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Suzuki GSX-R600 Manual

Other manuals for GSX-R600: Service Manual

Summary of GSX-R600

  • Page 1

    Gsx-r600 printed in japan k8 dic582 top bottom k8 gsx-r600 no.1400 gsx-r600 99500-35110-01e cover14 for ps printing (24 mm) 2008. 1.5.

  • Page 2: Foreword

    Foreword this manual contains an introductory description on the suzuki gsx-r600 and procedures for its inspection/ser- vice 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 9 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ..............................

  • 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 b837h10000001 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 and abs systems ins...

  • 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 b837h10101001 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 b837h10...

  • 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 evap canister: evaporative emission canister (evapc) exc system: exhaust control system (excs) ...

  • Page 16

    0a-3 general information: vehicle identification number b837h10101004 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 b837h10101006 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 b837h10101009 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b837h10101010 code country or area effective frame no. Gsx-r600 k8 (e-02) u.K. Js1cv111100100001 – gsx-r600 k8 (e-19) e.U. Js1cv111100100001 – gs...

  • Page 19

    General information: 0a-6 warning, caution and information labels location b837h10101011 1 2, 3 5 6 7, 9 8 10, 11 20 12, 13 18 14, 15, 16, 17 19, 21 4 [c] [d] [e] [a] [b] i837h1010005-01 1. Noise label (for e-03, 33) 15. General warning label (french) (for gsx-r600u2 e-19) 2. Noise label (for e-24) ...

  • Page 20

    0a-7 general information: component location electrical components location b837h10103001 11 21 20 13 14 15 16 17 18 19 24 1 2 5 4 3 6 7 8 10 9 12 23 22 i837h1010006-03 1. Excv actuator 9. Cmp sensor 17. Fuel pump relay 2. Iap sensor 10. Pair control solenoid valve 18. Cooling fan relay 3. Tp sensor...

  • Page 21

    General information: 0a-8 25 26 27 28 29 30 31 32 33 34 35 36 40 41 39 37 38 i837h1010007-03 25. Iat sensor 31. Head light relay 37. Oil pressure switch 26. Isc valve 32. Turn signal/side-stand relay 38. Generator 27. Secondary fuel injector 33. Steering damper solenoid valve 39. Gp switch 28. Prima...

  • Page 22

    0a-9 general information: specifications specifications b837h10107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification remark overall length 2 040 mm (80.3 in) overall width 715 mm (28.1 in) overall height 1 125 mm (44.3 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 120 mm (4.7 in) rear wheel travel 130 mm (5.1 in) caster 23 ° 45’ tail 97 mm (3....

  • Page 24

    0a-11 general information: special tools and equipment special tool b837h10108002 09900–06104 snap ring pliers 09900–06107 snap ring pliers 09900–06108 snap ring pliers 09900–18740 hexagon socket (24 mm) 09900–20102 vernier calipers (1/20 mm, 200 mm) 09900–20202 micrometer (1/100 mm, 25 – 50 mm) 099...

  • Page 25

    General information: 0a-12 09913–50121 oil seal remover 09913–70210 bearing installer set 09915–40610 oil filter wrench 09915–64512 compression gauge 09915–74521 oil pressure gauge hose 09915–74540 oil pressure gauge attachment 09915–77331 meter (for high pressure) 09916–10911 valve lapper set 09916...

  • Page 26

    0a-13 general information: 09924–84521 bearing installer set 09925–18011 steering bearing installer 09930–10121 spark plug wrench set 09930–11920 torx bit (jt40h) 09930–11940 bit holder 09930–11950 torx wrench 09930–30104 rotor remover slide shaft 09930–34980 rotor remover 09930–44520 rotor holder 0...

  • Page 27

    General information: 0a-14 09944–28320 hexagon socket (19 mm) 99565–01010–015 cd-rom ver.15.

  • Page 28: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance b837h10200001 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 lubrication points b837h10205002 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 30

    0b-3 maintenance and lubrication: repair instructions air cleaner element replacement b837h10206001 replace air cleaner element every 18 000 km (11 000 miles, 36 months) refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. Air cleaner element inspection b837h10206002 in...

  • Page 31

    Maintenance and lubrication: 0b-4 exhaust control valve inspection b837h10206028 inspect exhaust control valve initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter inspect exhaust control valve as follows: 1) lift and support the fuel tank. Refer to “fu...

  • Page 32

    0b-5 maintenance and lubrication: 4) remove the valve timing inspection cap (1). Note • the cam must be at positions, “a” or “b”, when checking or adjusting the valve clearance. Clearance readings should not be taken with the cam in any other position than these two positions. • the valve clearance ...

  • Page 33

    Maintenance and lubrication: 0b-6 7) turn the crankshaft 360 degrees (one rotation) to bring the line on the ckp sensor rotor to the rib behind the clutch cover and also to bring the notches “e” to the position as shown. 8) read the clearance at the rest of the valves “g” and adjust the clearance if...

  • 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-27)”. 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 b837h10206007 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). If the oil level is below the “l” line, add oil to the “f” line. If the level is above the “f” line, drain the oil until the level reaches the “f” line. Oil level inspectio...

  • Page 39

    Maintenance and lubrication: 0b-12 throttle cable play inspection and adjustment b837h10206009 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 b837h10206029 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: drive chain inspection and adjustment b837h10206017 inspect drive chain initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter drive chain visual check 1) with the transmission in neutral, support the motorcycle using a j...

  • Page 43

    Maintenance and lubrication: 0b-16 4) loosen or tighten both chain adjuster bolts (3) until there is 20 – 30 mm (0.8 – 1.2 in) of slack “a” at the middle of the chain between the engine and rear sprockets as shown in the figure. Caution ! The reference marks “a” on both sides of the swingarm and the...

  • Page 44

    0b-17 maintenance and lubrication: brake system inspection b837h10206019 inspect brake system initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter inspect brake hose and brake fluid every 6 000 km (4 000 miles, 12 months) warning ! • the brake system of ...

  • Page 45

    Maintenance and lubrication: 0b-18 front and rear brake hose inspection inspect the brake hoses and hose joints for crack, damage or brake oil leakage. If any defects are found, replace the brake hose with a new one. Refer to “front brake hose removal and installation in section 4a (page 4a-9)” and ...

  • Page 46

    0b-19 maintenance and lubrication: tire inspection b837h10206020 inspect tire every 6 000 km (4 000 miles, 12 months) tire tread condition operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to re...

  • Page 47

    Maintenance and lubrication: 0b-20 front fork inspection b837h10206022 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 48

    0b-21 maintenance and lubrication: 6 brake hose union bolt 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 10 front axle bolt 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 11 front axle pinch bolt 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 12 front brake disc bolt 18 n ⋅m (1.8 kgf-m, 13.0 lb-ft) 13 front brake caliper mounting bolt 39 n ...

  • Page 49

    Maintenance and lubrication: 0b-22 compression pressure check b837h10206025 refer to “compression pressure check in section 1d (page 1d-3)”. Oil pressure check b837h10206026 refer to “oil pressure check in section 1e (page 1e- 5)”. Sds check b837h10206027 refer to “sds check in section 1a (page 1a-1...

  • Page 50

    0b-23 maintenance and lubrication: special tools and equipment recommended service material b837h10208001 note required service material is also described in the following. “lubrication points (page 0b-2)” special tool b837h10208002 material suzuki recommended product or specification note brake flu...

  • Page 51: Service Data

    Service data: 0c-1 general information service data specifications service data b837h10307001 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 27.2 (1.07) — ex. 22.0 (0.87) — valve clearance (when cold) in. 0.08 – 0.18 (0.003 – 0.007) — ex. 0.18 ...

  • Page 52

    0c-2 service data: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit compression pressure 1 200 – 1 600 kpa (12 – 16 kgf/cm 2 , 171 – 228 psi) 900 kpa (9 kgf/cm 2 , 128 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , 28 psi) piston-to-cy...

  • Page 53

    Service data: 0c-3 oil pump clutch unit: mm (in) drive train unit: mm (in) except ratio item standard limit oil pressure (at 60 °c, 140 °f) 100 – 400 kpa (1.0 – 4.0 kgf/cm 2 , 14 – 57 psi) at 3 000 r/min — item standard limit clutch drive plate thickness no. 1, 2 & 3 2.72 – 2.88 (0.107 – 0.113) 2.42...

  • Page 54

    0c-4 service data: thermostat + radiator + 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 (68 °f)...

  • Page 55

    Service data: 0c-5 fi sensors item standard/specification note ckp sensor resistance 142 – 194 Ω ckp sensor peak voltage 0.28 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.7 v at idle speed tp sensor input voltage 4.5 – 5.5 v tp sensor output volta...

  • Page 56

    0c-6 service data: throttle body electrical unit: mm item specification bore size 40 mm (1.57 in) i.D. No. 37h1 (for e-33), 37h0 (for the others) idle r/min 1 300 ± 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: cr9...

  • Page 57

    Service data: 0c-7 wattage unit: w brake + wheel unit: mm (in) tire item specification e-02, 19, 24 the other countries headlight hi 60 x 2 ← lo 55 ← position light 5 ← brake light/taillight led ← turn signal light 21 x 4 ← license plate light 5 ← combination meter light led ← turn signal indicator ...

  • Page 58

    0c-8 service data: suspension unit: mm (in) fuel + oil item standard limit front fork stroke 120 (4.7) — front fork spring free length 266 (10.5) 260 (10.2) front fork oil level (without spring, outer tube fully compressed) 110 (4.3) — front fork oil type suzuki fork oil ss-05 or an equivalent fork ...

  • Page 59

    Service data: 0c-9 tightening torque list b837h10307002 engine item n ⋅m kgf-m lb-ft exhaust pipe bolt 23 2.3 16.5 exhaust pipe mounting bolt 23 2.3 16.5 exhaust pipe bracket bolt 25 2.5 18.0 muffler connecting bolt 23 2.3 16.5 muffler cover bolt 5.5 0.55 4.0 muffler mounting bolt 25 2.5 18.0 speed ...

  • Page 60

    0c-10 service data: fi system cooling system 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 gearshift arm stopper 19 1.9 13.5 gearshift cam stopper bolt 10 1.0 7.0 gearshift cam stopper plate bolt 13 1.3 ...

  • Page 61

    Service data: 0c-11 chassis item n ⋅m kgf-m lb-ft steering stem head nut 90 9.0 65.0 steering stem lock-nut 90 9.0 65.0 steering damper bolt 23 2.3 16.5 steering damper nut 23 2.3 16.5 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 23 2.3 16.5 front fork cap bolt 35 3.5 25.5 fro...

  • Page 62

    0c-12 service data: 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 lb-ft n ⋅m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 ...

  • 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 d...

  • Page 65

    Table of contents 1-iii cam chain guide / cam chain tensioner removal and installation.................................1d-37 cam chain guide inspection ............................1d-37 cam chain tensioner inspection......................1d-37 cylinder head disassembly and assembly ......1d-38 cylin...

  • Page 66

    1-iv table of contents fuel hose inspection ......................................... 1g-7 fuel level gauge inspection ............................. 1g-7 fuel tank construction ...................................... 1g-8 fuel tank removal and installation................... 1g-9 fuel pump components...

  • Page 67

    Table of contents 1-v exhaust pipe / muffler removal and installation.......................................................1k-11 exhaust system inspection...............................1k-14 specifications.....................................................1k-15 tightening torque specifications......

  • Page 68: Precautions

    1-1 precautions: engine precautions precautions precautions for engine b837h11000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”..

  • Page 69

    Engine general information and diagnosis: 1a-1 engine engine general information and diagnosis general description injection timing description b837h11101001 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 b837h11101002 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 b837h11102002 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 b837h11103001 “a” “k” “e” “i” “j” “f” “c” “d” “b” “g” “h” “l” i837h1110126-01 “a”: ecm “e”: intake air pressure sensor (iaps) “i”: fuel pump relay (fp relay) “b”: throttle position sensor (tps) “f”: exhaust co...

  • Page 76

    1a-8 engine general information and diagnosis: “m” “w” “z” “a” “x” “v” “s” “t” “u” “y” “p” “o” “q” “r” “n” i837h1110127-01 “a”: ecm “q”: camshaft position sensor (cmps) “v”: speed sensor “m”: cooling fan relay “r”: ignition coil (ig coil) “w”: atmospheric pressure sensor (aps) “n”: cooling fan “s”: ...

  • Page 77

    Engine general information and diagnosis: 1a-9 diagnostic information and procedures engine symptom diagnosis b837h11104001 condition possible cause correction / reference item engine will not start or is hard to start (compression too low) valve clearance out of adjustment. Adjust. Worn valve guide...

  • Page 78

    1a-10 engine general information and diagnosis: engine stalls often (incorrect fuel/air mixture) defective iap sensor or circuit. Repair or replace. Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace. Defective ect sensor. Replace. Defecti...

  • Page 79

    Engine general information and diagnosis: 1a-11 engine runs poorly in high speed range (defective engine internal/ electrical parts) weakened valve spring. Replace. Worn camshaft. Replace. Valve timing out of adjustment. Adjust. Too narrow spark plug gap. Adjust. Ignition not advanced sufficiently d...

  • Page 80

    1a-12 engine general information and diagnosis: engine lacks power (defective control circuit or sensor) low fuel pressure. Repair or replace. Defective tp sensor. Replace. Defective iat sensor. Replace. Defective ckp sensor. Replace. Defective gp switch. Replace. Defective iap sensor. Replace. Defe...

  • Page 81

    Engine general information and diagnosis: 1a-13 self-diagnostic procedures b837h11104002 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 82

    1a-14 engine general information and diagnosis: use of sds note • do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from the engine or main fuse before confirming dtc (diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information...

  • Page 83

    Engine general information and diagnosis: 1a-15 5) check the dtc to determine the malfunction part. Refer to “dtc table (page 1a-21)”. Note • read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the time of dtc) according to instructions displayed on sds. • not only ...

  • Page 84

    1a-16 engine general information and diagnosis: show data when trouble (displaying data at the time of dtc) b837h11104004 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 85

    Engine general information and diagnosis: 1a-17 2) click the drop down button (2), either “failure #1” or “failure #2” can be selected. Sds check b837h11104005 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 86

    1a-18 engine general information and diagnosis: 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 i837h1110131-01 check the engine coolan...

  • Page 87

    Engine general information and diagnosis: 1a-19 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 88

    1a-20 engine general information and diagnosis: data of manifold absolute pressure operation at the time of starting check the manifold absolute pressure. Xxx kpa i837h1110134-01.

  • Page 89

    Engine general information and diagnosis: 1a-21 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 90

    1a-22 engine general information and diagnosis: 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 91

    Engine general information and diagnosis: 1a-23 fail-safe function table b837h11104007 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 92

    1a-24 engine general information and diagnosis: 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 93

    Engine general information and diagnosis: 1a-25 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 94

    1a-26 engine general information and diagnosis: malfunction code and defective condition table b837h11104009 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 95

    Engine general information and diagnosis: 1a-27 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 96

    1a-28 engine general information and diagnosis: 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 97

    Engine general information and diagnosis: 1a-29 * : immobilizer system equipped model only. (e-02, 19, 24) 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 spee...

  • Page 98

    1a-30 engine general information and diagnosis: dtc “c11” (p0340): cmp sensor circuit malfunction b837h11104010 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 99

    Engine general information and diagnosis: 1a-31 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 secti...

  • Page 100

    1a-32 engine general information and diagnosis: 1 5) connect 3 new 1.5 v batteries in series, 1 k Ω resistor and the multi-circuit tester as shown in the figure. Special tool 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) 6) under this condition, if a suitable screwdriver ...

  • Page 101

    Engine general information and diagnosis: 1a-33 dtc “c12” (p0335): ckp sensor circuit malfunction b837h11104011 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 102

    1a-34 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 ckp sensor coupler (1) for loose or poor contacts. If ok, then measure the ck...

  • Page 103

    Engine general information and diagnosis: 1a-35 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, g – ground) are the resistance and continuity ok? Go to step 2. Replace th...

  • Page 104

    1a-36 engine general information and diagnosis: dtc “c13” (p0105-h/l): iap sensor circuit malfunction b837h11104012 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 105

    Engine general information and diagnosis: 1a-37 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 106

    1a-38 engine general information and diagnosis: 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 107

    Engine general information and diagnosis: 1a-39 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the g/b wire and terminal “19”. If ok, then check the cont...

  • Page 108

    1a-40 engine general information and diagnosis: 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 109

    Engine general information and diagnosis: 1a-41 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the r wire and terminal “7”. Also, check the continuity be...

  • Page 110

    1a-42 engine general information and diagnosis: 2 1) connect the ecm coupler. 2) turn the ignition switch off. 3) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 4) check the iap sensor coupler (1) for loose or poor contacts. If ok, then measu...

  • Page 111

    Engine general information and diagnosis: 1a-43 3 1) turn the ignition switch off. 2) connect the ecm coupler 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 112

    1a-44 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-3)”. 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 113

    Engine general information and diagnosis: 1a-45 dtc “c14” (p0120-h/l): tp sensor circuit malfunction b837h11104013 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 114

    1a-46 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) remove the right under cowling. Refer to “exterior part...

  • Page 115

    Engine general information and diagnosis: 1a-47 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) remove the right under cowling. Refer to “exterior parts removal a...

  • Page 116

    1a-48 engine general information and diagnosis: 1 7) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 8) 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): 099...

  • Page 117

    Engine general information and diagnosis: 1a-49 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) remove the right under cowling. Refer to “exterior parts removal a...

  • Page 118

    1a-50 engine general information and diagnosis: 1 7) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 8) 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): 09900–2...

  • Page 119

    Engine general information and diagnosis: 1a-51 3 1) turn the ignition switch off. 2) connect the special tool between the tp sensor and its coupler. 3) turn the ignition switch on. 4) measure the tp sensor output voltage between the p/b wire terminal (+) and b/br wire terminal (–) with turning the ...

  • Page 120

    1a-52 engine general information and diagnosis: dtc “c15” (p0115-h/l): ect sensor circuit malfunction b837h11104014 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 121

    Engine general information and diagnosis: 1a-53 c15 (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 ect sensor coupler (1) for loose or poor cont...

  • Page 122

    1a-54 engine general information and diagnosis: p0115-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 ect sensor coupler (1) for loose or poor contacts. If ok...

  • Page 123

    Engine general information and diagnosis: 1a-55 p0115-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 ect sensor coupler (1) for loose or poor contacts. If ok...

  • Page 124

    1a-56 engine general information and diagnosis: 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 pointed probe set) tester knob indication voltage ( ) ect sensor output voltage 0.15 – 4.85 v ((+) termi...

  • Page 125

    Engine general information and diagnosis: 1a-57 dtc “c21” (p0110-h/l): iat sensor circuit malfunction b837h11104015 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 126

    1a-58 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 by loosing the air clea...

  • Page 127

    Engine general information and diagnosis: 1a-59 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 by loosing the air cleaner box mou...

  • Page 128

    1a-60 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 by loosing the air cleaner box mou...

  • Page 129

    Engine general information and diagnosis: 1a-61 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 pointed probe set) tester knob indication voltage ( ) iat sensor output voltage 0.15 – 4.85 v ((+) termin...

  • Page 130

    1a-62 engine general information and diagnosis: dtc “c22” (p1450-h/l): ap sensor circuit malfunction b837h11104016 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 131

    Engine general information and diagnosis: 1a-63 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-11)”. 3) check the ap sensor coupler (1) for loose or poor contacts...

  • Page 132

    1a-64 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-11)”. 3) check the ap sensor coupler (1) for loose or poor contacts. If ok, th...

  • Page 133

    Engine general information and diagnosis: 1a-65 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the g/y wire and terminal “20”. If ok, then check the cont...

  • Page 134

    1a-66 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-11)”. 3) check the ap sensor coupler (1) for loose or poor contacts. If ok, th...

  • Page 135

    Engine general information and diagnosis: 1a-67 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the r wire and terminal “7”. Also, check the continuity be...

  • Page 136

    1a-68 engine general information and diagnosis: 2 1) turn the ignition switch off. 2) remove the front seat. Refer to “exterior parts removal and installation in section 9d (page 9d-11)”. 3) check the ap sensor coupler (1) for loose or poor contacts. If ok, then measure the ap sensor input voltage. ...

  • Page 137

    Engine general information and diagnosis: 1a-69 3 1) turn the ignition switch off. 2) connect the ecm coupler 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 wi...

  • Page 138

    1a-70 engine general information and diagnosis: 4 1) turn the ignition switch off. 2) remove the ap sensor. Refer to “ap sensor removal and installation in section 1c (page 1c-6)”. 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 139

    Engine general information and diagnosis: 1a-71 dtc “c23” (p1651-h/l): to sensor circuit malfunction b837h11104017 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 140

    1a-72 engine general information and diagnosis: 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-11)”. 3) check the to sensor coupler (1) for loose or poor contacts...

  • Page 141

    Engine general information and diagnosis: 1a-73 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-11)”. 3) check the to sensor coupler (1) for loose or poor contacts. If ok, th...

  • Page 142

    1a-74 engine general information and diagnosis: 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the b wire and terminal “31”. Also, check the continuity b...

  • Page 143

    Engine general information and diagnosis: 1a-75 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-11)”. 3) check the to sensor coupler (1) for loose or poor contacts. If ok, th...

  • Page 144

    1a-76 engine general information and diagnosis: 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the r wire and terminal “7”. Also, then check the continui...

  • Page 145

    Engine general information and diagnosis: 1a-77 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 146

    1a-78 engine general information and diagnosis: dtc “c24” (p0351), “c25” (p0352), “c26” (p0353) or “c27” (p0354): ignition system malfunction b837h11104018 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 147

    Engine general information and diagnosis: 1a-79 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. Refer to “air cleaner box removal and installation in section 1d (page 1d-7)”. 3) check the ...

  • Page 148

    1a-80 engine general information and diagnosis: 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 149

    Engine general information and diagnosis: 1a-81 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 150

    1a-82 engine general information and diagnosis: dtc “c29” (p1654-h/l): secondary throttle position sensor (stps) circuit malfunction b837h11104020 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not str...

  • Page 151

    Engine general information and diagnosis: 1a-83 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 coupler (1) for loose or poor cont...

  • Page 152

    1a-84 engine general information and diagnosis: 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 coupler (1) for loose or poor contacts. If ok...

  • Page 153

    Engine general information and diagnosis: 1a-85 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-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): 09...

  • Page 154

    1a-86 engine general information and diagnosis: 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 coupler (1) for loose or poor contacts. If ok...

  • Page 155

    Engine general information and diagnosis: 1a-87 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-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–...

  • Page 156

    1a-88 engine general information and diagnosis: 3 1) turn the ignition switch off. 2) connect the ecm coupler and stp sensor coupler. 3) disconnect the stva lead wire coupler. Refer to “dtc “c28” (p1655): secondary throttle valve actuator (stva) malfunction (page 1a-78)”. 4) insert the needle point ...

  • Page 157

    Engine general information and diagnosis: 1a-89 dtc “c31” (p0705): gp switch circuit malfunction b837h11104021 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 158

    1a-90 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 gp switch coupler (1) for loose or poor contacts. If ok, then measure the gp ...

  • Page 159

    Engine general information and diagnosis: 1a-91 dtc “c32” (p0201), “c33” (p0202), “c34” (p0203) or “c35” (p0204): primary fuel injector circuit malfunction b837h11104022 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-cir...

  • 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 primary fuel injector coupler (1) for loose or poor contacts. If ok, then mea...

  • Page 161

    Engine general information and diagnosis: 1a-93 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 injector with a new one. ...

  • Page 162

    1a-94 engine general information and diagnosis: dtc “c36” (p1764), “c37” (p1765), “c38” (p1766) or “c39” (p1767): secondary fuel injector circuit malfunction b837h11104023 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-c...

  • Page 163

    Engine general information and diagnosis: 1a-95 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 164

    1a-96 engine general information and diagnosis: 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 injector with a new one. ...

  • Page 165

    Engine general information and diagnosis: 1a-97 dtc “c40” (p0505 / p0506 / p0507): isc valve circuit malfunction b837h11104024 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 166

    1a-98 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 isc valve coupler (1) for loose or poor contacts. If ok, then check the isc...

  • Page 167

    Engine general information and diagnosis: 1a-99 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 168

    1a-100 engine general information and diagnosis: 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 ...

  • Page 169

    Engine general information and diagnosis: 1a-101 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 ...

  • Page 170

    1a-102 engine general information and diagnosis: 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 t...

  • Page 171

    Engine general information and diagnosis: 1a-103 p0230-h (use of sds) p0230-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-11)”. 3) check the fp relay coupler (1) for loose or poo...

  • Page 172

    1a-104 engine general information and diagnosis: dtc “c41” (p2505): ecm power input signal malfunction b837h11104026 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 173

    Engine general information and diagnosis: 1a-105 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-11)”. 3) check the ecm coupler for loose or poor contacts. If ok, then measure the ecm input volta...

  • Page 174

    1a-106 engine general information and diagnosis: dtc “c42” (p1650): ig switch circuit malfunction b837h11104027 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 175

    Engine general information and diagnosis: 1a-107 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 176

    1a-108 engine general information and diagnosis: 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”. Special tool (a): 0...

  • Page 177

    Engine general information and diagnosis: 1a-109 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 wire and b/br wire, in idling condition. Special...

  • Page 178

    1a-110 engine general information and diagnosis: 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-15)”. Step action yes no 1 1) turn the ignition switch off. 2) lift and support the f...

  • Page 179

    Engine general information and diagnosis: 1a-111 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 180

    1a-112 engine general information and diagnosis: dtc “c46” (p1657-h/l or p1658): excv actuator circuit malfunction b837h11104032 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 181

    Engine general information and diagnosis: 1a-113 c46 (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 excva position sensor coupler (1) and excva ...

  • Page 182

    1a-114 engine general information and diagnosis: p1657-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 excva position sensor coupler (1) for loose or poor con...

  • Page 183

    Engine general information and diagnosis: 1a-115 1 6) disconnect the ecm coupler. 7) check the continuity between y wire and terminal “14”. 8) also, check the continuity between b/br wire and terminal “35”. Special tool : 09900–25008 (multi-circuit tester set) : 09900–25009 (needle pointed probe set...

  • Page 184

    1a-116 engine general information and diagnosis: p1657-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 excva position sensor coupler (1) for loose or poor con...

  • Page 185

    Engine general information and diagnosis: 1a-117 1 7) disconnect the ecm coupler. 8) check the continuity between y wire and terminal “14”. 9) also, check the continuity between r wire and terminal “7”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe s...

  • Page 186

    1a-118 engine general information and diagnosis: p1658 (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 excva motor coupler (1) for loose or poor contacts. Is th...

  • Page 187

    Engine general information and diagnosis: 1a-119 2 5) turn the ignition switch on. 6) measure the voltage between the r wire and ground. 7) if ok, then measure the voltage between the r wire and b/br wire. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) ex...

  • Page 188

    1a-120 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 189

    Engine general information and diagnosis: 1a-121 4 1) turn the ignition switch off. 2) connect the excva position sensor coupler (1). 3) disconnect the excva motor coupler (2). 4) measure the excva position sensor output voltage at excv fully closed position and fully opened position. To set the exc...

  • Page 190

    1a-122 engine general information and diagnosis: 4 8) then, to set the excv to fully opened position, apply 12 v to the terminals oppositely. Positive wire – gr wire terminal negative wire – p wire terminal 9) measure the excva position sensor output voltage at excv fully opened position. Special to...

  • Page 191

    Engine general information and diagnosis: 1a-123 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 out the no. 1 cable adjuster (1). Refer to “excv cable removal and installation in section 1...

  • Page 192

    1a-124 engine general information and diagnosis: 6 1) turn the ignition switch off. 2) disconnect the excva motor 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 b...

  • Page 193

    Engine general information and diagnosis: 1a-125 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “exhaust valve operating control” (1). 4) click each button (2). At this time, if an operation sound is...

  • Page 194

    1a-126 engine general information and diagnosis: dtc “c49” (p1656): pair control solenoid valve circuit malfunction b837h11104029 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 195

    Engine general information and diagnosis: 1a-127 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 196

    1a-128 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 “pair sol operating control” (1). 4) click each button (2). At this time, if an operating sound is heard fr...

  • Page 197

    Engine general information and diagnosis: 1a-129 dtc “c60” (p0480): cooling fan relay circuit malfunction b837h11104030 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 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) 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 199

    Engine general information and diagnosis: 1a-131 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 200

    1a-132 engine general information and diagnosis: dtc “c62” (p0443): evap system purge control solenoid valve circuit malfunction (e-33 only) b837h11104031 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do...

  • Page 201

    Engine general information and diagnosis: 1a-133 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 202

    1a-134 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 203

    Engine general information and diagnosis: 1a-135 dtc “c91” (p0500): vehicle speed sensor circuit malfunction b837h11104033 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 204

    1a-136 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 205

    Engine general information and diagnosis: 1a-137 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 the speedometer senso...

  • Page 206

    1a-138 engine general information and diagnosis: dtc “c93” (p1769): steering damper solenoid valve circuit malfunction b837h11104034 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 207

    Engine general information and diagnosis: 1a-139 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 208

    1a-140 engine general information and diagnosis: 2 1) turn the ignition switch on. 2) measure the voltage between w 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 fully c...

  • Page 209

    Engine general information and diagnosis: 1a-141 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 210

    1a-142 engine general information and diagnosis: specifications service data b837h11107001 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 211

    Engine general information and diagnosis: 1a-143 special tools and equipment special tool b837h11108001 09900–25008 ) (page 1a-61) / ) (page 1a-61) / ) (page 1a-63) / ) (page 1a-64) / ) (page 1a-65) / ) (page 1a-66) / ) (page 1a-67) / ) (page 1a-68) / ) (page 1a-69) / ) (page 1a-70) / ) (page 1a-72)...

  • Page 212

    1a-144 engine general information and diagnosis: 09917–47011 09930–82720 vacuum pump gauge mode select switch ) (page 1a-44) / ) (page 1a-70) ) (page 1a-4) / )(page 1a- 13) / )(page 1a-13) 99565–01010–015 cd-rom ver.15 ) (page 1a-14) / ) (page 1a-17).

  • Page 213: Emission Control Devices

    Emission control devices: 1b-1 engine emission control devices precautions precautions for emission control devices b837h11200001 refer to “general precautions in section 00 (page 00-1)”. General description fuel injection system description b837h11201001 gsx-r600 motorcycles are equipped with a fue...

  • Page 214

    1b-2 emission control devices: crankcase emission control system description b837h11201002 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 215

    Emission control devices: 1b-3 exhaust emission control system description b837h11201003 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 port through the pair co...

  • Page 216

    1b-4 emission control devices: noise emission control system description b837h11201004 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 person, other than for purposes of ma...

  • Page 217

    Emission control devices: 1b-5 schematic and routing diagram pair system hose routing diagram b837h11202001 2 1 “c” “d” “ a ” “ b ” 1 “ b ” “ b ” “a” “a” “b” i837h1120044-03 1. Pair control solenoid valve “b”: yellow marking “a”: 45 ° 2. Pair reed valve “c”: face the clamp end rearward. “b”: 0 ° “a”...

  • Page 218

    1b-6 emission control devices: evap canister hose routing diagram (only for e-33) b837h11202002 1 1 1 2 2 2 2 2 2 3 3 3 3 2 3 3 3 2 3 5 6 7 8 8 “i” “c” “e” “f” 4 4 4 “h” “a” “b” “ a ” “a” “d” “g” i837h1120045-02 1. Evap system purge control solenoid valve 7. Seat rail “e”: clamp the hoses and batter...

  • Page 219

    Emission control devices: 1b-7 repair instructions heated oxygen sensor (ho2s) removal and installation b837h11206001 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 220

    1b-8 emission control devices: 6) disconnect the cmp sensor coupler (2) and remove the cylinder head cover shield (3). 7) remove the radiator mounting bolts. 8) move the radiator forward. 9) remove the front engine cover (4). 10) disconnect the horn couplers (5) and remove the horn (6). 11) remove t...

  • Page 221

    Emission control devices: 1b-9 pair control solenoid valve removal and installation b837h11206004 removal 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) remove the air cleaner box. Refer to “air cleaner box removal an...

  • Page 222

    1b-10 emission control devices: pair control solenoid valve note pair control solenoid valve can be checked without removing it from the motorcycle. Refer to “dtc “c49” (p1656): pair control solenoid valve circuit malfunction in section 1a (page 1a-126)”. 1) remove the pair control solenoid valve. R...

  • Page 223

    Emission control devices: 1b-11 crankcase breather (pcv) hose / reed valve / cover removal and installation b837h11206007 removal 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) remove the air cleaner box. Refer to “ai...

  • Page 224

    1b-12 emission control devices: crankcase breather (pcv) cover inspection b837h11206008 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 1b...

  • Page 225

    Emission control devices: 1b-13 evap system purge control solenoid valve removal 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) disconnect the coupler (1) and purge hoses (2). 3) remove the evap system purge control s...

  • Page 226

    1b-14 emission control devices: 9) remove the rear fender (rear) plate (6) and rear fender (rear) (7). 10) remove the rear fender (front) cover (8). 11) remove the battery rubber mat (9). 12) remove the rear fender (front) mounting bolts. 13) disconnect the surge hose (10). 14) move the rear fender ...

  • Page 227

    Emission control devices: 1b-15 • clamp the evap hoses at white taping point. Evaporative emission control system inspection (only for e-33) b837h11206010 refer to “evaporative emission control system removal and installation (only for e-33) (page 1b-12)”. Hose inspect the hoses for wear or damage. ...

  • Page 228

    1b-16 emission control devices: 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 229

    Emission control devices: 1b-17 specifications service data b837h11207001 fi sensors tightening torque specifications b837h11207002 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 230: Engine Electrical Devices

    1c-1 engine electrical devices: engine engine electrical devices precautions precautions for engine electrical device b837h11300001 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 electrica...

  • Page 231

    Engine electrical devices: 1c-2 cmp sensor inspection b837h11306002 refer to “dtc “c11” (p0340): cmp sensor circuit malfunction in section 1a (page 1a-30)”. Cmp sensor removal and installation b837h11306003 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation in ...

  • Page 232

    1c-3 engine electrical devices: installation install the cmp sensor in the reverse order of removal. Pay attention to the following points: caution ! When installing the cmp sensor, make sure to clean the sensor surface. • tighten the cmp sensor bolt (1) to the specified torque. Tightening torque cm...

  • Page 233

    Engine electrical devices: 1c-4 2) remove the tp sensor (1) with the special tool. Special tool : 09930–11950 (torx wrench) note prior to disassembly, mark the tp sensor’s original position with a paint or scribe for accurate reinstallation. Installation install the tp sensor in the reverse order of...

  • Page 234

    1c-5 engine electrical devices: installation install the ect sensor in the reverse order of removal. Pay attention to the following points: • tighten the ect sensor (1) to the specified torque. Caution ! Use new gasket washer to prevent engine coolant leakage. Tightening torque ect sensor (a): 18 n·...

  • Page 235

    Engine electrical devices: 1c-6 installation install the iat sensor in the reverse order of removal. Pay attention to the following point: • tighten the iat sensor screw (1) to the specified torque. Tightening torque iat sensor mounting screw (a): 1.3 n·m (0.13 kgf- m, 1.0 lb-ft) iat sensor inspecti...

  • Page 236

    1c-7 engine electrical devices: installation install the to sensor in the reverse order of removal. Pay attention to the following point: • when installing the to sensor, bring the “up” letters upward. Stp sensor inspection b837h11306019 refer to “dtc “c29” (p1654-h/l): secondary throttle position s...

  • Page 237

    Engine electrical devices: 1c-8 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 lb-ft) 9) reinstall the removed parts. Stp sensor removal and installation b837h11306021 removal 1) remove the throttle body. Refer...

  • Page 238

    1c-9 engine electrical devices: isc valve preset and opening initialization b837h11306026 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 239

    Engine electrical devices: 1c-10 specifications service data b837h11307001 fi sensors tightening torque specifications b837h11307002 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/specificatio...

  • Page 240

    1c-11 engine electrical devices: special tools and equipment special tool b837h11308001 09900–25008 09900–25009 multi-circuit tester set needle pointed probe set ) (page 1c-5) / )(page 1c- 7) ) (page 1c-7) 09930–11950 09930–82720 torx wrench mode select switch ) (page 1c-4) / )(page 1c- 4) / )(page ...

  • Page 241: Engine Mechanical

    Engine mechanical: 1d-1 engine engine mechanical schematic and routing diagram camshaft and sprocket assembly diagram b837h11402001 i837h1140299-01.

  • Page 242

    1d-2 engine mechanical: throttle cable routing diagram b837h11402002 1 2 “c” “b” “ a ” “ a ” “ a ” 3 1 2 “a” 3 4 2 1 5 6 i837h1140300-01 1. Throttle cable no. 1 6. Throttle cable guide no. 2 2. Throttle cable no. 2 “a”: pass the throttle cables to the front of brake hose. 3. Clutch cable “b”: pass t...

  • Page 243

    Engine mechanical: 1d-3 diagnostic information and procedures engine mechanical symptom diagnosis b837h11404001 refer to “engine symptom diagnosis in section 1a (page 1a-9)”. Compression pressure check b837h11404002 the compression pressure reading of a cylinder is a good indicator of its internal c...

  • Page 244

    1d-4 engine mechanical: repair instructions engine components removable with the engine in place b837h11406001 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 245

    Engine mechanical: 1d-5 engine right side item removal inspection installation exhaust pipes/muffler refer to “exhaust pipe / muffler removal and installation in section 1k (page 1k-11)”. Refer to “exhaust system inspection in section 1k (page 1k-14)”. Refer to “exhaust pipe / muffler removal and in...

  • Page 246

    1d-6 engine mechanical: engine left side air cleaner element removal and installation b837h11406002 removal 1) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g- 9)”. 2) disconnect the pcv hose (1). 3) remove the air cleaner box cover (2). 4) remove ...

  • Page 247

    Engine mechanical: 1d-7 air cleaner box removal and installation b837h11406003 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 mounting bolt (1). 3) remove the fasteners (2), right and left. 4) loosen ...

  • Page 248

    1d-8 engine mechanical: throttle body components b837h11406008 1 1 2 5 4 3 3 3 3 3 3 3 6 7 8 8 9 11 10 12 (a) (a) [a] i837h1140292-02 1. Fuel delivery pipe 5. Stp sensor 9. Isc valve [a]: for e-33 only 2. Fuel delivery pipe t-joint 6. Secondary fuel injector 10. Air screw : 3.5 nm (0.35 kgf-m, 2.5 l...

  • Page 249

    Engine mechanical: 1d-9 throttle body construction b837h11406009 (c) 1 2 3 5 6 “c” “d” “e” “f” “a” “a” “b” “g” fwd “1” “2” “3” “4” “5” (a) 4 (b) i837h1140304-05 1. Intake pipe “a”: turn and tighten the #1 and #4 clamps after tightening the #2 and #3 clamps. “g”: pass the fuel pump lead wire above th...

  • Page 250

    1d-10 engine mechanical: throttle body removal and installation b837h11406010 removal 1) remove the under cowlings. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) remove the air cleaner box. Refer to “air cleaner box removal and installation (page 1d-7)”. 3) loose...

  • Page 251

    Engine mechanical: 1d-11 11) disconnect the purge hose from the evap system purge control solenoid valve (8). (e-33 only) 12) disconnect the tp sensor lead wire coupler (9). 13) disconnect the isc valve lead wire coupler (10). 14) disconnect the throttle cables from their drum. 15) remove the thrott...

  • Page 252

    1d-12 engine mechanical: 4) remove the fuel delivery pipe assembly (6). Caution ! Be careful not to twist the fuel delivery pipe t-joint (7) when removing the fuel delivery pipes, or joint part “a” of the fuel delivery pipe get damage. 5) remove the primary fuel injectors (8) and secondary fuel inje...

  • Page 253

    Engine mechanical: 1d-13 caution ! Never remove the throttle valves (15) and secondary throttle valves (16). Caution ! These adjusting screws (17), (18) and (19) are factory-adjusted at the time of delivery and do not turn or remove them. Caution ! Do not separate the throttle body. Assembly reassem...

  • Page 254

    1d-14 engine mechanical: • apply a thin coat of engine oil to the o-ring, install the isc valve to the throttle body and tighten the isc valve mounting screw to the specified torque. Special tool : 09930–11950 (torx wrench) tightening torque isc valve mounting screw (a): 2 n·m (0.2 kgf-m, 1.5 lb-ft)...

  • Page 255

    Engine mechanical: 1d-15 • assemble the fuel delivery pipes as shown in the figure. Caution ! Be careful not to twist the fuel delivery pipe t-joint when installing the fuel delivery pipes, or joint part “e” of the fuel delivery pipe may get damage. • install the fuel injector (5) by pushing it stra...

  • Page 256

    1d-16 engine mechanical: inspection check following items for any defects or clogging. Replace the damaged part if necessary. • o-rings • throttle valves • secondary throttle valves • vacuum hoses • isc valve hoses • fuel delivery pipes • cushion seals • fuel injectors isc valve visual inspection b8...

  • Page 257

    Engine mechanical: 1d-17 11) click “active control”. 12) click “isc air volume control” (4). 13) click “on” button (5) to fix the isc air volume of four cylinders. Note when making this synchronization, be sure that the water temperature is within 80 – 100 °c (176 – 212 °f). 14) check for the synchr...

  • Page 258

    1d-18 engine mechanical: isc valve reset b837h11406015 when removing or replacing the throttle body assembly, reset the isc valve learned value in the following procedures: 1) turn the ignition switch on position. 2) set up the sds tools. (refer to the sds operation manual for further details.) 3) c...

  • Page 259

    Engine mechanical: 1d-19 5) click the “reset” button (2) to clear the tp learned value. Note the leaned value of the tp sensor is set at preset position. 6) close the sds tool and turn the ignition switch off. Note the tp sensor opening initialization is automatically started after the ignition swit...

  • Page 260

    1d-20 engine mechanical: 11) remove the oil cooler outlet hose (5). 12) remove the muffler (6) and exhaust pipes (7) along with the ho2 sensor. Refer to “exhaust pipe / muffler removal and installation in section 1k (page 1k- 11)”. 13) disconnect the horn coupler (8). 14) remove the horn (9) and fro...

  • Page 261

    Engine mechanical: 1d-21 20) disconnect the cmp sensor lead wire coupler (23), pair solenoid valve lead wire coupler (24) and pair solenoid valve hose (25). 21) remove the pair solenoid valve (26). 22) remove the ignition coil/plug caps (27) and cylinder head cover shield (28). Caution ! • do not pr...

  • Page 262

    1d-22 engine mechanical: 30) remove the engine mounting bolt (35). 31) remove the engine mounting nut (36). 32) remove the engine mounting thrust adjuster lock- nut (37) with the special tool. 33) loosen the engine mounting thrust adjuster (38) fully. Special tool (a): 09940–14980 (rotor remover) 34...

  • Page 263

    Engine mechanical: 1d-23 engine assembly installation b837h11406018 install the engine in the reverse order of engine removal. Pay attention to the following points: • gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft. Caution ! Be careful not to ca...

  • Page 264

    1d-24 engine mechanical: • tighten the engine mounting pinch bolt to the specified torque, as shown in the following illustration. “ a ” “ b ” “ c ” “ d ” “ f ” a b a c e f b d c d e f rh lh (d) (d) (e) (e) (d) (c) (c) 1 1 1 1 2 “ e ” 3 “ f ” (d) 3 (f) 4 (f) 4 i837h1140274-03 1. Engine mounting bolt...

  • Page 265

    Engine mechanical: 1d-25 • 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 “exhaust pipe / muffler removal and installation in section 1k (page 1k-11)”. • install the radiator. Refer...

  • Page 266

    1d-26 engine mechanical: 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 rib “b” behind the clutch cover and also to bring the cams to the position as shown. 3) remove the cam chain tension adjuster (2). 4) remove t...

  • Page 267

    Engine mechanical: 1d-27 7) remove the dowel pins. 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) remove the cylinder head bolts (m6) (1). 2) remove the o-rings (2). 3) remove the cylinde...

  • Page 268

    1d-28 engine mechanical: • tighten the cylinder head bolts (m10) to the specified torque with a torque wrench sequentially and diagonally. • additionally tighten the cylinder head bolts with the specified angles diagonally using an angular torque gauge. Tightening torque cylinder head bolt (m10): 31...

  • Page 269

    Engine mechanical: 1d-29 • pull the cam chain lightly. • turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. (the exhaust camshaft sprocket has an arrow marked “1” “c”.) • engage the cam chain with the exhaust camshaft sprocket. Note before installing...

  • Page 270

    1d-30 engine mechanical: • apply engine oil to journals and cam faces. • install the dowel pins. • install o-rings (3) to the camshaft journal holders. Caution ! Replace the o-rings with new ones. • apply engine oil to journals. • install the camshaft journal holders. Note • each camshaft journal ho...

  • Page 271

    Engine mechanical: 1d-31 • 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”. • hook the outer circlip “a” into the groove “b”, then turn ...

  • Page 272

    1d-32 engine mechanical: • rotate the crankshaft (some turns) and recheck the valve timing. Caution ! • make sure that the adjuster works properly by checking no slack at point “c”. • do not turn the adjuster body until the outer circlip “a” exceeds the groove “b”. If the inner circlip “c” is caught...

  • Page 273

    Engine mechanical: 1d-33 • install the pair reed valves (1) along with the gaskets. Note fit the projection of the gaskets to the depression of the camshaft holders. Caution ! Replace the gaskets with new ones. • install a new gasket to the cylinder head cover. • apply bond to the cam end cap points...

  • Page 274

    1d-34 engine mechanical: camshaft inspection b837h11406021 refer to “engine top side disassembly (page 1d-25)”. Refer to “engine top side assembly (page 1d-27)”. Camshaft identification the exhaust camshaft has the embossed letters “ex” and the intake camshaft has the embossed letters “in”. Cam wear...

  • Page 275

    Engine mechanical: 1d-35 4) tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque. Refer to “engine top side assembly (page 1d-27)”. Note do not rotate the camshafts with the plastigauge in place. Tightening torque camshaft journal holder bolt: 10 n·m (1.0 k...

  • Page 276

    1d-36 engine mechanical: camshaft sprocket b837h11406022 inspect the camshaft sprocket in the following procedures: 1) remove the intake and exhaust camshafts. Refer to “engine top side disassembly (page 1d-25)”. 2) inspect the teeth of each camshaft sprocket for wear or damage. If they are worn or ...

  • Page 277

    Engine mechanical: 1d-37 cam chain guide / cam chain tensioner removal and installation b837h11406024 removal 1) remove the cylinder head cover. Refer to “engine top side disassembly (page 1d-25)”. 2) remove the cam chain guide no. 2 (1). 3) remove the cylinder head. Refer to “engine top side disass...

  • Page 278

    1d-38 engine mechanical: cylinder head disassembly and assembly b837h11406027 refer to “engine top side disassembly (page 1d-25)”. Refer to “engine top side assembly (page 1d-27)”. Caution ! Identify the position of each removed part. Organize the parts in their respective groups (i.E., intake, exha...

  • Page 279

    Engine mechanical: 1d-39 10) remove the thermostat (11). 11) remove the thermostat connector (12). 12) remove the oil jet (13). 13) remove the intake pipes (14). 14) remove the oil gallery plug (15). 15) remove the cam chain tension adjuster service cap (16). Assembly assembly is in the reverse orde...

  • Page 280

    1d-40 engine mechanical: • apply thread lock to the intake pipe mounting bolts. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) • apply engine oil to the o-ring and install the oil jet. Caution ! Use new o-ring to prevent oil pressure leakage. • apply engine coolant to...

  • Page 281

    Engine mechanical: 1d-41 • apply engine oil to the oil seal (8), and press-fit it into the position. Caution ! Do not reuse the removed oil seal. • insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break. Caution ! When insertin...

  • Page 282

    1d-42 engine mechanical: • install the tappet shims and the tappets to their original positions. Note • apply engine oil to the stem end, shim and tappet before fitting them. • when seating the tappet shim, be sure the figure printed surface faces the tappet. Cylinder head related parts inspection b...

  • Page 283

    Engine mechanical: 1d-43 valve stem and valve face wear condition • visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one. Valve stem deflection lift the valve about 10 mm (0.39 in) from the valve seat. Measure the valve stem...

  • Page 284

    1d-44 engine mechanical: valve spring the force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring their free len...

  • Page 285

    Engine mechanical: 1d-45 valve seat sealing condition 1) clean and assemble the cylinder head and valve components. 2) fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from s...

  • Page 286

    1d-46 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 287

    Engine mechanical: 1d-47 valve seat repair b837h11406030 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 288

    1d-48 engine mechanical: starter motor remove the starter motor (1). Clutch remove the clutch component parts (1). Refer to “clutch removal in section 5c (page 5c-5)”. Oil pump drive sprocket 1) remove the spacer (1) and bearing (2). 2) remove the oil pump drive sprocket (3) and chain (4). 3) remove...

  • Page 289

    Engine mechanical: 1d-49 starter idle gear / generator cover 1) remove the starter idle gear component parts (1). Refer to “starter clutch removal and installation in section 1i (page 1i-10)”. 2) remove the generator cover (2). 3) remove the dowel pin (3) and gasket (4). 4) remove the starter idle g...

  • Page 290

    1d-50 engine mechanical: water pump 1) remove the oil cooler water hose (1), cylinder inlet hose (2) and water inlet connector (3). 2) remove the water pump (4). Gear position switch remove the gear position switch (1). Oil pressure switch remove the oil pressure switch (1). Oil filter remove the oi...

  • Page 291

    Engine mechanical: 1d-51 oil pressure regulator / oil strainer 1) remove the oil pressure regulator (1). 2) remove the oil strainer (2). Oil pump 1) remove the oil pump (1). 2) remove the dowel pins (2) and o-ring (3). Crankcase 1) remove the clutch push rod oil seal retainer (1). 2) remove the uppe...

  • Page 292

    1d-52 engine mechanical: transmission remove the transmission component. Refer to “transmission removal in section 5b (page 5b-3)”. Crankshaft 1) loosen the conrod cap bolts by using a 10 mm, 12- point socket wrench, and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing c...

  • Page 293

    Engine mechanical: 1d-53 2) remove the piston pin circlip (1). 3) draw out the piston pin (2) and remove the piston head (3). Note scribe the cylinder number on the piston head. Crankshaft journal bearing remove the crankshaft journal bearings, upper and lower. Caution ! • when removing the cranksha...

  • Page 294

    1d-54 engine mechanical: 2) remove the oil jet (2) (for transmission) from the lower crankcase. Oil gallery plug 1) remove the oil gallery plug (1) from the lower crankcase. 2) remove the oil gallery plugs (2) and (3) from the lower crankcase. Water jacket plug remove the water jacket plugs (1) from...

  • Page 295

    Engine mechanical: 1d-55 water jacket plug • apply engine coolant to the o-rings of the water jacket plugs. • 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 lb- ft) oil gallery plug • tighten e...

  • Page 296

    1d-56 engine mechanical: • install the oil jet (2) (for transmission). 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...

  • Page 297

    Engine mechanical: 1d-57 • apply a small quantity of molybdenum oil solution to the sliding surface of the pistons and cylinder walls. M/o: molybdenum oil (molybdenum oil solution) note be sure to install the pistons in the cylinders from which they were removed in disassembly, referring to the cyli...

  • Page 298

    1d-58 engine mechanical: • install each piston cooling oil jet. Note 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 (...

  • Page 299

    Engine mechanical: 1d-59 7) tighten the conrod cap bolt by using a 10 mm, 12 point socket wrench in the following two steps. Tightening torque conrod cap bolt: 15 n ⋅m (1.5 kgf-m, 11.0 lb-ft) then turn in 1/4 (90 °) turn 8) apply engine oil to the conrod big end side surfaces. 9) check the conrod mo...

  • Page 300

    1d-60 engine mechanical: crankcase • install the dowel pins (1), o-ring (2) and plug (3). Caution ! Replace the o-rings with new ones. • apply bond to the mating surface of the lower crankcase as follows. Note • make surfaces free from moisture, oil, dust and other foreign materials. • spread the se...

  • Page 301

    Engine mechanical: 1d-61 • 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 302

    1d-62 engine mechanical: • apply thread lock to the bolts. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) oil pump • install the o-ring. Caution ! Use a new o-ring to prevent oil leakage. • apply grease to the o-ring. : grease 99000–25010 (suzuki super grease a or equ...

  • Page 303

    Engine mechanical: 1d-63 • tighten the oil pan bolts diagonally to the specified torque. Note • fit the new gasket washer to the oil pan bolt “a”. • apply thread lock to the oil pan bolts “b” and plate bolts “c”. • fit the clamp to the oil pan bolt “d”. Tightening torque oil pan bolt: 10 n·m (1.0 kg...

  • Page 304

    1d-64 engine mechanical: gear position switch • apply grease to the o-ring. Caution ! Replace the o-ring with a new one. Note align the gear position switch pin “a” with the gearshift cam hole “b”. : grease 99000–25010 (suzuki super grease a or equivalent) • apply thread lock to the gear position sw...

  • Page 305

    Engine mechanical: 1d-65 • tighten the water inlet connector mounting bolts (3) to the specified torque. Tightening torque water inlet connector mounting bolt (b): 10 n·m ( 1.0 kgf-m, 7.0 lb-ft) generator rotor / starter driven gear install the generator rotor (1). Refer to “generator removal and in...

  • Page 306

    1d-66 engine mechanical: • while holding the generator rotor with the special tool, tighten the ckp sensor rotor/cam chain drive sprocket bolt (5) and tighten its bolt to the specified torque. Special tool (a): 09930–44520 (rotor holder) tightening torque ckp sensor rotor/cam chain drive sprocket bo...

  • Page 307

    Engine mechanical: 1d-67 • apply a small quantity of thread lock to the gearshift cam stopper plate bolt (6) and tighten it to the specified torque. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tightening torque gearshift cam stopper plate bolt (b): 13 n·m (1.3 kgf-...

  • Page 308

    1d-68 engine mechanical: • install the oil pump drive sprocket (2) to the countershaft. Note teeth “a” on the sprocket must face the clutch side. • pass the chain (3) between the oil pump drive and driven sprockets. • apply engine oil to the countershaft. • install the bearing (4) and spacer (5), an...

  • Page 309

    Engine mechanical: 1d-69 cylinder inspection b837h11406032 refer to “engine top side disassembly (page 1d-25)”. Refer to “engine top side assembly (page 1d-27)”. Cylinder distortion check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gauge. Take clearance readin...

  • Page 310

    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 311

    Engine mechanical: 1d-71 piston and piston ring inspection b837h11406034 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 312

    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 313

    Engine mechanical: 1d-73 conrod crank pin bearing removal and installation b837h11406044 refer to “engine bottom side disassembly (page 1d- 47)”. Refer to “engine bottom side assembly (page 1d-54)”. Removal remove the conrod crank pin bearings (1). Note • do not remove the bearings (1) unless absolu...

  • Page 314

    1d-74 engine mechanical: 2) if the clearance exceeds the limit, remove the conrod and measure the conrod big end width and crank pin width. Refer to “engine bottom side assembly (page 1d-54)”. If any of the measurements are out of specification, replace the conrod or crankshaft. Special tool (b): 09...

  • Page 315

    Engine mechanical: 1d-75 4) remove the conrod cap bolts and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. If the oil clearance exceeds the service limit, select the specified bearings from ...

  • Page 316

    1d-76 engine mechanical: 4) select the specified bearings from the bearing selection table. Caution ! The bearings should be replaced as a set. Bearing selection table bearing thickness specification crankshaft journal bearing inspection and selection b837h11406042 refer to “engine bottom side disas...

  • Page 317

    Engine mechanical: 1d-77 5) tighten the crankshaft journal bolts (m9). Tighten each bolt a little at a time to equalize the pressure in the following two steps. Note do not rotate the crankshaft when a piece of plastigauge is installed. Tightening torque crankshaft journal bolt (m9): 18 n ⋅m (1.8 kg...

  • Page 318

    1d-78 engine mechanical: 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. Specification special tool (a): 09900–20202 (micrometer (1/100 mm, 25 – 50 mm)) 4) select the specified bearings from th...

  • Page 319

    Engine mechanical: 1d-79 crankshaft thrust clearance inspection and selection b837h11406043 refer to “engine bottom side disassembly (page 1d- 47)”. Refer to “engine bottom side assembly (page 1d-54)”. Inspection 1) with the crankshaft’s right-side and left-side thrust bearings inserted into the upp...

  • Page 320

    1d-80 engine mechanical: 4) select a left-side thrust bearing from the selection table. Note right-side thrust bearing has the same specification as the green (12228-17e00-0d0) of left-side thrust bearing. Left-side thrust bearing selection table 5) after selecting a left-side thrust bearing, instal...

  • Page 321

    Engine mechanical: 1d-81 specifications service data b837h11407001 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 27.2 (1.07) — ex. 22.0 (0.87) — valve clearance (when cold) in. 0.08 – 0.18 (0.003 – 0.007) — ex. 0.18 – 0.28 (0.007 – 0.011) — va...

  • Page 322

    1d-82 engine mechanical: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) throttle body item standard limit compression pressure 1 200 – 1 600 kpa (12 – 16 kgf/cm 2 , 171 – 228 psi) 900 kpa (9 kgf/cm 2 , 128 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , ...

  • Page 323

    Engine mechanical: 1d-83 tightening torque specifications b837h11407002 fastening part tightening torque note n ⋅m kgf-m lb-ft stp sensor mounting screw 3.5 0.35 2.5 ) (page 1d-13) isc valve mounting screw 2 0.2 1.5 ) (page 1d-14) tp sensor mounting screw 3.5 0.35 2.5 ) (page 1d-14) fuel delivery pi...

  • Page 324

    1d-84 engine mechanical: note the specified tightening torque is also described in the following. “throttle body components (page 1d-8)” “throttle body construction (page 1d-9)” “engine assembly installation (page 1d-23)” reference: for the tightening torque of fastener not specified in this section...

  • Page 325

    Engine mechanical: 1d-85 09900–20203 09900–20205 micrometer (1/100 mm, 50 – 75 mm) micrometer (0 – 25 mm) ) (page 1d-71) ) (page 1d-35) / ) (page 1d-43) / ) (page 1d-71) / ) (page 1d-72) / ) (page 1d-74) / ) (page 1d-79) 09900–20530 09900–20602 cylinder gauge set dial gauge (1/1000 mm, 1 mm) ) (page...

  • Page 326

    1d-86 engine mechanical: 09915–40610 09915–64512 oil filter wrench compression gauge ) (page 1d-50) / ) (page 1d-63) ) (page 1d-3) 09916–10911 09916–14510 valve lapper set valve spring compressor ) (page 1d-44) ) (page 1d-38) / ) (page 1d-41) 09916–14522 09916–33210 valve spring compressor attachmen...

  • Page 327: Engine Lubrication System

    Engine lubrication system: 1e-1 engine engine lubrication system precautions precautions for engine oil b837h11500001 refer to “fuel and oil recommendation in section 0a (page 0a-3)”..

  • Page 328: Sub Gallery #2

    1e-2 engine lubrication system: schematic and routing diagram engine lubrication system chart diagram b837h11502001 intake camshaft cam drive chain cam chain tension adjuster #1 piston cooling oil jet #1 piston and cylinder wall #1 crank pin bearing #1 crankshaft journal bearing orifice generator ge...

  • Page 329

    Engine lubrication system: 1e-3 engine lubrication circuit diagram b837h11502002 i837h1150046-01.

  • Page 330

    1e-4 engine lubrication system: [a] [a] i837h1150040-01.

  • Page 331

    Engine lubrication system: 1e-5 diagnostic information and procedures engine lubrication symptom diagnosis b837h11504001 oil pressure check b837h11504002 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 332

    1e-6 engine lubrication system: 7) stop the engine and remove the oil pressure gauge and attachment. 8) reinstall the main oil gallery plug (1) and tighten it to the specified torque. Caution ! Use a new gasket to oil leakage. Tightening torque main oil gallery plug (m16) (a): 35 n·m (3.5 kgf- m, 25...

  • Page 333

    Engine lubrication system: 1e-7 • install the oil pressure regulator (1) and oil strainer (2). Note when installing the oil strainer, fit the concave part “a” of the oil strainer onto the convex part “b” of the crankcase. • tighten the oil pan bolts diagonally. Caution ! • use the new oil pan gasket...

  • Page 334

    1e-8 engine lubrication system: oil cooler / oil cooler hose inspection b837h11506005 oil cooler hose inspection refer to “water hose inspection in section 1f (page 1f- 6)”. Oil cooler inspection 1) remove the right under cowling. Refer to “exterior parts removal and installation in section 9d (page...

  • Page 335

    Engine lubrication system: 1e-9 oil pressure switch removal and installation b837h11506007 refer to “electrical components location in section 0a (page 0a-7)”. Removal 1) turn the ignition switch off. 2) remove the right under cowling. Refer to “exterior parts removal and installation in section 9d ...

  • Page 336

    1e-10 engine lubrication system: installation installation is in the reverse order of removal. Pay attention to the following points: • fit the new o-ring (1) to each piston cooling oil jet and apply engine oil to them. Caution ! Use the new o-rings to prevent oil pressure leakage. • apply a small q...

  • Page 337

    Engine lubrication system: 1e-11 oil jet (for transmission) removal 1) remove the engine assembly. Refer to “engine assembly removal in section 1d (page 1d-19)”. 2) separate the crankcases, upper and lower. Refer to “engine bottom side disassembly in section 1d (page 1d-47)”. 3) remove the oil jet (...

  • Page 338

    1e-12 engine lubrication system: oil gallery jet inspect the oil gallery jet for clogging. Clean the oil gallery if necessary. Oil pump removal and installation b837h11506011 note be careful not to drop any parts into the crankcase. Removal 1) remove the oil pan, oil strainer and oil pressure regula...

  • Page 339

    Engine lubrication system: 1e-13 3) tighten the oil pump mounting bolts to the specified torque. Tightening torque oil pump mounting bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) 4) install the washer (1). 5) install the oil pump driven gear (2) with the chain (3). 6) apply a small quantity of thread lock...

  • Page 340

    1e-14 engine lubrication system: 3) remove the oil pump drive sprocket (3) and chain (4). 4) remove the thrust washer (5). Installation installation is in the reverse order of removal. Pay attention to the following points: • install the thrust washer (1) to the countershaft. Note the chamfer side “...

  • Page 341

    Engine lubrication system: 1e-15 tightening torque specifications b837h11507002 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 recommended service material b837h11508001 special ...

  • Page 342: Engine Cooling System

    1f-1 engine cooling system: engine engine cooling system precautions precautions for engine cooling system b837h11600001 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 343

    Engine cooling system: 1f-2 schematic and routing diagram cooling circuit diagram b837h11602001 water pump radiator ect sensor thermostat cylinder head cylinder reservoir tank oil cooler i837h1160001-01.

  • Page 344

    1f-3 engine cooling system: water hose routing diagram b837h11602002 “d” “e” “l” “h” “b” “a” [a] “j” “k” “i” “l” “f” “p” “g” “l” “f” “m” “m” “m” “n” 1 “ a ” “ a ” “ a ” “c” “f” “e” “i” “i” “o” “f” “n” “ b ” “a” i837h1160053-01 1. Jiggle valve “g”: pass the hoses outside the excv cables. “n”: red mar...

  • Page 345

    Engine cooling system: 1f-4 diagnostic information and procedures engine cooling symptom diagnosis b837h11604001 repair instructions cooling circuit inspection b837h11606001 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 346

    1f-5 engine cooling system: radiator cap inspection b837h11606002 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 347

    Engine cooling system: 1f-6 4) disconnect the radiator outlet hose (3) and water bypass hose (4). 5) disconnect the radiator inlet hose (5) and oil cooler water inlet hose (6). 6) disconnect the cooling fan motor coupler (7). 7) remove the radiator assembly by removing the bolts. 8) remove the cooli...

  • Page 348

    1f-7 engine cooling system: 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 b837h11606006 removal 1)...

  • Page 349

    Engine cooling system: 1f-8 radiator reservoir tank removal and installation b837h11606007 removal 1) remove the right under cowling. Refer to “exterior parts removal and installation in section 9d (page 9d-11)”. 2) disconnect the reservoir tank over flow hose (1), reservoir tank inlet hose (2) and ...

  • Page 350

    1f-9 engine cooling system: 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 : 09900–25008...

  • Page 351

    Engine cooling system: 1f-10 • tighten the thermostat cover bolts to the specified torque. Tightening torque thermostat cover bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) • connect the water hoses securely. Refer to “water hose routing diagram (page 1f-3)”. • pour engine coolant and bleed air from the co...

  • Page 352

    1f-11 engine cooling system: water pump components b837h11606015 (a) 1 2 3 5 4 2 (b) fwd fwd (c) i837h1160026-02 1. Water pump case : 8 n ⋅m (0.8 kgf-n, 6.0 ib-ft) : apply molybdenum oil solution. 2. O-ring : 5.5 n ⋅m (0.55 kgf-n, 4.0 ib-ft) : apply thread lock. 3. Impeller : 10 n ⋅m (1.0 kgf-n, 7.0...

  • Page 353

    Engine cooling system: 1f-12 water pump construction b837h11606016 water pump removal and installation b837h11606017 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 354

    1f-13 engine cooling system: • install the water pump assembly with the slot on the pump shaft end “a” securely engaged with the flat “b” on 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 355

    Engine cooling system: 1f-14 7) remove the o-ring (7), impeller shaft (8) and washer (9) from the water pump body. 8) remove the mechanical seal with the special tool. Note if there is no abnormal condition, the mechanical seal removal is not necessary. Special tool (a): 09921–20240 (bearing remover...

  • Page 356

    1f-15 engine cooling system: 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 new mechanical seals, the sealer “a” has been applied. 4) apply molybdenum solution to the impeller shaft (1) and washer (...

  • Page 357

    Engine cooling system: 1f-16 10) apply a small quantity of thread lock to the impeller securing bolt and tighten it to the specified torque. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tightening torque impeller securing bolt (a): 8 n·m (0.8 kgf-m, 6.0 lb-ft) 11) i...

  • Page 358

    1f-17 engine cooling system: oil seal visually inspect the oil seal for damage, with particular attention given to the lip. Replace the oil seal that shows indications of leakage. Case visually inspect the case for damage or scratch. Replace the case if necessary. Seal washer visually inspect the se...

  • Page 359

    Engine cooling system: 1f-18 specifications service data b837h11607001 thermostat + radiator + fan + coolant tightening torque specifications b837h11607002 note the specified tightening torque is also described in the following. “water pump components (page 1f-11)” “water pump construction (page 1f-...

  • Page 360

    1f-19 engine cooling system: special tools and equipment recommended service material b837h11608001 note required service material is also described in the following. “water pump components (page 1f-11)” “water pump construction (page 1f-12)” special tool b837h11608002 material suzuki recommended pr...

  • Page 361: Fuel System

    Fuel system: 1g-1 engine fuel system precautions precautions for fuel system b837h11700001 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 362

    1g-2 fuel system: general description fuel injection system description b837h11701001 fuel system the fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filters (3) and (4), fuel feed hose (5), fuel delivery pipes (6) including fuel injectors (7) and (8), fuel pressure regulator...

  • Page 363

    Fuel system: 1g-3 schematic and routing diagram fuel tank drain hose and breather hose routing diagram b837h11702001 5 5 2 2 2 4 4 4 6 6 3 7 “ a ” “ a ” “ b ” “ d ” “ c ” 1 1 1 “a” “b” i837h1170001-03 1. Fuel tank water drain hose 6. Breather hose clamp (except for e-33) “b”: 13 mm (0.5 in) 2. Fuel ...

  • Page 364

    1g-4 fuel system: diagnostic information and procedures fuel system diagnosis b837h11704001 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 365

    Fuel system: 1g-5 repair instructions fuel pressure inspection b837h11706001 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 366

    1g-6 fuel system: fuel discharge amount inspection b837h11706003 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel discharge amount in the following procedures: 1) lift and support the fuel tank. Refer to ...

  • Page 367

    Fuel system: 1g-7 fuel pump relay inspection b837h11706004 refer to “electrical components location in section 0a (page 0a-7)”. Inspect the fuel pump relay in the following procedures: 1) remove the front seat. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) remove...

  • Page 368

    1g-8 fuel system: fuel tank construction b837h11706007 1 2 3 4 “a” “b” “b” “b” i837h1170032-02 1. Fuel tank heat shield : aluminum film side should face the engine side. 3. Fuel tank front bracket “a”: insert to the fuel tank heat shield bracket. 2. Fuel tank front cover 4. Velcro fastenings : clean...

  • Page 369

    Fuel system: 1g-9 fuel tank removal and installation b837h11706009 removal warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. 1) remove the frame cover assembly. Refer to “exterior parts removal and installation in section ...

  • Page 370

    1g-10 fuel system: fuel pump components b837h11706010 1 2 3 5 6 6 6 6 4 (a) fwd fwd i837h1170033-02 1. Fuel level gauge 4. Fuel pump case : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) : do not reuse. 2. Fuel filter cartridge 5. Fuel mesh filter : apply engine oil. 3. Fuel pump 6. O-ring : apply grease..

  • Page 371

    Fuel system: 1g-11 fuel pump disassembly and assembly b837h11706011 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 372

    1g-12 fuel system: 8) remove the o-ring (10) and lead wires (11). 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 f...

  • Page 373

    Fuel system: 1g-13 • install a new o-ring and apply grease to it. : grease 99000–25010 (suzuki super grease a or equivalent) warning ! The o-ring must be replaced with a new one to prevent fuel leakage. • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly ...

  • Page 374

    1g-14 fuel system: specifications service data b837h11707001 injector + fuel pump + fuel pressure regulator fuel tightening torque specifications b837h11707002 note the specified tightening torque is also described in the following. “fuel pump components (page 1g-10)” reference: for the tightening t...

  • Page 375

    Fuel system: 1g-15 special tools and equipment recommended service material b837h11708001 note required service material is also described in the following. “fuel pump components (page 1g-10)” special tool b837h11708002 material suzuki recommended product or specification note grease suzuki super gr...

  • Page 376: Ignition System

    1h-1 ignition system: engine ignition system general description immobilizer description (for e-02, 19, 24) b837h11801001 the immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key id agrees with ecm id by means of radio communication through t...

  • Page 377

    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 378

    1h-3 ignition system: schematic and routing diagram ignition system diagram b837h11802001 refer to “wire color symbols in section 0a (page 0a-5)”. Ignition system components location b837h11802002 refer to “electrical components location in section 0a (page 0a-7)”. #1 #2 #3 #4 ckp sensor tp sensor e...

  • Page 379

    Ignition system: 1h-4 diagnostic information and procedures ignition system symptom diagnosis b837h11804001 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 380

    1h-5 ignition system: no spark or poor spark b837h11804002 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 381

    Ignition system: 1h-6 repair instructions ignition coil / plug cap and spark plug removal and installation b837h11806001 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...

  • Page 382

    1h-7 ignition system: • install the ignition coil/plug caps and connect their lead wire couplers. Caution ! Do not hit the ignition coil/plug cap with a plastic hammer when installing it. Spark plug inspection and cleaning b837h11806002 refer to “spark plug inspection and cleaning in section 0b (pag...

  • Page 383

    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 384

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

  • Page 385

    Ignition system: 1h-10 5) repeat the b) procedure several times and measure the highest ckp sensor peak voltage. Ckp sensor peak voltage 0.28 v and more (b – g) 6) if the peak voltage is within the specification, check the continuity between the ckp sensor coupler and ecm coupler. Caution ! Normally...

  • Page 386

    1h-11 ignition system: ignition switch removal and installation b837h11806008 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 387

    Ignition system: 1h-12 drive mode selector inspection b837h11806009 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 “date monitor”. 4) make sure each of “driving mod...

  • Page 388

    1h-13 ignition system: specifications service data b837h11807001 electrical unit: mm (in) tightening torque specifications b837h11807002 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 389

    Ignition system: 1h-14 special tools and equipment recommended service material b837h11808001 special tool b837h11808002 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 390: Starting System

    1i-1 starting system: engine starting system schematic and routing diagram starting system diagram b837h11902001 refer to “wire color symbols in section 0a (page 0a-5)”. Component location starting system components location b837h11903001 refer to “electrical components location in section 0a (page ...

  • Page 391

    Starting system: 1i-2 starter motor will not run b837h11904002 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 b837h11904003 the starter motor runs when the transmission is in neutral, but doe...

  • Page 392

    1i-3 starting system: repair instructions starter motor components b837h11906001 (b) 4 3 (c) 7 (a) 8 5 5 6 2 1 fwd fwd i837h1190035-03 1. O-ring 6. Starter motor case : 3.5 n ⋅m (0.35 kgf-m, 2.5 lb-ft) 2. Housing end (inside) 7. Housing end (outside) : apply grease to sliding surface. 3. O-ring 8. S...

  • Page 393

    Starting system: 1i-4 starter motor removal and installation b837h11906002 removal 1) turn the ignition switch off and disconnect the battery (–) lead wire. Refer to “battery removal and installation in section 1j (page 1j-13)”. 2) remove the fuel tank. Refer to “fuel tank removal and installation i...

  • Page 394

    1i-5 starting system: • apply grease to the bearing. : grease 99000–25010 (suzuki super grease a or equivalent) • apply a small quantity of moly paste to the armature shaft. : moly paste 99000–25140 (suzuki moly paste or equivalent) • align the match marks on the starter motor case with the match ma...

  • Page 395

    Starting system: 1i-6 commutator inspect the commutator for discoloration, abnormal wear or undercut “a”. If the commutator is abnormally worn, replace the armature assembly. If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth. If there is no u...

  • Page 396

    1i-7 starting system: starter relay inspection b837h11906006 inspect the starter relay in the following procedures: 1) remove the starter relay. Refer to “starter relay removal and installation (page 1i-6)”. 2) apply 12 v to “a” and “b” terminals and check for continuity between the positive and neg...

  • Page 397

    Starting system: 1i-8 side-stand / ignition interlock system parts inspection b837h11906008 check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a ...

  • Page 398

    1i-9 starting system: diode inspection 1) remove the turn signal/side-stand relay. Refer to “turn signal / side-stand relay removal and installation (page 1i-7)”. 2) measure the voltage between the “a”, “b” and “c” terminals using the multi-circuit tester. Special tool : 09900–25008 (multi-circuit t...

  • Page 399

    Starting system: 1i-10 7) measure the voltage between p and b/w lead wires using the multi-circuit tester when shifting the gearshift lever from low to top. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication voltage ( ) gear po...

  • Page 400

    1i-11 starting system: 8) remove the starter driven gear (12). 9) hold the generator rotor with the special tool and remove the starter clutch bolts. Special tool (a): 09930–44530 (rotor holder) 10) remove the one way clutch (13) from the starter clutch guide (14). Installation install the starter c...

  • Page 401

    Starting system: 1i-12 • tighten the starter clutch bolts to the specified torque while holding the rotor with the special tool. Caution ! Use new precoated starter clutch bolts. Special tool (a): 09930–44520 (rotor holder) tightening torque starter clutch bolt (a): 13 n·m (1.3 kgf-m, 9.5 lb-ft) • a...

  • Page 402

    1i-13 starting system: starter clutch 1) install the starter driven gear onto the starter clutch. 2) turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns in one direction only. If a large resistance is felt for rotation, inspect the starter clutch ...

  • Page 403

    Starting system: 1i-14 specifications service data b837h11907001 electrical unit: mm tightening torque specifications b837h11907002 note the specified tightening torque is also described in the following. “starter motor components (page 1i-3)” reference: for the tightening torque of fastener not spe...

  • Page 404

    1i-15 starting system: special tools and equipment recommended service material b837h11908001 note required service material is also described in the following. “starter motor components (page 1i-3)” special tool b837h11908002 material suzuki recommended product or specification note grease suzuki s...

  • Page 405: Charging System

    Charging system: 1j-1 engine charging system schematic and routing diagram charging system diagram b837h11a02001 component location charging system components location b837h11a03001 refer to “electrical components location in section 0a (page 0a-7)”. Diagnostic information and procedures charging sy...

  • Page 406

    1j-2 charging system: battery runs down quickly b837h11a04002 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 407

    Charging system: 1j-3 repair instructions battery current leakage inspection b837h11a06002 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- 11)”. 3) di...

  • Page 408

    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 409

    Charging system: 1j-5 4) remove the starter idle gear no. 1 component parts (2). Refer to “starter clutch removal and installation in section 1i (page 1i-10)”. 5) remove the generator cover (3). 6) remove the gasket (4) and dowel pin. 7) remove the shaft (5) and starter idle gear no. 2 (6). 8) hold ...

  • Page 410

    1j-6 charging system: 12) remove the generator stator (8). Installation install the generator in the reverse order of removal. Pay attention to the following points: • tighten the generator stator set bolts and generator lead wire set bolt to the specified torque. Note be sure the grommet (1) is set...

  • Page 411

    Charging system: 1j-7 • apply molybdenum oil solution to the starter idle gear no. 2 shaft holes. M/o: molybdenum oil (molybdenum oil solution) • install the dowel pin and new gasket (2). Caution ! Use a new gasket to prevent oil leakage. • apply grease to the starter motor o-ring. : grease 99000–25...

  • Page 412

    1j-8 charging system: regulator / rectifier construction b837h11a06006 “a” “b” (a) (a) “c” (a) 3 2 1 5 4 i837h11a0027-02 1. Regulator/rectifier 4. Clamp “b”: pass the regulator/rectifier harness between the bracket and frame. 2. Regulator/rectifier bracket mold 5. Frame “c”: after the clamp has cont...

  • Page 413

    Charging system: 1j-9 regulator / rectifier removal and installation b837h11a06007 removal 1) turn the ignition switch off. 2) lift the air cleaner box upside. Refer to “air cleaner box removal and installation in section 1d (page 1d-7)”. 3) remove the left under cowling. Refer to “exterior parts re...

  • Page 414

    1j-10 charging system: regulator / rectifier inspection b837h11a06008 inspect the regulator/rectifier in the following procedures: 1) turn the ignition switch off. 2) disconnect the regulator/rectifier couplers. Refer to “regulator / rectifier removal and installation (page 1j-9)”. 3) measure the vo...

  • Page 415

    Charging system: 1j-11 battery components b837h11a06009 battery charging b837h11a06010 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 ...

  • Page 416

    1j-12 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 417

    Charging system: 1j-13 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 418

    1j-14 charging system: • tighten the battery lead wire mounting bolts securely. Battery visual inspection b837h11a06012 inspect the battery in the following procedures: 1) remove the front seat. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) visually inspect the s...

  • Page 419

    Charging system: 1j-15 special tools and equipment recommended service material b837h11a08001 special tool b837h11a08002 material suzuki recommended product or specification note grease suzuki super grease a or equivalent p/no.: 99000–25010 ) (page 1j-7) molybdenum oil molybdenum oil solution — ) (p...

  • Page 420: Exhaust System

    1k-1 exhaust system: engine exhaust system precautions precautions for exhaust system b837h11b00001 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 421

    Exhaust system: 1k-2 exhaust control system operation b837h11b01002 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 422

    1k-3 exhaust system: full open i837h11b0043-02.

  • Page 423

    Exhaust system: 1k-4 repair instructions exhaust control system construction b837h11b06001 “ a ” “ b ” “ c ” 1 2 (b) 2 1 2 1 (a) (a) 1 2 “a” i837h11b0040-02 1. Excv cable no. 1 “a”: when loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or excva may get da...

  • Page 424

    1k-5 exhaust system: exhaust system components b837h11b06004 caution ! Replace the gaskets and connector with new ones when reassembling. 1 2 4 5 6 6 7 7 (i) (f) (g) (e) (b) 3 (d) (c) (a) “a” (h) i837h11b0041-04 1. Exhaust pipe gasket “a”: when loosening or tightening the pulley bolt, be sure to fix...

  • Page 425

    Exhaust system: 1k-6 excv cable removal and installation b837h11b06005 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) remove the right under cowling assembly. Refer to “exterior parts removal an...

  • Page 426

    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 (37h0cl) (1) and no. 2 (37h0op) (2) to the excv cable bracket (3) and install them to the exhaust pipe. Note the excv cables are identified by ...

  • Page 427

    Exhaust system: 1k-8 5) after turning the mode select switch on, turn the ignition switch on. Special tool (a): 09930–82720 (mode select switch) 6) check that the cable slots of the excva pulley comes to the middle (adjustment position) “a”. 7) turn the ignition switch off. Caution ! Before removing...

  • Page 428

    1k-9 exhaust system: • hold the pulley with an adjustable wrench, and then tighten the pulley mounting bolt (1) to the specified torque. Tightening torque excva pulley mounting bolt (a): 5 n·m (0.5 kgf- m, 3.5 lb-ft) caution ! When loosening or tightening the pulley bolt, be sure to fix the pulley w...

  • Page 429

    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) disconnect the excva motor coupler (1). 3) ...

  • Page 430

    1k-11 exhaust system: step 4 1) to set the excv to fully opened position, apply 12 v to the terminal oppositely. Positive wire — gr wire terminal negative wire — p wire terminal caution ! To prevent the motor damage, stop applying 12 v as soon as the excv reaches fully opened position. 2) measure th...

  • Page 431

    Exhaust system: 1k-12 5) lift and support the fuel tank with the prop stay. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 6) disconnect the ho2 sensor coupler (4). 7) release the ho2 sensor lead wire from the clamp. 8) disconnect the excv cables (5) from the excv pulley. 9...

  • Page 432

    1k-13 exhaust system: 14) remove the ho2 sensor (8) from the exhaust pipe. Caution ! • be careful not to expose the ho2 sensor to an excessive shock. • be careful not to twist or damage the ho2 sensor lead wire. Installation installation is in the reverse order of removal. Pay attention to the follo...

  • Page 433

    Exhaust system: 1k-14 • tighten the excv cables mounting nuts to the specified torque. Tightening torque excv cable mounting nut (d): 5.5 n·m (0.55 kgf- m, 4.0 lb-ft) • install the connector (2). Caution ! Replace the connectors with new one. Note • when installing a new connector, remove all of the...

  • Page 434

    1k-15 exhaust system: specifications tightening torque specifications b837h11b07001 note the specified tightening torque is also described in the following. “exhaust control system construction (page 1k-4)” “exhaust system components (page 1k-5)” reference: for the tightening torque of fastener not ...

  • Page 435: 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 436: Precautions

    2-1 precautions: suspension precautions precautions precautions for suspension b837h12000001 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 437: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b837h12104001 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn front wheel bearings. Repla...

  • Page 438: Front Suspension

    2b-1 front suspension: 9suspension front suspension repair instructions front fork components b837h12206001 fwd fwd (a) 1 (b) 7 2 3 5 6 8 9 11 10 12 13 14 15 4 (a) 16 (d) 18 (c) 17 i837h1220040-03 1. Front fork cap bolt 10. Oil seal retainer : 35 n ⋅m (3.5 kgf-m, 25.5 lb-ft) 2. O-ring 11. Oil seal :...

  • Page 439

    Front suspension: 2b-2 front fork removal and installation b837h12206002 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 assembly. Refer to “front wheel assembly...

  • Page 440

    2b-3 front suspension: 2) tighten the front fork cap bolt (2) to the specified torque. Tightening torque front fork cap bolt (a): 35 n·m (3.5 kgf-m, 25.5 lb-ft) 3) loosen the lower clamp bolts. 4) set the front fork with the upper surface “t” of the outer tube positioned 5.0 mm (0.20 in) “a” from th...

  • Page 441

    Front suspension: 2b-4 front suspension adjustment b837h12206003 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 damping force adjuster (1...

  • Page 442

    2b-5 front suspension: 3) compress the fork spring with the special tool (a) and insert the special tool (b) between the lock-nut (2) and spring retainer (3). Special tool (a): 09940–94930 (front fork spacer holder) (b): 09940–94922 (front fork spring stopper plate) 4) remove the front fork cap bolt...

  • Page 443

    Front suspension: 2b-6 11) remove the damper rod bolt with the special tool. Special tool (c): 09940–30221 (front fork assembling tool) 12) remove the inner rod/damper rod (cartridge) (9). Caution ! Do not disassemble the inner rod/damper rod (cartridge). 13) remove the outer tube from the inner tub...

  • Page 444

    2b-7 front suspension: • apply fork oil to the oil seal lip. : fork oil 99000–99001–ss5 (suzuki fork oil ss-05 or equivalent) • apply fork oil to the anti-friction metals “a” and “b”. : fork oil 99000–99001–ss5 (suzuki fork oil ss-05 or equivalent) • install the inner tube into the outer tube and fi...

  • Page 445

    Front suspension: 2b-8 • apply thread lock to the damper rod bolt (2) and tighten it to the specified torque with the special tools. Caution ! Use a new damper rod bolt gasket (3) to prevent oil leakage. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) special tool (a):...

  • Page 446

    2b-9 front suspension: • move the inner rod slowly with the special tool (a) more than ten times until bubbles do not come out from the oil. Note refill front fork oil up to the top of the outer tube to find bubbles while bleeding air. Special tool (a): 09940–52841 (inner rod holder) • refill specif...

  • Page 447

    Front suspension: 2b-10 front fork cap bolt note turn the inner rod lock-nut until stops on the inner rod threads. • pull up the inner rod with the special tool (a). • compress the spring with the special tool (b) and then insert the special tool (c) between the lock-nut and spring retainer. Special...

  • Page 448

    2b-11 front suspension: • apply fork oil to the o-ring. Caution ! Use a new o-ring to prevent oil leakage. : fork oil 99000–99001–ss5 (suzuki fork oil ss-05 or equivalent) • remove the special tools. • tighten the front fork cap to the outer tube temporarily. Front fork parts inspection b837h1220600...

  • Page 449

    Front suspension: 2b-12 specifications service data b837h12207001 suspension unit: mm (in) tightening torque specifications b837h12207002 note the specified tightening torque is also described in the following. “front fork components (page 2b-1)” reference: for the tightening torque of fastener not ...

  • Page 450

    2b-13 front suspension: special tools and equipment recommended service material b837h12208001 note required service material is also described in the following. “front fork components (page 2b-1)” special tool b837h12208002 material suzuki recommended product or specification note fork oil suzuki f...

  • Page 451: Rear Suspension

    Rear suspension: 2c-1 suspension rear suspension repair instructions rear suspension components b837h12306001 1 3 5 11 10 12 13 14 (e) 8 (d) 7 (b) 4 (c) 4 (b) 6 (a) 2 fwd fwd (a) 2 (f) 9 (g) i837h1230055-05 1. Rear shock absorber 9. Swingarm pivot nut : 78 n ⋅m (7.8 kgf-m, 56.5 lb-ft) 2. Rear shock ...

  • Page 452

    2c-2 rear suspension: rear suspension assembly construction b837h12306002 1 1 2 2 3 5 6 4 4 (a) (a) (c) (b) 3 (b) 5 “ a ” “ b ” “ a ” “ a ” “ a ” “ b ” “ b ” “ b ” (d) i837h1230056-02 1. Rear shock absorber mounting bolt (upper) 6. Swingarm pivot shaft : 78 n ⋅m (7.8 kgf-m, 56.5 lb-ft) 2. Rear shock...

  • Page 453

    Rear suspension: 2c-3 rear shock absorber removal and installation b837h12306003 removal 1) remove the under cowlings. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) support the motorcycle with a jack to relieve load on the rear shock absorber. 3) remove the muffl...

  • Page 454

    2c-4 rear suspension: • tighten the cushion rod rear mounting bolt and nut. Tightening torque cushion rod rear mounting nut (d): 78 n·m (7.8 kgf-m, 56.5 lb-ft) rear suspension inspection b837h12306004 refer to “rear suspension inspection in section 0b (page 0b-20)”. Rear shock absorber inspection b8...

  • Page 455

    Rear suspension: 2c-5 rebound side turn the damping force adjuster (1) to the desired position. Std position 2 turns out from stiffest position compression side (low speed) turn the damping force adjuster (2) to the desired position. Std position 1-3/4 turns out of from stiffest position compression...

  • Page 456

    2c-6 rear suspension: cushion lever removal and installation b837h12306008 removal 1) remove the under cowlings. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) support the motorcycle with a jack to relieve load on the cushion lever. 3) remove the muffler. Refer to...

  • Page 457

    Rear suspension: 2c-7 cushion lever bearing removal and installation b837h12306010 removal 1) remove the cushion lever. Refer to “cushion lever removal and installation (page 2c-6)”. 2) remove the cushion lever bearings with the special tool. Special tool (a): 09921–20240 (bearing remover set) insta...

  • Page 458

    2c-8 rear suspension: 2) apply grease to the bearings. : grease 99000–25010 (suzuki super grease a or equivalent) 3) install the cushion lever. Refer to “cushion lever removal and installation (page 2c-6)”. Cushion rod removal and installation b837h12306014 removal 1) remove the cushion lever (1). R...

  • Page 459

    Rear suspension: 2c-9 cushion rod bearing 1) insert the spacer into bearing. 2) check the play by moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. Refer to “cushion rod bearing removal and installation (page 2c-9)”. Cushion rod inspect the cushion lever ...

  • Page 460

    2c-10 rear suspension: swingarm removal and installation b837h12306011 removal 1) cut the drive chain. Refer to “drive chain replacement in section 3a (page 3a-7)”. 2) remove the rear wheel assembly. Refer to “rear wheel assembly removal and installation in section 2d (page 2d-11)”. 3) disconnect th...

  • Page 461

    Rear suspension: 2c-11 12) remove the plate (10). Installation install the swingarm in the reverse order of removal. Pay attention to the following points: • install the plate. Note when reusing the removed screw (1), apply a small quantity of the thread lock to them. : thread lock cement 99000–3211...

  • Page 462

    2c-12 rear suspension: – tighten the swingarm pivot lock-nut (4) to the specified torque with the special tool. Special tool (b): 09940–14940 (swingarm pivot thrust adjuster socket wrench) tightening torque swingarm pivot lock-nut (c): 90 n·m (9.0 kgf- m, 65.0 lb-ft) • tighten the cushion lever, cus...

  • Page 463

    Rear suspension: 2c-13 swingarm bearing 1) insert the spacers into bearings. 2) check the play by moving the spacers up and down. If excessive play is noted, replace the bearing with a new ones. Refer to “swingarm bearing removal and installation (page 2c-13)”. Swingarm inspect the swingarm for dama...

  • Page 464

    2c-14 rear suspension: installation caution ! The removed bearings must be replaced with new ones. 1) install the center spacer. 2) press the bearings into the swingarm pivot with the special tool. Note when installing the bearing, stamped mark on the bearing must face outside. Special tool (a): 099...

  • Page 465

    Rear suspension: 2c-15 specifications service data b837h12307001 suspension unit: mm (in) tightening torque specifications b837h12307002 note the specified tightening torque is also described in the following. “rear suspension components (page 2c-1)” “rear suspension assembly construction (page 2c-2...

  • Page 466

    2c-16 rear suspension: special tools and equipment recommended service material b837h12308001 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 b837h12308002 material suzuki rec...

  • Page 467: Wheels and Tires

    Wheels and tires: 2d-1 suspension wheels and tires precautions precautions for wheel and tire b837h12400001 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 468

    2d-2 wheels and tires: repair instructions front wheel components b837h12406001 1 3 3 5 6 7 8 9 11 10 4 4 5 (a) 2 (a) 2 (b) 12 fwd fwd i837h1240035-02 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 469

    Wheels and tires: 2d-3 front wheel assembly construction b837h12406002 (b) 2 (c) 3 (a) 1 (a) 1 lh rh (d) 4 (d) 4 “ a ” i837h1240036-01 1. Brake disk bolt “a”: clearance : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake caliper mounting bolt : 18 n ⋅m (1.8 kgf-m, 13.0 lb-ft) : apply grease. 3. Front axle bo...

  • Page 470

    2d-4 wheels and tires: front wheel assembly removal and installation b837h12406003 removal 1) remove the under cowlings. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) remove the brake calipers, left and right. Caution ! Do not operate the brake lever with the cal...

  • Page 471

    Wheels and tires: 2d-5 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 lb-ft) warning ! After remounting the brake calipers, pump the brake lever until the pistons push the pads correctly. 4) h...

  • Page 472

    2d-6 wheels and tires: front wheel related parts inspection b837h12406004 refer to “front wheel assembly removal and installation (page 2d-4)”. Tire refer to “tire inspection in section 0b (page 0b-19)”. Front brake disc refer to “front brake disc inspection in section 4b (page 4b-7)”. Dust seal ins...

  • Page 473

    Wheels and tires: 2d-7 front wheel dust seal / bearing removal and installation b837h12406005 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installation (page 2d-4)”. 2) remove the dust seals (1) using the special tool. Special tool (a): 09913–50121 (oil seal...

  • Page 474

    2d-8 wheels and tires: 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 (steering race installer) caution ! The sealed cover of the bearing must face outside. 3) ...

  • Page 475

    Wheels and tires: 2d-9 rear wheel components b837h12406006 2 3 5 6 7 8 9 11 10 12 13 14 15 4 3 4 4 16 (b) (c) (a) 1 fwd fwd i837h1240038-01 1. Rear axel nut 9. Spacer : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Spacer 10. Air valve : 35 n ⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Dust seal 11. Rear wheel : 60 n ⋅m (...

  • Page 476

    2d-10 wheels and tires: rear wheel assembly construction b837h12406007 lh rh (a) 1 (b) 2 (c) 3 “ a ” i837h1240039-03 1. Rear sprocket nut “a”: clearance : 35 n ⋅m (3.5 kgf-m, 25.5 lb-ft) 2. Rear axle nut : 60 n ⋅m (6.0 kgf-m, 43.0 lb-ft) : apply grease. 3. Brake disc bolt : 100 n ⋅m (10 kgf-m, 72.5 ...

  • Page 477

    Wheels and tires: 2d-11 rear wheel assembly removal and installation b837h12406008 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 478

    2d-12 wheels and tires: sprocket refer to “drive chain related components in section 3a (page 3a-1)”. Dust seal inspect the dust seal lip for wear or damage. If any defects is found, replace the dust seal with a new one. Refer to “rear wheel dust seal / bearing removal and installation (page 2d-13)”...

  • Page 479

    Wheels and tires: 2d-13 rear wheel dust seal / bearing removal and installation b837h12406010 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 dus...

  • Page 480

    2d-14 wheels and tires: 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 (steering race installer) (b): 09924–84510 (bearing installer set) caution ! The sealed cover of the bearing must face outside. 3...

  • Page 481

    Wheels and tires: 2d-15 tire removal and installation b837h12406011 removal the most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation e...

  • Page 482

    2d-16 wheels and tires: 4) install the valve core and inflate the tire. Warning ! • do not inflate the tire to more than 400 kpa (4.0 kgf/cm 2 , 57 psi). If inflated beyond this limit, the tire can burst and possibly cause injury. Do not stand directly over the tire while inflating. • in the case of...

  • Page 483

    Wheels and tires: 2d-17 air valve inspect the air valve for peeling and damage. If any defect is found, replace the air valve with a new one. Refer to “air valve removal and installation (page 2d- 17)”. Inspect the valve core seal (1) for wear and damage. If any defect is found, replace the valve co...

  • Page 484

    2d-18 wheels and tires: wheel balance check and adjustment b837h12406014 check and adjust the wheel balance in the following procedures: 1) removal the wheel assembly. Refer to “front wheel assembly removal and installation (page 2d-4)” and “rear wheel assembly removal and installation (page 2d-11)”...

  • Page 485

    Wheels and tires: 2d-19 specifications service data b837h12407001 wheel unit: mm (in) tire tightening torque specifications b837h12407002 note the specified tightening torque is also described in the following. “front wheel components (page 2d-2)” “front wheel assembly construction (page 2d-3)” “rea...

  • Page 486

    2d-20 wheels and tires: special tools and equipment recommended service material b837h12408001 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 487: 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 488: Precautions

    3-1 precautions: driveline / axle precautions precautions precautions for driveline / axle b837h13000001 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 489

    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 b837h13104001 repair instructions drive chain related components b837h13106001 condition possible cause correction /...

  • Page 490

    3a-2 drive chain / drive train / drive shaft: engine sprocket removal and installation b837h13106002 removal 1) remove the gearshift link arm (1) by removing the bolt. Note mark the gearshift shaft head at which the gearshift link arm slit set for correct reinstallation. 2) remove the speed sensor (...

  • Page 491

    Drive chain / drive train / drive shaft: 3a-3 • tighten the engine sprocket nut (1) to the specified torque. Tightening torque engine sprocket nut (a): 115 n·m (11.5 kgf-m, 83.0 lb-ft) • tighten the speed sensor rotor bolt (2) to the specified torque. Tightening torque speed sensor rotor bolt (b): 2...

  • Page 492

    3a-4 drive chain / drive train / drive shaft: 4) remove the retainer (4). 5) remove the wheel dampers (5). 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 493

    Drive chain / drive train / drive shaft: 3a-5 engine sprocket and rear sprocket inspect the sprocket teeth for wear. If they are worn as shown, replace the engine sprocket, rear sprocket and drive chain as a set. Wheel damper inspect the dampers for wear and damage. Replace the damper if there is an...

  • Page 494

    3a-6 drive chain / drive train / drive shaft: 4) remove the sprocket mounting drum dust seal (3) 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) installatio...

  • Page 495

    Drive chain / drive train / drive shaft: 3a-7 6) install the spacer. 7) install the rear wheel assembly. Refer to “rear wheel assembly removal and installation in section 2d (page 2d-11)”. Drive chain replacement b837h13106006 use the special tool in the following procedures, to cut and rejoin the d...

  • Page 496

    3a-8 drive chain / drive train / drive shaft: 4) tighten the pressure bolt [a] (3) with the bar. 5) turn in the pressure bolt [b] (4) with the bar (5) and force out the drive chain joint pin (9). Caution ! Continue turning in the pressure bolt [b] (4) until the joint pin should been completely pushe...

  • Page 497

    Drive chain / drive train / drive shaft: 3a-9 4) apply grease on the recessed portion of the joint plate holder (3) and set the joint plate (10). Note when positioning the joint plate (10) on the tool, its stamp mark must face the joint plate holder (3) side. 5) set the drive chain on the tool as il...

  • Page 498

    3a-10 drive chain / drive train / drive shaft: 2) stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [a] (3) with the bar until the pin end diameter becomes the specified dimension. Caution ! • after joining of the chain has been completed, check to make sure that the link is ...

  • Page 499

    Drive chain / drive train / drive shaft: 3a-11 special tools and equipment recommended service material b837h13108001 note required service material is also described in the following. “drive chain related components (page 3a-1)” special tool b837h13108002 material suzuki recommended product or spec...

  • Page 500

    3a-12 drive chain / drive train / drive shaft:.

  • Page 501: 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 502: Precautions

    4-1 precautions: brake precautions precautions precautions for brake system b837h14000001 refer to “general precautions in section 00 (page 00-1)”. Brake fluid information b837h14000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix differe...

  • Page 503

    Brake control system and diagnosis: 4a-1 brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b837h14102001 1 2 2 3 4 5 2 “ a ” “ b ” “ c ” “ d ” “b” “b” “a” “c” (a) (b) (c) rh lh i837h1410054-03 1. Hose clamp : clamp end should face downward. “b”: ...

  • Page 504

    4a-2 brake control system and diagnosis: rear brake hose routing diagram b837h14102002 1 2 “ a ” “ b ” “ c ” “ d ” (a) (b) (c) (d) (e) (f) 3 4 1 “a” “b” i837h1410055-01 1. Stopper : after the brake hose union has contacted to the stopper, tighten the union bolt. : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) “a”...

  • Page 505

    Brake control system and diagnosis: 4a-3 diagnostic information and procedures brake symptom diagnosis b837h14104001 condition possible cause correction / reference item insufficient brake power leakage of brake fluid from hydraulic system. Repair or replace. Worn pads and disc. Replace. Oil adhesio...

  • Page 506

    4a-4 brake control system and diagnosis: repair instructions brake pedal height inspection and adjustment b837h14106001 refer to “brake system inspection in section 0b (page 0b-17)”. Front brake light switch inspection b837h14106002 inspect the front brake light switch in the following procedures: 1...

  • Page 507

    Brake control system and diagnosis: 4a-5 brake fluid level check b837h14106005 refer to “brake system inspection in section 0b (page 0b-17)”. Brake hose inspection b837h14106006 refer to “brake system inspection in section 0b (page 0b-17)”. Air bleeding from brake fluid circuit b837h14106007 air tra...

  • Page 508

    4a-6 brake control system and diagnosis: 8) fill the reservoir with brake fluid to the upper mark of the reservoir. 9) install the reservoir cap. Rear brake bleed air from the rear brake system as the same manner of front brake. • remove the reservoir tank mounting bolt (1). • remove the reservoir c...

  • Page 509

    Brake control system and diagnosis: 4a-7 • fill the reservoir with brake fluid to the upper mark of the reservoir. • reinstall the reservoir tank. Brake fluid replacement b837h14106008 caution ! Handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc. Fro...

  • Page 510

    4a-8 brake control system and diagnosis: 8) fill the reservoir with brake fluid to the upper mark of the reservoir. 9) install the reservoir cap. Rear brake 1) place the motorcycle on a level surface. 2) remove the brake fluid reservoir tank mounting bolt. 3) remove the brake fluid reservoir cap and...

  • Page 511

    Brake control system and diagnosis: 4a-9 9) fill the reservoir with brake fluid to the upper mark of the reservoir. 10) reinstall the reservoir tank. Front brake hose removal and installation b837h14106009 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-7)”. 2) remove the fr...

  • Page 512

    4a-10 brake control system and diagnosis: front brake master cylinder components b837h14106011 fwd fwd 1 2 3 6 5 7 8 11 4 (c) (d) (b) 9 (a) 12 (c) 10 (a) 12 (a) 12 13 i837h1410056-02 1. Reservoir cap 8. Brake lever : 1 n ⋅m (0.1 kgf-m, 0.7 lb-ft) 2. Insulator 9. Brake lever pivot bolt : 6 n ⋅m (0.6 ...

  • Page 513

    Brake control system and diagnosis: 4a-11 front brake master cylinder assembly removal and installation b837h14106012 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-7)”. 2) disconnect the front brake light switch lead wire coupler (1). 3) place a rag underneath the brake ho...

  • Page 514

    4a-12 brake control system and diagnosis: • bleed air from the master cylinder in the same manner as caliper side. Note if air is trapped in the master cylinder, bleed air from the master cylinder first. Tightening torque air bleeder valve (master cylinder) (c): 6 n·m (0.6 kgf-m, 4.5 lb-ft) • bleed ...

  • Page 515

    Brake control system and diagnosis: 4a-13 6) remove the dust rubber (15) and snap ring (16). 7) remove the connector (17), o-ring (18) and air bleeder valve (19). Assembly assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: caution ! • wash the ma...

  • Page 516

    4a-14 brake control system and diagnosis: • tighten the pivot bolt (1) and lock-nut (2) to the specified torque. Tightening torque brake lever pivot bolt (a): 1 n·m (0.1 kgf-m, 0.7 lb-ft) brake lever pivot bolt lock-nut (b): 6 n·m (0.6 kgf-m, 4.5 lb-ft) • when installing the brake light switch, alig...

  • Page 517

    Brake control system and diagnosis: 4a-15 rear brake master cylinder components b837h14106015 1 2 3 5 6 8 9 11 10 12 4 (a) 7 (a) 7 (b) (c) fwd fwd i837h1410057-02 1. Reservoir cap 6. Brake hose 11. Push rod : apply silicone grease. 2. Insulator 7. Brake hose union bolt 12. Dust boot : apply thread l...

  • Page 518

    4a-16 brake control system and diagnosis: rear brake master cylinder assembly removal and installation b837h14106016 refer to “rear brake hose routing diagram (page 4a- 2)”. Removal 1) remove the reservoir tank mounting bolt (1). 2) remove the reservoir cap (2) and diaphragm. 3) drain brake fluid. R...

  • Page 519

    Brake control system and diagnosis: 4a-17 3) remove the snap ring (3), brake hose connector (4) and o-ring (5). Special tool : 09900–06108 (snap ring pliers) 4) pull out the dust boot (6) and remove the snap ring (7) with the special tool. Special tool : 09900–06108 (snap ring pliers) 5) remove the ...

  • Page 520

    4a-18 brake control system and diagnosis: rear brake master cylinder parts inspection b837h14106018 refer to “rear brake master cylinder disassembly and assembly (page 4a-16)”. Master cylinder inspect the master cylinder bore for any scratches or other damage. Piston / rubber parts inspect the pisto...

  • Page 521

    Brake control system and diagnosis: 4a-19 rear brake pedal removal and installation b837h14106020 removal 1) remove the master cylinder assembly. Refer to “rear brake master cylinder assembly removal and installation (page 4a-16)”. 2) disconnect the rear brake light switch lead wire coupler. Refer t...

  • Page 522

    4a-20 brake control system and diagnosis: special tools and equipment recommended service material b837h14108001 note required service material is also described in the following. “front brake master cylinder components (page 4a-10)” “rear brake master cylinder components (page 4a-15)” “rear brake p...

  • Page 523: Front Brakes

    Front brakes: 4b-1 brake front brakes repair instructions front brake components b837h14206001 (c) 1 2 3 3 3 3 2 5 6 7 4 4 (a) (b) (d) (e) fwd fwd i837h1420022-02 1. O-ring 7. Front brake disc : apply thread lock to the thread part. 2. Piston seal : 22 n ⋅m (2.2 kgf-m, 16.0 lb-ft) : apply brake flui...

  • Page 524

    4b-2 front brakes: front brake pad inspection b837h14206002 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 525

    Front brakes: 4b-3 8) tighten the front brake caliper mounting bolts (4) and front brake pad mounting pins (5) to the specified torque. Tightening torque front brake caliper mounting bolt (a): 39 n·m ( 3.9 kgf-m, 28.0 lb-ft) front brake pad mounting pin (b): 15 n·m (1.5 kgf-m, 11.0 lb-ft) note after...

  • Page 526

    4b-4 front brakes: installation install the brake caliper in the reverse order of removal. Pay attention to the following points: • tighten each bolt to the specified torque. Tightening torque front brake caliper mounting bolt (a): 39 n·m (3.9 kgf-m, 28.0 lb-ft) front brake caliper housing bolt (b):...

  • Page 527

    Front brakes: 4b-5 4) place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air. Caution ! Do not use high pressure air to prevent piston damage. 5) remove the dust seals (3) and piston seals (4). Assembly assemble the caliper in the reverse orde...

  • Page 528

    4b-6 front brakes: • install a new o-ring and reassemble caliper halves. Caution ! Replace the o-ring with a new one. • temporarily tighten the brake caliper housing bolts (3) with the special tools. Caution ! After installing the brake caliper to the front fork, tighten the brake caliper housing bo...

  • Page 529

    Front brakes: 4b-7 brake pad spring inspect the brake pad spring for damage and excessive bend. If any damage is found, replace it with a new one. Front brake disc removal and installation b837h14206007 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installati...

  • Page 530

    4b-8 front brakes: brake disc runout 1) dismount the front brake caliper. Refer to “front brake caliper removal and installation (page 4b- 3)”. 2) measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit. Special tool (a): 09900–20607 (dial gauge (1/100 mm, 1...

  • Page 531

    Front brakes: 4b-9 special tools and equipment recommended service material b837h14208001 note required service material is also described in the following. “front brake components (page 4b-1)” special tool b837h14208002 material suzuki recommended product or specification note brake fluid dot 4 — )...

  • Page 532: Rear Brakes

    4c-1 rear brakes: brake rear brakes repair instructions rear brake components b837h14306001 1 2 3 5 6 7 8 8 4 (e) (a) fwd fwd (b) (c) (d) i837h1430022-02 1. Rear caliper 7. Rear brake disc : 35 n ⋅m (3.5 kgf-m, 2.5 lb-ft) 2. Piston seal 8. Brake pad spring : apply silicone grease to sliding surface....

  • Page 533

    Rear brakes: 4c-2 rear brake pad inspection b837h14306002 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 534

    4c-3 rear brakes: 6) tighten the caliper mounting bolt (4) and pad mounting pin (5) to the specified torque. Tightening torque rear brake caliper mounting bolt (a): 18 n·m ( 1.8 kgf-m, 13.0 lb-ft) rear brake pad mounting pin (b): 16 n·m (1.6 kgf-m, 11.5 lb-ft) note after replacing the brake pads, pu...

  • Page 535

    Rear brakes: 4c-4 rear brake caliper disassembly and assembly b837h14306005 refer to “rear brake caliper removal and installation (page 4c-3)”. Disassembly 1) remove the pad spring (1), rubber boot (2) and sliding pin (3). 2) remove the pad spring (4). 3) remove the spacer (5) and rubber boot (6) fr...

  • Page 536

    4c-5 rear brakes: • install the piston seal (1) as shown in the figure. • apply grease to the inside of the rubber boot. : grease 99000–25100 (suzuki silicone grease or equivalent) • set the rubber boot (3) to the caliper. • install the spacer (4) into the rubber boot. • tighten the sliding pin (5) ...

  • Page 537

    Rear brakes: 4c-6 brake caliper sliding pin inspect the brake caliper sliding pin for wear and other damage. If any damage is found, replace the sliding pin with a new one. Boot and spacer inspect the boots and spacer for damage and wear. If any defects are found, replace them with new ones. Brake p...

  • Page 538

    4c-7 rear brakes: rear brake disc inspection b837h14306008 brake disc thickness check the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if defect is found. Special tool (a): 09900–20205 (micro...

  • Page 539

    Rear brakes: 4c-8 special tools and equipment recommended service material b837h14308001 note required service material is also described in the following. “rear brake components (page 4c-1)” special tool b837h14308002 material suzuki recommended product or specification note brake fluid dot 4 — ) (...

  • Page 540

    4c-9 rear brakes:.

  • Page 541: 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 542: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions for transmission / transaxle b837h15000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 543: Manual Transmission

    Manual transmission: 5b-1 transmission / transaxle manual transmission diagnostic information and procedures manual transmission symptom diagnosis b837h15204001 condition possible cause correction / reference item engine is noisy (noise seems to come from the transmission) worn or rubbing gear. Repl...

  • Page 544

    5b-2 manual transmission: repair instructions transmission components b837h15206001 1 2 3 5 6 7 8 9 11 10 19 20 12 13 14 15 16 17 18 4 fwd fwd (d) (b) (c) (a) i837h1520070-03 1. 2nd drive gear 11. 5th driven gear : 115 n ⋅m (11.5 kgf-m, 83.0 lb-ft) 2. 6th drive gear 12. 1st driven gear : 10 n ⋅m (1....

  • Page 545

    Manual transmission: 5b-3 transmission removal b837h15206002 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-19)”. 2) remove the engine top side. Refer to “engine top side disassembly in section 1d (page 1d-25)”. 3) separate the upper and lower ...

  • Page 546

    5b-4 manual transmission: 5) remove the dowel pin (5). 6) remove the driveshaft right bearing case bolts. 7) by using suitable size bolts (3), remove the driveshaft right bearing assembly (6). 8) remove the driveshaft assembly (7). Bearing and oil seal 1) remove the gearshift cam bearing (1) with th...

  • Page 547

    Manual transmission: 5b-5 4) remove the driveshaft left bearing (4) with the special tool. Special tool (d): 09913–70210 (bearing installer set) 5) remove the driveshaft left bearing oil seal (5) from the retainer using the special tool. Special tool (d): 09913–70210 (bearing installer set) transmis...

  • Page 548

    5b-6 manual transmission: • install the gearshift shaft bearings (3) with the special tool. Note the stamped mark side of the gearshift shaft bearing faces outside. Special tool (a): 09913–70210 (bearing installer set) • install the gearshift shaft oil seal (4) with the special tool. Special tool (a...

  • Page 549

    Manual transmission: 5b-7 • apply 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 driveshaft left bearing case bolt (b): 12 n·m (1.2 kgf-m, 8.7 lb-ft) • apply grease to the dust seal l...

  • Page 550

    5b-8 manual transmission: • 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 or equivalent) tightening torque bearing retainer screw (a...

  • Page 551

    Manual transmission: 5b-9 transmission construction b837h15206004 countershaft gear / driveshaft gear disassembly and assembly b837h15206005 refer to “transmission removal (page 5b-3)” and “transmission installation (page 5b-5)”. Disassembly caution ! Identify the position of each removed part. Orga...

  • Page 552

    5b-10 manual transmission: • slide the 6th (3) and 2nd (4) drive gears toward the 3rd/4th drive gears (2), then remove the 2nd drive gear circlip (5). • remove the 2nd drive gear (4) and 6th drive gear (3). • remove the countershaft bearing (6) using hydraulic press. Driveshaft • disassembly the dri...

  • Page 553

    Manual transmission: 5b-11 driveshaft • when installing the gear bushings onto the driveshaft, align the shaft oil holes “a” with the bushing oil hole “b”. Countershaft • install the countershaft bearing (1) using a hydraulic press and special tool. Special tool (a): 09913–70210 (bearing installer s...

  • Page 554

    5b-12 manual transmission: gearshift fork groove width measure the gearshift fork groove width using the vernier calipers. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) gearshift fork groove width standard: 5.0 – 5.1 mm (0.197 – 0.201 in) gearshift fork thickness measure the gea...

  • Page 555

    Manual transmission: 5b-13 gear position (gp) switch inspection b837h15206007 refer to “side-stand / ignition interlock system parts inspection in section 1i (page 1i-8)”. Gear position (gp) switch removal and installation b837h15206008 removal 1) turn the ignition switch off. 2) lift and support th...

  • Page 556

    5b-14 manual transmission: gearshift lever construction b837h15206009 gearshift lever removal and installation b837h15206010 removal remove the gearshift lever as shown in the gearshift lever construction. Refer to “gearshift lever construction (page 5b-14)”. Installation 1) install the gearshift le...

  • Page 557

    Manual transmission: 5b-15 gearshift shaft / gearshift cam plate components b837h15206012 gearshift shaft construction b837h15206013 1. Gearshift shaft : 19 n ⋅m (1.9 kgf-m, 13.5 lb-ft) : apply thread lock to the thread part. 2. Gearshift cam drive plate : 13 n ⋅m (1.3 kgf-m, 9.5 lb-ft) : apply thre...

  • Page 558

    5b-16 manual transmission: gearshift shaft / gearshift cam plate removal and installation b837h15206014 removal 1) remove the engine sprocket cover. Refer to “engine sprocket removal and installation in section 3a (page 3a-2)”. 2) remove the clutch components. Refer to “clutch removal in section 5c ...

  • Page 559

    Manual transmission: 5b-17 • install the gearshift cam stopper (1), bolt (2), collar (3) and return spring (4). • tighten the gearshift cam stopper bolt (2) to the specified torque. Note hook the return spring end “a” to the stopper (1). Tightening torque gearshift cam stopper bolt (b): 10 n·m (1.0 ...

  • Page 560

    5b-18 manual transmission: • install the washer (6) and gearshift shaft assembly (7) as shown in the figure. Note pinch the gearshift arm stopper (8) with return spring ends “f”. • install a new snap ring (9). Special tool : 09900–06107 (snap ring pliers) • after installing the gearshift lever, chec...

  • Page 561

    Manual transmission: 5b-19 gearshift shaft oil seal / bearing removal and installation b837h15206016 removal 1) remove the gearshift shaft. Refer to “gearshift shaft / gearshift cam plate removal and installation (page 5b-16)”. 2) remove the gearshift shaft oil seal (1). 3) remove the bearings (2) a...

  • Page 562

    5b-20 manual transmission: specifications service data b837h15207001 transmission + drive chain unit: mm (in) except ratio tightening torque specifications b837h15207002 note the specified tightening torque is also described in the following. “transmission components (page 5b-2)” “gearshift lever co...

  • Page 563

    Manual transmission: 5b-21 special tools and equipment recommended service material b837h15208001 note required service material is also described in the following. “transmission components (page 5b-2)” “gearshift lever construction (page 5b-14)” “gearshift shaft / gearshift cam plate components (pa...

  • Page 564

    5b-22 manual transmission: 09930–30104 rotor remover slide shaft ) (page 5b-4) / )(page 5b- 19).

  • Page 565: Clutch

    Clutch: 5c-1 transmission / transaxle clutch precautions precautions for clutch system b837h15300001 refer to “general precautions in section 00 (page 00-1)”. Schematic and routing diagram clutch cable routing diagram b837h15302001 refer to “throttle cable routing diagram in section 1d (page 1d-2)”....

  • Page 566

    5c-2 clutch: repair instructions clutch lever position switch inspection b837h15306001 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 567

    Clutch: 5c-3 clutch control system components b837h15306007 1 2 3 4 (a) (b) (c) i837h1530049-04 1. Push rod 4. Clutch cable : 10 n ⋅m (1.0 kgf-m, 0.7 lb-ft) 2. Clutch release camshaft : 1 n ⋅m (0.1 kgf-m, 0.7 lb-ft) : apply grease. 3. Clutch release arm : 6 n ⋅m (0.6 kgf-m, 4.5 lb-ft) : do not reuse...

  • Page 568

    5c-4 clutch: clutch components b837h15306015 (a) (b) 1 2 3 5 6 6 5 6 5 6 5 6 5 6 5 5 6/7 6/7 8 9 11 10 12 13 14 15 16 4 fwd fwd i837h1530047-02 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. 2 drive plate 10. ...

  • Page 569

    Clutch: 5c-5 clutch removal b837h15306016 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 570

    5c-6 clutch: 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 571

    Clutch: 5c-7 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 b837h15306017 1) insta...

  • Page 572

    5c-8 clutch: 7) install the clutch lifter drive cam (8). 8) install the clutch sleeve hub (9), 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 ho...

  • Page 573

    Clutch: 5c-9 13) install the clutch push piece (13), bearing (14) and thrust washer (15) to the countershaft. Note thrust washer (15) is located between the pressure plate and bearing (14). 14) install the spring washer seat (16) and spring washer (17) onto the clutch sleeve hub correctly. 15) inser...

  • Page 574

    5c-10 clutch: 16) install the pressure plate (23). Note when install the pressure plate, fit the convex part “e” of the pressure plate onto the concave part “f” of the clutch sleeve hub. 17) install the clutch springs and bolts. 18) tighten the clutch spring set bolts to the specified torque. Tighte...

  • Page 575

    Clutch: 5c-11 24) install the clutch cover and tighten the clutch cover bolts. Note fit the new gasket washer to the bolt “g”. 25) rout the ckp sensor lead wire properly. Refer to “wiring harness routing diagram in section 9a (page 9a-5)”. 26) install the fuel tank. Refer to “fuel tank removal and i...

  • Page 576

    5c-12 clutch: clutch spring measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit. Replace all the springs if any spring is not within the limit. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) clutch spring free lengt...

  • Page 577

    Clutch: 5c-13 clutch lifter pin inspection and adjustment b837h15306019 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 578

    5c-14 clutch: 7) slowly turn in the adjusting pin screw (1) until resistance is felt. Tighten the lock-nut (2). Tightening torque clutch lifter lock-nut: 23 n·m (2.3 kgf-m, 16.5 lb- ft) specifications service data b837h15307001 clutch unit: mm (in) tightening torque specifications b837h15307002 note...

  • Page 579

    Clutch: 5c-15 special tools and equipment recommended service material b837h15308001 note required service material is also described in the following. “clutch control system components (page 5c-3)” “clutch components (page 5c-4)” special tool b837h15308002 material suzuki recommended product or spe...

  • Page 580

    5c-16 clutch:.

  • Page 581: 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 582: Precautions

    6-1 precautions: steering precautions precautions precautions for steering b837h16000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 583: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering steering general diagnosis diagnostic information and procedures steering symptom diagnosis b837h16104001 condition possible cause correction / reference item heavy steering over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. ...

  • Page 584: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar repair instructions handlebar components b837h16206001 fwd fwd fwd fwd 1 2 3 5 6 7 8 4 “a” (b) (a) i837h1620038-01 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 lb-...

  • Page 585

    Steering / handlebar: 6b-2 handlebar removal and installation b837h16206003 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) disconnect the clutch cable (4) e) clutch lever (5) 2) remove the following part...

  • Page 586

    6b-3 steering / handlebar: installation install the handlebars in the reverse order of removal. Pay attention to the following points: • install the handlebars temporarily. • install the upper bracket (1), washer (2) and steering stem head nut (3) temporarily. Note pay attention to the direction of ...

  • Page 587

    Steering / handlebar: 6b-4 • insert the projection “c” of the right handlebar switch box into the hole of the handlebars. • install the clutch lever holder. Refer to “clutch control system components in section 5c (page 5c-3)”. • apply a handle grip bond “d” onto the left handlebar before installing...

  • Page 588

    6b-5 steering / handlebar: steering components b837h16206005 2 3 3 5 7 8 9 12 11 10 (a) 1 (b) 4 (c) 6 (d) (d) (a) (b) (c) fwd fwd i837h1620039-02 1. Steering stem head nut 7. Dust seal cover : 90 n ⋅m (9.0 kgf-m, 65.0 lb-ft) 2. Steering stem upper bracket 8. Dust seal : 80 n ⋅m (8.0 kgf-m, 58.0 lb-f...

  • Page 589

    Steering / handlebar: 6b-6 steering damper construction b837h16206006 steering / steering damper removal and installation b837h16206012 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 590

    6b-7 steering / handlebar: 6) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g- 9)”. 7) remove the air cleaner box. Refer to “air cleaner box removal and installation in section 1d (page 1d-7)”. 8) disconnect the ignition switch lead wire coupler (1...

  • Page 591

    Steering / handlebar: 6b-8 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) steering stem nut • tighten the steering stem nut (1) to the specified torque with the special tools. Specia...

  • Page 592

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

  • Page 593

    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 594

    6b-11 steering / handlebar: installation install the steering stem bearings in the reverse order of removal. Pay attention to the following points: caution ! The removed bearings and races should be replaced with new ones. Outer race • press in the upper and lower outer races using the special tool....

  • Page 595

    Steering / handlebar: 6b-12 specifications tightening torque specifications b837h16207001 note the specified tightening torque is also described in the following. “handlebar components (page 6b-1)” “steering components (page 6b-5)” “steering damper construction (page 6b-6)” reference: for the tighte...

  • Page 596

    6b-13 steering / handlebar: special tools and equipment recommended service material b837h16208001 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 b837h1620...

  • Page 597: 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 598

    9-ii table of contents rear fender construction...................................9d-4 frame cover construction ..................................9d-5 frame side cover cushion attachment..............9d-6 fuel tank cover cushion attachment ................9d-7 rear view mirror construction ............

  • Page 599: Precautions

    Precautions: 9-1 body and accessories precautions precautions precautions for electrical system b837h19000001 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 b837h19...

  • Page 600: Wiring Systems

    9a-1 wiring systems: body and accessories wiring systems schematic and routing diagram wiring diagram b837h19102001 refer to “wire color symbols in section 0a (page 0a-5)”. For e-02, 19, 24 b b lg b/w b/r p y/bl b/g g/y b/lg bl/b lg b/y b br b/w br/y r/bl o/g b/br b/r p y/bl b/g g/y b/lg bl/b lg y b...

  • Page 601

    Wiring systems: 9a-2 g b/w w/r b/y b/w bl b/w o/bl br/y o/bl gr y lg lg/w lg/g lg/bl w/g y/g r/y 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/g y/bl r/bl g/w b/y r p/b b/w p/w w/b p b/r b/r r/b r y b/br...

  • Page 602

    9a-3 wiring systems: for e-03, 28, 33 b b lg b/w b/r p y/bl b/g g/y b/lg bl/b lg b/y b br b/w br/y r/bl o/g b/br b/r p y/bl b/g g/y b/lg bl/b lg y b br b/w r/bl o/g w b/r p y/bl b/g b/w b/lg br/y g/y o/g bl/b b/y lg b r/bl o/bl o/r b/w o/b o/w b/r b/bl y/g o/r y/w b/r b/w b r o o/y gr br g b/w b/r b...

  • Page 603

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

  • Page 604

    9a-5 wiring systems: wiring harness routing diagram b837h19102002 1 2 3 4 4 5 5 6 7 9 “d” “f” 8 18 19 10 11 12 13 14 15 16 17 “b” “a” “c” 10 “e” “g” i837h1910901-03 1. Horn 10. Clamp : bind the wiring harness, ckp sensor lead wire, rear brake light switch lead wire, ho2 sensor lead wire and side-sta...

  • Page 605

    Wiring systems: 9a-6 1 2 3 5 6 7 8 9 “c” “d” 11 10 10 4 “a” “b” “ a ” “ a ” i837h1910902-02 1. Ecm cushion 7. Clamp : bind the wiring harness and battery (–) lead wire with the clamp. Set the lock part of the clamp to inside. “b”: do not slacken the lead wires. 2. Purge hose (e-33 only) 8. Guide : p...

  • Page 606

    9a-7 wiring systems: 7 “c” “b” 1 (a) 2 (a) (b) (b) 3 (f) 6 “a” (c) 4 5 (e) (d) i837h1910903-04 1. Cmp sensor 7. Clamp : fix the clamp in parallel with the cover surface. : 14 n ⋅m (1.4 kgf-m, 10 lb-ft) 2. Ckp sensor “a”: white tape : 6.5 n ⋅m (0.65 kgf-m, 4.7 lb-ft) 3. Battery (–) lead wire “b”: pas...

  • Page 607

    Wiring systems: 9a-8 2 “c” “a” “b” (a) 1 3 i837h1910904-04 1. Ho2 sensor “b”: pass the ho2 sensor lead wire between the frame and engine. 2. Clutch cable “c”: pass the ho2 sensor lead wire rear of the clutch cable. 3. Oil pan : 25 n ⋅m (2.5 kgf-m, 18.0 lb-ft) “a”: pass the ho2 sensor lead wire insid...

  • Page 608

    9a-9 wiring systems: specifications service data b837h19107001 electrical tightening torque specifications b837h19107002 note the specified tightening torque is also described in the following. “wiring harness routing diagram (page 9a-5)” reference: for the tightening torque of fastener not specifie...

  • Page 609: Lighting Systems

    Lighting systems: 9b-1 body and accessories lighting systems repair instructions headlight components b837h19206001 fwd fwd 3 2 2 1 i837h1920001-02 1. Headlight low beam bulb (12 v 55 w, h11) 2. Headlight high beam bulb (12 v 60 w, hb3 x 2) 3. Position light bulb (12 v 5 w).

  • Page 610

    9b-2 lighting systems: headlight removal and installation b837h19206002 removal 1) remove the body cowlings. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) remove the air intake pipes. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”....

  • Page 611

    Lighting systems: 9b-3 3) remove the headlight bulb/socket (low beam) (2) by turning it counterclockwise. 4) replace the headlight bulb (low beam) with a new one. 5) disconnect the headlight (high beam) couplers (3). 6) remove the headlight bulb/sockets (high beam) (4) by turning it counterclockwise...

  • Page 612

    9b-4 lighting systems: headlight beam adjustment b837h19206004 adjust the headlight beam, both horizontally and vertically. Note to adjust the headlight beam, adjust the beam horizontally first, then vertically. Front turn signal light components b837h19206005 “a”: vertical adjuster “a” i837h1920014...

  • Page 613

    Lighting systems: 9b-5 front turn signal light removal and installation b837h19206006 removal 1) remove the turn signal light assembly (1). 2) disconnect the front turn signal coupler (2). Installation install the front turn signal light in the reverse order of removal. Front turn signal light bulb ...

  • Page 614

    9b-6 lighting systems: rear lighting system construction b837h19206008 (b) 1 2 2 4 4 (a) (c) 3 i837h1920021-03 1. License plate light assembly : 5 n ⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Reflex reflector (e-03, 28, 33 only) : 1.8 n ⋅m (0.18 kgf-m, 1.5 lb-ft) 3. Rear combination light screw : 2.8 n ⋅m (0.28 k...

  • Page 615

    Lighting systems: 9b-7 rear combination light removal and installation b837h19206009 removal 1) remove the frame cover assembly. Refer to “exterior parts removal and installation in section 9d (page 9d-11)”. 2) disconnect the combination light coupler (1). 3) disconnect the combination light lead wi...

  • Page 616

    9b-8 lighting systems: rear combination light replacement b837h19206010 caution ! If led operation is abnormal, replace the rear combination light with a new one. License plate light components b837h19206011 license plate light removal and installation b837h19206012 removal 1) remove the frame cover...

  • Page 617

    Lighting systems: 9b-9 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 lb-ft)...

  • Page 618

    9b-10 lighting systems: rear turn signal light components b837h19206014 rear turn signal light removal and installation b837h19206015 removal 1) remove the frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) remove the rear combination light. 3) disconnect...

  • Page 619

    Lighting systems: 9b-11 installation install the rear turn signal light in the reverse order of removal. Pay attention to the following point: • insert the convex part “a” of the side frame cover to the hole “b” of the center frame cover. Rear turn signal light bulb replacement b837h19206016 caution...

  • Page 620

    9b-12 lighting systems: headlight relay inspection b837h19206024 refer to “electrical components location in section 0a (page 0a-7)”. Inspect the headlight relay in the following procedure: 1) remove the frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 11)”. 2) ...

  • Page 621

    Lighting systems: 9b-13 3) inspect the hazard switch for continuity with a tester. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “handlebar removal and installation in section 6b (page 6b-2)”. Special tool : 09900–25008 (multi-circuit tester set) te...

  • Page 622

    9b-14 lighting systems: dimmer switch inspection b837h19206023 inspect the dimmer 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). 3) inspect the dimm...

  • Page 623

    Lighting systems: 9b-15 special tools and equipment recommended service material b837h19208001 special tool b837h19208002 material suzuki recommended product or specification note thread lock cement thread lock cement super 1322 or equivalent p/no.: 99000–32110 ) (page 9b-7) / )(page 9b- 9) 09900–25...

  • Page 624

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn general description combination meter system description b837h19301001 this combination meter mainly consists of the stepping motor, lcd (liquid crystal display) and led (light emitting diode). The...

  • Page 625

    Combination meter / fuel meter / horn: 9c-2 repair instructions combination meter components b837h19306001 combination meter removal and installation b837h19306002 removal 1) remove the combination meter mounting bolt (1). 2) disconnect the coupler (2) and remove the combination meter assembly. Inst...

  • Page 626

    9c-3 combination meter / fuel meter / horn: combination meter inspection b837h19306004 led inspection check that the leds (fi, fuel, engine rpm, indicator lights, immobilizer indicator light (e-02, 19, 24) and meter panel illumination) immediately light up when the ignition switch is turned on. Chec...

  • Page 627

    Combination meter / fuel meter / horn: 9c-4 3) connect a variable resistor (2) between the terminals. 4) turn the ignition switch on. 5) check the engine coolant temperature meter (3) and indicator light (led) (4) operations when the resistance is adjusted to the specified values. If either one or b...

  • Page 628

    9c-5 combination meter / fuel meter / horn: fuel level indicator inspection b837h19306007 if the fuel level indicator light 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 combin...

  • Page 629

    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): 4.5 n·m (0.45 kgf-m, 3.25 ...

  • Page 630

    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 631

    Combination meter / fuel meter / horn: 9c-8 ignition switch removal and installation b837h19306016 refer to “ignition switch removal and installation in section 1h (page 1h-11)”. Horn inspection b837h19306017 note if the horn sound condition is normal, it is not necessary to inspect the horn button ...

  • Page 632

    9c-9 combination meter / fuel meter / horn: specifications service data b837h19307001 wattage unit: w tightening torque specifications b837h19307002 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 633: Exterior Parts

    Exterior parts: 9d-1 body and accessories exterior parts repair instructions exterior parts construction b837h19406001 “a” “a” “a” “a” “a” “b” “b” (a) i837h1940026-02 “a”: to frame “b”: to headlight assembly : 5.5 n ⋅m (0.55 kgf-m, 4.0 lb-ft).

  • Page 634

    9d-2 exterior parts: body cowling cushion attachment b837h19406017 1 2 3 i837h1940027-01 1. Cushion 2. Velcro fastening 3. Body cowling.

  • Page 635

    Exterior parts: 9d-3 under cowling heat shield / cushion attachment b837h19406018 1 2 3 4 “ a ” i837h1940028-01 1. Cushion 2. Heat shield 3. Heat shield 4. Cushion “a”: 15 mm (0.59 in).

  • Page 636

    9d-4 exterior parts: rear fender construction b837h19406008 1 2 2 3 3 5 6 7 8 4 4 i837h1940029-02 1. Rear fender (front) 3. Plate 5. Rear fender (lower) 7. Rivet 2. Rear fender (rear) 4. Bracket 6. Bracket (for e-24) 8. Hooking.

  • Page 637

    Exterior parts: 9d-5 frame cover construction b837h19406009 1 2 6 4 3 7 8 5 “ a ” “ b ” outside i837h1940030-02 1. Frame cover (rear) 3. Frame cover (center) 5. Frame cover (lh/rh) 7. Rear fender front cover “a”: 3 mm (0.12 in) 2. Cushion 4. Cushion 6. Cushion 8. Frame cover (rear, lh/rh) “b”: 4.5 m...

  • Page 638

    9d-6 exterior parts: frame side cover cushion attachment b837h19406019 1 2 3 4 4 4 3 “ a ” i837h1940031-02 1. Frame side cover 3. Cushion “a”: 15 mm (0.59 in) 2. Cushion : adhere the cushion along the rib of the cover. 4. Double-faced adhesive tape.

  • Page 639

    Exterior parts: 9d-7 fuel tank cover cushion attachment b837h19406020 1 1 2 2 2 2 3 3 3 3 i837h1940032-01 1. Fuel tank cover no. 2 2. Cushion 3. Velcro fastenings.

  • Page 640

    9d-8 exterior parts: rear view mirror construction b837h19406021 1 2 3 5 6 7 4 (a) i837h1940033-01 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 641

    Exterior parts: 9d-9 rear view mirror cushion attachment b837h19406022 1 2 3 4 4 “ a ” i837h1940034-03 1. Tape affix mark rib 4. Cushion : align the cushion corner to the indicated point. 2. Tape : tape should not run over the indicated line. “a”: 1.5 mm (0.06 in) 3. Boss : bosses should contact to ...

  • Page 642

    9d-10 exterior parts: fastener removal and installation b837h19406015 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 installati...

  • Page 643

    Exterior parts: 9d-11 exterior parts removal and installation b837h19406016 front seat removal remove the front seat by removing the bolts. Installation 1) slide the seat hooks into the seat hook retainers on the frame. 2) insert the spacer to each side and tighten the bolts securely. Rear seat / se...

  • Page 644

    9d-12 exterior parts: installation install the windscreen in the reverse order of removal. Pay attention to the following point: note the screws “a” are 3 mm longer than the others. Body cowling cover removal 1) remove the fasteners (6 pcs.). 2) remove the body cowling cover (1). Installation instal...

  • Page 645

    Exterior parts: 9d-13 3) pull out the hooked points “a” from each lug hole and remove the side cowling (2). 4) remove the drain hose (3) from left side of the cowling (2). Installation install each side cowling in the reverse order of removal. Body cowling removal 1) remove the left and right side c...

  • Page 646

    9d-14 exterior parts: installation install the body cowling in the reverse order of removal. Pay attention to the following points: • fit the lead wire clamp to the screw “a”. • tighten the mounting nuts to the specified torque. Tightening torque rear view mirror mounting nut (a): 10 n·m (1.0 kgf-m,...

  • Page 647

    Exterior parts: 9d-15 4) remove the following fasteners. 5) remove the frame cover assembly from the frame. Installation install the frame cover assembly in the reverse order of removal. Front fender removal refer to “front fork removal and installation in section 2b (page 2b-2)”. Installation refer...

  • Page 648: Body Structure

    9e-1 body structure: body and accessories body structure repair instructions body frame construction b837h19506001 1 2 2 4 fwd fwd (a) 3 (b) 7 (c) 6 (b) 5 i837h1950001-03 1. Frame 5. Adjuster : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Seat rail 6. Adjuster lock-nut : 45 n ⋅m (4.5 kgf-m, 32.5 lb-ft) 3. Sea...

  • Page 649

    Body structure: 9e-2 front footrest bracket construction b837h19506002 “a” (c) 3 (b) 2 (a) 1 (a) 1 (d) 11 10 5 6 7 10 8 4 9 8 (e) 12 i837h1950002-03 1. Footrest bracket bolt 8. Rear brake pedal : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Rear master cylinder bolt 9. Footrest bracket no. 2 (left) : 4.5 n ⋅m ...

  • Page 650

    9e-3 body structure: side-stand construction b837h19506003 pillion footrest construction b837h19506004 (a) (c) (b) i837h1950003-02 : 40 n ⋅m (4.0 kgf-m, 29.0 lb-ft) : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) : apply grease to sliding surface. 1 2 3 5 4 i837h1950004-03 1. Foo...

  • Page 651

    Body structure: 9e-4 side-stand removal and installation b837h19506006 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) remove the side-stand as shown in the side...

  • Page 652

    Prepared by february, 2008 printed in japan.

  • Page 653

    Gsx-r600 printed in japan k8 dic582 top bottom k8 9 9 5 0 0 - 3 5 1 1 0 - 0 1 e gsx-r600 no.1400 gsx-r600 99500-35110-01e cover14 for ps printing (24 mm) 2008. 1.5.