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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 1

    Top bottom no. 1298 gsx-r1000 s/m 99500-39380-01e for ps printing 2009.3.3 (back: 23 mm) 5/0 dic255 gsx-r1000 printed in japan k9 k9 gsx-r1000 service manual service manual 9 9 5 0 0 - 3 9 3 8 0 - 0 1 e manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk ...

  • Page 2: Foreword

    Foreword this manual contains an introductory description on the suzuki gsx-r1000 and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the general information section to familiarize yourself with the mot...

  • Page 3: Table of Contents

    00 0 1 2 3 4 5 6 7 8 9 10 11 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ....................

  • Page 4

    Manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 5: Section 00

    Table of contents 00- i 00 section 00 contents precautions precautions ...............................................00-1 precautions........................................................... 00-1 warning / caution / note..................................... 00-1 general precautions .................

  • Page 6: Precautions

    00-1 precautions: precautions precautions precautions warning / caution / note b947h10000001 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 message...

  • Page 7

    Precautions: 00-2 • never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. • use a torque wrench to ti...

  • Page 8

    00-3 precautions: • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possible), 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 termina...

  • Page 9

    Precautions: 00-4 • when disconnecting and connecting the coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. Battery • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi system instantly wh...

  • Page 10

    00-5 precautions: 2) check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock if equipped. 3) using a test male terminal, check the female terminals of the circuit being checked for contact tension. Check each terminal ...

  • Page 11

    Precautions: 00-6 3) also, if measured values are as listed following, a resistance (abnormality) exists which causes the voltage drop in the circuit between terminals “a” and “b”. Voltage between “a” and body ground: approx. 5 v “b” and body ground: approx. 5 v – 2 v voltage drop “c” and body groun...

  • Page 12

    00-7 precautions: 4) disconnect the connector/coupler included in circuit (coupler “b”) and measure resistance between terminal “a” and body ground. If continuity is indicated, the circuit is shorted to ground between terminals “a” and “b”. Using the multi-circuit testers • use the suzuki multi-circ...

  • Page 13: Section 0

    Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 symbols .............................................................. 0a-1 abbreviations .....................

  • Page 14: General Information

    0a-1 general information: general information general information general description symbols b947h10101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Abbreviations b947h10...

  • Page 15

    General information: 0a-2 e: ecm: engine control module engine control unit (ecu) (fi control unit) ect sensor: engine coolant temperature sensor (ects) water temp. Sensor (wts) evap: evaporative emission exc system: exhaust control system (excs) exc valve: exhaust control valve (excv) excv actuator...

  • Page 16

    0a-3 general information: vehicle identification number b947h10101004 the frame serial number or v.I.N. (vehicle identification number) “a” is stamped on the right side of the steering head tube. The engine serial number “b” is located on the lower crankcase. These numbers are required especially fo...

  • Page 17

    General information: 0a-4 engine coolant recommendation b947h10101006 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 the aluminum ...

  • Page 18

    0a-5 general information: country and area codes b947h10101009 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b947h10101010 code country or area effective frame no. Gsx-r1000 k9 (e-02) u.K. Js1cy111100100001 – gsx-r1000 k9 (e-14) thailand js1cy12140010000...

  • Page 19

    General information: 0a-6 warning, caution and information labels location b947h10101011 1 (e-24), 2 1 (e-03, 33) 3, 21, 23 13, 14, 15 10, 11, 12 16, 17, 18, 19, 20 6, 7, 8, 9 6 (e-28) 5 4 [c] [d] [e] [a] [b] 22, 24 i947h1010008-04 1. Noise label (for e-03, 24, 33) 16. General warning label (english...

  • Page 20

    0a-7 general information: component location electrical components location b947h10103001 1 2 5 4 3 7 6 8 9 10 16 11 12 13 14 15 17 18 19 21 20 22 i947h1010006-06 1. Steering damper solenoid valve 9. Fuel level gauge 17. To sensor 2. Pair control solenoid valve 10. Fuel pump 18. Ckp sensor 3. Cmp se...

  • Page 21

    General information: 0a-8 23 24 27 25 28 26 29 30 31 32 33 34 35 36 37 38 39 40 41 i947h1010007-02 23. Ignition switch/immobilizer antenna (e-02, 19, 24, 51) 30. Turn signal/side-stand relay 37. Horn 24. Iat sensor 31. Cooling fan relay 38. Excv actuator 25. Secondary fuel injector 32. Ect sensor 39...

  • Page 22

    0a-9 general information: specifications specifications b947h10107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification remark overall length 2 045 mm (80.5 in) overall width 720 mm (28.3 in) overall height 1 130 mm (44.5 in...

  • Page 23

    General information: 0a-10 chassis electrical capacities item specification remark front suspension inverted telescopic, coil spring, oil damped rear suspension link type, coil spring, oil damped front suspension stroke 125 mm (4.9 in) rear wheel travel 130 mm (5.1 in) caster 23 ° 50’ trail 98 mm (3...

  • Page 24

    0a-11 general information: special tools and equipment special tool b947h10108002 09900–06104 snap ring remover (open type) 09900–06107 snap ring remover (open type) 09900–06108 snap ring remover (close type) 09900–18740 hexagon socket (24 mm) 09900–20102 vernier calipers (200 mm) 09900–20202 microm...

  • Page 25

    General information: 0a-12 09915–17410 oil pressure gauge adapter 09915–40610 oil filter wrench 09915–63311 compression gauge attachment 09915–64512 compression gauge 09915–74521 adapter hose 09915–77331 oil pressure gauge (1000 kpa) 09916–10911 valve lapper set 09916–14510 valve lifter 09916–14522 ...

  • Page 26

    0a-13 general information: 09925–18011 bearing installer 09930–10121 spark plug wrench set 09930–11920 torx bit (jt40h) 09930–11940 torx bit holder 09930–11950 torx wrench (5 mm) 09930–11960 torx wrench (4 mm) 09930–30104 rotor remover sliding shaft 09930–30460 rotor remover bolt 09930–34970 rotor r...

  • Page 27

    General information: 0a-14 09943–74111 front fork oil level gauge 09943–88211 pinion bearing installer 09944–28321 hexagon socket (19 mm) 99565–01010–020 cd-rom ver.20 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 28: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance b947h10200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at p...

  • Page 29

    Maintenance and lubrication: 0b-2 scheduled maintenance periodic maintenance schedule chart b947h10205001 note i = inspect and clean, adjust, replace or lubricate as necessary. R = replace. T = tighten. Item interval km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12...

  • Page 30

    0b-3 maintenance and lubrication: lubrication points b947h10205002 proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots and wipe off...

  • Page 31

    Maintenance and lubrication: 0b-4 3) drain water from the air cleaner box by removing the drain plug (1). 4) reinstall the removed parts. Exhaust pipe bolt and muffler bolt inspection b947h10206003 tighten exhaust pipe bolts and muffler bolts initially at 1 000 km (600 miles, 2 months) and every 12 ...

  • Page 32

    0b-5 maintenance and lubrication: valve clearance inspection and adjustment b947h10206005 inspect valve clearance initially every 24 000 km (14 500 miles, 48 months) inspection valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism...

  • Page 33

    Maintenance and lubrication: 0b-6 7) in this condition, read the valve clearance at the valves “f” (in and ex of no. 4 cylinder, ex of no. 3 and in of no. 2). If the clearance is out of specification, adjust the clearance. Special tool : 09900–20803 (thickness gauge) 8) turn the crankshaft 360 ° deg...

  • Page 34

    0b-7 maintenance and lubrication: (intake side) measured va lv e 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....

  • Page 35

    Maintenance and lubrication: 0b-8 (exhaust side) how t o use this char t : i. Measure valve clearance. “engine is cold” ii. Measure present shim size. Iii. Match clearance in vertical column with present shim size in horizontal column. Example v alve clearance is 0.33 mm present shim size 1.70 mm sh...

  • Page 36

    0b-9 maintenance and lubrication: 6) install the camshafts and cam chain tension adjuster. Refer to “engine top side assembly” in section 1d (page 1d-28). 7) rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an...

  • Page 37

    Maintenance and lubrication: 0b-10 fuel line inspection b947h10206008 inspect fuel line every 6 000 km (4 000 miles, 12 months) inspect the fuel line in the following procedures: 1) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). 2) inspect t...

  • Page 38

    0b-11 maintenance and lubrication: 7) hold the motorcycle vertically and check the oil level through the inspection window (3). The oil level should be between the low level “l” and full level “f”. Oil level inspection 1) place the motorcycle on the side-stand. 2) start up the engine and allow it to...

  • Page 39

    Maintenance and lubrication: 0b-12 throttle cable play inspection and adjustment b947h10206011 inspect throttle cable play initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter inspect and adjust the throttle cable play “a” as follows: throttle cable play...

  • Page 40

    0b-13 maintenance and lubrication: engine coolant change refer to “engine coolant description” in section 1f (page 1f-1). Warning ! Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. Engine coolant may be harmful if swallowed or if it comes in...

  • Page 41

    Maintenance and lubrication: 0b-14 clutch cable play inspection and adjustment b947h10206015 inspect clutch cable play every 6 000 km (4 000 miles, 12 months) inspect and adjust the clutch cable play “a” as follows. Clutch cable play “a” 10 – 15 mm (0.4 – 0.6 in) 1) lift and support the fuel tank. R...

  • Page 42

    0b-15 maintenance and lubrication: 2) visually check the drive chain for the possible defects listed as follows. If any defects are found, the drive chain must be replaced. Refer to “drive chain replacement” in section 3a (page 3a-7). • loose pins • damaged rollers • dry or rusted links • kinked or ...

  • Page 43

    Maintenance and lubrication: 0b-16 drive chain cleaning and lubricating b947h10206017 clean and lubricate drive chain every 1 000 km (600 miles) clean and lubricate the drive chain in the following procedures: 1) clean the drive chain with kerosine. If the drive chain tends to rust quickly, the inte...

  • Page 44

    0b-17 maintenance and lubrication: brake pads check the extent of brake pad wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement” in section 4b (page 4b-2) and “rea...

  • Page 45

    Maintenance and lubrication: 0b-18 air bleeding from brake fluid circuit refer to “air bleeding from brake fluid circuit” in section 4a (page 4a-4). Rear brake light switch adjustment refer to “rear brake light switch inspection and adjustment” in section 4a (page 4a-4). Tire inspection b947h1020601...

  • Page 46

    0b-19 maintenance and lubrication: front fork inspection b947h10206021 inspect front fork every 12 000 km (7 500 miles, 24 months) inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. Refer to “front fork di...

  • Page 47

    Maintenance and lubrication: 0b-20 6 brake hose union bolt 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 10 front axle bolt 100 n ⋅m (10.0 kgf-m, 72.5 lbf-ft) 11 front axle pinch bolt 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 12 front brake disc bolt 18 n ⋅m (1.8 kgf-m, 13.0 lbf-ft) 13 front brake caliper mounting bolt 3...

  • Page 48

    0b-21 maintenance and lubrication: compression pressure check b947h10206024 refer to “compression pressure check” in section 1d (page 1d-3). Oil pressure check b947h10206025 refer to “oil pressure check” in section 1e (page 1e- 5). Sds check b947h10206026 refer to “sds check” in section 1a (page 1a-...

  • Page 49

    Maintenance and lubrication: 0b-22 special tools and equipment recommended service material b947h10208001 note required service material is also described in the following. “lubrication points” (page 0b-3) special tool b947h10208002 material suzuki recommended product or specification note brake flu...

  • Page 50: Service Data

    0c-1 service data: general information service data specifications service data b947h10307001 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 31.0 (1.22) — ex. 25.0 (0.98) — valve clearance (when cold) in. 0.08 – 0.18 (0.003 – 0.007) — ex. 0.18 ...

  • Page 51

    Service data: 0c-2 cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit compression pressure 1 400 – 1 800 kpa (14 – 18 kgf/cm 2 , 199 – 256 psi) 1 000 kpa (10 kgf/cm 2 , 142 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , 28 psi) piston-to...

  • Page 52

    0c-3 service data: balancer unit: mm (in) oil pump clutch unit: mm (in) drive train unit: mm (in) except ratio item standard limit balancer shaft journal oil clearance 0.028 – 0.052 (0.0011 – 0.0020) 0.080 (0.0031) balancer shaft journal o.D. 19.992 – 20.000 (0.7871 – 0.7874) — item standard limit o...

  • Page 53

    Service data: 0c-4 thermostat + radiator + cooling fan + coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temperature approx. 82 °c (180 °f) — thermostat valve lift over 8 mm (0.31 in) and at 95 °c (203 °f) — ect sensor resistance 20 °c...

  • Page 54

    0c-5 service data: fi sensors item standard/specification note ckp sensor resistance 142 – 194 Ω ckp sensor peak voltage 0.5 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.7 v at idle speed tp sensor input voltage 4.5 – 5.5 v tp sensor output voltag...

  • Page 55

    Service data: 0c-6 throttle body electrical unit: mm item specification bore size 44 mm (1.73 in) i.D. No. 47h1 (for e-33), 47h0 (for others) idle r/min 1 150 ± 100 r/min throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specification note firing order 1 ⋅ 2 ⋅ 4 ⋅ 3 spark plug type ngk: cr9eia-...

  • Page 56

    0c-7 service data: wattage unit: w brake + wheel unit: mm (in) tire item specification e-02, 19, 24, 51 e-03, 14, 28, 33 headlight hi 65 ← lo 55 ← position light 5 x 2 ← brake light/taillight led ← turn signal light 21 x 4 ← license plate light 5 ← combination meter light led ← turn signal indicator...

  • Page 57

    Service data: 0c-8 suspension unit: mm (in) fuel + oil item standard limit front fork stroke 125 (4.9) — front fork spring free length 241 (9.49) 236 (9.29) front fork oil level (without spring, outer tube fully compressed) 75 (2.95) 70 (2.76) 10 min. After adjustment — front fork oil type suzuki fo...

  • Page 58

    0c-9 service data: tightening torque list b947h10307002 engine item n ⋅m kgf-m lbf-ft exhaust pipe bolt 23 2.3 16.5 muffler chamber connecting bolt 30 3.0 21.5 muffler chamber bracket bolt 25 2.5 18.0 muffler chamber mounting bolt 23 2.3 16.5 muffler connecting bolt 23 2.3 16.5 muffler mounting bolt...

  • Page 59

    Service data: 0c-10 fi system + intake air system cooling system conrod cap bolt 37 n ⋅m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/6 (60 °) turn breather cover bolt 10 1.0 7.0 oil pan bolt 10 1.0 7.0 oil cooler mounting bolt 10 1.0 7.0 driveshaft bearing case bolt (lh and rh) 12 1.2 8.7 driveshaft oil...

  • Page 60

    0c-11 service data: chassis item n ⋅m kgf-m lbf-ft steering stem head nut 90 9.0 65.0 steering stem lock-nut 80 8.0 58.0 steering damper bolt 23 2.3 16.5 steering damper nut 23 2.3 16.5 front fork clamp bolt (upper and lower) 23 2.3 16.5 front fork cap 35 3.5 25.5 front fork piston rod nut 28 2.8 20...

  • Page 61

    Service data: 0c-12 tightening torque chart for other bolts and nuts 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 lbf-ft n ⋅m kgf-m lbf-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 1...

  • Page 62

    0c-13 service data: manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 63: Section 1

    Table of contents 1- i 1 section 1 contents engine precautions .................................................1-1 precautions............................................................. 1-1 precautions for engine.......................................... 1-1 engine general information and diagnos...

  • Page 64

    1-ii table of contents emission control devices ...................... 1b-1 precautions...........................................................1b-1 precautions for emission control devices .......... 1b-1 general description .............................................1b-1 fuel injection system ...

  • Page 65

    Table of contents 1-iii camshaft inspection .........................................1d-36 camshaft sprocket ...........................................1d-38 cam chain tension adjuster inspection...........1d-38 cam chain guide / cam chain tensioner removal and installation.............................

  • Page 66

    1-iv table of contents schematic and routing diagram ....................... 1g-3 fuel tank drain hose and breather hose routing diagram .............................................. 1g-3 diagnostic information and procedures ........... 1g-4 fuel system diagnosis .....................................

  • Page 67

    Table of contents 1-v exhaust system....................................... 1k-1 precautions...........................................................1k-1 precautions for exhaust system ......................... 1k-1 general description .............................................1k-1 exhaust cont...

  • Page 68: Precautions

    1-1 precautions: engine precautions precautions precautions for engine b947h11000001 refer to “general precautions” in section 00 (page 00-1) and “precautions for electrical circuit service” in section 00 (page 00-2). Manuals by motomatrix / the solution for lost motorcycle coded keys email: info@mo...

  • Page 69

    Engine general information and diagnosis: 1a-1 engine engine general information and diagnosis general description injection timing description b947h11101001 injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on th...

  • Page 70

    1a-2 engine general information and diagnosis: 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 descriptions atmospheric pressure sensor signal when atmos...

  • Page 71

    Engine general information and diagnosis: 1a-3 self-diagnosis function b947h11101002 the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi indicator light). To check the ...

  • Page 72

    1a-4 engine general information and diagnosis: dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive sig...

  • Page 73

    Engine general information and diagnosis: 1a-5 combination meter speed sensor cmps ckps tps stps iaps aps ects iats tos ho2s drive mode selector stva isc valve clutch lever position switch starter motor starter relay starter button side-stand switch battery side-stand relay engine stop switch gp swi...

  • Page 74

    1a-6 engine general information and diagnosis: terminal alignment of ecm coupler b947h11102002 i837h1110004-01 terminal no. Circuit terminal no. Circuit 1 excva power (mo+) 37 isc valve signal (isc, 2a) 2 speed sensor signal 38 isc valve signal (isc, 1b) 3 stva signal (stva, 2a) 39 isc valve signal ...

  • Page 75

    Engine general information and diagnosis: 1a-7 component location fi system parts location b947h11103001 “h” “g” “f” “j” “d” “c” “e” “k” “b” “i” “a” i947h1110005-01 “a”: ecm “e”: intake air pressure sensor (iaps) “i”: fuel pump relay (fp relay) “b”: throttle position sensor (tps) “f”: evap system pu...

  • Page 76

    1a-8 engine general information and diagnosis: diagnostic information and procedures engine symptom diagnosis b947h11104001 “o” “s” “t” “u” “l” “r” “m” “y” “z” “n” “v” “a” “p” “q” “w” “x” i947h1110006-01 “a”: ecm “q”: camshaft position sensor (cmps) “w”: atmospheric pressure sensor (aps) “l”: exhaus...

  • Page 77

    Engine general information and diagnosis: 1a-9 engine will not start or is hard to start (incorrect fuel/air mixture) tp sensor out of adjustment. Adjust. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace. Defective tp sensor. Replace. Defective ckp sensor. Replace. Defective ...

  • Page 78

    1a-10 engine general information and diagnosis: noisy engine (noise seems to come from piston) worn down piston or cylinder. Replace. Combustion chamber fouled with carbon. Clean. Worn piston pin or piston pin bore. Replace. Worn piston ring or ring groove. Replace. Noisy engine (noise seems to come...

  • Page 79

    Engine general information and diagnosis: 1a-11 engine runs poorly in high speed range (defective control circuit or sensor) low fuel pressure. Repair or replace. Defective tp sensor. Replace. Defective iat sensors. Replace. Defective cmp sensor. Replace. Defective ckp sensor. Replace. Defective gp ...

  • Page 80

    1a-12 engine general information and diagnosis: self-diagnostic procedures b947h11104002 use of mode select switch note • do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming dtc (diagnostic trouble code) stored in memory. Suc...

  • Page 81

    Engine general information and diagnosis: 1a-13 7) turn the ignition switch off and disconnect the special tool from the mode select switch coupler. 8) reinstall the front seat. Use of sds note • do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from the engine or m...

  • Page 82

    1a-14 engine general information and diagnosis: 4) start the engine or crank the engine for more than 4 seconds. 5) check the dtc to determine the malfunction part. Refer to “dtc table” (page 1a-20). Note • read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the tim...

  • Page 83

    Engine general information and diagnosis: 1a-15 show data when trouble (displaying data at the time of dtc) b947h11104004 use of sds 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 c...

  • Page 84

    1a-16 engine general information and diagnosis: 2) click the drop down button (2), either “failure #1” or “failure #2” can be selected. Sds check b947h11104005 using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by ...

  • Page 85

    Engine general information and diagnosis: 1a-17 sample data sampled from cold starting through warm-up data at 3 000 r/min under no load check the engine r/min. Xxx r/min check the engine coolant temperature. Xx ˚c check the manifold absolute pressure. Xxx kpa i947h1110146-01 check the engine coolan...

  • Page 86

    1a-18 engine general information and diagnosis: data at the time of racing data of intake negative pressure during idling (100 °c) throttle: slowly open pair control solenoid valve on off in according with the throttle valve opens closes throttle: quick wide open secondary throttle valve opens close...

  • Page 87

    Engine general information and diagnosis: 1a-19 data of manifold absolute pressure operation at the time of starting check the manifold absolute pressure. Xxx kpa i947h1110150-01 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 88

    1a-20 engine general information and diagnosis: example of trouble three data; value 3 (current data 3), value 1 (past data 1) and value 2 (past data 2); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been sav...

  • Page 89

    Engine general information and diagnosis: 1a-21 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 indic...

  • Page 90

    1a-22 engine general information and diagnosis: fail-safe function table b947h11104007 fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item fail-safe mode starting ability runnin...

  • Page 91

    Engine general information and diagnosis: 1a-23 the engine can start and can run even if the signal in the table 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 necessary to bring the motor...

  • Page 92

    1a-24 engine general information and diagnosis: visual inspection prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mod...

  • Page 93

    Engine general information and diagnosis: 1a-25 malfunction code and defective condition table b947h11104009 malfunction code 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 s...

  • Page 94

    1a-26 engine general information and diagnosis: c23 to sensor the sensor voltage should be the following for 2 sec. And more, after ignition switch is turned on. 0.2 v ≤ sensor voltage in other than the above value, c23 (p1651) is indicated. To sensor, lead wire/coupler connection p1651 h sensor vol...

  • Page 95

    Engine general information and diagnosis: 1a-27 c41 fp relay no voltage is applied to the fuel pump, although fuel pump relay is turned on, or voltage is applied to fuel pump although fuel pump relay is turned off. Fuel pump relay, lead wire/ coupler connection, power source to fuel pump relay and f...

  • Page 96

    1a-28 engine general information and diagnosis: * : immobilizer system equipped model only. (e-02, 19, 24, 51) c91 vehicle speed sensor speedometer does not receive signal from the vehicle speed sensor for more than 6 sec. When the motorcycle is running. Ecm does not receive signal from the vehicle ...

  • Page 97

    Engine general information and diagnosis: 1a-29 dtc “c11” (p0340): cmp sensor circuit malfunction b947h11104010 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm...

  • Page 98

    1a-30 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) remove the air cleaner box. Refer to “air cleaner box removal and installation” in sect...

  • Page 99

    Engine general information and diagnosis: 1a-31 step action yes no 1 6) under this condition, if a suitable screwdriver touching the pick-up surface of the cmp sensor is moved, the tester reading voltage changes (0.8 v and less ↔ 4.3 v and more). Is the voltage ok? • b/y, r or b/br wire open or shor...

  • Page 100

    1a-32 engine general information and diagnosis: dtc “c12” (p0335): ckp sensor circuit malfunction b947h11104011 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm...

  • Page 101

    Engine general information and diagnosis: 1a-33 step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the ckp sensor coupler (1) for loose or poor contacts. If ok, then measure the ck...

  • Page 102

    1a-34 engine general information and diagnosis: step action yes no 1 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi circuit tester set) ckp sensor continuity ∞Ω (infinity) (b – ground, bl/y– ground) are the resistance and continuity ok? Go ...

  • Page 103

    Engine general information and diagnosis: 1a-35 dtc “c13” (p0105-h/l): iap sensor circuit malfunction b947h11104012 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 104

    1a-36 engine general information and diagnosis: c13 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the iap sensor coupler (1) for loose or poor cont...

  • Page 105

    Engine general information and diagnosis: 1a-37 p0105-h for iap sensor (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the iap sensor coupler (1) for loose or poor ...

  • Page 106

    1a-38 engine general information and diagnosis: step action yes no 1 8) check the continuity between the g/b wire and terminal “19”. If ok, then check the continuity between the b/br wire and terminal “35”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe...

  • Page 107

    Engine general information and diagnosis: 1a-39 p0105-l for iap sensor (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the iap sensor coupler (1) for loose or poor ...

  • Page 108

    1a-40 engine general information and diagnosis: step action yes no 1 8) check the continuity between the r wire and terminal “7”. Also, check the continuity between the g/b wire and terminal “19”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) test...

  • Page 109

    Engine general information and diagnosis: 1a-41 3 1) turn the ignition switch off. 2) connect the ecm couplers and iap sensor coupler. 3) insert the needle pointed probes to the lead wire coupler. 4) run the engine at idle speed and measure the iap sensor output voltage between the g/b wire and b/br...

  • Page 110

    1a-42 engine general information and diagnosis: 4 1) turn the ignition switch off. 2) remove the iap sensor. Refer to “iap sensor removal and installation” in section 1c (page 1c-2). 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. 4) arrange 3 new 1.5 v batteries (1) in series...

  • Page 111

    Engine general information and diagnosis: 1a-43 dtc “c14” (p0120-h/l): tp sensor circuit malfunction b947h11104013 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 112

    1a-44 engine general information and diagnosis: c14 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the tp sensor couplers (1) and (2) for loose or p...

  • Page 113

    Engine general information and diagnosis: 1a-45 p0120-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the tp sensor couplers (1) and (2) for loose or poor contact...

  • Page 114

    1a-46 engine general information and diagnosis: step action yes no 1 7) check the continuity between the p/b wire and terminal “6”. Also, check the continuity between the b/br wire and terminal “35”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) t...

  • Page 115

    Engine general information and diagnosis: 1a-47 p0120-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the tp sensor couplers (1) and (2) for loose or poor contact...

  • Page 116

    1a-48 engine general information and diagnosis: step action yes no 1 7) check the continuity between the p/b wire and terminal “6”. Also, check the continuity between the r wire and terminal “7”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) teste...

  • Page 117

    Engine general information and diagnosis: 1a-49 3 1) turn the ignition switch off. 2) connect the ecm couplers and tp sensor couplers. 3) insert the needle point probes to the lead wire coupler. 4) turn the ignition switch on. 5) measure the tp sensor output voltage between the p/b wire (+) and b/br...

  • Page 118

    1a-50 engine general information and diagnosis: dtc “c15” (p0115-h/l): ect sensor circuit malfunction b947h11104014 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 119

    Engine general information and diagnosis: 1a-51 c15 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the ect sensor coupler (1) for loose or poor c...

  • Page 120

    1a-52 engine general information and diagnosis: p0115-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the ect sensor coupler (1) for loose or poor contacts. If...

  • Page 121

    Engine general information and diagnosis: 1a-53 p0115-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the ect sensor coupler (1) for loose or poor contacts. If...

  • Page 122

    1a-54 engine general information and diagnosis: step action yes no 1 9) measure the output voltage between the b/bl wire and ground. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication voltage ( ) ect sensor output voltage 0.15 – ...

  • Page 123

    Engine general information and diagnosis: 1a-55 dtc “c21” (p0110-h/l): iat sensor circuit malfunction b947h11104015 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 124

    1a-56 engine general information and diagnosis: c21 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) move the air cleaner box upward. Refer to “air cleaner ...

  • Page 125

    Engine general information and diagnosis: 1a-57 p0110-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) move the air cleaner box upward. Refer to “air cleaner box removal...

  • Page 126

    1a-58 engine general information and diagnosis: p0110-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) move the air cleaner box upward. Refer to “air cleaner box removal...

  • Page 127

    Engine general information and diagnosis: 1a-59 step action yes no 1 10) measure the output voltage between the dg wire and ground. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication voltage ( ) iat sensor output voltage 0.15 – 4...

  • Page 128

    1a-60 engine general information and diagnosis: dtc “c22” (p1450-h/l): ap sensor circuit malfunction b947h11104016 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 129

    Engine general information and diagnosis: 1a-61 c22 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) remove the starter relay from the bracket. 4) check the ap ...

  • Page 130

    1a-62 engine general information and diagnosis: p1450-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) remove the starter relay from the bracket. 4) check the ap sensor coup...

  • Page 131

    Engine general information and diagnosis: 1a-63 step action yes no 1 9) check the continuity between the g/y wire and terminal “20”. If ok, then check the continuity between the b/br wire and terminal “35”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe...

  • Page 132

    1a-64 engine general information and diagnosis: p1450-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) remove the starter relay from the bracket. 4) check the ap sensor coup...

  • Page 133

    Engine general information and diagnosis: 1a-65 step action yes no 1 9) check the continuity between the r wire and terminal “7”. Also, check the continuity between the g/y wire and terminal “20”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) test...

  • Page 134

    1a-66 engine general information and diagnosis: 3 1) turn the ignition switch off. 2) connect the ecm couplers and ap sensor coupler. 3) insert the needle pointed probes to the lead wire coupler. 4) run the engine at idle speed and measure the ap sensor output voltage between the g/y wire and b/br w...

  • Page 135

    Engine general information and diagnosis: 1a-67 4 1) turn the ignition switch off. 2) remove the ap sensor. Refer to “ap sensor removal and installation” in section 1c (page 1c-5). 3) connect the vacuum pump gauge to the vacuum port of the ap sensor. 4) arrange 3 new 1.5 v batteries in series (1) (c...

  • Page 136

    1a-68 engine general information and diagnosis: dtc “c23” (p1651-h/l): to sensor circuit malfunction b947h11104017 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 137

    Engine general information and diagnosis: 1a-69 c23 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) remove the ap sensor from the bracket. 4) check the to sens...

  • Page 138

    1a-70 engine general information and diagnosis: p1651-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the to sensor coupler (1) for loose or poor contacts. If ok, the...

  • Page 139

    Engine general information and diagnosis: 1a-71 step action yes no 1 8) check the continuity between the b wire and terminal “31”. Also, check the continuity between b/br wire and terminal “35”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester...

  • Page 140

    1a-72 engine general information and diagnosis: p1651-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the to sensor coupler (1) for loose or poor contacts. If ok, the...

  • Page 141

    Engine general information and diagnosis: 1a-73 step action yes no 1 8) check the continuity between the r wire and terminal “7”. Also, then check the continuity between b wire and terminal “31”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) teste...

  • Page 142

    1a-74 engine general information and diagnosis: 2 1) connect the ecm coupler and to sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage at the wire side coupler between b wire and b/br wire. Special tool (a): 09900–2500...

  • Page 143

    Engine general information and diagnosis: 1a-75 dtc “c24” (p0351), “c25” (p0352), “c26” (p0353) or “c27” (p0354): ignition system malfunction b947h11104018 note refer to “no spark or poor spark” in section 1h (page 1h-5) for details. Dtc “c28” (p1655): secondary throttle valve actuator (stva) malfun...

  • Page 144

    1a-76 engine general information and diagnosis: step action yes no 1 1) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 2) remove the air cleaner box cover. Refer to “air cleaner element removal and installation” in section 1d (page 1d-6). 3) ...

  • Page 145

    Engine general information and diagnosis: 1a-77 2 1) turn the ignition switch off. 2) disconnect the stva lead wire coupler. 3) check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication resistance ( Ω) stva continuity ∞Ω (i...

  • Page 146

    1a-78 engine general information and diagnosis: active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “secondary throttle operating control” (1). 4) click each button (2). At this time, if an operation soun...

  • Page 147

    Engine general information and diagnosis: 1a-79 dtc “c29” (p1654-h/l): secondary throttle position sensor (stps) circuit malfunction b947h11104020 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not str...

  • Page 148

    1a-80 engine general information and diagnosis: c29 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the stp sensor couplers (1) and (2) for loose or ...

  • Page 149

    Engine general information and diagnosis: 1a-81 p1654-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the stp sensor couplers (1) and (2) for loose or poor contac...

  • Page 150

    1a-82 engine general information and diagnosis: step action yes no 1 7) check the continuity between the y/w wire and terminal “18”. Also, check the continuity between the b/br wire and terminal “35”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) ...

  • Page 151

    Engine general information and diagnosis: 1a-83 p1654-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the stp sensor couplers (1) and (2) for loose or poor contac...

  • Page 152

    1a-84 engine general information and diagnosis: step action yes no 1 7) check the continuity between the y/w wire and terminal “18”. Also, check the continuity between the r wire and terminal “7”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) test...

  • Page 153

    Engine general information and diagnosis: 1a-85 3 1) turn the ignition switch off. 2) connect the ecm couplers and stp sensor couplers. 3) remove the air cleaner box cover. Refer to “air cleaner element removal and installation” in section 1d (page 1d-6). 4) disconnect the stva lead wire coupler (1)...

  • Page 154

    1a-86 engine general information and diagnosis: dtc “c31” (p0705): gp switch circuit malfunction b947h11104021 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm ...

  • Page 155

    Engine general information and diagnosis: 1a-87 step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the gp switch coupler (1) for loose or poor contacts. If ok, then measure the gp ...

  • Page 156

    1a-88 engine general information and diagnosis: dtc “c32” (p0201), “c33” (p0202), “c34” (p0203) or “c35” (p0204): primary fuel injector circuit malfunction b947h11104022 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-cir...

  • Page 157

    Engine general information and diagnosis: 1a-89 step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the primary fuel injector coupler (1) for loose or poor contacts. If ok, then mea...

  • Page 158

    1a-90 engine general information and diagnosis: step action yes no 1 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi circuit tester set) injector continuity ∞Ω (infinity) are the resistance and continuity ok? Go to step 2. Replace the inject...

  • Page 159

    Engine general information and diagnosis: 1a-91 dtc “c36” (p1764), “c37” (p1765), “c38” (p1766) or “c39” (p1767): secondary fuel injector circuit malfunction b947h11104023 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-c...

  • Page 160

    1a-92 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the secondary fuel injector coupler (1) for loose or poor contacts. If ok, then m...

  • Page 161

    Engine general information and diagnosis: 1a-93 step action yes no 1 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi circuit tester set) injector continuity ∞Ω (infinity) are the resistance and continuity ok? Go to step 2. Replace the inject...

  • Page 162

    1a-94 engine general information and diagnosis: dtc “c40” (p0505 / p0506 / p0507): isc valve circuit malfunction b947h11104024 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! • be careful not to disconnect the isc valve coupler at least 5 sec...

  • Page 163

    Engine general information and diagnosis: 1a-95 step action yes no 1 1) turn the ignition switch off. 2) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (page 1d-7). 3) check the isc valve coupler (1) for loose or poor contacts. If ok, then check the isc...

  • Page 164

    1a-96 engine general information and diagnosis: 2 1) check the continuity between each isc valve terminal and ground. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication resistance ( Ω) isc valve continuity ∞Ω (infinity) (terminal – ground) 2) if ok, then measure the resi...

  • Page 165

    Engine general information and diagnosis: 1a-97 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” (1). 5) check that t...

  • Page 166

    1a-98 engine general information and diagnosis: check 4 1) click the button (6) and increase the “spec” (2) to 1 900 rpm. 2) check that the “desired idle speed” (3) is approx. 1 900 rpm. 3) check that the “engine speed” (7) is close to 1 900 rpm. Note be careful not to increase the “spec” to 2 000 r...

  • Page 167

    Engine general information and diagnosis: 1a-99 troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent terminal damage. Note after repairing the trouble, clear the dtc using sds tool. Refer to...

  • Page 168

    1a-100 engine general information and diagnosis: p0230-h (use of sds) p0230-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the frame covers. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the fp relay coupler (1) for loose or po...

  • Page 169

    Engine general information and diagnosis: 1a-101 dtc “c41” (p2505): ecm power input signal malfunction b947h11104026 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of th...

  • Page 170

    1a-102 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the ecm coupler for loose or poor contacts. If ok, then measure the ecm input voltag...

  • Page 171

    Engine general information and diagnosis: 1a-103 dtc “c42” (p1650): ig switch circuit malfunction b947h11104027 detected condition and possible cause troubleshooting note • refer to “ignition switch inspection” in section 9c (page 9c-7) for details. • after repairing the trouble, clear the dtc using...

  • Page 172

    1a-104 engine general information and diagnosis: troubleshooting (when indicating c44/p0130:) caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent terminal damage. Note after repairing the trouble, clear th...

  • Page 173

    Engine general information and diagnosis: 1a-105 step action yes no 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation” in section 1c (page 1c-1). 7) check the continuity between the w/g wire and terminal “34”. Also, check the continuity between the b/br wire and terminal “35”. ...

  • Page 174

    1a-106 engine general information and diagnosis: 2 1) connect the ecm coupler and ho2 sensor coupler. 2) warm up the engine enough. 3) insert the needle pointed probes to the lead wire coupler. 4) measure the ho2 sensor output voltage between the w/ g (b) wire and b/br (gr) wire, in idling condition...

  • Page 175

    Engine general information and diagnosis: 1a-107 troubleshooting (when indicating c44/p0135:) note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures” (page 1a-14). Step action yes no 1 1) turn the ignition switch off. 2) lift and support the f...

  • Page 176

    1a-108 engine general information and diagnosis: 2 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on and measure the heater voltage between the w/b wire and ground. If the tester voltage indicates the battery voltage, it i...

  • Page 177

    Engine general information and diagnosis: 1a-109 dtc “c46” (p1657-h/l or p1658): excv actuator circuit malfunction b947h11104029 wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needl...

  • Page 178

    1a-110 engine general information and diagnosis: c46 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the excva coupler (1) for loose or poor conta...

  • Page 179

    Engine general information and diagnosis: 1a-111 p1657-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the excva coupler (1) for loose or poor contacts. If ok,...

  • Page 180

    1a-112 engine general information and diagnosis: step action yes no 1 8) also, check the continuity between b/br wire and terminal “35”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication continuity ( ) excva lead wire continuity...

  • Page 181

    Engine general information and diagnosis: 1a-113 p1657-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) check the excva coupler (1) for loose or poor contacts. If ok,...

  • Page 182

    1a-114 engine general information and diagnosis: p1658 (use of sds) step action yes no 1 9) also, check the continuity between r wire and terminal “7”. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication continuity ( ) excva lead ...

  • Page 183

    Engine general information and diagnosis: 1a-115 2 1) turn the ignition switch off. 2) check the installation of excv cables. If it is necessary, adjust the excv cables. Refer to “excv cable removal and installation” in section 1k (page 1k-6). 3) disconnect the excva coupler (1). 4) turn the ignitio...

  • Page 184

    1a-116 engine general information and diagnosis: 3 1) turn the ignition switch off. 2) check the continuity between y wire and ground. Special tool (a): 09900–25008 (multi circuit tester set) excva position sensor continuity ∞Ω (infinity) 3) if ok, then measure the excva position sensor resistance. ...

  • Page 185

    Engine general information and diagnosis: 1a-117 4 1) turn the ignition switch off. 2) connect the excva coupler. 3) set up the sds tools. Refer to “self-diagnostic procedures” (page 1a-12). 4) turn the ignition switch on. 5) click “exhaust valve operating control” (1). 6) click “full closed” (2). 7...

  • Page 186

    1a-118 engine general information and diagnosis: 4 9) click “full opened” (4). 10) measure the excva position sensor output voltage at excv fully opened position. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) excva position sensor output voltage e...

  • Page 187

    Engine general information and diagnosis: 1a-119 5 1) if the excva position sensor output voltage is 0.45 v and less at excv fully closed position, adjust the output voltage to the specified value by turning the no. 1 cable adjuster (1). Refer to “excv cable removal and installation” in section 1k (...

  • Page 188

    1a-120 engine general information and diagnosis: 6 1) turn the ignition switch off. 2) disconnect the excva coupler (1). 3) apply 12 v to the terminals and check the operation of excva. 4) then, switch the wires supplied 12 v and check the operation of excva. (check the operation of excva in both wa...

  • Page 189

    Engine general information and diagnosis: 1a-121 dtc “c49” (p1656): pair control solenoid valve circuit malfunction b947h11104030 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the t...

  • Page 190

    1a-122 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (page 1d-7). 3) check the pair control solenoid valve coupler (1) for loose or poor contacts. If ok,...

  • Page 191

    Engine general information and diagnosis: 1a-123 active control inspection 1) set up the sds tool. (refer to sds operation manual for further details.) 2) turn the ignition switch on. 3) click “pair sol operating control” (1). 4) click each button (2). At this time, if an operating sound is heard fr...

  • Page 192

    1a-124 engine general information and diagnosis: dtc “c60” (p0480): cooling fan relay circuit malfunction b947h11104031 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of...

  • Page 193

    Engine general information and diagnosis: 1a-125 active control inspection 1) set up the sds tool. (refer to sds operation manual for further details.) 2) start the engine and run it in idling condition. 3) click “cooling fan relay control” (1). Step action yes no 1 1) turn the ignition switch off. ...

  • Page 194

    1a-126 engine general information and diagnosis: 4) click the “operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. Note the cooling fan relay and cooling fan motor inspection is operational at any engine c...

  • Page 195

    Engine general information and diagnosis: 1a-127 dtc “c62” (p0443): evap system purge control solenoid valve circuit malfunction (e-33 only) b947h11104032 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do...

  • Page 196

    1a-128 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the evap system purge control valve coupler (1) for loose or poor contacts. If o...

  • Page 197

    Engine general information and diagnosis: 1a-129 2 1) turn the ignition switch on. 2) measure the voltage between the o/w wire and ground. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication voltage ( ) evap system purge control valve voltage battery voltage ((+) terminal...

  • Page 198

    1a-130 engine general information and diagnosis: active control inspection 1) set up the sds tool. (refer to sds operation manual for further details.) 2) turn the ignition switch on. 3) click “evap purge valve operating control” (1). 4) click each button (2). At this time, if an operating sound is ...

  • Page 199

    Engine general information and diagnosis: 1a-131 dtc “c91” (p0500): vehicle speed sensor circuit malfunction b947h11104033 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal...

  • Page 200

    1a-132 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) check the speed sensor coupler (1) for loose or poor contacts. If ok, remove the speed...

  • Page 201

    Engine general information and diagnosis: 1a-133 step action yes no 1 5) under this condition, if a suitable screwdriver touching the pick-up surface of the speed sensor is moved, the tester reading voltage changes (0 v → 12 v or 12 v → 0 v). If the tester reading voltage does not change, replace th...

  • Page 202

    1a-134 engine general information and diagnosis: dtc “c93” (p1769): steering damper solenoid valve circuit malfunction b947h11104034 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch th...

  • Page 203

    Engine general information and diagnosis: 1a-135 step action yes no 1 1) turn the ignition switch off. 2) check the steering damper solenoid valve coupler (1) for loose or poor contacts. If ok, then measure the steering damper solenoid valve resistance. 3) disconnect the steering damper solenoid val...

  • Page 204

    1a-136 engine general information and diagnosis: 2 1) turn the ignition switch on. 2) measure the voltage between b/bl wire and ground. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication voltage ( ) steering damper solenoid valve voltage approx. 10 v when battery is full...

  • Page 205

    Engine general information and diagnosis: 1a-137 active control inspection 1) set up the sds tool. (refer to sds operation manual for further details.) 2) raise the front wheel off the ground. 3) turn the ignition switch on. 4) click “steering damper solenoid operating control” (1). 5) click each bu...

  • Page 206

    1a-138 engine general information and diagnosis: specifications service data b947h11107001 injector + fuel pump + fuel pressure regulator fi sensors item specification note injector resistance 11 – 13 Ω at 20 °c (68 °f) item standard/specification note ckp sensor resistance 142 – 194 Ω ckp sensor pe...

  • Page 207

    Engine general information and diagnosis: 1a-139 special tools and equipment special tool b947h11108001 09900–25008 )(page 1a-59) / )(page 1a-59) / )(page 1a-61) / )(page 1a-62) / )(page 1a-63) / )(page 1a-64) / )(page 1a-65) / )(page 1a-65) / )(page 1a-66) / )(page 1a-67) / )(page 1a-69) / )(page 1...

  • Page 208

    1a-140 engine general information and diagnosis: 09930–82720 99565–01010–020 mode selection switch cd-rom ver.20 )(page 1a-4) / )(page 1a- 12) / )(page 1a-12) )(page 1a-13) / )(page 1a-16) manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatr...

  • Page 209: Emission Control Devices

    Emission control devices: 1b-1 engine emission control devices precautions precautions for emission control devices b947h11200001 refer to “general precautions” in section 00 (page 00-1). General description fuel injection system description b947h11201001 gsx-r1000 motorcycles are equipped with a fu...

  • Page 210

    1b-2 emission control devices: crankcase emission control system description b947h11201002 the engine is equipped with a pcv system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion ch...

  • Page 211

    Emission control devices: 1b-3 exhaust emission control system description b947h11201003 the exhaust emission control system is composed of the pair system, exhaust control system, ho2 sensor, three- way catalyst system and isc system. The fresh air is drawn into the exhaust ports through the pair c...

  • Page 212

    1b-4 emission control devices: pair system diagram b947h11201006 noise emission control system description b947h11201004 tampering with the noise control system prohibited: local law or federal law prohibits the following acts or the causing thereof: • the removal or rendering inoperative by any per...

  • Page 213

    Emission control devices: 1b-5 among those acts presumed to constitute tampering are the acts listed below: • removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases. • removing or puncturing the air clea...

  • Page 214

    1b-6 emission control devices: schematic and routing diagram pair system hose routing diagram b947h11202001 1 2 “c” “d” “e” “b” “b” “ b ” “ a ” “ b ” “ b ” “ c ” “f” “a” i947h1120006-03 1. Pair control solenoid valve “c”: blue marking “a”: 90 ° 2. Pair reed valve “d”: red marking “b”: 45 ° “a”: whit...

  • Page 215

    Emission control devices: 1b-7 evap canister hose routing diagram (only for e-33) b947h11202002 1 1 2 2 2 2 2 2 3 3 3 3 3 3 5 1 6 6 6 7 “j” “d” “e” 4 “i” “b” “a” “a” “c” “l” “h” “g” “f” “k” i947h1120007-03 1. Evap system purge control solenoid valve “a”: white marking “h”: stick the clamp firmly in ...

  • Page 216

    1b-8 emission control devices: repair instructions heated oxygen sensor (ho2s) removal and installation b947h11206001 removal warning ! Do not remove the ho2 sensor while it is hot. Caution ! • be careful not to expose the ho2 sensor to excessive shock. • do not use an impact wrench when removing or...

  • Page 217

    Emission control devices: 1b-9 4) remove the pair reed valves (3). Installation install the pair reed valve in the reverse order of removal. Pay attention to the following points: • apply thread lock to the pair reed valve cover bolts and tighten them to the specified torque. : thread lock cement 99...

  • Page 218

    1b-10 emission control devices: 3) inspect the pair hoses for wear or damage. If it is worn or damaged, replace the pair hose with a new one. Refer to “pair system hose routing diagram” (page 1b-6). 4) reinstall the removed parts. Pair reed valve 1) remove the pair reed valves. Refer to “pair reed v...

  • Page 219

    Emission control devices: 1b-11 crankcase breather (pcv) hose inspection b947h11206006 inspect the crankcase breather (pcv) hose in the following procedures: 1) lift and support the fuel tank with the prop stay. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 2) inspect the ...

  • Page 220

    1b-12 emission control devices: crankcase breather (pcv) cover inspection b947h11206008 inspect the crankcase breather (pcv) cover in the following procedures: 1) remove the crankcase breather (pcv) cover. Refer to “crankcase breather (pcv) hose / reed valve / cover removal and installation” (page 1...

  • Page 221

    Emission control devices: 1b-13 installation install the evap system purge control solenoid valve in the reverse order of removal. Pay attention to the following point: • tighten the evap system purge control solenoid valve mounting nut to the specified torque. Tightening torque evap system purge co...

  • Page 222

    1b-14 emission control devices: 11) disconnect the surge hose (9). 12) move the rear fender (front) backward. 13) disconnect the surge hose (10). 14) remove the bracket (11) and fuel shaft-off valve (12). Installation install the fuel shut-off valve in the reverse order of removal. Pay attention to ...

  • Page 223

    Emission control devices: 1b-15 3) check the resistance between the terminals of the evap system purge control solenoid valve. If the resistance is not within the standard range, replace the evap system purge control solenoid valve with a new one. Special tool (a): 09900–25008 (multi circuit tester ...

  • Page 224

    1b-16 emission control devices: specifications service data b947h11207001 fi sensors tightening torque specifications b947h11207002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c (page 0c-9). Special tools and equipment...

  • Page 225: Engine Electrical Devices

    Engine electrical devices: 1c-1 8engine engine electrical devices precautions precautions for engine electrical device b947h11300001 refer to “general precautions” in section 00 (page 00-1) and “precautions for electrical circuit service” in section 00 (page 00-2). Component location engine electric...

  • Page 226

    1c-2 engine electrical devices: cmp sensor inspection b947h11306002 refer to “dtc “c11” (p0340): cmp sensor circuit malfunction” in section 1a (page 1a-29). Cmp sensor removal and installation b947h11306003 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation” in...

  • Page 227

    Engine electrical devices: 1c-3 tp sensor removal and installation b947h11306009 refer to “throttle body disassembly and assembly” in section 1d (page 1d-11). Removal 1) remove the throttle body. Refer to “throttle body removal and installation” in section 1d (page 1d- 10). 2) remove the tp sensor (...

  • Page 228

    1c-4 engine electrical devices: ect sensor removal and installation b947h11306011 removal 1) remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 2) drain engine coolant. Refer to “cooling system inspection” in section 0b (page 0b-12). 3) discon...

  • Page 229

    Engine electrical devices: 1c-5 iat sensor removal and installation b947h11306013 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (page 1d-7). 2) remove the iat sensor (1) from the air cleaner box. Installation install the iat sensor in the re...

  • Page 230

    1c-6 engine electrical devices: to sensor removal and installation b947h11306018 removal 1) remove the ap sensor. Refer to “ap sensor removal and installation” (page 1c-5). 2) disconnect the coupler (1) and remove the to sensor (2). Installation install the to sensor in the reverse order of removal....

  • Page 231

    Engine electrical devices: 1c-7 8) tighten the stp sensor mounting screw to the specified torque. Tightening torque stp sensor mounting screw: 3.5 n·m (0.35 kgf- m, 2.5 lbf-ft) 9) reinstall the removed parts. Stp sensor removal and installation b947h11306021 removal 1) remove the throttle body. Refe...

  • Page 232

    1c-8 engine electrical devices: isc valve preset and opening initialization b947h11306026 when removing or replacing the isc valve, set the isc valve to the following procedures: 1) turn the ignition switch on. 2) set up the sds tool. (refer to the sds operation manual for further details.) 3) click...

  • Page 233

    Engine electrical devices: 1c-9 specifications service data b947h11307001 fi sensors tightening torque specifications b947h11307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c (page 0c-9). Item standard/specification...

  • Page 234

    1c-10 engine electrical devices: special tools and equipment special tool b947h11308001 09900–25008 09900–25009 multi circuit tester set needle-point probe set )(page 1c-4) / )(page 1c- 6) )(page 1c-6) 09930–11950 09930–82720 torx wrench (5 mm) mode selection switch )(page 1c-3) / )(page 1c- 3) / )(...

  • Page 235: Engine Mechanical

    Engine mechanical: 1d-1 engine engine mechanical schematic and routing diagram camshaft and sprocket assembly diagram b947h11402001 i947h1140249-02 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 236

    1d-2 engine mechanical: throttle cable routing diagram b947h11402002 1 1 1 2 2 2 3 3 3 3 “c” 4 “ a ” “ a ” “ a ” “a” 3 (a) (a) “b” “d” 2 1 i947h1140250-02 1. Throttle cable no. 1 “b”: pass the clutch cable above the right air intake pipe. 2. Throttle cable no. 2 “c”: clamp the clutch cable at the wh...

  • Page 237

    Engine mechanical: 1d-3 diagnostic information and procedures engine mechanical symptom diagnosis b947h11404001 refer to “engine symptom diagnosis” in section 1a (page 1a-8). Compression pressure check b947h11404002 the compression pressure reading of a cylinder is a good indicator of its internal c...

  • Page 238

    1d-4 engine mechanical: repair instructions engine components removable with the engine in place b947h11406001 engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each ...

  • Page 239

    Engine mechanical: 1d-5 engine right side item removal inspection installation cam chain tension adjuster refer to “engine top side disassembly” (page 1d-26). Refer to “cam chain tension adjuster inspection” (page 1d-38). Refer to “engine top side assembly” (page 1d-28). Clutch cover refer to “clutc...

  • Page 240

    1d-6 engine mechanical: engine left side air cleaner element removal and installation b947h11406002 removal 1) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). 2) remove the air cleaner box cover (1). 3) remove the air cleaner element (2). Ins...

  • Page 241

    Engine mechanical: 1d-7 air cleaner box removal and installation b947h11406003 removal 1) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). 2) remove the air cleaner box cover. Refer to “air cleaner element removal and installation” (page 1d-6)...

  • Page 242

    1d-8 engine mechanical: throttle body components b947h11406008 [a] 1 1 2 3 3 3 3 3 3 3 5 6 7 8 9 11 10 4 (a) (a) (a) (a) (b) 8 12 (d) (c) fwd fwd i947h1140252-03 1. Fuel delivery pipe 6. Secondary fuel injector 11. Vacuum hose : 6.5 nm (0.65 kgf-m, 4.5 lbf-ft) 2. Fuel delivery pipe t-joint 7. Primar...

  • Page 243

    Engine mechanical: 1d-9 throttle body construction b947h11406009 1 2 3 5 “i” “c” “d” “g” “e” “f” 4 “h” “h” “a” “g” (a) (b) (c) (d) (d) (d) (e) (f) fwd “k” “b” “7” “1” “1” “6” “3” “2” “2” “3” “4” “4” “6” “5” “5” “j” (g) 6 i947h1140253-03 1. Intake pipe “c”: face the end of clamps upward and keep clea...

  • Page 244

    1d-10 engine mechanical: throttle body removal and installation b947h11406010 removal 1) remove the side cowlings. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). 2) remove the air cleaner box. Refer to “air cleaner box removal and installation” (page 1d-7). 3) remove ...

  • Page 245

    Engine mechanical: 1d-11 14) disconnect the throttle cables. Caution ! After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body. 15) remove the throttle body. Installation installation is in the ...

  • Page 246

    1d-12 engine mechanical: 2) disconnect the purge hose (4). (e-33 only) 3) remove the fuel delivery pipe assembly (5). Caution ! Be careful not to twist the fuel delivery pipes and t-joint (6) when removing them, or joint part “a” of the fuel delivery pipe get damage. 4) remove the primary fuel injec...

  • Page 247

    Engine mechanical: 1d-13 8) remove the tp sensor (12) and stp sensor (13) with the special tool. Special tool : 09930–11950 (torx wrench (5 mm)) note prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. Caution ! Never remove the stva (14) fr...

  • Page 248

    1d-14 engine mechanical: note • make sure the secondary throttle valves smoothly open and close. • if necessary, adjust the stp sensor. Refer to “stp sensor adjustment” in section 1c (page 1c-6). • with the throttle valves fully closed, install the tp sensor (gray) and tighten the tp sensor mounting...

  • Page 249

    Engine mechanical: 1d-15 • apply thin coat of engine oil to the new o-rings (1) and cushion seals (2). Caution ! Replace the o-rings and cushion seals with new ones. • assemble the fuel delivery pipes so the t-joint is set in proper angle as shown in the figure. Caution ! Be careful not to twist the...

  • Page 250

    1d-16 engine mechanical: throttle body inspection and cleaning b947h11406012 refer to “throttle body disassembly and assembly” (page 1d-11). Cleaning warning ! Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow t...

  • Page 251

    Engine mechanical: 1d-17 5) disconnect the respective vacuum hoses (2) from vacuum nipples on the throttle body. 6) disconnect the iap sensor coupler (3). 7) connect the respective vacuum tester hoses (4) to the vacuum nipples. 8) set up the sds tool. (refer to the sds operation manual for further d...

  • Page 252

    1d-18 engine mechanical: 15) check for the synchronization of vacuum from #1 to #4 cylinders. 16) equalize the vacuum of the cylinders by turning each air screw (7) and keep it running at idling speed. Note always set the engine rpm at idle rpm. 17) if the adjustment is not yet correct, remove each ...

  • Page 253

    Engine mechanical: 1d-19 note the learned value of the isc valve is set at reset position. 6) close the sds tool. 7) turn the ignition switch off position. Note the isc valve opening initialization is automatically started after the ignition switch is turned off. Tp reset b947h11406016 when replacin...

  • Page 254

    1d-20 engine mechanical: engine assembly removal b947h11406017 before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps: 1) remove the side cowlings. Refer to “exterior parts removal and installation” in section...

  • Page 255

    Engine mechanical: 1d-21 15) remove the exhaust system components. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k (page 1k-11). 16) remove the clamp (7). 17) disconnect the oil pressure switch lead wire coupler (8), generator lead wire coupler (9) and ect ...

  • Page 256

    1d-22 engine mechanical: 25) remove the engine sprocket cover (19). Refer to “engine sprocket removal and installation” in section 3a (page 3a-2). 26) remove the dowel pins and clutch push rod (20). 27) remove the engine sprocket (21). Refer to “engine sprocket removal and installation” in section 3...

  • Page 257

    Engine mechanical: 1d-23 34) loosen the engine mounting thrust adjuster (27) fully. Special tool (a): 09940–14990 (engine mounting adjust wrench) note do not remove the engine mounting bolt at this stage. 35) remove the engine mounting nut (28). 36) loosen the engine mounting thrust adjuster lock-nu...

  • Page 258

    1d-24 engine mechanical: engine assembly installation b947h11406018 install the engine in the reverse order of engine removal. Pay attention to the following points: • before installing the engine, install the collars (1). • before installing the engine, install the engine mounting thrust adjusters ...

  • Page 259

    Engine mechanical: 1d-25 • tighten all engine mounting bolts and nuts to the specified torque, as shown in the following illustration. Note the engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. • tighten the engine mounting pinch bolt to the speci...

  • Page 260

    1d-26 engine mechanical: • install the engine sprocket. Refer to “engine sprocket removal and installation” in section 3a (page 3a-2). • install the exhaust pipe assembly and muffler. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k (page 1k-11). • install t...

  • Page 261

    Engine mechanical: 1d-27 camshafts 1) remove the valve timing inspection cap (1). 2) turn the crankshaft to bring the line “a” on the ckp sensor rotor to the slit “b” of cap hole thread and also to bring the camshafts to the position as shown. 3) remove the cam chain tension adjuster (2). 4) remove ...

  • Page 262

    1d-28 engine mechanical: 8) remove the intake camshaft (6) and exhaust camshaft (7). Cylinder head note the cylinder head can not be serviced with the engine installed in the frame. 1) disconnect the water bypass hose (1). 2) remove the cylinder head bolts (m6) (2). 3) remove the cylinder head bolts...

  • Page 263

    Engine mechanical: 1d-29 • place the cylinder head on the gasket. Note • when installing the cylinder head, keep the cam chain taut. • apply engine oil to the washer and thread portion of the cylinder head bolts (m10) before tightening them. • tighten the cylinder head bolts (m10) to the specified t...

  • Page 264

    1d-30 engine mechanical: • turn the crankshaft clockwise and align the line “a” on the ckp sensor rotor to the slit “b” of cap hole thread while keeping the cam chain pulled upward. Caution ! • pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. • to adju...

  • Page 265

    Engine mechanical: 1d-31 • install the dowel pins. • install the camshaft journal holders and cam chain guide no. 2 (3). • have the camshaft journal holders seated evenly by tightening the camshaft journal holder bolts lightly, in the ascending order of numbers. Note • damage to head or camshaft jou...

  • Page 266

    1d-32 engine mechanical: • remove the clamps. Cam chain tension adjuster • holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body until the outer circlip “a” reaches the groove “b”. Caution ! Do not turn the adjuster body until the outer circ...

  • Page 267

    Engine mechanical: 1d-33 • hook the outer circlip “a” into the groove “b”, then turn the plunger head clockwise more than 90 ° to make a little play in the inner thread mechanism. • fit a new gasket (1). Caution ! Use a new gasket to prevent oil leakage. • install the cam chain tension adjuster (2)....

  • Page 268

    1d-34 engine mechanical: • tighten the cam chain tension adjuster service cap (6) to the specified torque. Caution ! Use a new gasket to prevent oil leakage. Tightening torque cam chain tension adjuster service cap (b): 23 n·m (2.3 kgf-m, 16.5 lbf-ft) • tighten the valve timing inspection cap (7) to...

  • Page 269

    Engine mechanical: 1d-35 • tighten the cylinder head cover bolts to the specified torque in two steps. Tightening torque cylinder head cover bolt (initial): 10 n·m (1.0 kgf- m, 7.0 lbf-ft) cylinder head cover bolt (final): 14 n·m (1.4 kgf- m, 10.0 lbf-ft) • install the spark plugs. Refer to “ignitio...

  • Page 270

    1d-36 engine mechanical: • apply thread lock to the pair reed valve cover bolts (2) and tighten them to the specified torque. : thread lock cement 99000–32110 (thread lock cement super “1322” or equivalent) tightening torque pair reed valve cover bolt (b): 10 n·m (1.0 kgf-m, 7.0 lbf-ft) • fit new ga...

  • Page 271

    Engine mechanical: 1d-37 camshaft runout measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit. Special tool (a): 09900–20607 (dial gauge) (b): 09900–20701 (dial gauge chuck) (c): 09900–21304 (v blocks) camshaft runout (in. & ex.) service limit: 0.10 mm (0.004...

  • Page 272

    1d-38 engine mechanical: 7) if the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification. Special tool...

  • Page 273

    Engine mechanical: 1d-39 3) hook the outer circlip “a” into the groove “b”, then turn the plunger head clockwise more than 90 ° to make a little play in the inner thread mechanism. Note if it is difficult to compress the plunger because of internal engine oil, disassemble the adjuster by releasing t...

  • Page 274

    1d-40 engine mechanical: installation install the cam chain guides/cam chain tensioner in the reverse order of removal. Cam chain guide inspection b947h11406025 inspect the cam chain guide in the following procedures: 1) remove the cam chain guides. Refer to “cam chain guide / cam chain tensioner re...

  • Page 275

    Engine mechanical: 1d-41 5) pull out the valve (6) from the combustion chamber side. 6) remove the oil seal (7) and spring seat (8). 7) remove the other valves in the same manner as described previously. 8) remove the ect sensor (9). 9) remove the thermostat cover (10). 10) remove the thermostat (11...

  • Page 276

    1d-42 engine mechanical: assembly assembly is in the reverse order of disassembly. Pay attention to the following points: • tighten the cam chain tension adjuster service cap (1) and oil gallery plug (2) to the specified torque. Caution ! Replace the gaskets with new ones. Tightening torque cam chai...

  • Page 277

    Engine mechanical: 1d-43 • tighten the thermostat cover bolts (6) to the specified torque. Tightening torque thermostat cover bolt (e): 10 n·m (1.0 kgf-m, 7.0 lbf-ft) • tighten the ect sensor (7) to the specified torque. Tightening torque ect sensor (f): 18 n·m (1.8 kgf-m, 13.0 lbf-ft) caution ! • t...

  • Page 278

    1d-44 engine mechanical: • put on the valve spring retainer (10), and using the special tools, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem. Caution ! • be sure to restore each spring and valve ...

  • Page 279

    Engine mechanical: 1d-45 valve stem runout support the valve using v-blocks, as shown in the figure, and check its runout using the dial gauge. If the runout exceeds the service limit, replace the valve. Special tool (a): 09900–20607 (dial gauge) (b): 09900–20701 (dial gauge chuck) (c): 09900–21304 ...

  • Page 280

    1d-46 engine mechanical: valve stem wear measure the valve stem o.D. Using the micrometer. If it is out of specification, replace the valve with a new one. If the valve stem o.D. Is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve...

  • Page 281

    Engine mechanical: 1d-47 4) check that the transferred red lead (blue) on the valve face is uniform all around and in center of the valve face. If the seat width “a” measured exceeds the standard value, or seat width is not uniform reface the seat using the seat cutter. Refer to “valve seat repair” ...

  • Page 282

    1d-48 engine mechanical: 5) cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c (212 – 302 °f) with a hot plate. Caution ! Do not use a burner to heat the valve guide hole to prevent cylinder head distortion. 6) apply engine oil to each valve gui...

  • Page 283

    Engine mechanical: 1d-49 valve seat repair b947h11406030 the valve seats (1) for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45 °. Caution ! • the valve seat contact area must be inspected after each cut. • do not use lapping compound...

  • Page 284

    1d-50 engine mechanical: gearshift system remove the gearshift shaft (1) and gearshift cam plate (2). Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b (page 5b-17). Starter torque limiter / starter clutch remove the starter torque limiter (1) and starter clutch...

  • Page 285

    Engine mechanical: 1d-51 2) remove the water pump (2). Gear position switch remove the gear position switch (1). Oil pressure switch remove the oil pressure switch lead wire (1) and switch (2). Oil filter remove the oil filter (1) with the special tool. Special tool (a): 09915–40610 (oil filter wren...

  • Page 286

    1d-52 engine mechanical: oil pump 1) remove the spacer (1) and bearing (2). 2) remove the oil pump drive sprocket (3) and chain (4). 3) remove the thrust washer (5). 4) remove the oil pump assembly (6). 5) remove the dowel pins and o-ring (7). 6) remove the breather oil return pipe (8). Crankcase 1)...

  • Page 287

    Engine mechanical: 1d-53 5) remove the crankshaft journal bolts (m9). 6) make sure that all of the bolts are removed. Then, tap the sides of the lower crankcase using a plastic hammer to separate the upper and lower crankcase halves and then lift the lower crankcase off the upper crankcase. 7) remov...

  • Page 288

    1d-54 engine mechanical: 3) remove the crankshaft (1) and thrust bearings (2). Piston cooling oil jet remove the piston cooling oil jet (1) from the upper crankcase. Piston / conrod 1) push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase. Caution ! Be caref...

  • Page 289

    Engine mechanical: 1d-55 crankshaft journal bearing remove the crankshaft journal bearings, upper and lower. Caution ! • when removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings. • do not touch the bearing surfaces with your hands. Gr...

  • Page 290

    1d-56 engine mechanical: 2) remove the oil gallery plug (4) from the upper crankcase. Water jacket plug remove the water jacket plugs (1) from the upper crankcase. Oil seal / bearing remove the oil seal and bearings if necessary. Refer to “transmission removal” in section 5b (page 5b-3). Breather oi...

  • Page 291

    Engine mechanical: 1d-57 • tighten each plug to the specified torque. Caution ! Replace the o-rings with new ones. Tightening torque water jacket plug (a): 9.5 n·m (0.95 kgf-m, 6.9 lbf- ft) oil gallery plug caution ! Replace the gaskets with new ones. • apply thread lock to the oil gallery plug (m10...

  • Page 292

    1d-58 engine mechanical: crankshaft journal bearing when fitting the crankshaft journal bearings to the upper and lower crankcases, be sure to fix the stopper part “a” first and press the other end. Caution ! Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell. ...

  • Page 293

    Engine mechanical: 1d-59 • install the pistons with conrods into the cylinders from topside using the special tool. Note when installing the pistons, the indent “d” of each piston head must be brought to the exhaust side. Special tool (a): 09916–77310 (piston ring compressor) • check that i.D. Code ...

  • Page 294

    1d-60 engine mechanical: 2) position the no. 2 and no. 3 conrod big ends on the same side, and the no. 1 and no. 4 conrod big ends on the opposite side of no. 2 and no. 3. 3) set the crankshaft onto the conrods and upper crankcase. 4) apply molybdenum oil to each crank pin and bearing surface. Cauti...

  • Page 295

    Engine mechanical: 1d-61 10) check the conrod movement for smooth turning. 11) insert the right and left thrust bearings with the oil grooves “b” facing towards the crankshaft web. Note • right-thrust bearing has green painting. • inspect and select the crankshaft thrust clearance if necessary. Refe...

  • Page 296

    1d-62 engine mechanical: crankcase • install the dowel pins and o-rings (1). Caution ! Replace the o-rings with new ones. • apply bond to the mating surface of the lower crankcase as follows. Note • make mating surfaces free from moisture, oil, dust and other foreign materials. • spread the sealant ...

  • Page 297

    Engine mechanical: 1d-63 • tighten the crankshaft journal bolts (m9). Tighten each bolt a little at a time to equalize the pressure in the following two steps. Caution ! Fit new gasket washers to the bolts “a” to prevent oil leakage. Tightening torque crankshaft journal bolt (m9): 18 n ⋅m (1.8 kgf-m...

  • Page 298

    1d-64 engine mechanical: • apply thread lock to the bolts. : thread lock cement 99000–32110 (thread lock cement super “1322” or equivalent) oil pump • install the breather oil return pipe (1). • apply grease to new o-ring (2). : grease 99000–25010 (suzuki super grease “a” or equivalent) caution ! Us...

  • Page 299

    Engine mechanical: 1d-65 • apply engine oil to the bearing (7) and spacer (8) and install them into the sprocket. Oil strainer / oil pressure regulator • apply grease to new o-ring (1). Caution ! Use a new o-ring to prevent oil leakage. : grease 99000–25010 (suzuki super grease “a” or equivalent) • ...

  • Page 300

    1d-66 engine mechanical: oil pressure switch • apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. Note be careful not to apply bond to the hole of thread end. : sealant 99000–31140 (suzuki bond no.1207b or equivalent) tightening torque oil p...

  • Page 301

    Engine mechanical: 1d-67 • tighten the water pump mounting bolts (2) to the specified torque. Tightening torque water pump mounting bolt (a): 10 n·m (1.0 kgf- m, 7.0 lbf-ft) • apply engine coolant to the o-ring. Caution ! Replace the o-ring with a new one. • tighten the water inlet connector mountin...

  • Page 302

    1d-68 engine mechanical: • install the washer (5). Starter clutch / starter torque limiter install the starter clutch (1) and starter torque limiter (2) component parts. Refer to “starter clutch removal and installation” in section 1i (page 1i-10) and “starter torque limiter removal and installation...

  • Page 303

    Engine mechanical: 1d-69 • tighten the crankcase breather (pcv) cover bolts. Engine top side assemble the engine top side. Refer to “engine top side disassembly” (page 1d-26). Cylinder inspection b947h11406033 refer to “engine top side disassembly” (page 1d-26). Refer to “engine top side assembly” (...

  • Page 304

    1d-70 engine mechanical: installation note • when installing the piston ring, be careful not to damage the piston. • do not expand the piston ring excessively since it is apt to be broken down. 1) install the piston rings in the order of the oil ring, second ring and top ring. A) the first member to...

  • Page 305

    Engine mechanical: 1d-71 piston and piston ring inspection b947h11406035 refer to “piston ring removal and installation” (page 1d-69). Piston diameter measure the piston diameter using the micrometer at 15 mm (0.6 in) “a” from the skirt end. If the piston diameter is less than the service limit, rep...

  • Page 306

    1d-72 engine mechanical: piston ring free end gap and piston ring end gap measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceed the service lim...

  • Page 307

    Engine mechanical: 1d-73 balancer shaft disassembly and assembly b947h11406036 refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” (page 1d-56). Disassembly 1) remove the balancer shaft. Refer to “engine bottom side disassembly” (page 1d-49). 2) remove the...

  • Page 308

    1d-74 engine mechanical: balancer shaft journal bearing removal and installation b947h11406038 refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” (page 1d-56). Removal remove the balancer shaft journal bearings (1). Note • do not remove the bearings (1) u...

  • Page 309

    Engine mechanical: 1d-75 balancer shaft journal bearing inspection and selection b947h11406039 refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” (page 1d-56). Inspection inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any...

  • Page 310

    1d-76 engine mechanical: 4) check the corresponding crankcase journal i.D. Code number “a”, [a], [b] or [c] which is stamped on the rear of upper crankcase. Bearing selection table crankcase i.D. Specification balancer shaft journal o.D. Specification 19.992 – 20.000 mm (0.7871 – 0.7874 in) bearing ...

  • Page 311

    Engine mechanical: 1d-77 conrod and crankshaft inspection b947h11406041 refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” (page 1d-56). Conrod small end i.D. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end...

  • Page 312

    1d-78 engine mechanical: conrod crank pin bearing inspection and selection b947h11406042 refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” (page 1d-56). Inspection 1) inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, r...

  • Page 313

    Engine mechanical: 1d-79 2) check the corresponding crank pin o.D. Code numbers ([1], [2] or [3]) “b”. 3) measure the conrod crank pin o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft. Crank pin o.D. Specification special tool (a): 09900–20202 (...

  • Page 314

    1d-80 engine mechanical: 2) set the crankshaft onto the upper crank case. 3) install the plastigauge onto each crankshaft journal. Special tool (a): 09900–22301 (plastigage (0.025 – 0.076 mm)) 4) mate the lower crankcase with the upper crankcase. 5) tighten the crankshaft journal bolts (m9). Tighten...

  • Page 315

    Engine mechanical: 1d-81 2) check the corresponding crankshaft journal o.D. Codes “b” ([a], [b] or [c]), which are stamped on the crankshaft. 3) measure the crankshaft o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft. Crankshaft journal o.D. Spe...

  • Page 316

    1d-82 engine mechanical: crankshaft thrust clearance inspection and selection b947h11406044 refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” (page 1d-56). Inspection 1) with the crankshaft’s right-side and left-side thrust bearings inserted into the upp...

  • Page 317

    Engine mechanical: 1d-83 4) select a left-side thrust bearing from the selection table. Note right-side thrust bearing has the same specification as the green (12228-48b00-0e0) of left-side thrust bearing. Thrust bearing selection table 5) after selecting a left-side thrust bearing, install it and t...

  • Page 318

    1d-84 engine mechanical: specifications service data b947h11407001 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 31.0 (1.22) — ex. 25.0 (0.98) — valve clearance (when cold) in. 0.08 – 0.18 (0.003 – 0.007) — ex. 0.18 – 0.28 (0.007 – 0.011) — va...

  • Page 319

    Engine mechanical: 1d-85 cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) balancer unit: mm (in) throttle body item standard limit compression pressure 1 400 – 1 800 kpa (14 – 18 kgf/cm 2 , 199 – 256 psi) 1 000 kpa (10 kgf/cm 2 , 142 psi) compression pressure differenc...

  • Page 320

    1d-86 engine mechanical: tightening torque specifications b947h11407002 fastening part tightening torque note n ⋅m kgf-m lbf-ft throttle cable lock-nut 4.5 0.45 3.0 )(page 1d-11) stp sensor mounting screw 3.5 0.35 2.5 )(page 1d-13) tp sensor mounting screw 3.5 0.35 2.5 )(page 1d-14) isc valve mounti...

  • Page 321

    Engine mechanical: 1d-87 note the specified tightening torque is described in the following. “throttle cable routing diagram” (page 1d-2) “throttle body components” (page 1d-8) “throttle body construction” (page 1d-9) “engine assembly installation” (page 1d-24) reference: for the tightening torque o...

  • Page 322

    1d-88 engine mechanical: special tool b947h11408002 09900–20102 09900–20202 vernier calipers (200 mm) micrometer (25 – 50 mm) )(page 1d-46) / )(page 1d-72) )(page 1d-36) / )(page 1d-79) / )(page 1d-81) 09900–20203 09900–20205 micrometer (50 – 75 mm) micrometer (0 – 25 mm) )(page 1d-71) )(page 1d-38)...

  • Page 323

    Engine mechanical: 1d-89 09900–22403 09915–40610 small bore gauge (18 – 35 mm) oil filter wrench )(page 1d-38) )(page 1d-51) / )(page 1d-65) 09915–63311 09915–64512 compression gauge attachment compression gauge )(page 1d-3) )(page 1d-3) 09916–10911 09916–14510 valve lapper set valve lifter )(page 1...

  • Page 324

    1d-90 engine mechanical: 09930–11960 09940–14990 torx wrench (4 mm) engine mounting adjust wrench )(page 1d-14) )(page 1d-23) / )(page 1d-23) / )(page 1d-24) manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 325: Engine Lubrication System

    Engine lubrication system: 1e-1 engine engine lubrication system precautions precautions for engine oil b947h11500001 refer to “fuel and oil recommendation” in section 0a (page 0a-3). Manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co...

  • Page 326: Sub Gallery

    1e-2 engine lubrication system: schematic and routing diagram engine lubrication system chart diagram b947h11502001 intake camshaft intake camshaft journal holder cam chain starter clutch oil jet (#16) cam chain tension adjuster #1 piston cooling oil jet #1 piston and cylinder wall #1 crank pin bear...

  • Page 327

    Engine lubrication system: 1e-3 engine lubrication circuit diagram b947h11502002 i947h1150002-03 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 328

    1e-4 engine lubrication system: i947h1150003-01 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 329

    Engine lubrication system: 1e-5 diagnostic information and procedures engine lubrication symptom diagnosis b947h11504001 oil pressure check b947h11504002 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 330

    1e-6 engine lubrication system: 10) check the engine oil level. Refer to “engine oil and filter replacement” in section 0b (page 0b-10). 11) install the left side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). Repair instructions engine oil and filter replace...

  • Page 331

    Engine lubrication system: 1e-7 • push in the oil pressure regulator (4) to the oil pump as shown. • install new gasket (5). Caution ! Use new gasket to prevent oil leakage. • apply thread lock to the plate bolts “a”. : thread lock cement 99000–32110 (thread lock cement super “1322” or equivalent) •...

  • Page 332

    1e-8 engine lubrication system: oil cooler inspection 1) remove the oil cooler guard (1). 2) inspect the oil cooler for oil leakage. If any defects are found, replace the oil cooler with a new one. If the fins are bent or dented, repair them by carefully straightening them with the blade of a small ...

  • Page 333

    Engine lubrication system: 1e-9 5) remove the oil cooler guard (4). Installation install the oil cooler and oil cooler hoses in the reverse order of removal. Pay attention to the following points: • apply thread lock to the oil cooler mounting bolt and tighten them securely. : thread lock cement 990...

  • Page 334

    1e-10 engine lubrication system: 5) remove the oil pressure switch (2). Installation 1) apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. Note be careful not to apply bond to the hole of thread end. : sealant 99000–31140 (suzuki bond no.120...

  • Page 335

    Engine lubrication system: 1e-11 • apply a small quantity of thread lock to the bolts and tighten them to the specified torque. : thread lock cement 99000–32110 (thread lock cement super “1322” or equivalent) tightening torque piston cooling oil jet bolt (a): 10 n·m (1.0 kgf-m, 7.0 lbf-ft) oil jet (...

  • Page 336

    1e-12 engine lubrication system: oil jet (for transmission) removal 1) remove the engine assembly. Refer to “engine assembly removal” in section 1d (page 1d-20). 2) separate the crankcases, upper and lower. Refer to “engine bottom side disassembly” in section 1d (page 1d-49). 3) remove the oil jet (...

  • Page 337

    Engine lubrication system: 1e-13 installation 1) install the dowel pins. 2) apply grease to new o-ring. Caution ! Use a new o-ring to prevent oil leakage. : grease 99000–25010 (suzuki super grease “a” or equivalent) 3) install the oil pump. Note engage the oil pump shaft end with the water pump shaf...

  • Page 338

    1e-14 engine lubrication system: oil pump inspection b947h11506012 inspect the oil pump in the following procedures: 1) remove the oil pump. Refer to “oil pump removal and installation” (page 1e-12). 2) rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, repla...

  • Page 339

    Engine lubrication system: 1e-15 special tools and equipment recommended service material b947h11508001 special tool b947h11508002 material suzuki recommended product or specification note grease suzuki super grease “a” or equivalent p/no.: 99000–25010 )(page 1e-6) / )(page 1e- 6) / )(page 1e-13) se...

  • Page 340: Engine Cooling System

    1f-1 engine cooling system: engine engine cooling system precautions precautions for engine cooling system b947h11600001 warning ! • you can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully r...

  • Page 341

    Engine cooling system: 1f-2 schematic and routing diagram cooling circuit diagram b947h11602001 water pump radiator ect sensor thermostat cylinder head cylinder reservoir tank i947h1160001-02 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motom...

  • Page 342

    1f-3 engine cooling system: water hose routing diagram b947h11602002 “i” “c” “f” “h” “a” “a” “a” “b” “b” “g” “ a ” “ b ” (a) (b) “b” 1 (c) “k” “a” “j” “d” 2 3 4 “e” i947h1160053-03 1. Thermostat air bleeder hole “d”: clamp end should face right side. “k”: screw head should face left side. 2. Cushion...

  • Page 343

    Engine cooling system: 1f-4 diagnostic information and procedures engine cooling symptom diagnosis b947h11604001 repair instructions cooling circuit inspection b947h11606001 warning ! • do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. • when...

  • Page 344

    1f-5 engine cooling system: radiator cap inspection b947h11606002 inspect the radiator cap in the following procedures: 1) remove the radiator cap. Refer to “cooling circuit inspection” (page 1f-4). 2) attach the radiator cap (1) to the radiator tester (2) as shown. 3) slowly apply pressure to the r...

  • Page 345

    Engine cooling system: 1f-6 4) remove the radiator mounting bolts. 5) move the radiator forward. 6) apply compressed air from the engine side. 7) tighten the upper radiator mounting bolts. 8) apply thread lock to the radiator bracket bolts and tighten all bolts securely. : thread lock cement 99000–3...

  • Page 346

    1f-7 engine cooling system: 7) remove the oil cooler (6) from the bracket. 8) remove the radiator assembly by removing the bolts. 9) remove the radiator outlet hose (7) and cooling fan motor (8) from the radiator. Installation install the radiator in the reverse order of removal. Pay attention to th...

  • Page 347

    Engine cooling system: 1f-8 3) any leakage from the connecting section should be corrected by proper tightening. Refer to “water hose routing diagram” (page 1f-3). 4) after finishing the water hoses inspection, reinstall the removed parts. Water hose removal and installation b947h11606006 removal 1)...

  • Page 348

    1f-9 engine cooling system: 4) disconnect the reservoir tank overflow hose (3). Installation 1) install the reservoir tank. Refer to “radiator / cooling fan motor removal and installation” (page 1f-6). 2) fill the reservoir tank with engine coolant to the upper level. Refer to “cooling system inspec...

  • Page 349

    Engine cooling system: 1f-10 3) first check the insulation between “a” and “b” terminals with tester. Then apply 12 volts to “c” and “d” terminals, (+) to “c” and (–) to “d”, and check the continuity between “a” and “b”. If there is no continuity, replace it with a new one. Special tool : 09900–2500...

  • Page 350

    1f-11 engine cooling system: thermostat inspection b947h11606014 inspect the thermostat in the following procedures: 1) remove the thermostat. Refer to “thermostat removal and installation” (page 1f-10). 2) inspect the thermostat pellet for signs of cracking. 3) test the thermostat at the bench for ...

  • Page 351

    Engine cooling system: 1f-12 water pump components b947h11606015 1 2 5 fwd fwd (d) 3 (a) (c) (b) 4 i947h1160055-02 1. Impeller : 8 n ⋅m (0.8 kgf-n, 6.0 ib-ft) : apply engine coolant. 2. Mechanical seal : 10 n ⋅m (1.0 kgf-n, 7.0 ib-ft) : apply molybdenum oil solution. 3. Oil seal : 6 n ⋅m (0.6 kgf-n,...

  • Page 352

    1f-13 engine cooling system: water pump construction b947h11606016 water pump removal and installation b947h11606017 removal 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...

  • Page 353

    Engine cooling system: 1f-14 • install the water pump assembly with the slot of the pump shaft end “a” securely engaged with the flat “b” of the oil pump shaft. • tighten the water pump mounting bolts (1) to the specified torque. Tightening torque water pump mounting bolt (a): 10 n·m (1.0 kgf- m, 7....

  • Page 354

    1f-15 engine cooling system: 5) remove the impeller (3). 6) remove the mechanical seal ring (5) and rubber seal (6) from the impeller. 7) remove the o-ring (7), impeller shaft (8) and washer (9) from the holder. 8) remove the mechanical seal (10) with the special tool. Note if there is no abnormal c...

  • Page 355

    Engine cooling system: 1f-16 2) apply a small quantity of the grease to the oil seal lip. : grease 99000–25010 (suzuki super grease “a” or equivalent) 3) install a new mechanical seal using a suitable size socket wrench. Caution ! The removed mechanical seal must be replaced with a new one. Note on ...

  • Page 356

    1f-17 engine cooling system: 10) hold the impeller with water pump pliers and tighten the impeller securing bolt to the specified torque. Tightening torque impeller securing bolt (a): 8 n·m (0.8 kgf-m, 6.0 lbf-ft) 11) install new o-ring (8) and apply engine coolant to it. Caution ! Use a new o-ring ...

  • Page 357

    Engine cooling system: 1f-18 seal washer visually inspect the seal washer for damage, with particular attention given to the sealing face. Replace the seal washer that shows indications of leakage. Impeller / shaft visually inspect the impeller and its shaft for damage. Replace the impeller or shaft...

  • Page 358

    1f-19 engine cooling system: tightening torque specifications b947h11607002 note the specified tightening torque is described in the following. “water hose routing diagram” (page 1f-3) “water pump components” (page 1f-12) “water pump construction” (page 1f-13) reference: for the tightening torque of...

  • Page 359: Fuel System

    Fuel system: 1g-1 engine fuel system precautions precautions for fuel system b947h11700001 warning ! • keep away from fire or spark. • during disassembling, use care to minimize spillage of gasoline. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. • for e-33 mod...

  • Page 360

    1g-2 fuel system: general description fuel injection system description b947h11701001 fuel system the fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipes (5) including fuel injectors (6) and (7), fuel pressure regulator (8). The...

  • Page 361

    Fuel system: 1g-3 schematic and routing diagram fuel tank drain hose and breather hose routing diagram b947h11702001 1 2 2 3 5 6 “c” “d” “e” “f” 4 “a” “b” “g” “ a ” “ b ” “ c ” “h” “i” i947h1170020-02 1. Fuel tank water drain hose “a”: white marking “g”: stick the hose clamp along the line behind th...

  • Page 362

    1g-4 fuel system: diagnostic information and procedures fuel system diagnosis b947h11704001 condition possible cause correction / reference item engine will not start or is hard to start (no fuel reaching the intake manifold) clogged fuel filter or fuel hose. Clean or replace. Defective fuel pump. R...

  • Page 363

    Fuel system: 1g-5 repair instructions fuel pressure inspection b947h11706001 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel pressure in the following procedures: 1) lift and support the fuel tank. Refer...

  • Page 364

    1g-6 fuel system: fuel pump inspection b947h11706002 turn the ignition switch on and check that the fuel pump operates for a 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 to sensor. Refer to “fuel pump ...

  • Page 365

    Fuel system: 1g-7 fuel pump relay inspection b947h11706004 refer to “electrical components location” in section 0a (page 0a-7). Inspect the fuel pump relay in the following procedures: 1) remove the frame covers. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). 2) remov...

  • Page 366

    1g-8 fuel system: fuel tank construction b947h11706007 1 4 2 3 4 4 “b” “b” “b” “a” i947h1170025-02 1. Fuel tank heat shield : aluminum film side should face the engine side. 3. Fuel tank front bracket “a”: insert to the bracket. 2. Fuel tank front cover 4. Velcro fastenings : clean the adhesive surf...

  • Page 367

    Fuel system: 1g-9 fuel tank removal and installation b947h11706008 removal warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. 1) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page ...

  • Page 368

    1g-10 fuel system: fuel pump components b947h11706009 1 2 3 5 6 7 4 3 3 3 (a) fwd fwd i947h1170030-02 1. Fuel level gauge 4. Joint 7. Fuel mesh filter : apply grease. 2. Fuel pressure regulator assembly 5. Fuel pump : 10 n ⋅m (1.0 kgf-m, 7.0 lbf-ft) : do not reuse. 3. O-ring 6. Fuel pump case : appl...

  • Page 369

    Fuel system: 1g-11 fuel pump disassembly and assembly b947h11706010 disassembly 1) remove the fuel tank. Refer to “fuel tank removal and installation” (page 1g-9). 2) remove the fuel pump assembly (1) by removing its mounting bolts diagonally. Warning ! • spilled gasoline should be wipe off immediat...

  • Page 370

    1g-12 fuel system: 9) remove the fuel mesh filter (12). 10) remove the fuel pump (13). Assembly refer to “fuel mesh filter inspection and cleaning” (page 1g-13). Assemble the fuel tank pump in the reverse order of the disassembly. Pay attention to the following points: caution ! • to prevent fuel le...

  • Page 371

    Fuel system: 1g-13 • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending of numbers. Tightening torque fuel pump mounting bolt (a): 10 n·m (1.0 kgf-m, 7.0 lbf-ft) fuel mesh filter inspection and cleaning b94...

  • Page 372

    1g-14 fuel system: specifications service data b947h11707001 injector + fuel pump + fuel pressure regulator fuel tightening torque specifications b947h11707002 note the specified tightening torque is described in the following. “fuel pump components” (page 1g-10) reference: for the tightening torque...

  • Page 373

    Fuel system: 1g-15 special tools and equipment recommended service material b947h11708001 note required service material is also described in the following. “fuel pump components” (page 1g-10) special tool b947h11708002 material suzuki recommended product or specification note grease suzuki super gr...

  • Page 374: Ignition System

    1h-1 ignition system: engine ignition system general description immobilizer description (for e-02, 19, 24, 51) b947h11801001 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 throu...

  • Page 375

    Ignition system: 1h-2 note if the indicator light flashes fast, turn the ignition switch off then on to make judgment again as there is possible misjudgment due to environmental radio interference. Caution ! When the battery performance is lowered in winter (low temperature), the system may at times...

  • Page 376

    1h-3 ignition system: schematic and routing diagram ignition system diagram b947h11802001 refer to “wire color symbols” in section 0a (page 0a-5). Ignition system components location b947h11802002 refer to “electrical components location” in section 0a (page 0a-7). #1 #2 #3 #4 ckp sensor tp sensor e...

  • Page 377

    Ignition system: 1h-4 diagnostic information and procedures ignition system symptom diagnosis b947h11804001 condition possible cause correction / reference item spark plug not sparking damaged spark plug. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defec...

  • Page 378

    1h-5 ignition system: no spark or poor spark b947h11804002 troubleshooting 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 action yes ...

  • Page 379

    Ignition system: 1h-6 repair instructions ignition coil and spark plug removal and installation b947h11806001 removal warning ! The hot engine can burn you. Wait until the engine is cool enough to touch. 1) turn the ignition switch off. 2) remove the air cleaner box. Refer to “air cleaner box remova...

  • Page 380

    1h-7 ignition system: • install the ignition coil and connect their lead wire couplers. Caution ! Do not hit the ignition coil with a plastic hammer when installing it. Spark plug inspection and cleaning b947h11806002 refer to “spark plug inspection and cleaning” in section 0b (page 0b-9). Ignition ...

  • Page 381

    Ignition system: 1h-8 5) insert the needle pointed probe to the lead wire coupler. Caution ! Use the special tool to prevent the rubber of the water proof coupler from damage. 6) connect the multi-circuit tester with the peak voltage adaptor as follows. Caution ! Before using the multi-circuit teste...

  • Page 382

    1h-9 ignition system: ignition coil resistance 1) remove the ignition coil. Refer to “ignition coil and spark plug removal and installation” (page 1h-6). 2) measure the ignition coil for resistance in both primary and secondary coils. If the resistance is not within the standard range, replace the i...

  • Page 383

    Ignition system: 1h-10 6) if the peak voltage is within the specification, check the continuity between the ckp sensor coupler and ecm coupler. Caution ! Normally, use the needle pointed probe to the backside of the lead wire coupler to prevent the terminal bend and terminal alignment. 7) after meas...

  • Page 384

    1h-11 ignition system: ignition switch removal and installation b947h11806008 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (page 1d-7). 2) disconnect the ignition switch lead wire coupler (1). 3) disconnect the immobilizer lead wire coupler...

  • Page 385

    Ignition system: 1h-12 drive mode selector inspection b947h11806009 inspect the drive mode selector in the following procedures: 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “data monitor”. 4) make sure each of “driving mod...

  • Page 386

    1h-13 ignition system: specifications service data b947h11807001 electrical unit: mm (in) tightening torque specifications b947h11807002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c (page 0c-9). Item specification not...

  • Page 387

    Ignition system: 1h-14 special tools and equipment recommended service material b947h11808001 special tool b947h11808002 material suzuki recommended product or specification note thread lock cement thread lock cement super “1322” or equivalent p/no.: 99000–32110 )(page 1h-11) 09900–25008 09900–25009...

  • Page 388: Starting System

    1i-1 starting system: engine starting system schematic and routing diagram starting system diagram b947h11902001 refer to “wire color symbols” in section 0a (page 0a-5). Component location starting system components location b947h11903001 refer to “electrical components location” in section 0a (page...

  • Page 389

    Starting system: 1i-2 starter motor will not run b947h11904002 note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting starter motor runs but does not crank the engine b947h11904003 the starter motor runs when the transmission is in neutral, but doe...

  • Page 390

    1i-3 starting system: repair instructions starter motor components b947h11906001 1 2 3 3 5 6 4 fwd fwd (b) (a) (c) i947h1190032-02 1. O-ring 5. Armature : 5 n ⋅m (0.5 kgf-m, 3.5 lbf-ft) 2. Housing end (inside) 6. Housing end (outside) : apply grease to sliding surface. 3. O-ring : 10 n ⋅m (1.0 kgf-m...

  • Page 391

    Starting system: 1i-4 starter motor removal and installation b947h11906002 removal 1) turn the ignition switch off and disconnect the battery (–) lead wire (1). 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). 3) disconnect the starter moto...

  • Page 392

    1i-5 starting system: • tighten the starter motor housing bolts (1) to the specified torque. Tightening torque starter motor housing bolt (a): 5 n·m (0.5 kgf-m, 3.5 lbf-ft) starter motor inspection b947h11906004 refer to “starter motor disassembly and assembly” (page 1i-4). Carbon brush inspect the ...

  • Page 393

    Starting system: 1i-6 oil seal check the seal lip for damage. If any damage is found, replace the housing end. Starter relay removal and installation b947h11906005 removal 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (pag...

  • Page 394

    1i-7 starting system: 3) measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. Special tool (a): 09900–25008 (multi circuit tester set) starter relay resistance 3 – 6 Ω 4)...

  • Page 395

    Starting system: 1i-8 5) connect the side-stand switch coupler. 6) install the removed parts. Turn signal / side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Side-stand relay 1) remove the turn signal/side-stand relay. Refer to “turn ...

  • Page 396

    1i-9 starting system: 2) disconnect the gear position switch coupler (1). Caution ! When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. 3) check the continuity between bl and b lead wires with the transmi...

  • Page 397

    Starting system: 1i-10 starter torque limiter inspection b947h11906013 refer to “starter torque limiter removal and installation” (page 1i-9). Caution ! • do not attempt to disassemble the starter torque limiter. • the starter torque limiter is available only as an assembly part. 1) hold the starter...

  • Page 398

    1i-11 starting system: • when installing the starter clutch and ckp sensor rotor, align the wide spline tooth of them with that of crankshaft. • hold the starter clutch with the special tool and tighten the starter clutch bolt to the specified torque. Special tool (a): 09930–40113 (flywheel rotor ho...

  • Page 399

    Starting system: 1i-12 starter button inspection b947h11906011 inspect the starter button in the following procedures: 1) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (page 1d-7). 2) disconnect the right handlebar switch coupler (1). 3) inspect the st...

  • Page 400

    1i-13 starting system: special tools and equipment recommended service material b947h11908001 note required service material is also described in the following. “starter motor components” (page 1i-3) special tool b947h11908002 material suzuki recommended product or specification note grease suzuki s...

  • Page 401: Charging System

    Charging system: 1j-1 engine charging system schematic and routing diagram charging system diagram b947h11a02001 component location charging system components location b947h11a03001 refer to “electrical components location” in section 0a (page 0a-7). Diagnostic information and procedures charging sy...

  • Page 402

    1j-2 charging system: battery runs down quickly b947h11a04002 troubleshooting battery overcharges faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire coupler. Repair. Battery runs down quickly trouble in charging system. Check the generator, regulator/re...

  • Page 403

    Charging system: 1j-3 repair instructions battery current leakage inspection b947h11a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). 3) dis...

  • Page 404

    1j-4 charging system: 3) measure the resistance between the three lead wires. If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insulated properly. Note when making this test, be sure that the battery is in fully charged condition....

  • Page 405

    Charging system: 1j-5 5) remove the gasket (3) and dowel pins. 6) hold the generator rotor with the special tool and remove the generator rotor bolt. Special tool (a): 09930–44530 (rotor holder) 7) screw in the special tool to the crankshaft. 8) remove the generator rotor (4) using the special tool....

  • Page 406

    1j-6 charging system: • degrease the tapered portion “a” of generator rotor and also the crankshaft “b” with nonflammable cleaning solvent. Caution ! Dry these parts naturally. Do not wipe them with a cloth or use compressed air to dry. • install the generator rotor onto crankshaft. • hold the gener...

  • Page 407

    Charging system: 1j-7 regulator / rectifier construction b947h11a06005 regulator / rectifier removal and installation b947h11a06006 removal 1) turn the ignition switch off. 2) remove the right side cowling. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 3) lift and sup...

  • Page 408

    1j-8 charging system: 5) disconnect the regulator/rectifier couplers (1). 6) remove the regulator/rectifier as shown in the regulator/rectifier construction. Refer to “regulator / rectifier construction” (page 1j-7). Installation 1) install the regulator/rectifier as shown in the regulator/rectifier...

  • Page 409

    Charging system: 1j-9 battery components b947h11a06008 battery charging b947h11a06009 initial charging filling electrolyte note when filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground. 1) remove the aluminum tape (1) which seals the battery filler h...

  • Page 410

    1j-10 charging system: 5) make sure that air bubbles (4) rise to the top of each electrolyte container, and leave in this position for about more than 20 minutes. Note if no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the cont...

  • Page 411

    Charging system: 1j-11 battery recharging caution ! Do not remove the caps on the battery top while recharging. Note when the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge. 1) remove the battery from the motorcycle. Refer to “battery remov...

  • Page 412

    1j-12 charging system: installation install the battery in the reverse order of removal. Pay attention to following points: caution ! Never use anything except the specified battery. • tighten the battery lead wire bolts securely. Battery visual inspection b947h11a06011 inspect the battery in the fo...

  • Page 413

    Charging system: 1j-13 special tools and equipment recommended service material b947h11a08001 special tool b947h11a08002 material suzuki recommended product or specification note sealant suzuki bond no.1207b or equivalent p/no.: 99000–31140 )(page 1j-5) / )(page 1j- 6) 09900–25008 09930–30460 multi ...

  • Page 414: Exhaust System

    1k-1 exhaust system: engine exhaust system precautions precautions for exhaust system b947h11b00001 warning ! To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Caution ! Make sure ...

  • Page 415

    Exhaust system: 1k-2 exhaust control system operation b947h11b01002 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 (in...

  • Page 416

    1k-3 exhaust system: full open i947h11b0003-01 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 417

    Exhaust system: 1k-4 repair instructions exhaust control system construction b947h11b06001 1 2 1 2 “ a ” “ b ” “ c ” (a) “a” i947h11b0004-02 1. Excv cable no. 1 (cl) : 5 n ⋅m (0.5 kgf-m, 3.5 lbf-ft) “c”: 11 – 12 mm (0.43 – 0.47 in) 2. Excv cable no. 2 (op) “a”: 42 – 43 mm (1.65 – 1.69 in) “a”: when ...

  • Page 418

    1k-5 exhaust system: exhaust system components b947h11b06002 caution ! Replace the gaskets and connectors with new ones when reassembling. (b) (b) (b) (b) 1 2 3 5 6 6 7 8 4 “a” (a) (a) (a) (a) (a) (a) (f) (c) (d) (e) 4 4 (c) i947h11b0005-03 1. Exhaust pipe gasket 7. Excv cable no. 1 : 5.5 n ⋅m (0.55...

  • Page 419

    Exhaust system: 1k-6 excv cable removal and installation b947h11b06003 removal 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). 3) remove the left side cowling. Refer to “exterior parts removal and installation”...

  • Page 420

    1k-7 exhaust system: installation caution ! The cable slots of excva pulley must be located adjustment position. 1) temporarily connect the excv cable no. 1 (47h0cl) (1) and no. 2 (47h0op) (2) to the exhaust pipe and excv pulley. Note the excv cables are identified by the letters. No. 1 cable (1): 4...

  • Page 421

    Exhaust system: 1k-8 4) after turning the mode select switch on, turn the ignition switch on. Special tool (a): 09930–82720 (mode selection switch) 5) check that the cable slots of the excva pulley comes to the middle (adjustment position) “a”. 6) turn the ignition switch off. Caution ! Before remov...

  • Page 422

    1k-9 exhaust system: installation install the excva in the reverse order of removal. Pay attention to the following points: • install the excva pulley to the shaft. Note align the shaft’s line “a” and cable slots “b”. • hold the pulley with an adjustable wrench, and then tighten the pulley mounting ...

  • Page 423

    Exhaust system: 1k-10 4) turn the mode select switch on. If dtc “c46” is not indicated on the lcd display, the adjustment is correctly completed. If “c46” is indicated, repeat the procedures from step 3 to step 4. Step 3 1) turn the ignition switch off. 2) set up the sds tools. Refer to “self-diagno...

  • Page 424

    1k-11 exhaust system: step 4 1) click “full opened” (1). 2) measure the excva position sensor output voltage at excv fully opened position. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) excva position sensor out put voltage excv is fully opened: 3...

  • Page 425

    Exhaust system: 1k-12 3) remove the side cowlings. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). 4) lift and support the fuel tank with the prop stay. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 5) disconnect the ho2 sensor coupler (4). 6...

  • Page 426

    1k-13 exhaust system: 12) remove the exhaust pipe assembly by removing the exhaust pipe bolts. Caution ! Take care not to bend the radiator/oil cooler fins. Note support the exhaust pipe assembly to prevent it from falling. 13) remove the exhaust pipe gaskets (11). Installation installation is in th...

  • Page 427

    Exhaust system: 1k-14 specifications service data b947h11b07001 fi sensors tightening torque specifications b947h11b07002 note the specified tightening torque is described in the following. “exhaust control system construction” (page 1k-4) “exhaust system components” (page 1k-5) reference: for the t...

  • Page 428

    1k-15 exhaust system: special tools and equipment recommended service material b947h11b08001 note required service material is also described in the following. “exhaust system components” (page 1k-5) special tool b947h11b08002 material suzuki recommended product or specification note muffler seal mu...

  • Page 429: Section 2

    Table of contents 2- i 2 section 2 contents suspension precautions .................................................2-1 precautions............................................................. 2-1 precautions for suspension .................................. 2-1 suspension general diagnosis............

  • Page 430: Precautions

    2-1 precautions: suspension precautions precautions precautions for suspension b947h12000001 refer to “general precautions” in section 00 (page 00-1). Warning ! All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the...

  • Page 431: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b947h12104001 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn front wheel bearings. Repla...

  • Page 432: Front Suspension

    2b-1 front suspension: suspension front suspension repair instructions front fork components b947h12206001 fwd fwd 3 9 11 10 20 21 12 13 14 15 16 17 18 19 4 (d) 22 (a) 1 2 (c) 8 (b) 5 7 6 i947h1220001-03 1. Front fork cap 8. Rod guide case 15. Outer tube 22. Front axle pinch bolt 2. O-ring 9. Spring...

  • Page 433

    Front suspension: 2b-2 front fork removal and installation b947h12206002 note the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) remove the front wheel. Refer to “front wheel assembly removal ...

  • Page 434

    2b-3 front suspension: 2) tighten the front fork cap (2) to the specified torque. Tightening torque front fork cap (a): 35 n·m (3.5 kgf-m, 25.5 lbf-ft) 3) loosen the lower clamp bolts. 4) set the front fork with the edge of the outer tube positioned 7.0 mm (0.28 in) “a” from the upper surface of the...

  • Page 435

    Front suspension: 2b-4 front suspension adjustment b947h12206003 after installing the front fork, adjust the spring pre-load and two kinds of damping force as follows: warning ! Adjust the left and right front forks to the same setting. Spring pre-load adjustment turn the spring pre-load adjuster (1...

  • Page 436

    2b-5 front suspension: 2) loosen the front fork cap using the special tool and vise. Caution ! Do not clamp the outer tube too tight. Special tool (a): 09941–53670 (front fork cap socket wrench (45 mm)) 3) loosen the rod guide case installed in the inner tube using the special tool. Special tool (b)...

  • Page 437

    Front suspension: 2b-6 9) pull out the inner tube from the outer tube. 10) remove the slide bushing (8) from the inner tube. 11) remove the following parts from the inner tube. A) guide bushing (9) b) oil seal spacer (10) c) oil seal (11) d) oil seal stopper ring (7) e) dust seal (6) 12) hold the pi...

  • Page 438

    2b-7 front suspension: 3) remove the plastic film and install the oil seal spacer (4), guide bushing (5) and slide bushing (6) keep them free from dust. Caution ! • face the grooved side “b” of the oil seal spacer to the outer tube side. • position the slit “c” of slide bushing 90 ° against the trav...

  • Page 439

    Front suspension: 2b-8 10) insert the spring collar b (9) into the inner tube. Caution ! Face the flange “d” of the collar to the spring side. 11) pour specified fork oil until its surface passes the side holes of inner tube. : fork oil 99000–99001–ss5 (suzuki fork oil ss-05 or equivalent) 12) slowl...

  • Page 440

    2b-9 front suspension: 16) tighten the rod guide case to the specified torque. Refer to “rod guide case tightening torque” (page 2b-10). Special tool (b): 09940–84710 (rod guide case wrench) tightening torque rod guide case: 90 n·m (9.0 kgf-m, 65.0 lbf-ft) 17) pour specified fork oil up to the top o...

  • Page 441

    Front suspension: 2b-10 front fork parts inspection b947h12206005 refer to “front fork disassembly and assembly” (page 2b-4). Inner and outer tubes inspect the inner tube and outer tube for scratches. Slide bushing / guide bushing inspect the slide bushing and guide bushing for wear or damage. If th...

  • Page 442

    2b-11 front suspension: specifications service data b947h12207001 suspension unit: mm (in) tightening torque specifications b947h12207002 note the specified tightening torque is described in the following. “front fork components” (page 2b-1) reference: for the tightening torque of fastener not speci...

  • Page 443

    Front suspension: 2b-12 special tools and equipment recommended service material b947h12208001 note required service material is also described in the following. “front fork components” (page 2b-1) special tool b947h12208002 material suzuki recommended product or specification note fork oil suzuki f...

  • Page 444: Rear Suspension

    2c-1 rear suspension: suspension rear suspension repair instructions rear suspension components b947h12306001 1 3 5 5 11 10 12 13 13 14 16 16 (g) 7 (a) 2 (a) 2 (b) 4 (b) 6 (d) 9 (f) 8 (b) 4 (c) (e) 15 (e) 15 fwd fwd i947h1230001-02 1. Rear shock absorber 10. Swingarm : 115 n ⋅m (11.5 kgf-m, 83.0 lbf...

  • Page 445

    Rear suspension: 2c-2 rear suspension assembly construction b947h12306002 1 1 (a) (c) (a) 2 (b) 4 (f) 8 (g) 9 (d) 6 (b) 3 2 3 5 6 4 “ a ” “ c ” “ c ” “ a ” “ a ” “ a ” “ a ” “ a ” (b) 5 “ b ” “ b ” (e) 7 (e) 7 i947h1230002-04 1. Rear shock absorber mounting bolt (upper) 8. Swingarm pivot shaft : 115...

  • Page 446

    2c-3 rear suspension: rear shock absorber removal and installation b947h12306003 removal 1) remove the right side cowling and side frame covers. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 2) support the motorcycle with a jack to relieve load on the rear shock absor...

  • Page 447

    Rear suspension: 2c-4 rear shock absorber inspection b947h12306005 refer to “rear shock absorber removal and installation” (page 2c-3). Shock absorber inspect the rear shock absorber for damage and oil leakage, and absorber bushing for wear and damage. If any defect is found, replace the rear shock ...

  • Page 448

    2c-5 rear suspension: installation caution ! The removed bearing must be replaced with a new one. 1) press the bearing into the rear shock absorber at 0.5 mm (0.02 in) depth “a” from the rear shock absorber side surface with the special tool and suitable size socket wrench. Note apply a small quanti...

  • Page 449

    Rear suspension: 2c-6 compression side (low speed) fully turn the compression damping force (low speed) adjuster (1) clockwise. From that position (stiffest), turn it out to standard setting position. Std position 2-1/4 turns out of from stiffest position compression side (high speed) fully turn the...

  • Page 450

    2c-7 rear suspension: cushion lever removal and installation b947h12306008 removal 1) remove the right side cowling and side frame covers. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 2) support the motorcycle with a jack to relieve load on the cushion levers. 3) rem...

  • Page 451

    Rear suspension: 2c-8 installation install the cushion rod in the reverse order of removal. Pay attention to the following points: • before installing the cushion rod to the frame, insert the collar into the bearing from the left side. • install the washer between the cushion rod right side and fram...

  • Page 452

    2c-9 rear suspension: cushion rod bearing removal and installation b947h12306013 removal 1) remove the cushion rod. Refer to “cushion rod removal and installation” (page 2c-7). 2) remove the cushion rod bearing with the special tool. Special tool (a): 09921–20240 (bearing remover set) installation c...

  • Page 453

    Rear suspension: 2c-10 6) remove the left muffler and muffler chamber heat guard no. 2. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k (page 1k-11). 7) remove the rear shock absorber (3) and cushion lever mounting bolt and nut (4). Refer to “rear shock abs...

  • Page 454

    2c-11 rear suspension: • adjust swingarm pivot thrust clearance in the following procedures: – insert the swingarm pivot shaft (2) and tighten it to the specified torque with the special tool. Special tool (a): 09944–28321 (hexagon socket (19 mm)) tightening torque swingarm pivot shaft (a): 15 n·m (...

  • Page 455

    Rear suspension: 2c-12 swingarm pivot boss removal and installation b947h12306018 removal 1) remove the swingarm. Refer to “swingarm removal and installation” (page 2c-9). 2) remove the swingarm pivot boss nut (1). Note remove the swingarm pivot boss only when replacing it. 3) remove the swingarm pi...

  • Page 456

    2c-13 rear suspension: plate inspect the plate for damage and excessive bend. If any defect is found, replace the plate with a new one. Swingarm bearing 1) insert the collars and spacer into bearings. 2) check the play by moving the collars and spacer up and down. If excessive play is noted, replace...

  • Page 457

    Rear suspension: 2c-14 4) remove the cushion lever bearing (3) using the special tool. Special tool (a): 09921–20240 (bearing remover set) installation caution ! The removed bearings must be replaced with new ones. 1) install the center spacer. 2) press the pivot bearings into the swingarm pivot to ...

  • Page 458

    2c-15 rear suspension: specifications service data b947h12307001 suspension unit: mm (in) tightening torque specifications b947h12307002 note the specified tightening torque is described in the following. “rear suspension components” (page 2c-1) “rear suspension assembly construction” (page 2c-2) re...

  • Page 459

    Rear suspension: 2c-16 special tools and equipment recommended service material b947h12308001 note required service material is also described in the following. “rear suspension components” (page 2c-1) “rear suspension assembly construction” (page 2c-2) special tool b947h12308002 material suzuki rec...

  • Page 460: Wheels and Tires

    2d-1 wheels and tires: suspension wheels and tires precautions precautions for wheel and tire b947h12400001 warning ! • proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. • under-inflated tires make smooth co...

  • Page 461

    Wheels and tires: 2d-2 repair instructions front wheel components b947h12406001 1 3 3 5 6 7 8 9 11 10 4 5 4 (b) 12 (a) 2 (a) 2 fwd fwd i947h1240030-01 1. Front axle 6. Spacer 11. Collar : apply thread lock to the thread part. 2. Brake disc bolt 7. Air valve 12. Front axle bolt : do not reuse. 3. Bra...

  • Page 462

    2d-3 wheels and tires: front wheel assembly construction b947h12406002 (d) 4 “ a ” lh rh (b) 2 (d) 4 (a) 1 (a) 1 (c) 3 i947h1240031-02 1. Brake disc bolt “a”: clearance : 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake caliper mounting bolt : 18 n ⋅m (1.8 kgf-m, 13.0 lbf-ft) : apply grease. 3. Front axle ...

  • Page 463

    Wheels and tires: 2d-4 front wheel assembly removal and installation b947h12406003 removal 1) remove the brake calipers, left and right. Caution ! Do not operate the brake lever with the caliper removed. 2) loosen two axle pinch bolts (1) on the right front fork leg. 3) remove the front axle bolt (2...

  • Page 464

    2d-5 wheels and tires: 2) insert the front axle from the left side and tighten the front axle bolt temporarily. 3) tighten the brake caliper mounting bolts (2) to the specified torque. Tightening torque front brake caliper mounting bolt (a): 39 n·m ( 3.9 kgf-m, 28.0 lbf-ft) warning ! After remountin...

  • Page 465

    Wheels and tires: 2d-6 front wheel related parts inspection b947h12406004 refer to “front wheel assembly removal and installation” (page 2d-4). Tire refer to “tire inspection” in section 0b (page 0b-18). Front brake disc refer to “front brake disc inspection” in section 4b (page 4b-6). Dust seal ins...

  • Page 466

    2d-7 wheels and tires: front wheel dust seal / bearing removal and installation b947h12406005 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installation” (page 2d-4). 2) remove the dust seals using the special tool. Special tool (a): 09913–50121 (oil seal rem...

  • Page 467

    Wheels and tires: 2d-8 2) first install the right wheel bearing, then install the spacer (1) and left wheel bearing with the special tool. Special tool (a): 09924–84510 (bearing installer set) (b): 09941–34513 (bearing installer) caution ! The sealed cover of the bearing must face outside. 3) instal...

  • Page 468

    2d-9 wheels and tires: rear wheel components b947h12406006 fwd fwd 2 3 5 6 7 8 9 11 10 12 13 14 15 16 17 18 4 (b) (c) 9 (a) 1 i947h1240033-01 1. Rear axel nut 9. Bearing 17. Rear brake disc 2. Collar 10. Spacer 18. Rear axle 3. Dust seal 11. Air valve : 100 n ⋅m (10.0 kgf-m, 72.5 lbf-ft) 4. Bearing ...

  • Page 469

    Wheels and tires: 2d-10 rear wheel assembly construction b947h12406007 rh lh “ a ” (a) 1 (b) 2 (c) 3 i947h1240034-02 1. Rear sprocket nut “a”: clearance : 35 n ⋅m (3.5 kgf-m, 25.5 lbf-ft) 2. Rear axle nut : 60 n ⋅m (6.0 kgf-m, 43.0 lbf-ft) : apply grease. 3. Brake disc bolt : 100 n ⋅m (10 kgf-m, 72....

  • Page 470

    2d-11 wheels and tires: rear wheel assembly removal and installation b947h12406008 removal 1) loosen the axle nut (1). 2) raise the rear wheel off the ground and support the motorcycle with a jack or wooden block. Caution ! Make sure that the motorcycle is supported securely. 3) remove the axle nut ...

  • Page 471

    Wheels and tires: 2d-12 rear wheel related parts inspection b947h12406009 refer to “rear wheel assembly removal and installation” (page 2d-11). Tire refer to “tire inspection” in section 0b (page 0b-18). Rear brake disc refer to “rear brake disc inspection” in section 4c (page 4c-7). Wheel damper re...

  • Page 472

    2d-13 wheels and tires: rear wheel dust seal / bearing removal and installation b947h12406010 removal 1) remove the rear wheel assembly. Refer to “rear wheel assembly removal and installation” (page 2d-11). 2) remove the rear sprocket mounting drum assembly (1) from the rear wheel. 3) remove the whe...

  • Page 473

    Wheels and tires: 2d-14 2) first install the right wheel bearing, then install the spacer (1) and left wheel bearing with the special tools. Special tool (a): 09941–34513 (bearing installer) (b): 09924–84510 (bearing installer set) caution ! The sealed cover of the bearing must face outside. 3) inst...

  • Page 474

    2d-15 wheels and tires: 4) remove the tire using the tire changer. Caution ! For operating procedures, refer to the instructions supplied by the tire changer manufacturer. Note when removing the tire in case of repair or inspection, mark the tire with a chalk to indicate the tire position relative t...

  • Page 475

    Wheels and tires: 2d-16 7) when the bead has been fitted properly, adjust the pressure to specification. 8) as necessary, adjust the tire balance. Refer to “wheel balance check and adjustment” (page 2d- 17). Cold inflation tire pressure 9) install the mounting drum to the rear wheel. (for rear wheel...

  • Page 476

    2d-17 wheels and tires: 3) remove the air valve (1) from the wheel. Installation install the air valve in the reverse order of removal. Pay attention to the following points: • any dust or rust around the valve hole (1) must be cleaned off. • install the air valve (2) in the wheel (3). Caution ! • b...

  • Page 477

    Wheels and tires: 2d-18 specifications service data b947h12407001 wheel unit: mm (in) tire tightening torque specifications b947h12407002 note the specified tightening torque is described in the following. “front wheel components” (page 2d-2) “front wheel assembly construction” (page 2d-3) “rear whe...

  • Page 478

    2d-19 wheels and tires: special tools and equipment recommended service material b947h12408001 note required service material is also described in the following. “front wheel components” (page 2d-2) “front wheel assembly construction” (page 2d-3) “rear wheel components” (page 2d-9) “rear wheel assem...

  • Page 479: Section 3

    Table of contents 3- i 3 section 3 contents driveline / axle precautions .................................................3-1 precautions............................................................. 3-1 precautions for driveline / axle ............................. 3-1 drive chain / drive train / dr...

  • Page 480: Precautions

    3-1 precautions: driveline / axle precautions precautions precautions for driveline / axle b947h13000001 refer to “general precautions” in section 00 (page 00-1). Warning ! Never inspect or adjust the drive chain while the engine is running. Caution ! • do not use trichloroethylene, gasoline or such...

  • Page 481

    Drive chain / drive train / drive shaft: 3a-1 driveline / axle drive chain / drive train / drive shaft diagnostic information and procedures drive chain and sprocket symptom diagnosis b947h13104001 repair instructions drive chain related components b947h13106001 condition possible cause correction /...

  • Page 482

    3a-2 drive chain / drive train / drive shaft: engine sprocket removal and installation b947h13106002 removal 1) remove the gearshift link arm (1) from the gearshift shaft. Note mark the gearshift shaft head at which the gearshift link arm slit set for correct reinstallation. 2) remove the speed sens...

  • Page 483

    Drive chain / drive train / drive shaft: 3a-3 • tighten the engine sprocket nut (1) to the specified torque. Tightening torque engine sprocket nut (a): 145 n·m (14.5 kgf-m, 105.0 lbf-ft) • tighten the speed sensor rotor bolt (2) to the specified torque. Tightening torque speed sensor rotor bolt (b):...

  • Page 484

    3a-4 drive chain / drive train / drive shaft: 5) remove the retainer (3). 6) remove the wheel dampers (4). Installation install the rear sprocket and rear sprocket mounting drum in the reverse order of removal. Pay attention to the following points: • apply grease to the contacting surface between t...

  • Page 485

    Drive chain / drive train / drive shaft: 3a-5 drive chain related parts inspection b947h13106004 refer to “rear sprocket / rear sprocket mounting drum removal and installation” (page 3a-3). Dust seal inspect the dust seal for wear or damage. If any damage is found, replace the dust seal with a new o...

  • Page 486

    3a-6 drive chain / drive train / drive shaft: 4) remove the sprocket mounting drum dust seal with the special tool. Special tool (a): 09913–50121 (oil seal remover) 5) remove the sprocket mounting drum bearing with the special tool. Special tool (b): 09921–20240 (bearing remover set) installation ca...

  • Page 487

    Drive chain / drive train / drive shaft: 3a-7 drive chain replacement b947h13106006 use the special tool in the following procedures, to cut and rejoin the drive chain. Note when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Special tool : 09922–...

  • Page 488

    3a-8 drive chain / drive train / drive shaft: 6) remove the joint pin (9) of the other side of joint plate. Caution ! Never reuse joint pins, o-rings and plates. Drive chain connecting warning ! Do not use joint clip type of drive chain. The joint clip may have a chance to drop which may cause sever...

  • Page 489

    Drive chain / drive train / drive shaft: 3a-9 7) turn in the pressure bolt [a] (6) further using the bar (7) to press the joint plate over the joint pins. 8) continue pressing the joint plate until the distance between the two joint plates comes to the specification. Joint plate distance specificati...

  • Page 490

    3a-10 drive chain / drive train / drive shaft: specifications service data b947h13107001 drive train unit: mm (in) except ratio tightening torque specifications b947h13107002 note the specified tightening torque is described in the following. “drive chain related components” (page 3a-1) reference: f...

  • Page 491

    Drive chain / drive train / drive shaft: 3a-11 special tools and equipment recommended service material b947h13108001 note required service material is also described in the following. “drive chain related components” (page 3a-1) special tool b947h13108002 material suzuki recommended product or spec...

  • Page 492

    3a-12 drive chain / drive train / drive shaft: manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 493: Section 4

    Table of contents 4- i 4 section 4 contents brake precautions .................................................4-1 precautions............................................................. 4-1 precautions for brake system .............................. 4-1 brake fluid information .......................

  • Page 494: Precautions

    4-1 precautions: brake precautions precautions precautions for brake system b947h14000001 refer to “general precautions” in section 00 (page 00-1). Brake fluid information b947h14000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix differe...

  • Page 495

    Brake control system and diagnosis: 4a-1 brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b947h14102001 1 2 2 2 3 5 “c” 4 “a” “b” “b” (a) (a) (a) i947h1410046-02 1. Hose clamp : clamp end should face downward. “a”: white marking : white marking ...

  • Page 496

    4a-2 brake control system and diagnosis: rear brake hose routing diagram b947h14102002 1 2 2 “a” “b” “c” (c) 5 (e) 3 (d) 6 (f) 4 (a) (e) (g) (a) (b) i947h1410047-04 1. Hose clamp : face the clamp end backward. “a”: white marking : 12 n ⋅m (1.2 kgf-m, 8.5 lbf-ft) 2. Stopper : after the brake hose uni...

  • Page 497

    Brake control system and diagnosis: 4a-3 diagnostic information and procedures brake symptom diagnosis b947h14104001 repair instructions brake pedal height inspection and adjustment b947h14106001 refer to “brake system inspection” in section 0b (page 0b-16). Front brake light switch inspection b947h...

  • Page 498

    4a-4 brake control system and diagnosis: rear brake light switch inspection b947h14106003 inspect the rear brake light switch in the following procedures: 1) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). 2) disconnect the rear brake light s...

  • Page 499

    Brake control system and diagnosis: 4a-5 front brake note if air is trapped in the master cylinder, bleed air from the master cylinder first in the same manner as follows. Refer to “front brake master cylinder assembly removal and installation” (page 4a-10). 1) remove the reservoir cap and diaphragm...

  • Page 500

    4a-6 brake control system and diagnosis: 4) fill the reservoir with brake fluid to the upper line of the reservoir. Place the reservoir cap to prevent dirt from entering. Note the difference of bleeding operation from the front brake is that the rear master cylinder is actuated by a pedal. Tightenin...

  • Page 501

    Brake control system and diagnosis: 4a-7 6) loosen the air bleeder valve and pump the brake lever until the old brake fluid flows out of the brake system. 7) close the air bleeder valve and disconnect the clear hose. Tightening torque air bleeder valve (front caliper): 7.5 n·m (0.75 kgf-m, 5.5 lbf-f...

  • Page 502

    4a-8 brake control system and diagnosis: 8) loosen the air bleeder valve and pump the brake pedal until the old brake fluid flows out of the brake system. 9) close the air bleeder valve and disconnect the clear hose. Tightening torque air bleeder valve (rear caliper): 6 n·m (0.6 kgf- m, 4.5 lbf-ft) ...

  • Page 503

    Brake control system and diagnosis: 4a-9 front brake master cylinder components b947h14106011 1 2 3 5 6 7 8 11 13 4 fwd fwd (b) 9 (a) 12 (c) 10 (a) 12 (a) 12 (e) (d) i947h1410051-02 1. Reservoir cap 8. Brake lever : 1 n ⋅m (0.1 kgf-m, 0.5 lbf-ft) 2. Plate 9. Brake lever pivot bolt : 6 n ⋅m (0.6 kgf-...

  • Page 504

    4a-10 brake control system and diagnosis: front brake master cylinder assembly removal and installation b947h14106012 removal 1) drain brake fluid. Refer to “brake fluid replacement” (page 4a-6). 2) disconnect the front brake light switch coupler (1). 3) place a rag underneath the brake hose union b...

  • Page 505

    Brake control system and diagnosis: 4a-11 • after setting the brake hose union to the stopper, tighten the union bolt (2) to the specified torque. Caution ! The seal washers should be replaced with the new ones to prevent fluid leakage. Tightening torque brake hose union bolt (b): 23 n·m (2.3 kgf-m,...

  • Page 506

    4a-12 brake control system and diagnosis: 5) remove the following parts from the master cylinder. • piston (10) • return spring (11) • return spring guide (12) 6) remove the dust rubber (13) and snap ring (14). 7) remove the connector (15), o-ring (16) and air bleeder valve (17). Assembly assemble t...

  • Page 507

    Brake control system and diagnosis: 4a-13 • apply grease to the push rod. : grease 99000–25100 (suzuki silicone grease or equivalent) • apply grease to the brake lever pivot bolt. : grease 99000–25100 (suzuki silicone grease or equivalent) • tighten the pivot bolt (1) and lock-nut (2) to the specifi...

  • Page 508

    4a-14 brake control system and diagnosis: rear brake master cylinder components b947h14106015 fwd fwd 1 2 3 5 6 9 8 11 10 12 13 4 (a) 7 (a) 7 (c) (b) i947h1410052-02 1. Reservoir cap 6. Brake hose 11. Piston/cup set : 17 n ⋅m (1.7 kgf-m, 12.5 lbf-ft) 2. Plate 7. Brake hose union bolt 12. Push rod : ...

  • Page 509

    Brake control system and diagnosis: 4a-15 rear brake master cylinder assembly removal and installation b947h14106016 refer to “rear brake hose routing diagram” (page 4a- 2). Removal 1) remove the right side frame cover. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 2)...

  • Page 510

    4a-16 brake control system and diagnosis: rear brake master cylinder disassembly and assembly b947h14106017 refer to “rear brake master cylinder assembly removal and installation” (page 4a-15). Disassembly 1) disconnect the reservoir hose (1). 2) remove the lock-nut (2). 3) remove the brake hose con...

  • Page 511

    Brake control system and diagnosis: 4a-17 assembly assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: caution ! • wash the master cylinder components with new brake fluid before reassembly. • do not wipe the brake fluid off after washing the comp...

  • Page 512

    4a-18 brake control system and diagnosis: rear brake pedal construction b947h14106019 rear brake pedal removal and installation b947h14106020 removal 1) remove the master cylinder assembly. Refer to “rear brake master cylinder assembly removal and installation” (page 4a-15). 2) disconnect the rear b...

  • Page 513

    Brake control system and diagnosis: 4a-19 specifications service data b947h14107001 brake unit: mm (in) tightening torque specifications b947h14107002 note the specified tightening torque is described in the following. “front brake hose routing diagram” (page 4a-1) “rear brake hose routing diagram” ...

  • Page 514

    4a-20 brake control system and diagnosis: special tools and equipment recommended service material b947h14108001 note required service material is also described in the following. “front brake master cylinder components” (page 4a-9) “rear brake master cylinder components” (page 4a-14) “rear brake pe...

  • Page 515: Front Brakes

    Front brakes: 4b-1 brake front brakes repair instructions front brake components b947h14206001 1 2 3 5 4 fwd fwd (a) (b) (c) (d) i947h1420020-01 1. Seal set 5. Front brake disc : 18 n ⋅m (1.8 kgf-m, 13.0 lbf-ft) 2. Piston and seal set : 7.5 n ⋅m (0.75 kgf-m, 5.5 lbf-ft) : apply thread lock to the th...

  • Page 516

    4b-2 front brakes: front brake pad inspection b947h14206002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement” (page 4b-2). Caution ! Re...

  • Page 517

    Front brakes: 4b-3 front brake caliper removal and installation b947h14206004 note the right and left calipers are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) drain brake fluid. Refer to “brake fluid replacement” in sect...

  • Page 518

    4b-4 front brakes: disassembly 1) remove the brake pads (1) and spring from the caliper by removing the pad mounting pins. 2) place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air. Caution ! Do not use high pressure air to prevent piston da...

  • Page 519

    Front brakes: 4b-5 • when installing the spring to the caliper, bring its wider pawl “a” facing top side. • install the brake pads and temporarily tighten the pad mounting pins (3). Front brake caliper parts inspection b947h14206006 refer to “front brake caliper disassembly and assembly” (page 4b-3)...

  • Page 520

    4b-6 front brakes: front brake disc removal and installation b947h14206007 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installation” in section 2d (page 2d-4). 2) remove the front brake disc. Installation install the front brake disc in the reverse order of...

  • Page 521

    Front brakes: 4b-7 specifications service data b947h14207001 brake unit: mm (in) tightening torque specifications b947h14207002 note the specified tightening torque is described in the following. “front brake components” (page 4b-1) reference: for the tightening torque of fastener not specified in t...

  • Page 522

    4b-8 front brakes: special tools and equipment recommended service material b947h14208001 note required service material is also described in the following. “front brake components” (page 4b-1) special tool b947h14208002 material suzuki recommended product or specification note brake fluid dot 4 — )...

  • Page 523: Rear Brakes

    Rear brakes: 4c-1 .Brake rear brakes repair instructions rear brake components b947h14306001 7 (f) fwd fwd 6 8 8 5 (c) 4 3 2 (a) (b) (e) (d) 1 i947h1430026-02 1. Rear brake caliper 8. Brake pad spring : apply silicone grease to sliding surface. 2. Piston seal : 6 n ⋅m (0.6 kgf-m, 4.5 lbf-ft) : apply...

  • Page 524

    4c-2 rear brakes: rear brake pad inspection b947h14306002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “rear brake pad replacement” (page 4c-2). Caution ! Repla...

  • Page 525

    Rear brakes: 4c-3 5) tighten the brake pad mounting pin (2) and plug (1) to the specified torque. Tightening torque rear brake pad mounting pin (a): 17 n·m (1.7 kgf-m, 12.5 lbf-ft) rear brake pad mounting pin plug (b): 2.5 n·m ( 0.25 kgf-m, 2.0 lbf-ft) note after replacing the brake pads, pump the b...

  • Page 526

    4c-4 rear brakes: • tighten the caliper sliding pin a (1) to the specified torque. Tightening torque rear brake caliper sliding pin a (a): 27 n·m (2.7 kgf-m, 19.5 lbf-ft) • fit each boot end into the sliding pin groove. • install the rear wheel. Refer to “rear wheel assembly removal and installation...

  • Page 527

    Rear brakes: 4c-5 3) remove the dust seal (3) and piston seal (4). 4) remove the rubber boot (5), pad spring (6) and sliding pin b (7) from the bracket. Assembly assemble the caliper in the reverse order of disassembly. Pay attention to the following points: • wash the caliper bore and piston with s...

  • Page 528

    4c-6 rear brakes: • install the rear brake caliper. Refer to “rear brake caliper removal and installation” (page 4c-3). Rear brake caliper parts inspection b947h14306006 refer to “rear brake caliper disassembly and assembly” (page 4c-4). Brake caliper cylinder inspect the brake caliper cylinder wall...

  • Page 529

    Rear brakes: 4c-7 installation install the rear brake disc in the reverse order of removal. Pay attention to the following points: • make sure that the brake disc is clean and free of any grease. • apply thread lock to the brake disc bolts (1) and tighten them to the specified torque. : thread lock ...

  • Page 530

    4c-8 rear brakes: tightening torque specifications b947h14307002 note the specified tightening torque is described in the following. “rear brake components” (page 4c-1) reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c (pa...

  • Page 531: Section 5

    Table of contents 5- i 5 section 5 contents transmission / transaxle precautions .................................................5-1 precautions............................................................. 5-1 precautions for transmission / transaxle............. 5-1 manual transmission...............

  • Page 532: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions for transmission / transaxle b947h15000001 refer to “general precautions” in section 00 (page 00-1). Manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 533: Manual Transmission

    Manual transmission: 5b-1 transmission / transaxle manual transmission diagnostic information and procedures manual transmission symptom diagnosis b947h15204001 condition possible cause correction / reference item engine is noisy (noise seems to come from the transmission) worn or rubbing gear. Repl...

  • Page 534

    5b-2 manual transmission: repair instructions transmission components b947h15206001 1 2 3 5 6 7 8 9 11 10 20 12 13 14 15 16 17 18 19 4 fwd fwd (a) (b) (c) (d) i947h1520072-02 1. 2nd drive gear 11. 5th driven gear : 145 n ⋅m (14.5 kgf-m, 105.0 lbf-ft) 2. 6th drive gear 12. 1st driven gear : 10 n ⋅m (...

  • Page 535

    Manual transmission: 5b-3 transmission removal b947h15206002 1) remove the engine assembly from the frame. Refer to “engine assembly removal” in section 1d (page 1d-20). 2) remove the engine top side. Refer to “engine top side disassembly” in section 1d (page 1d-26). 3) separate the upper and lower ...

  • Page 536

    5b-4 manual transmission: 4) using suitable size bolts (3), remove the driveshaft left bearing case (4). 5) remove the dowel pin. 6) remove the driveshaft right bearing case bolts. 7) using suitable size bolts (5), remove the driveshaft right bearing assembly (6). 8) remove the driveshaft assembly (...

  • Page 537

    Manual transmission: 5b-5 3) remove the gearshift shaft bearings (3) and (4) with the special tool. Special tool (c): 09921–20240 (bearing remover set) 4) remove the driveshaft left bearing with the special tool. Special tool (d): 09913–70210 (bearing installing set (10 – 75 Φ)) 5) remove the drives...

  • Page 538

    5b-6 manual transmission: • install the gearshift shaft bearings (1) and (2) with the special tool. Note the stamped mark side of the gearshift shaft bearing faces outside. Special tool (a): 09913–70210 (bearing installing set (10 – 75 Φ)) • install the gearshift shaft oil seal (3) with the special ...

  • Page 539

    Manual transmission: 5b-7 • apply grease to the o-ring and install the driveshaft left bearing case (3). Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease “a” or equivalent) • apply thread lock to the bolts and tighten them to the specified torque. : thread lock ...

  • Page 540

    5b-8 manual transmission: • install the gearshift cam (2) with the bearing fitted. • with engaging each fork end to the cam groove, insert the fork shaft (3). • apply thread lock to the screws and tighten them to the specified torque. : thread lock cement 99000–32110 (thread lock cement super “1322”...

  • Page 541

    Manual transmission: 5b-9 transmission construction b947h15206004 1 2 i947h1520060-02 1. Countershaft 2. Driveshaft manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 542

    5b-10 manual transmission: countershaft gear / driveshaft gear disassembly and assembly b947h15206005 refer to “transmission removal” (page 5b-3) and “transmission installation” (page 5b-5). Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective grou...

  • Page 543

    Manual transmission: 5b-11 assembly note when reassembling the transmission gears, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, bushings, washers and snap rings. Refer to “transmission construction...

  • Page 544

    5b-12 manual transmission: • when installing the gear bushing onto the countershaft, align the shaft oil hole “a” with the bushing oil hole “b”. Transmission related parts inspection b947h15206006 refer to “transmission removal” (page 5b-3), “transmission installation” (page 5b-5) and “countershaft ...

  • Page 545

    Manual transmission: 5b-13 gearshift cam inspect the gearshift cam groove for abnormal wear and damage. If any defects are found, replace the gearshift cam with a new one. Gearshift cam bearing inspect the gearshift cam bearings, left and right for abnormal noise and smooth rotation. Replace the bea...

  • Page 546

    5b-14 manual transmission: gear position (gp) switch removal and installation b947h15206008 removal 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). 3) disconnect the gear position switch lead wire coupler (...

  • Page 547

    Manual transmission: 5b-15 gearshift lever construction b947h15206009 gearshift lever removal and installation b947h15206010 removal remove the gearshift lever as shown in the gearshift lever construction. Refer to “gearshift lever construction” (page 5b-15). Installation 1) install the gearshift le...

  • Page 548

    5b-16 manual transmission: gearshift lever height inspection and adjustment b947h15206011 inspect and adjust the gearshift lever height in the following procedures: 1) inspect the gearshift lever height “a” between the lever top and footrest. Adjust the gearshift lever height if necessary. Gearshift...

  • Page 549

    Manual transmission: 5b-17 gearshift shaft construction b947h15206013 gearshift shaft / gearshift cam plate removal and installation b947h15206014 removal 1) remove the engine sprocket cover. Refer to “engine sprocket removal and installation” in section 3a (page 3a-2). 2) remove the clutch componen...

  • Page 550

    5b-18 manual transmission: 5) remove the following parts from the gearshift shaft. Special tool : 09900–06107 (snap ring remover (open type)) 6) remove the gearshift cam plate bolt (11) and gearshift cam plate (12). 7) remove the gearshift cam stopper (13). 8) remove the gearshift arm stopper (14). ...

  • Page 551

    Manual transmission: 5b-19 • check the gearshift cam stopper moves smoothly. • locate the gearshift cam in the neutral position. • install the gearshift cam plate (5). Note align the gearshift cam pin “b” with the gearshift cam plate hole “c”. • apply a small quantity of thread lock to the gearshift...

  • Page 552

    5b-20 manual transmission: • install a new snap ring (9). Special tool : 09900–06107 (snap ring remover (open type)) • after installing the gearshift lever, check the gearshift lever height. Refer to “gearshift lever height inspection and adjustment” (page 5b-16). Gearshift linkage inspection b947h1...

  • Page 553

    Manual transmission: 5b-21 installation install the oil seal and bearing in the reverse order of removal. Pay attention to the following points: caution ! The removed oil seal and bearings must be replaced with new ones. • install the bearings with the special tool. Note the stamped mark side of gea...

  • Page 554

    5b-22 manual transmission: tightening torque specifications b947h15207002 note the specified tightening torque is described in the following. “transmission components” (page 5b-2) “gearshift lever construction” (page 5b-15) “gearshift shaft / gearshift cam plate components” (page 5b-16) “gearshift s...

  • Page 555

    Manual transmission: 5b-23 special tool b947h15208002 09900–06104 09900–06107 snap ring remover (open type) snap ring remover (open type) )(page 5b-10) )(page 5b-17) / )(page 5b-18) / )(page 5b-20) 09900–20102 09900–20803 vernier calipers (200 mm) thickness gauge )(page 5b-12) / )(page 5b-12) )(page...

  • Page 556: Clutch

    5c-1 clutch: transmission / transaxle clutch precautions precautions for clutch system b947h15300001 refer to “general precautions” in section 00 (page 00-1). Schematic and routing diagram clutch cable routing diagram b947h15302001 refer to “throttle cable routing diagram” in section 1d (page 1d-2)....

  • Page 557

    Clutch: 5c-2 repair instructions clutch lever position switch inspection b947h15306001 inspect the clutch lever position switch in the following procedures: 1) disconnect the clutch lever position switch lead wires (1). 2) inspect the clutch lever position switch for continuity with the tester. If a...

  • Page 558

    5c-3 clutch: clutch control system components b947h15306004 1 2 3 4 (a) (b) (c) i947h1530043-02 1. Push rod 4. Clutch cable : 10 n ⋅m (1.0 kgf-m, 0.7 lbf-ft) 2. Clutch release camshaft : 1 n ⋅m (0.1 kgf-m, 0.7 lbf-ft) : apply grease. 3. Clutch release arm : 6 n ⋅m (0.6 kgf-m, 4.5 lbf-ft) : do not re...

  • Page 559

    Clutch: 5c-4 clutch components b947h15306005 1 2 3 11 10 12 13 14 15 16 4/5 3 3 5 3 5 3 5 3 5 3 5 3 6 7 8 9 4/5 (a) (b) fwd fwd i947h1530044-03 1. Clutch pressure plate 8. Spring washer 15. Primary driven gear assembly 2. Clutch push piece 9. Spring washer seat 16. Push rod 3. No. 1 drive plate (8 p...

  • Page 560

    5c-5 clutch: clutch removal b947h15306006 1) drain engine oil. Refer to “engine oil and filter replacement” in section 0b (page 0b-10). 2) lift and support the fuel tank with the prop stay. Refer to “fuel tank removal and installation” in section 1g (page 1g-9). 3) disconnect the ckp sensor coupler ...

  • Page 561

    Clutch: 5c-6 9) remove the thrust washer (9), bearing (10) and clutch push piece (11). 10) remove the clutch push rod (12). Note if it is difficult to pull out the push rod (12), use a magnetic hand or wire. 11) unlock the clutch sleeve hub nut. 12) hold the clutch sleeve hub with the special tool. ...

  • Page 562

    5c-7 clutch: 17) remove the clutch lifter drive cam (19) and thrust washer (20). 18) remove the spacer (21) and bearing (22). 19) remove the primary driven gear assembly (23). Note if it is difficult to remove the primary driven gear, rotate the crankshaft. Clutch installation b947h15306007 1) insta...

  • Page 563

    Clutch: 5c-8 7) install the clutch lifter drive cam (9). 8) install the clutch sleeve hub, washer (10) and spring washer (11). Note the conical curve side of spring washer (11) faces outside. 9) hold the clutch sleeve hub with the special tool. Special tool (a): 09920–53740 (clutch sleeve hub holder...

  • Page 564

    5c-9 clutch: 14) install the spring washer seat (16) and spring washer (17) onto the clutch sleeve hub correctly. 15) apply engine oil to the clutch drive plates. 16) insert the clutch drive plates and driven plate one by one into the clutch sleeve hub in the prescribed order. Note insert the outerm...

  • Page 565

    Clutch: 5c-10 19) tighten the clutch spring set bolts to the specified torque. Tightening torque clutch spring set bolt: 10 n·m (1.0 kgf-m, 7.0 lbf- ft) note tighten the clutch spring set bolt little by little and diagonally. 20) loosen the lock-nut (24) and turn in the clutch release adjusting scre...

  • Page 566

    5c-11 clutch: 26) install the clutch cover and tighten the clutch cover bolts. Note fit new gasket washer to the bolt “f” and clamp to the bolt “g”. 27) route the ckp sensor lead wire properly. Refer to “wiring harness routing diagram” in section 9a (page 9a-7). 28) install the fuel tank. Refer to “...

  • Page 567

    Clutch: 5c-12 clutch release bearing inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced. Smooth engagement and disengagement of the clutch depends on the condition of this b...

  • Page 568

    5c-13 clutch: clutch lifter pin inspection and adjustment b947h15306009 refer to “clutch removal” (page 5c-5) and “clutch installation” (page 5c-7). Note when inspection and adjusting the clutch lifter pin, it is not necessary to install the clutch onto the countershaft. Inspect and adjust the clutc...

  • Page 569

    Clutch: 5c-14 8) tighten the lock-nut (1). Tightening torque clutch lifter pin lock-nut (b): 23 n·m (2.3 kgf-m, 16.5 lbf-ft) specifications service data b947h15307001 clutch unit: mm (in) tightening torque specifications b947h15307002 note the specified tightening torque is described in the followin...

  • Page 570

    5c-15 clutch: special tools and equipment recommended service material b947h15308001 note required service material is also described in the following. “clutch control system components” (page 5c-3) “clutch components” (page 5c-4) special tool b947h15308002 material suzuki recommended product or spe...

  • Page 571: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions for steering ....................................... 6-1 steering general diagnosis.............

  • Page 572: Precautions

    6-1 precautions: steering precautions precautions precautions for steering b947h16000001 refer to “general precautions” in section 00 (page 00-1). Manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 573: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering steering general diagnosis diagnostic information and procedures steering symptom diagnosis b947h16104001 condition possible cause correction / reference item heavy steering over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. ...

  • Page 574: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar repair instructions handlebar components b947h16206001 1 2 3 5 6 7 8 4 “a” (b) (a) fwd fwd fwd fwd i947h1620001-05 1. Throttle grip 5. Right handlebar “a”: apply handle grip bond. 2. Grip rubber 6. Left handlebar : 23 n ⋅m (2.3 kgf-m, 16.5 lbf...

  • Page 575

    Steering / handlebar: 6b-2 handlebar removal and installation b947h16206002 removal 1) remove the following parts from the left handlebar. A) left handlebar switch box (1) b) handlebar balancer (2) c) grip rubber (3) d) clutch cable (4) 2) remove the following parts from the right handlebar. A) righ...

  • Page 576

    6b-3 steering / handlebar: 7) remove the clutch lever assembly (15) from the left handlebar. Installation install the handlebars in the reverse order of removal. Pay attention to the following points: • when installing the clutch lever assembly to the left handlebar, align the slit of lever holder w...

  • Page 577

    Steering / handlebar: 6b-4 • install the front brake master cylinder. Refer to “front brake master cylinder assembly removal and installation” in section 4a (page 4a-10). • apply grease to the end of the throttle cables and cable pulley. : grease 99000–25010 (suzuki super grease “a” or equivalent) •...

  • Page 578

    6b-5 steering / handlebar: steering components b947h16206004 2 6 7 8 9 11 10 12 4 (a) 1 (d) (b) 3 fwd fwd (c) 5 i947h1620017-04 1. Steering stem head nut 7. Dust seal : 90 n ⋅m (9.0 kgf-m, 65.0 lbf-ft) 2. Steering stem upper bracket 8. Steering stem upper bearing : 80 n ⋅m (8.0 kgf-m, 58.0 lbf-ft) 3...

  • Page 579

    Steering / handlebar: 6b-6 steering damper construction b947h16206005 steering / steering damper removal and installation b947h16206006 removal steering damper 1) turn the ignition switch off. 2) disconnect the steering damper solenoid coupler (1). 3) remove the lower bracket cover (2). 4) remove th...

  • Page 580

    6b-7 steering / handlebar: 6) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (page 1d-7). 7) disconnect the ignition switch lead wire coupler (1) and immobilizer antenna lead wire coupler (for e- 02, 19, 24, 51) (2). 8) remove the brake hose clamp bolt ...

  • Page 581

    Steering / handlebar: 6b-8 installation install the steering in the reverse order of removal. Pay attention to the following points: bearing • apply grease to the bearings, bearing races and dust seals before remounting the steering stem. : grease 99000–25010 (suzuki super grease “a” or equivalent) ...

  • Page 582

    6b-9 steering / handlebar: steering stem upper bracket install the front forks and steering stem upper bracket in the following points: • temporarily install the upper bracket (1), washer (2) and steering stem head nut (3). Refer to “handlebar removal and installation” (page 6b-2). • temporarily ins...

  • Page 583

    Steering / handlebar: 6b-10 bearing • bearing wear or damage • abnormal bearing noise • race wear or damage • bearing lower seal damage steering damper • inspect the steering damper body, bearing and oil seal for damage and oil leaking. • move the steering damper rod by hand to inspect for a smooth ...

  • Page 584

    6b-11 steering / handlebar: outer race • press in the upper and lower outer races using the special tool. Special tool (a): 09941–34513 (bearing installer) (b): 09913–70210 (bearing installing set (10 – 75 Φ)) inner race • press in the lower bearing inner race using the special tool. Special tool (a...

  • Page 585

    Steering / handlebar: 6b-12 specifications tightening torque specifications b947h16207001 note the specified tightening torque is described in the following. “handlebar components” (page 6b-1) “steering components” (page 6b-5) “steering damper construction” (page 6b-6) reference: for the tightening ...

  • Page 586

    6b-13 steering / handlebar: special tools and equipment recommended service material b947h16208001 note required service material is also described in the following. “handlebar components” (page 6b-1) “steering components” (page 6b-5) “steering damper construction” (page 6b-6) special tool b947h1620...

  • Page 587: Section 9

    Table of contents 9- i 9 section 9 contents body and accessories precautions .................................................9-1 precautions............................................................. 9-1 precautions for electrical system ......................... 9-1 component location .............

  • Page 588

    9-ii table of contents specifications.....................................................9d-12 tightening torque specifications......................9d-12 body structure .........................................9e-1 repair instructions .............................................. 9e-1 body frame ...

  • Page 589: Precautions

    Precautions: 9-1 body and accessories precautions precautions precautions for electrical system b947h19000001 refer to “general precautions” in section 00 (page 00-1) and “precautions for electrical circuit service” in section 00 (page 00-2). Component location electrical components location b947h19...

  • Page 590: Wiring Systems

    9a-1 wiring systems: body and accessories wiring systems schematic and routing diagram wiring diagram b947h19102001 refer to “wire color symbols” in section 0a (page 0a-5). For e-02, 19, 24, 51 headlight (lo) headlight (hi) position light (lh) steering damper solenoid valve position light (rh) front...

  • Page 591

    Wiring systems: 9a-2 ecm regulator/ rectifier primary injector #4 primary injector #2 primary injector #3 primary injector #1 secondary injector #4 secondary injector #2 secondary injector #1 secondary injector #3 tp sensor stva iap sensor iat sensor isc valve stp sensor ho2 sensor cooling fan relay...

  • Page 592

    9a-3 wiring systems: for e-03, 28 off run off on push free on off lock p free push on off free up down 1 on off 1 2 3 4 5 6 b bl hi lo pass push on off push push l push r free m b/w b/w b b b/bl b/w dg dbr b/r p y/bl b/g g/y b/lg bl/b w br o/g r/bl lg w b br b/w y b/w b/bl b/o b b b b/w w b/w b/br b...

  • Page 593

    Wiring systems: 9a-4 ecm g b/w w/r b/y b/w bl b/w o/y o/bl gr y lg lg/w lg/b lg/bl w/g y/g bl/w bl/b o/r br w/bl b gr/w gr/b gr/y gr/r g/r w/b y/b bl y g b/w b/br w/g dg b/bl b b/lg g w br y/r b/g p g/bl g/y g/b y/w bl/g bl/y y r/b o/w y/bl r/bl g/w b/y r p/b b/w p/w w/b p b/r b/br bl/w bl/b bl/g bl...

  • Page 594

    9a-5 wiring systems: for e-14, 33 off run off on push free on off lock p free push on off free up down 1 on off 1 2 3 4 5 6 b bl hi lo pass push on off push push l push r free m b/w b/w b b b/bl b/w dg dbr b/r p y/bl b/g g/y b/lg bl/b w br o/g r/bl lg w b br b/w y b/w b/bl b/o b b b b/w w b/w b/br b...

  • Page 595

    Wiring systems: 9a-6 ecm evap system purge control solenoid valve g b/w w/r b/y b/w bl b/w o/y o/bl gr dbr y lg lg/w lg/b lg/bl w/g y/g bl/w bl/b o/r br w/bl b gr/w gr/b gr/y gr/r g/r w/b y/b bl y g b/w b/br w/g dg b/bl b b/lg g w br y/r b/g p g/bl g/y g/b y/w bl/g bl/y y r/b o/w y/bl r/bl g/w b/y r...

  • Page 596

    9a-7 wiring systems: wiring harness routing diagram b947h19102002 1 1 “c” “d” “f” 4 “a”, “b” “a” 3 “e” 2 i947h1910907-03 1. Wiring harness no. 2 “b”: pass the left position light lead wires under the wiring harness no. 2. 2. Tapping clamp : insert the clamp from the front side. Place the turn signal...

  • Page 597

    Wiring systems: 9a-8 6 7 upside “b” 1 “a” “d” “e” 3 4 5 12 16 13 15 14 17 “ a ” 2 11 13 14 9 8 9 10 “c” i947h1910908-03 1. Clamp : pass the side-stand switch lead wire left side of the water by- pass hose and clamp them in this range. Cut off the excess tip of the clamp. 13. Battery negative lead wi...

  • Page 598

    9a-9 wiring systems: 1 2 3 5 6 7 8 “c” “d” “e” 4 4 “a” “b” upside i947h1910909-03 1. Steel clamp : set the clamp facing downward and bend it to outside. 8. Clamp : put the coupler in the frame rib and face the clamp end inside. 2. Clamp : bind the wiring harness and battery negative lead wires at bl...

  • Page 599

    Wiring systems: 9a-10 “ a ” “ a ” “ a ” “ b ” “ c ” “ d ” (f) 3 2 1 6 7 8 4 4 “a” fwd fwd fwd fwd fwd (d) 5 (a) (a) (b) (c) (h) (f) (e) (g) i947h1910910-02 1. Cylinder head cover “a”: pass the oil pressure switch lead wire between cylinder and generator lead wires. : 14 n ⋅m (1.4 kgf-m, 10.0 lbf-ft)...

  • Page 600

    9a-11 wiring systems: specifications service data b947h1910s001 electrical tightening torque specifications b947h1910s002 note the specified tightening torque is described in the following. “wiring harness routing diagram” (page 9a-7) reference: for the tightening torque of fastener not specified in...

  • Page 601: Lighting Systems

    Lighting systems: 9b-1 body and accessories lighting systems repair instructions headlight components b947h19206001 headlight removal and installation b947h19206002 removal 1) remove the body cowling assembly. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 2) remove th...

  • Page 602

    9b-2 lighting systems: 4) remove the intake pipe covers (3). 5) remove the intake cover (4). 6) remove the body cowling (5). Installation installation is in the reverse order of removal. Pay attention to the following point: • route the wiring harness properly. Refer to “wiring harness routing diagr...

  • Page 603

    Lighting systems: 9b-3 position light bulb 1) disconnect the position light socket (1). 2) replace the position light bulb (2) with a new one. 3) reinstall the position light socket. Headlight beam adjustment b947h19206004 adjust the headlight beam, both horizontally and vertically. Note • to adjust...

  • Page 604

    9b-4 lighting systems: front turn signal light removal and installation b947h19206006 removal 1) remove the screw. 2) disconnect the front turn signal coupler (1). 3) remove the turn signal light assembly (2). Installation install the front turn signal light in the reverse order of removal. Front tu...

  • Page 605

    Lighting systems: 9b-5 rear lighting system construction b947h19206008 (b) 1 2 2 3 5 4 (a) (c) i947h1920017-01 1. License plate light assembly 4. Rear combination light : 1.8 n ⋅m (0.18 kgf-m, 1.5 lbf-ft) 2. Reflex reflector (e-03, 28, 33 only) 5. Rear turn signal light assembly (lh/rh) : 2.8 n ⋅m (...

  • Page 606

    9b-6 lighting systems: rear combination light removal and installation b947h19206009 removal 1) remove the frame cover assembly. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 2) remove the clamps (1). 3) disconnect the combination light coupler (2). 4) remove the rear...

  • Page 607

    Lighting systems: 9b-7 license plate light components b947h19206011 license plate light removal and installation b947h19206012 removal 1) remove the frame cover. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). 2) disconnect the license plate light coupler (1). 3) remov...

  • Page 608

    9b-8 lighting systems: installation install the license plate light in the reverse order of removal. Pay attention to the following point: • tighten the license plate light mounting nuts (1) to the specified torque. Tightening torque license plate light mounting nut (a): 5 n·m (0.5 kgf-m, 3.5 lbf-ft...

  • Page 609

    Lighting systems: 9b-9 rear turn signal light components b947h19206014 rear turn signal light removal and installation b947h19206015 removal 1) remove the frame cover assembly. Refer to “exterior parts removal and installation” in section 9d (page 9d-6). 2) remove the rear combination light. Refer t...

  • Page 610

    9b-10 lighting systems: 6) remove the rear turn signal light (5). Installation install the rear turn signal light in the reverse order of removal. Rear turn signal light bulb replacement b947h19206016 caution ! When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with ...

  • Page 611

    Lighting systems: 9b-11 turn signal / side-stand relay inspection b947h19206019 refer to “electrical components location” in section 0a (page 0a-7). Note make sure that the battery is fully charged. Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If th...

  • Page 612

    9b-12 lighting systems: turn signal switch inspection b947h19206022 inspect the turn signal switch in the following procedures: 1) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (page 1d-7). 2) disconnect the left handlebar switch coupler (1). (yellow) ...

  • Page 613

    Lighting systems: 9b-13 specifications service data b947h19207001 wattage unit: w tightening torque specifications b947h19207002 note the specified tightening torque is described in the following. “rear lighting system construction” (page 9b-5) “license plate light components” (page 9b-7) “reflex re...

  • Page 614

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn general description combination meter system description b947h19301001 this combination meter mainly consists of a stepping motor, lcd (liquid crystal display) and leds (light emitting diode). The ...

  • Page 615

    Combination meter / fuel meter / horn: 9c-2 repair instructions combination meter components b947h19306001 combination meter removal and installation b947h19306002 removal 1) remove the combination meter mounting bolt (1). 2) disconnect the coupler (2) and remove the combination meter assembly (3). ...

  • Page 616

    9c-3 combination meter / fuel meter / horn: combination meter disassembly and assembly b947h19306003 refer to “combination meter removal and installation” (page 9c-2). Disassembly disassemble the combination meter as shown in the combination meter components. Refer to “combination meter components” ...

  • Page 617

    Combination meter / fuel meter / horn: 9c-4 engine coolant temperature indicator light inspection b947h19306005 inspect the engine coolant temperature meter and indicator light (led) in the following procedures: 1) remove the left side cowling. Refer to “exterior parts removal and installation” in s...

  • Page 618

    9c-5 combination meter / fuel meter / horn: fuel level indicator inspection b947h19306007 if the fuel level indicator light (1) does not function properly, check the fuel level gauge and its lead wire/ coupler. If the fuel level gauge and its lead wire/coupler are functioning properly, replace the c...

  • Page 619

    Combination meter / fuel meter / horn: 9c-6 installation install the speed sensor in the reverse order of removal. Pay attention to the following points: • tighten the speed sensor mounting bolt (1) to the specified torque. Tightening torque speed sensor mounting bolt (a): 6.5 n·m (0.65 kgf-m, 4.5 l...

  • Page 620

    9c-7 combination meter / fuel meter / horn: 4) check if the oil pressure indicator (led) (2) will light up and lcd (3) will flicker when grounding the lead wire (1). If the oil pressure indicator does not light up, replace the combination meter assembly with a new one after checking the connection o...

  • Page 621

    Combination meter / fuel meter / horn: 9c-8 horn inspection b947h19306017 note if the horn sound condition is normal, it is not necessary to inspect the horn button continuity. Horn button inspection 1) remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d (pa...

  • Page 622

    9c-9 combination meter / fuel meter / horn: specifications service data b947h19307001 wattage unit: w tightening torque specifications b947h19307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c (page 0c-9). Special to...

  • Page 623: Exterior Parts

    Exterior parts: 9d-1 body and accessories exterior parts repair instructions exterior parts construction b947h19406001 “c” “d” “a” “a” “a” “a” “b” 2 1 i947h1940001-01 1. Upper cowling bracket : set the punch mark to the front and upper side. “a”: to frame “c”: to sprocket cover 2. Rear view mirror c...

  • Page 624

    9d-2 exterior parts: rear fender construction b947h19406004 3 3 2 1 4 5 i947h1940002-02 1. Electric parts holder bracket 3. Rear fender (rear) 5. Rear fender guard (e-24 only) 2. Rear fender (front) 4. Rear fender (lower) manuals by motomatrix / the solution for lost motorcycle coded keys email: inf...

  • Page 625

    Exterior parts: 9d-3 frame cover construction b947h19406005 1 2 3 i947h1940003-01 1. Frame cover (center) 2. Frame cover (rear), lh/rh 3. Frame cover (lh/rh) manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 626

    9d-4 exterior parts: rear view mirror construction b947h19406008 1 2 3 4 (a) 5 6 7 i947h1940004-01 1. Body cowling 4. Turn signal lead wire 7. Mirror body 2. Cowling brace 5. Turn signal lead wire coupler : locate the turn signal lead wire coupler (5) between the mirror cover (6) and mirror body (7)...

  • Page 627

    Exterior parts: 9d-5 fastener removal and installation b947h19406010 type a removal 1) depress the head of fastener center piece (1). 2) pull out the fastener (2). Installation 1) let the center piece stick out toward the head so that the pawls “a” closes. 2) insert the fastener into the installatio...

  • Page 628

    9d-6 exterior parts: exterior parts removal and installation b947h19406011 side frame cover removal note the left and right side frame covers are installed symmetrically and therefore the removal/installation procedure for one side is the same as that for the other side. 1) remove the bolt (1). 2) r...

  • Page 629

    Exterior parts: 9d-7 installation slide the hook into the hook retainer and push down firmly until the rear seat/seat tail cover snaps into the locked position. Windscreen removal 1) loosen the rear view mirror mounting nuts. 2) remove the windscreen (1) by removing the screws. Installation install ...

  • Page 630

    9d-8 exterior parts: • tighten the rear view mirror mounting nuts to the specified torque. Tightening torque rear view mirror mounting nut (a): 10 n·m (1.0 kgf-m, 7.0 lbf-ft) body cowling cover removal 1) remove the fasteners (8 pcs.). 2) remove the body cowling cover (1). Installation install the b...

  • Page 631

    Exterior parts: 9d-9 installation install side cowling in the reverse order of removal. Pay attention to the following points: • when installing the right side cowling, make sure that the fuel tank drain hose and breather hose are routed properly. Refer to “fuel tank drain hose and breather hose rou...

  • Page 632

    9d-10 exterior parts: 12) remove the body cowling assembly (4) forward. 13) disassemble the body cowling assembly. Refer to “headlight removal and installation” in section 9b (page 9b-1). Installation install the body cowling in the reverse order of removal. Pay attention to the following point: • a...

  • Page 633

    Exterior parts: 9d-11 frame cover removal 1) remove the front and rear seats. 2) remove the bolts and fasteners. 3) disconnect the seat lock cable (1). 4) disconnect the rear combination light coupler (2). 5) remove the frame cover assembly from the frame. 6) disassemble the frame cover assembly. Re...

  • Page 634

    9d-12 exterior parts: specifications tightening torque specifications b947h19407001 note the specified tightening torque is described in the following. “rear view mirror construction” (page 9d-4) reference: for the tightening torque of fastener not specified in this section, refer to “tightening tor...

  • Page 635: Body Structure

    Body structure: 9e-1 body and accessories body structure repair instructions body frame construction b947h19506001 1 2 2 4 fwd fwd (b) 7 (c) 6 (a) 3 (b) 5 (c) 6 (b) 5 i947h1950001-01 1. Frame 5. Engine mounting thrust adjuster : 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Seat rail 6. Engine mounting thrust...

  • Page 636

    9e-2 body structure: front footrest bracket construction b947h19506002 (b) 2 (a) 1 (a) 1 5 6 7 8 8 9 10 4 “ a ” “a” (d) 11 (e) 12 (c) 3 i947h1950002-02 1. Footrest bracket bolt 8. Rear brake pedal : 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Rear brake master cylinder mounting bolt 9. Footrest bracket no. ...

  • Page 637

    Body structure: 9e-3 side-stand construction b947h19506003 2 3 1 (a) (b) 3 4 (a) i947h1950003-03 1. Frame 3. Washer : 50 n ⋅m (5.0 kgf-m, 36.0 lbf-ft) : apply grease to sliding surface. 2. Side-stand bracket 4. Side-stand : 40 n ⋅m (4.0 kgf-m, 29.0 lbf-ft) manuals by motomatrix / the solution for lo...

  • Page 638

    9e-4 body structure: pillion footrest construction b947h19506004 side-stand removal and installation b947h19506005 removal 1) support the motorcycle with a jack or wooden block. Caution ! • do not support the motorcycle with the exhaust pipes. • make sure that the motorcycle is supported securely. 2...

  • Page 639

    Body structure: 9e-5 specifications tightening torque specifications b947h19507001 note the specified tightening torque is described in the following. “body frame construction” (page 9e-1) “front footrest bracket construction” (page 9e-2) “side-stand construction” (page 9e-3) reference: for the tigh...

  • Page 640

    Prepared by march, 2009 part no. 99500-39380-01e printed in japan 640 manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk / www.Motomatrix.Co.Uk.

  • Page 641: Service Manual

    Top bottom no. 1298 gsx-r1000 s/m 99500-39380-01e for ps printing 2009.3.3 (back: 23 mm) 5/0 dic255 gsx-r1000 printed in japan k9 k9 gsx-r1000 service manual service manual 9 9 5 0 0 - 3 9 3 8 0 - 0 1 e manuals by motomatrix / the solution for lost motorcycle coded keys email: info@motomatrix.Co.Uk ...