8-55 • set the swingarm pivot boss by its set screws. • tighten the swingarm boss nut to the specified torque.  swingarm pivot boss nut: 65 n·m (6.5 kgf-m, 47.0 lb-ft) inspection and disassembly spacer • remove the spacers from swingarm. • remove the spacers from the cushion lever. • inspec...

  • Page 379: 8-56     Chassis

    8-56 chassis • draw out the swingarm pivot bearings 1 and the swingarm cushion rod upper bearings 2 with the special tool.  09921-20240: bearing remover set (1 28 mm) (2 17 mm) cushion lever bearing • insert the spacer into bearing and check the play when mov- ing the spacer up and down. • if exces...

  • Page 380: Chassis     8-57

    Chassis 8-57 swingarm pivot shaft • using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit.  swingarm pivot shaft runout: service limit: 0.3 mm (0.01 in)  09900-20607: dial gauge (1/100 mm, 10 mm) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm...

  • Page 381: 8-58     Chassis

    8-58 chassis reassembly reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: 100 n·m 10.0 kgf-m 72.5 lb-ft ( ( 15 n·m 1.5 kgf-m 11.0 lb-ft ( ( 90 n·m 9.0 kgf-m 65.0 lb-ft ( ( 65 n·m 6.5 kgf-m 47.0 lb-ft ( ( 65 n·m 6.5 kgf-m 47.0 lb-ft ( ( ap...

  • Page 382: Chassis     8-59

    Chassis 8-59 swingarm bearing • install the center spacer. • press the bearings into the swingarm pivot with the special tool.  09941-34513: steering race installer note: when installing the bearing, stamped mark on the bearing must face outside. • press the swingarm cushion rod upper side bearings...

  • Page 383: 8-60     Chassis

    8-60 chassis • assemble the cushion rod onto the swingarm temporarily. Note: the stamped marks a on the cushion rod should be face out- side. • remount the chain cases 1 chain buffer 2 and rear fender 3. Installation install the swingarm in the reverse order of disassembly and removal, and pay atten...

  • Page 384: Chassis     8-61

    Chassis 8-61 shock absorber and cushion lever mounting nut • install the washers a and cushion lever. ( 8-58) • tighten the cushion lever mounting nut 1 to the specified torque.  cushion lever mounting nut: 78 n·m (7.8 kgf-m, 56.5 lb-ft) • assemble the cushion lever, cushion rod. ( 8-58)  cushio...

  • Page 385: 8-62     Chassis

    8-62 chassis front brake construction 1 brake lever 9 brake hose 2 dust boot a master cylinder mounting bolt item n·m kgf-m lb-ft 3 piston set b brake hose union bolt a 10 1.0 7.0 4 piston seal c caliper mounting bolt b 23 2.3 16.5 5 dust seal d caliper air bleeder valve c 39 3.9 28.0 6 brake calipe...

  • Page 386: Chassis     8-63

    Chassis 8-63 brake pad replacement • loosen the pad mounting pins 1. • remove the brake caliper by removing the caliper mounting bolts 2. • remove the pad mounting pins 1, brake pads and spring. Note: * when the brake caliper is removed, care must be used so as not to cause stress to the brake hose....

  • Page 387: 8-64     Chassis

    8-64 chassis • install the spring to the caliper, bring its wider side of pawl a facing top. • install the new brake pads. • install the brake caliper. • tighten each bolt to the specified torque.  pad mounting pin 1: 15 n·m (1.5 kgf-m, 11.0 lb-ft) front brake caliper mounting bolt 2: 39 n·m (3.9 k...

  • Page 388: Chassis     8-65

    Chassis 8-65 caliper removal • remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta- cle. Note: place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. • remove the brake pads and spring. ( 8-63) calip...

  • Page 389: 8-66     Chassis

    8-66 chassis • remove the dust seals 4 and piston seals 5. Caliper inspection brake caliper • inspect the brake caliper cylinder wall for nicks, scratches or other damage. Brake caliper piston • inspect the brake caliper piston surface for any scratches or other damage. Caliper reassembly reassemble...

  • Page 390: Chassis     8-67

    Chassis 8-67 piston seal • install the piston seals as shown in the illustration. O-ring • install the new o-ring 1 and reassemble caliper halves. • temporarily tighten the air bleeder valve 2. • tighten each bolt to the specified torque.  front brake caliper housing bolt 3: 22 n·m (2.2 kgf-m, 16.0...

  • Page 391: 8-68     Chassis

    8-68 chassis brake disc inspection • visually check the brake disc for damage or cracks. • measure the thickness with a micrometer. • replace the disc if the thickness is less than the service limit or if damage is found.  front disc thickness: service limit: 5.0 mm (0.20 in)  09900-20205: microme...

  • Page 392: Chassis     8-69

    Chassis 8-69 master cylinder removal and disas- sembly • drain the brake fluid. ( 8-64) • disconnect the front brake light switch lead wires 1. • place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose. • r...

  • Page 393: 8-70     Chassis

    8-70 chassis • remove the dust boot 9 push rod 0 and snap ring a. • remove the following parts. B secondary cup c piston d primary cup e return spring f return spring guide g air bleeder valve • remove the dust rubber h and snap ring i. • remove the air bleeder valve j, connector k and o-ring l. Mas...

  • Page 394: Chassis     8-71

    Chassis 8-71 • inspect the piston surface for any scratches or other damage. • inspect the primary cup, secondary cup and dust seal for wear or damage. Master cylinder reassembly reassemble the master cylinder in the reverse order of disas- sembly. Pay attention to the following points:  specificat...

  • Page 395: 8-72     Chassis

    8-72 chassis • apply suzuki silicone grease to the brake lever mount- ing bolt.  99000-25100: suzuki silicone grease • align the convex part a of brake light switch with the hole b of master cylinder when installing the brake light switch. Master cylinder installation install the master cylinder in...

  • Page 396: Chassis     8-73

    Chassis 8-73 rear brake construction 1 brake pedal a caliper air bleeder valve 2 piston/cup set b brake hose union bolt item n·m kgf-m lb-ft 3 reservoir hose c brake caliper mounting bolt a 6.0 0.6 4.5 4 brake hose d brake master cylinder mounting bolt b 23 2.3 16.5 5 brake pad e brake master cylind...

  • Page 397: 8-74     Chassis

    8-74 chassis brake pad replacement • remove the pad mounting pin 1 and spring 2. • remove the brake pads. • install the new brake pads and shims.  pad mounting pin: 17 n·m (1.7 kgf-m, 12.5 lb-ft) note: after replacing the brake pads, pump the brake pedal a few times to set the brake parts correctly...

  • Page 398: Chassis     8-75

    Chassis 8-75 brake fluid replacement • remove the brake fluid reservoir cap 1. • replace the brake fluid in the same manner as the front brake. ( 8-64)  specification and classification: dot 4 caliper removal • remove the cotter pin. (for e-03, 28, 33) • loosen the rear axle nut 1. • loosen the ch...

  • Page 399: 8-76     Chassis

    8-76 chassis caliper disassembly • remove the caliper air bleeder valve 1. • remove the caliper housing bolts 2. • separate the caliper halves. • remove the o-ring 3. • place a rag over the piston to prevent it from popping out and then force out the pistons using compressed air. • remove the dust s...

  • Page 400: Chassis     8-77

    Chassis 8-77 caliper reassembly reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves.  specification and classification: dot 4 pis...

  • Page 401: 8-78     Chassis

    8-78 chassis • completely clean the thread of caliper housing and bolts. • apply thread lock to the caliper housing bolts.  99000-32130: thread lock super “1360” caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • tighten each bolt to t...

  • Page 402: Chassis     8-79

    Chassis 8-79 master cylinder removal • drain the brake fluid. ( 8-64) • remove the brake fluid reservoir mounting bolt 1. • place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 2 and disconnect the brake hose. • loosen the lock-nu...

  • Page 403: 8-80     Chassis

    8-80 chassis • pull out the dust boot 5, then remove the snap ring 6.  09900-06108: snap ring pliers • remove the push rod 7, piston/primary cup 8 and spring 9. Master cylinder inspection cylinder, piston and cup set • inspect the cylinder bore wall for any scratches or other dam- age. • inspect th...

  • Page 404: Chassis     8-81

    Chassis 8-81 • apply suzuki silicone grease to the push rod end.  99000-25100: suzuki silicone grease master cylinder installation install the master cylinder in the reverse order of removal. Pay attention to the following points: • apply thread lock to the master cylinder mounting bolts.  99000-3...

  • Page 405: 8-82     Chassis

    8-82 chassis 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 406: Chassis     8-83

    Chassis 8-83 valve inspection • inspect the valve after the tire is removed from the rim. • replace the valve with a new one if the seal a rubber is peel- ing or has damage. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the se...

  • Page 407: 8-84     Chassis

    8-84 chassis tire installation • apply tire lubricant to the tire bead. • when installing the tire onto the wheel, observe the following points. • when installing the tire, the arrow a on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the tim...

  • Page 408: Chassis     8-85

    Chassis 8-85 • in this condition, check the “rim line” b cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire comp...

  • Page 409: 8-86     Chassis

    8-86 chassis drive chain use the special tool in the following procedures, to cut and rejoin the drive chain.  09922-22711: drive chain cutting and joining tool set note: when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Drive chain cutting • s...

  • Page 410: Chassis     8-87

    Chassis 8-87 • place the drive chain link being disjointed on the holder part 8 of the tool. • turn in both the adjuster bolt 6 and pressure bolt “a” 3 so that each of their end hole fits over the chain joint pin properly. • tighten the pressure bolt “a” 3 with the bar. • turn in the pressure bolt “...

  • Page 411: 8-88     Chassis

    8-88 chassis • apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0. Note: when positioning the joint plate 0 on the tool, its stamp mark must face the joint plate holder 3 side. • set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 to...

  • Page 412: Chassis     8-89

    Chassis 8-89 • stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “a” 3 with the bar until the pin end diameter becomes the specified dimension.  pin end diameter specification d • adjust the drive chain, after connecting it. ( 2-21) did 5.50 – 5.80 mm (0.217 – 0.228 in) * a...

  • Page 413: Electrical System     9-1

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

  • Page 414: Electrical System

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

  • Page 415: Electrical System     9-3

    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 416: 9-4     Electrical System

    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 417: Electrical System     9-5

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

  • Page 418: 9-6     Electrical System

    9-6 electrical system location of electrical components 1 battery 2 cooling fan relay ( 7-7) 3 fuel pump relay ( 5-6) 4 ap sensor ( 4-56) 5 ecm (engine control module) 6 mode selection switch coupler ( 4-25) 7 starter relay/main fuse 8 pair control solenoid valve ( 11-6) 9 cmp sensor ( 4-33) 0...

  • Page 419: Electrical System     9-7

    Electrical system 9-7 1 iap sensor ( 4-37) 2 secondary fuel injector ( 4-77) 3 primary fuel injector ( 4-75) 4 ect sensor ( 4-48) 5 fuel level gauge ( 5-8) 6 fuel pump ( 5-8) 7 to sensor ( 4-61) 8 excva ( 6-4) 9 regulator/rectifier 0 horn a generator b fuse box c turn signal/side-stand relay...

  • Page 420: 9-8     Electrical System

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

  • Page 421: Electrical System     9-9

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

  • Page 422: 9-10     Electrical System

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

  • Page 423: Electrical System     9-11

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

  • Page 424: 9-12     Electrical System

    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 425: Electrical System     9-13

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

  • Page 426: 9-14     Electrical System

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

  • Page 427: Electrical System     9-15

    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 428: 9-16     Electrical System

    9-16 electrical system • tighten the starter motor lead wire mounting bolt to the speci- fied torque.  lead wire mounting bolt: 3 n·m (0.3 kgf-m, 2.0 lb-ft) starter relay inspection • remove the front seat. ( 8-7) • disconnect the battery - lead wire from the battery. • remove the frame cover. ( ...

  • Page 429: Electrical System     9-17

    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 430: 9-18     Electrical System

    9-18 electrical system gear position switch • lift and support the fuel tank. ( 5-3) • disconnect the gear position switch coupler and check the continuity between blue and black/white with the transmis- sion in “neutral”.  09900-25008: multi-circuit tester set  tester knob indication: continuity...

  • Page 431: Electrical System     9-19

    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 d and e terminals with the tester. Then app...

  • Page 432: 9-20     Electrical 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 13 300 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 433: Electrical System     9-21

    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 434: 9-22     Electrical System

    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 435: Electrical System     9-23

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

  • Page 436: 9-24     Electrical System

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

  • Page 437: Electrical System     9-25

    Electrical system 9-25 inspection ignition coil primary peak voltage • remove the air cleaner box. ( 5-13) • disconnect all the ignition coil/plug cap lead wire couplers before removing the ignition coil/plug caps. • remove all of the ignition coil/plug caps. • connect the new four spark plugs to e...

  • Page 438: 9-26     Electrical System

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

  • Page 439: Electrical System     9-27

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

  • Page 440: 9-28     Electrical System

    9-28 electrical system if the peak voltage is lower than the standard range, check the peak voltage at the ckp sensor lead wire coupler. • 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 adaptor. Black wire...

  • Page 441: Electrical System     9-29

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

  • Page 442: 9-30     Electrical System

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

  • Page 443: Electrical System     9-31

    Electrical system 9-31 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 444: 9-32     Electrical System

    9-32 electrical system 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 1. • connect the variable resistor a between the terminals. • disconnect the oil pressure switch lead wire from the ...

  • Page 445: Electrical System     9-33

    Electrical system 9-33 fuel level gauge inspection • remove and disassemble the fuel pump assembly. ( 5-8) • 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 ...

  • Page 446: 9-34     Electrical System

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

  • Page 447: Electrical System     9-35

    Electrical system 9-35 lamps headlight, brake light/taillight, license plate light and turn signal light headlight 12 v 55 w h7 1 12 v 60 w hb3 2 position light 3 12 v 5 w × 2 brake light/taillight: led licence plate light 4 12 v 5 w turn signal light 5 12 v 21 w × 4 if you have touched and the bulb...

  • Page 448: 9-36     Electrical System

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

  • Page 449: Electrical System     9-37

    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 450: 9-38     Electrical System

    9-38 electrical system ignition switch removal • remove the air cleaner box. ( 5-13) • disconnect the ignition switch lead wire coupler (green) 1. • disconnect the immobilizer lead wire coupler (black) 2. (for e-02, 19, 24) • remove the cable guide 3. • remove the ignition switch mounting bolts wit...

  • Page 451: Electrical System     9-39

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

  • Page 452: 9-40     Electrical System

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

  • Page 453: Electrical System     9-41

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

  • Page 454: 9-42     Electrical System

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

  • Page 455: Servicing Information

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

  • Page 456: Servicing Information

    Servicing information contents 10-2 servicing information tightening torque .............................................................................. 10-45 engine ................................................................................................ 10-45 fi system and intake air syst...

  • Page 457: Troubleshooting

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

  • Page 458

    10-4 servicing information dtc no. Detected item detected failure condition check for c21 iat sensor the sensor voltage should be the fol- lowing. 0.15 v sensor voltage in other than the above range, c21 (p0110) is indicated. Iat sensor, lead wire/coupler connection p0110 h sensor voltage is higher ...

  • Page 459

    Servicing information 10-5 * : immobilizer system is equipped model only. Dtc no. Detected item detected failure condition check for c29 stp sensor the sensor should produce following voltage. 0.15 v sensor voltage in other than the above range, c29 (p1654) is indicated. Stp sensor, lead wire/couple...

  • Page 460

    10-6 servicing information dtc no. Detected item detected failure condition check for c46 exhaust con- trol valve 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 fro...

  • Page 461: Engine

    Servicing information 10-7 engine complaint symptom and possible causes remedy engine will not start or is hard to start. Compression too low 1. Valve clearance out of adjustment 2. Worn valve guides or poor seating of valves 3. Mistiming valves 4. Excessively worn piston rings 5. Worn-down cylinder...

  • Page 462: Complaint

    10-8 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 463: Complaint

    Servicing information 10-9 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 464: Complaint

    10-10 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 sufficientl...

  • Page 465: Complaint

    Servicing information 10-11 complaint symptom and possible causes remedy engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance 2. Weakened valve springs 3. Valve timing out of adjustment 4. Worn piston rings or cylinders 5. Poor seating of valves 6. Fouled spark ...

  • Page 466: Complaint

    10-12 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 467: Radiator (Cooling System)

    Servicing information 10-13 radiator (cooling system) complaint symptom and possible causes remedy engine overheats 1. Not enough engine coolant 2. Radiator core clogged with dirt or scale 3. Faulty cooling fan 4. Defective cooling fan relay, or open- or short- circuited 5. Defective ecm 6. Defectiv...

  • Page 468: Chassis

    10-14 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 adjust. Replace. Replace. Adjust. Wobbly handlebars 1. Loss of balance betw...

  • Page 469: Brakes

    Servicing information 10-15 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 470: Electrical

    10-16 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 471: Battery

    Servicing information 10-17 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 472: Wiring Harness Routing

    10-18 servicing information wiring harness, cable and hose routing wiring harness routing clamp clamp clamp clamp clamp clamp clamp clamp pass the generator lead wire between the water hoses. Fuse ecm pair control solenoid valve engine ground lead wire fixed clamp fixed clamp fixed clamp fixed clamp...

  • Page 473

    Servicing information 10-19 clamp (after binding the lead wires, cut the clamp end.) clamp (after binding the lead wires, cut the clamp end.) clamp 10 mm (0.4 in) immobilizer label (e-02, 19, 24) locate the junction of the wire harness to the center of the headlight. Wire harness protector tape iat ...

  • Page 474

    10-20 servicing information grommet clamp ckp sensor oil pressure switch 14 n·m 1.4 kgf-m 10.0 lb-ft speed sensor engine ground lead wire 1.5 n·m (0.15 kgf-m, 1.0 lb-ft) 6 n·m (0.6 kgf-m, 4.5 lb-ft) gp switch lead wire clamp clamp generator gp switch lead wire is made to slacken. Gp switch clamp 5 n...

  • Page 475: Cable Routing

    Servicing information 10-21 cable routing throttle cable clutch cable throttle cable guide *1 clutch cable guide clutch cable, lot no. Clutch cable, part no. Clutch cable *2 water bypass hose *3 0 mm (0 in) 0 mm (0 in) throttle cable no. 1 throttle cable no. 2 0 mm (0 in) clutch cable clutch cable g...

  • Page 476: Throttle Body Hose Routing

    10-22 servicing information throttle body hose routing 1 fuel feed hose 4 purge hose (e-33 only) 2 pcv (breather) hose 5 surge hose (e-33 only) 3 iap sensor vacuum hose 6 evap canister (e-33 only) sa mp le.

  • Page 477: Fuel Tank Drain Hose Routing

    Servicing information 10-23 fuel tank drain hose routing *3 *3 *2 *1 45˚ 45˚ 1 fuel feed hose 5 hose clamp 2 breather hose *1 pass the breather hose 2 and drain hose 3 through under the wiring harness. 3 drain hose *2 pass the breather hose 2 and drain hose 3 through ahead of the fuse box. 4 wiring ...

  • Page 478: Cooling System Hose Routing

    10-24 servicing information cooling system hose routing align the marking with the rib of pipe. Union bolt 12 n·m (1.2 kgf-m, 8.5 lb-ft) jiggle valve thermostat left down side. Do not touch the end of clamp to the hose. 45˚ backward. Left side. Left side. Backward. Backward. Air bleeder 6 n·m 0.6 kg...

  • Page 479: Front Brake Hose Routing

    Servicing information 10-25 front brake hose routing *1 *2 *5 1 – 2 mm (0.04 – 0.08 in) 42˚ 49˚ 42˚ *3 *4 *3 *6 *7 *3 42˚ 14˚ *4 *1 clamp ends should face downward. *5 after positioning the clamp with stopper, tighten the clamp bolt. *2 clamp ends should face backward. *6 insert the clamp to the hol...

  • Page 480: Rear Brake Hose Routing

    10-26 servicing information rear brake hose routing *1 *2 28˚ *1 *3 *1 5˚ *2 *1 clamp ends should face backward. *3 white paint faces topside. *2 after the brake hose union has contacted the stopper, tighten the union bolt. Sa mp le.

  • Page 481

    Servicing information 10-27 pair (air supply) system hose routing approx. 45˚ approx. 0˚ *1 approx. 0˚ 1 pair control solenoid valve 3 air cleaner box 2 pair reed valve *1 to air cleaner box sa mp le.

  • Page 482: Fuel Tank Installation

    10-28 servicing information fuel tank installation 4 mm (0.16 in) 5 mm (0.20 in) 2 mm (0.08 in) a apply an adhesive agent. 3 fuel tank cover 1 velcro fastening 4 fuel tank side cushion 2 frame cover cushion sa mp le.

  • Page 483: Fastener Installation

    Servicing information 10-29 fuel tank lower side cover cushion rubber/ fastener installation air intake pipe cushion rubber installation note: clean an adhesive surface before adhering the cushion rubber. 33 – 39 mm (1.30 – 1.54 in) 41 – 47 mm (1.61 – 1.85 in) 1 cushion tape 2 velcro fastening 3 cus...

  • Page 484: Cowling Installation

    10-30 servicing information cowling installation right under cowling cover body cowling windscreen cowling brace frame cushion rubber left under cowling cover clamp connector e right under cowling oil pan right air intake pipe right air intake cover right-side cowling left air intake pipe left air i...

  • Page 485: Frame Cover Installation

    Servicing information 10-31 frame cover installation seat lock cable routing sa mp le.

  • Page 486: Rear Fender Installation

    10-32 servicing information rear fender installation *1 35 mm (1.38 in) 1 seat rail 5 rear fender (lower) 2 rear fender (front) 6 chain cover no.1 3 rear fender cover (front) 7 swingarm 4 rear fender (rear) *1 cushion rubber sa mp le.

  • Page 487

    Servicing information 10-33 under cowling heat shield installation note: clean an adhesive surface before adhering the heat shield. 1 left under cowling 3 heat shield (l) 5 fuel tank hose clamp 2 right under cowling 4 heat shield (r) up side forward 1 mm (0.04 in) 1 mm (0.04 in) 15 mm (0.59 in) 2 mm...

  • Page 488

    10-34 servicing information body cowling cover cushion installation windscreen tape cushion installation 15 mm (0.59 in) 15 mm (0.59 in) 25 mm (0.98 in) 4 mm (0.16 in) 4 mm (0.16 in) 7 mm (0.28 in) 5 mm (0.20 in) 10 mm (0.40 in) 10 mm (0.40 in) sa mp le.

  • Page 489

    Servicing information 10-35 headlight tape cushion installation air intake cover tape cushion installation note: align the tape cushion to the aligned mark. Clean an adhesive surface before adhering the tape cushion. 3 – 7 mm (0.12 – 0.28 in) sa mp le.

  • Page 490: Side-Stand Installation

    10-36 servicing information side-stand installation gearshift pedal installation 40 n·m (4.0 kgf-m, 29.0 lb-ft) 50 n·m (5.0 kgf-m, 36.0 lb-ft) 50 n·m (5.0 kgf-m, 36.0 lb-ft) (usa) (others) footrest 50 – 60 mm (1.97 – 2.36 in) sa mp le.

  • Page 491: Handlebar Balancer

    Servicing information 10-37 handlebar balancer front footrest installation 1 handlebar 4 handle balancer expander 2 throttle grip 5 handlebar balancer item n·m kgf-m lb-ft 3 nut 6 screw a 5.5 0.5 4.0 1 footrest 5 spring 2 bank sensor 6 e-ring 3 holder *1 align the cutaway. 4 pin 18 n.M (1.8 kgf-m, 1...

  • Page 492

    10-38 servicing information rear view mirror installation 1 body cowling 5 turn signal lead wire coupler 2 cowling brace 6 mirror cover 3 cushion 7 mirror body 4 turn signal lead wire *a locate the turn signal lead wire coupler 5 between the mirror cover 6 and mirror body 7. *a sa mp le.

  • Page 493

    Servicing information 10-39 rear combination light installation 1 frame cover 5 license plate light 2 brake light/taillight cushion 6 rear fender 3 brake light/taillight *a align the brake light/taillight cushion to the parting line. 4 brake light/taillight bracket * a (2 pcs.) (2 pcs.) (2 pcs.) (2 ...

  • Page 494

    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 2 battery holder rubber cushion fwd 20 mm (0.8 in) sa mp le.

  • Page 495: Special Tools

    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) 09900-20508 cylinder gauge set 09900-20602 dia...

  • Page 496: 09913-10750

    10-42 servicing information 09913-10750 adapter 09913-13121 vacuum balancer gauge 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 m...

  • Page 497: 09916-53330

    Servicing information 10-43 09916-53330 attachment 09916-84511 tweezers 09917-47011 vacuum pump gauge 09920-34830 starter clutch holder 09920-53740 clutch sleeve hub holder 09921-20210 bearing remover 09921-20240 bearing remover set 09922-22711 drive chain cutting and joining tool 09923-74511 bearin...

  • Page 498: 09940-14960

    10-44 servicing information note: when order the special tool, please confirm whether it is available or not. 09940-14960 steering nut wrench socket 09940-14940 swingarm pivot thrust adjuster socket wrench 09940-14990 engine mounting thrust adjuster socket wrench 09940-30221 front fork assem- bling ...

  • Page 499: 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 23 2.3 16.5 speed sensor rotor bolt 25 2.5 18.0 speed sensor bolt 4.5 0.45 3.0 engine sprocket nut 115 11.5 83.0 engine mounting bolt and ...

  • Page 500: Cooling System

    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 501: Chassis

    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 90 9.0 65.0 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 502: Tightening Torque Chart

    10-48 servicing information tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter a (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 503: 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. 0.10 – 0.20 (0.004 – 0.008) — ex. 0.20 – 0.30 (0.008 – 0.012) — valve guide to valve stem ...

  • Page 504: Item

    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 505: Conrod + Crankshaft

    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 506: Clutch

    10-52 servicing information clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio item standard limit clutch lever play 10 – 15 (0.4 – 0.6) — clutch release screw 1/2 turn back — drive plate thickness no. 1, 2 and 3 2.72 – 2.88 (0.107 – 0.113) 2.42 (0.095) drive plate claw width...

  • Page 507: Item

    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 508: Fi Sensors

    10-54 servicing information fi sensors item specification note cmp sensor resistance 0.9 – 1.7 k Ω cmp sensor peak voltage 0.5 v and more when cranking 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 voltag...

  • Page 509: Throttle Body

    Servicing information 10-55 throttle body electrical unit: mm (in) item specification bore size 44 mm i.D. No. 41g1 (for e-33), 41g0 (for the others) idle r/min 1 150 ± 100 r/min fast idle r/min 1 400 – 2 000 r/min (when cold engine) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specificati...

  • Page 510: Wattage

    10-56 servicing information wattage unit: w brake + wheel unit: mm (in) item standard/specification e-03, 28, 33 others headlight hi 60 ← lo 55 ← position/parking light 5 × 2 ← brake light/taillight led ← turn signal light 21 × 4 ← license plate light 5 ← combination meter light led ← turn signal in...

  • Page 511: Tire

    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 512: Suspension

    10-58 servicing information suspension unit: mm (in) fuel + oil item standard limit front fork stroke 120 (4.92) — front fork spring free length 230.0 (9.06) 225 (8.86) front fork oil level (without spring, outer tube fully compressed) 101 (3.98) — front fork oil type suzuki fork oil l01 or an equiv...

  • Page 513: 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 514: 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. 1 fu...

  • Page 515

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

  • Page 516

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

  • Page 517

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

  • Page 518: 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...

  • Page 519: Installation

    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: ...

  • Page 520

    11-8 emission control information pair (air supply) system diagram *1 *2 *3 *1 *1 1 pair control solenoid valve *1 from air cleaner 2 pair reed valve *2 to #1 and #2 cylinders a fresh air *3 to #3 and #4 cylinders b exhaust gas sa mp le.

  • Page 521

    Emission control information 11-9 pair (air supply) system hose routing approx. 45˚ approx. 0˚ *1 approx. 0˚ 1 pair control solenoid valve 3 air cleaner box 2 pair reed valve *1 to air cleaner box sa mp le.

  • Page 522: Wiring Diagram

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

  • Page 523: E-03, 28, 33

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

  • Page 524

    Prepared by january, 2005 part no. 99500-39270-01e printed in japan 524 sa mp le.

  • Page 525: Printed In Japan

    Printed in japan k5 no.7892 gsx-r1000_01e 99500-39270-01e 2005.1.19 cover_14 for ps printing (20mm) 1/1 9 9 5 0 0 - 3 9 2 7 0 - 0 1 e top bottom k5 gsx-r1000 gsx-r1000 tdp7.