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Suzuki GSX-R750 Service Manual

Other manuals for GSX-R750: Service Manual, Service Manual, Brochure, Service Manual

Summary of GSX-R750

  • Page 1

    Gsx-r750 suzuki motor corporation printed in japan february, 2000 99500-37112-03e.

  • Page 2: Group Index

    Group index 1 foreword this manual contains an introductory description on the suzuki gsx-r750 and procedures for its inspection/service and overhaul of its main com- ponents. Other information considered as generally known is not included. Read the general information section to fa- miliarize yours...

  • Page 3: How To  Use This  Manual

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

  • Page 4

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

  • Page 5

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

  • Page 6

    A air cleaner acl air cleaner, air cleaner box b barometric pressure baro barometric pressure, atmospheric pressure (aps, ap sensor) battery positive voltage b+ battery voltage, +b c camshaft position sensor cmp sensor camshaft position sensor (cmps) crankshaft position sensor ckp sensor crankshaft ...

  • Page 7

    I idle speed control isc ––– ignition control ic electronic spark advance(esa) ignition control module icm ––– intake air temperature iat intake air temperature(iat), air temperature m malfunction indicator lamp mil led lamp malfunction indicator lamp(mil) manifold absolute pressure map intake air p...

  • Page 8: General Information

    General information 1-1 1 general information contents warning/caution/note ............................................................. 1- 2 general precautions .............................................................. 1- 2 suzuki gsx-r750y (2000-model) ..........................................

  • Page 9: Warning/caution/note

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

  • Page 10

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

  • Page 11: Serial Number Location

    1-4 general information serial number location the frame serial number or v.I.N. (vehicle identification number) a is stamped on the right side of the steering head pipe. The engine serial number b is located on the rear side of the crank- case. These numbers are required especially for registering ...

  • Page 12

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

  • Page 13: Break-In Procedures

    1-6 general information 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 radiator. Anti-freeze/engine coolant the engin...

  • Page 14: Information Labels

    General information 1-7 information labels gsx-r750 gsx-r750ud gsx-r750uf 1 noise label for e-03, 24, 33 2 information label for e-03, 24, 33 3 vacuum hose routing label for e-33 4 fuel caution label for e-02, 24 5 manual notice label for e-03, 33 6 frame caution label 7 screen warning label 8 steer...

  • Page 15: Specifications

    1-8 general information specifications dimensions and dry mass overall length ................................................................ 2 040 mm (80.3 in) overall width ................................................................. 715 mm (28.1 in) overall height .............................

  • Page 16

    General information 1-9 chassis front suspension .......................................................... Inverted telescopic, coil spring, spring pre-load fully adjustable, rebound and compression damping force fully adjustable. Rear suspension .......................................................

  • Page 17: Country and Area Codes

    1-10 general information country and area codes the following codes stand for the applicable country(-ies) and area(-s). Model code country or area e-02 u.K. E-03 usa (except for california) gsx-r750 e-19 eu e-24 australia e-28 canada e-33 california (usa) gsx-r750ud e-19 eu gsx-r750uf e-19 eu.

  • Page 18: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance periodic maintenance schedule ......................................... 2- 2 periodic maintenance chart ............................................. 2- 2 lubrication points ................................................................ 2- 3 maintena...

  • Page 19

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and months, a...

  • Page 20

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

  • Page 21: Maintenance And Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item mentioned in the periodic maintenance chart. Air cleaner inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months). • remove the front ...

  • Page 22

    Periodic maintenance 2-5 spark plug inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months). Spark plug and ignition coil/plug cap removal • remove the front and rear seat. ( 6-8) • lift and support the fuel tank. ( 4-51) • remove the air cleaner box 1 . (...

  • Page 23

    2-6 periodic maintenance heat range • check to see the heat range of the plug. If the electrode of the plug is wet appearing or dark color, re- place the plug with hotter type one. If it is white or glazed ap- pearing, replace the plug with colder type one. Ngk denso hotter type cr8e u24esr-n standa...

  • Page 24

    Periodic maintenance 2-7 spark plug and ignition coil/plug cap installation • install the spark plugs to the cylinder head by finger tight, and then tighten them to the specified torque. ! ! ! ! ! Spark plug: 11 n.M (1.1 kgf.M, 8.0 ib-ft) # to avoid damaging the cylinder head threads, first finger t...

  • Page 25

    2-8 periodic maintenance valve clearance inspect every 24 000 km (15 000 miles, 24 months). • remove the right under cowling. ( 6-5) • remove the front and rear seats. ( 6-8) • lift and support the fuel tank. ( 4-51) • remove the spark plugs. ( 2-5) • remove the cylinder head covers. ( 3-16) the val...

  • Page 26

    Periodic maintenance 2-9 • turn the crankshaft to bring the “top” line on the starter clutch to the index mark and also to bring the notches a on the left ends of both camshafts (ex and in) to the positions as shown. • in this condition, read the valve clearance at the valves b (in and ex of no.4 cy...

  • Page 27: 170

    2-10 periodic maintenance valve clearance adjustment the clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • remove the intake or exhaust camshafts. ( 3-17) • remove the tappet and shim by fingers or magnetic hand. • check the figures printed on the shim. Thes...

  • Page 28

    Periodic maintenance 2-11 (intake side) t appet shim selection t able [int ake] t appet shim no . (12892-05c00-xxx) ho w t o use this char t : i. Measure v alv e clear ance . “engine is cold” ii . Measure present shim siz e . Iii. Match clear ance in v e rtical column with present shim siz e in hor ...

  • Page 29

    2-12 periodic maintenance (exhaust side) t appet shim selection t able [exha ust] t appet shim no . (12892-05c00-xxx) ho w t o use this char t : i. Measure v alv e clear ance . “engine is cold ” ii . Measure present shim siz e . Iii. Match clear ance in v e rtical column with present shim siz e in h...

  • Page 30

    Periodic maintenance 2-13 engine oil and oil filter (engine oil) replace initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. (oil filter) replace initially at 1 000 km (600 miles, 1 month) and ev- ery 18 000 km (11 000 miles, 18 months) thereafter. Oil...

  • Page 31

    2-14 periodic maintenance oil filter replacement • drain the engine oil as described in the engine oil replacement procedure. • remove the oil filter 1 using the special tool. [ [ [ [ [ 09915-40610: oil filter wrench • apply engine oil lightly to the gasket of the new oil filter before installation....

  • Page 32

    Periodic maintenance 2-15 fuel hose inspect every 6 000 km (4 000 miles,6 months). Replace every 4 years. Inspect the fuel hose 1 for damage and fuel leakage. If any de- fects are found, the hoses must be replaced. Engine idle speed inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 00...

  • Page 33

    2-16 periodic maintenance throttle cable play inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. Adjust the throttle cable play a as follows. Minor adjustment 1st step: • loosen the locknut 1 of the throttle returning cable 2 and fully turn in...

  • Page 34

    Periodic maintenance 2-17 major adjustment • lift and support the fuel tank with its prop stay. ( 4-51) • loosen the lock nuts 1 of the throttle returning cable 2 . • turn the returning cable adjuster 3 to obtain proper cable play. • loosen the lock nuts 4 of the throttle pulling cable 5 . • turn th...

  • Page 35

    2-18 periodic maintenance cooling system inspect every 6 000 km (4 000 miles, 6 months). Replace engine coolant every 2 years. Engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank. A full l...

  • Page 36

    Periodic maintenance 2-19 air bleeding the cooling circuit • add engine coolant up to the radiator inlet. • support the motorcycle upright. • slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • add engine coolant up to the radiator inlet. • start up the en...

  • Page 37

    2-20 periodic maintenance drive chain inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed be- low. (support the motorcycle by a jack an...

  • Page 38

    Periodic maintenance 2-21 adjusting • loosen or tighten both chain adjuster nuts 1 until there is 20 – 30 mm (0.8 – 1.2 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The refer- ence marks a on both sides of the swingarm and the edge of each chain adjuster mu...

  • Page 39

    2-22 periodic maintenance brake (brake) inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (brake hose and brake fluid) inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years. Replace fluid every 2 years. Brake fluid level c...

  • Page 40

    Periodic maintenance 2-23 rear brake • the extent of brake pad wear can be checked by observing the grooved limit line a on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ( 6-69) # replace the brake pads as a set, otherwise braking per- formance will be advers...

  • Page 41

    2-24 periodic maintenance air bleeding the brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper. The presence of air is...

  • Page 42

    Periodic maintenance 2-25 rear brake • bleed air from the rear brake system as the same manner of front brake. Note: the only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal. Tires inspect every 6 000 km (4 000 miles, 6 months). Tire trea...

  • Page 43

    2-26 periodic maintenance tire pressure if the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Cold inflatio...

  • Page 44

    Periodic maintenance 2-27 front fork inspect every 12 000 km (7 500 miles, 12 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. ( 6-17) rear suspension inspect every 12 000 km (7 500 miles, 12 mo...

  • Page 45

    2-28 periodic maintenance chassis bolts and nuts tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle.: ...

  • Page 46

    Periodic maintenance 2-29.

  • Page 47: Compression Pressure Check

    2-30 periodic maintenance overhaul the engine in the following cases: * compression pressure in one of the cylinders is less than 900 kpa (9 kg/cm 2 , 128 psi). * the difference in compression pressure between any two cyl- inders is more than 200 kpa (2 kgf/cm 2 , 28 psi). * all compression pressure...

  • Page 48: Oil Pressure Check

    Periodic maintenance 2-31 oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specification 200 – 500 kpa (2.0 – 5.0 kgf/cm 2 , 28 – 71 psi) at 3 000 r/min., oil temp. At 60°c (140°f) if the oil pressure i...

  • Page 49: Engine

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

  • Page 50

    3-2 engine engine center item removal inspection reinstallation 1 pair valve 3-16 3-29 3-98 2 starter motor 3-16 7-14 3-98 3 breather cover 3-25 ––––– 3-78 4 thermostat 3-18 5-10 3-91 5 cylinder head cover 3-16 3-30 3-97 6 camshaft 3-17 3-30 3-92 7 intake pipe ––––– ––––– 3-42 8 oil filter 3-25 ––––...

  • Page 51

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure. • remove the under cowlings. ( 6-5) ...

  • Page 52

    3-4 engine • remove the air cleaner box. ( 4-61) radiator • disconnect the reserve tank hose. • disconnect the radiator inlet hoses. • remove the throttle body and stv actuator. ( 4-61).

  • Page 53

    Engine 3-5 • disconnect the cooling fan thermo-switch coupler 1 and cool- ing fan coupler 2 . • remove the radiator mounting bolt. • remove the radiator. # be careful not to bent the radiator fin. • remove the front engine cover 1 . Exhaust pipe and muffler • remove the exhaust pipe bolts. • remove ...

  • Page 54

    3-6 engine • remove the radiator mounting bracket 1 . Electric parts • disconnect the oil pressure switch lead wire 1 and remove it from the clamps. • disconnect the starter motor lead wire 2 . • disconnect the ground lead wire 3 . • disconnect the crankshaft position sensor coupler 4 . • disconnect...

  • Page 55

    Engine 3-7 • disconnect the lead wire couplers from each ignition coil/plug cap and camshaft position sensor. # do not remove the ignition coil/plug cap before discon- necting its lead wire coupler. • remove the ignition coils/plug caps. # * do not pry up the ignition coil/plug cap with a driver or ...

  • Page 56

    3-8 engine • remove the speed sensor rotor 1 . • remove the engine sprocket nut 2 and the washer. • remove the cotter pin. (for e-03, 28, 33) • loosen the rear axle nut 3 and the rear torque link nut 4 . • loosen the left and right chain adjusters 5 . • push the rear wheel forward and make sure that...

  • Page 57

    Engine 3-9 engine mounting • support the engine using an engine jack. • remove the engine mounting bolts 1 , 2 . • loosen the engine mounting pinch bolts 3 . • remove the engine mounting bolts 4 . • remove the engine mounting nut 5 . • remove the engine mounting thrust adjuster locknut 6 with the sp...

  • Page 58

    3-10 engine • remove the engine mounting nut 1 . • loosen the engine mounting thrust adjuster locknut 2 . • loosen the engine mounting thrust adjuster 3 . Note: do not remove the engine mounting bolts at this stage. • remove the engine mounting bolts and gradually lower the front side of the engine....

  • Page 59

    Engine 3-11 engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: note: be careful not to damage the frame and engine when installing the engine. • before installing the engine, install the spacer 1 . • before installing the engine, ins...

  • Page 60

    3-12 engine item n.M kgf.M lb-ft abc 55 5.5 39.8 36 75 7.5 54.0 1 23 2.3 16.5 47 10 1.0 7.3 58 45 4.5 32.5 ! Length item mm in ac 45 1.77 bolt b 55 2.17 de 215 8.46 spacer 2 30.5 1.20 adjuster 47 40 1.57 left right.

  • Page 61

    Engine 3-13 footrest 52 – 62 mm (2.05 – 2.44 in) • install the engine sprocket and the washer. • apply a small quantity of thread lock “1342” to the drive shaft thread portion. I i i i i 99000-32050: thread lock “1342” • tighten the engine sprocket nut 1 to the specified torque. ! ! ! ! ! Engine spr...

  • Page 62

    3-14 engine 23 n.M (2.3 kgf.M, 16.5 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) • install the radiator mounting bracket 1 . • install the exhaust pipe/muffler. # replace the gaskets with new ones. • install and adjust the following items. * engine oil ( 2-13) * engine coolan...

  • Page 63: Engine Disassembly

    Engine 3-15 gearshift cam and forks cylinder head cover cam chain tensioner adjuster cam shaft (in. & ex) cylinder head starter idle gear cam chain guide no.1 and cam chain tensioner cam chain and sprocket ckp sensor starter clutch generator cover generator rotor piston, conrod and upper crankcase (...

  • Page 64

    3-16 engine engine disassembly # identify the position of each removed part. Organize the parts in their respective groups (e.G., intake, exhaust) so that they can be reinstalled in their original posi- tions. • remove the spark plugs. ( 2-5) pair valve • remove the pair valve 1 . Starter motor • re...

  • Page 65

    Engine 3-17 3 2 35f 1 3 2 35f 1 1 2 3 1413 2 3 1413 camshafts • remove the valve timing inspection cap 1 . • turn the crankshaft to bring the line a on the starter clutch to the index mark b of the valve timing inspection hole and also to bring the cams to the position as shown. • remove the cam cha...

  • Page 66

    3-18 engine • remove the intake camshaft 1 . • remove the exhaust camshaft 2 . Cylinder head • remove the water hose 1 . • remove the thermostat cover 2 and thermostat. Thermostat inspection: 5-9 • remove the engine coolant temp. Gauge 3 . Engine coolant temp. Gauge inspection: 5-8 • remove the cyli...

  • Page 67

    Engine 3-19 clutch • remove the clutch cover. • hold the clutch housing with the special tool. # do not damage the clutch plates by the special tool. [ [ [ [ [ 09920-53740: clutch sleeve hub holder • remove the clutch springs. Note: loosen the clutch spring set bolts little by little and diagonally....

  • Page 68

    3-20 engine • unlock the clutch sleeve hub nut. • hold the clutch sleeve hub with the special tool. [ [ [ [ [ 09920-53740: clutch sleeve hub holder • remove the clutch sleeve hub nut. • remove the wave washer 1 washer 2 , clutch sleeve hub 3 and washer 4 . • remove the spacer 5 and bearing 6 . • rem...

  • Page 69

    Engine 3-21 oil pump • remove the circlip 1 . • remove the oil pump driven gear 2 . Note: do not drop the circlip 1 , the pin 3 and the washer 4 into the crankcase. • remove the pin 3 and the washer 4 . • remove the oil pump 5 . Gear shift system • with the circlip 1 removed, remove the gearshift sh...

  • Page 70

    3-22 engine starter idle gear • remove the starter idle gear cover. • remove the shaft 1 , wave washer 2 washer 3 starter idle gear no.1 4 , bearing 5 and washer 6 . • remove the starter clutch cover. • remove the wave washer 1 , the starter idle gear no.2 2 and its shaft 3 ..

  • Page 71

    Engine 3-23 starter clutch • hold the starter clutch with the special tool. [ [ [ [ [ 09920-34830: starter clutch holder • remove the starter clutch bolt and washer. • remove the starter clutch assembly. Cam chain, cam chain tensioner, cam chain guide • remove the cam chain tensioner 1 and cam chain...

  • Page 72

    3-24 engine 28 – 38 mm generator cover • remove the generator cover. Generator rotor • hold the generator rotor with the special tool. [ [ [ [ [ 09930-44530: rotor holder • loosen the generator rotor bolt. Note: install the bolt (m 12, length: 28 – 38 mm) to the left end of crankshaft as shown in il...

  • Page 73

    Engine 3-25 gear position switch • remove the gear position switch. • remove the switch contacts and springs. Breather cover • remove the breather cover. Oil filter • remove the oil filter with the special tool. ( 2-14) [ [ [ [ [ 09915-40610: oil filter wrench oil cooler • remove the oil cooler..

  • Page 74

    3-26 engine oil pan • remove the cowling brackets 1 . • remove the oil pan. Oil pressure regulator • remove the oil pressure regulator 1 . Oil pressure switch • remove the oil pressure switch 2 . Oil strainer • remove the oil strainer 3 and o-ring. Lower crank case • remove the lower crankcase bolts...

  • Page 75

    Engine 3-27 middle crankcase • remove the crankcase bolts (6 mm). Note: loosen the crankcase bolts diagonally and the smaller sizes first. • remove the crankcase bolts (8 mm). Crankshaft • remove the o-ring 1 . • loosen the bearing cap bolts by using 10 mm, 12 point socket wrench, and tap the bearin...

  • Page 76

    3-28 engine piston and conrod • push the conrod to upward and remove the piston and conrod from the upper crankcase. # be careful not to damage the cylinder wall by the conrod. • remove the piston pin circlip. • separate the piston and conrod by driving out the piston pin. Note: scribe the cylinder ...

  • Page 77: Engine Components Inspection

    Engine 3-29 engine components inspection and service # identify the position of each removed part. Organize the parts in their respective groups (i.E., intake, exhaust, no.1 or no.2) so that they can be installed in their original locations. Pair valve pair reed valve • remove the pair valve cover. ...

  • Page 78

    3-30 engine cylinder head cover cam position sensor • install the oil seal 1 and cam position sensor 2 . Note: when installing, clean the cam position sensor’s face. ! Cam position sensor bolt: 8 n.M (0.8 kgf.M, 5.8 lb-ft) camshaft camshaft identification the exhaust camshaft can be distinguished fr...

  • Page 79

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

  • Page 80

    3-32 engine camshaft runout • measure the runout using the dial gauge. • replace the camshaft if the runout exceeds the limit. [ 09900-20606: dial gauge (1/100 mm) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm) camshaft runout: service limit (in & ex): 0.10 mm (0.004 in) cam chain ten...

  • Page 81

    Engine 3-33 cylinder head and valve valve and valve spring disassembly • remove the tappets 1 and shims 2 by fingers or magnetic hand. # identify the position of each removed part. • using special tools, compress the valve springs and remove the two cotter halves 3 from valve stem. [ 09916-14510: va...

  • Page 82

    3-34 engine • remove the oil seal 1 and the spring seat 2 . # do not reuse the removed oil seal. • remove the other valves in the same manner as described previously. Cylinder head distortion • decarbonize the combustion chambers. • check the gasketed surface of the cylinder head for distortion with...

  • Page 83

    Engine 3-35 valve stem deflection • lift the valve about 10 mm (0.39 in) from the valve seat. • measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • if the deflection measured exceeds the limit, then determine whether the valve...

  • Page 84

    3-36 engine 12.8 mm valve guide servicing • using the valve guide remover, drive the valve guide out to- ward the intake or exhaust camshaft side. [ [ [ [ [ 09916-53310: valve guide remover/installer note: * discard the removed valve guide subassemblies. * only oversized valve guides are available a...

  • Page 85

    Engine 3-37 valve seat width inspection • visually check for valve seat width on each valve face. • if the valve face has worn abnormally, replace the valve. • coat the valve seat with prussian blue and set the valve in place. Rotate the valve with light pressure. • check that the transferred blue o...

  • Page 86

    3-38 engine initial seat cut • using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • measure the valve seat width w after every cut. • if the valve seat is pitted or burned, use the 45° cutter to condi- tion the seat some more. Note: cut only the minimum amount n...

  • Page 87

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

  • Page 88

    3-40 engine valve stem end condition • check the valve stem end face for pitting and wear. Valve spring the force of the coil springs keeps the valve seat tight. Weak- ened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • ...

  • Page 89

    Engine 3-41 valve and valve spring reassembly • install the valve spring seats. • apply molybdenum oil solution to each oil seal, and press-fit them into position with the valve guide installer. [ [ [ [ [ 09916-44310: valve guide remover/installer o o o o o molybdenum oil solution # do not reuse the...

  • Page 90

    3-42 engine • install the tappet shims and the tappets to their original posi- tion. Note: * apply engine oil to the shim and tappet before fitting them. * when seating the tappet shim, be sure the figure printed sur- face faces the tappet. Intake pipe • install the intake pipe in the following proc...

  • Page 91

    Engine 3-43 clutch clutch drive plates inspection note: * wipe off engine oil from the clutch drive plates with a clean rag. * clutch drive plate no.1: purple paint * clutch drive plate no.2: green paint • measure the thickness of drive plates with a vernier calipers. • if each drive plate is not wi...

  • Page 92

    3-44 engine oil pump inspection • rotate the oil pump by hand and check that it moves smoothly. • if it does not move smoothly, replace the oil pump assembly. # * do not attempt to disassemble the oil pump assembly. * the oil pump is available only as an assembly. Starter clutch inspection • install...

  • Page 93

    Engine 3-45 gearshift system gearshift shaft/gearshift arm disassembly • remove the following parts from the gearshift shaft/gearshift arm. 1 washer 5 plate return spring 2 circlip 6 washer 3 gearshift shaft return spring 7 circlip 4 gearshift cam drive plate [ 09900-06107: snap ring pliers gearshif...

  • Page 94

    3-46 engine oil pressure regulator • inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • if the piston does not operate, replace the oil pressure regula- tor with a new one. Oil strainer • inspect the oil strainer body for damage. • clean the oil straine...

  • Page 95

    Engine 3-47 115 n.M 11.5 kgf.M 83.2 lb-ft ( ) transmission • disassemble the countershaft and drive shaft. Pay attention to the following point. [ 09900-06104: snap ring pliers • remove the 6th drive gear circlip from its groove and slide it towards the 3rd/4th drive gear. • slide the 6th 1 and 2nd ...

  • Page 96

    3-48 engine reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: note: * rotate the bearings by hand to inspect for smooth rotation. Re- place the bearings if there is anything unusual. * before installing the gears, apply en...

  • Page 97

    Engine 3-49 dr iv eshaft countershaft transmission parts location.

  • Page 98

    3-50 engine cylinder crankcase servicing: 3-54 cylinder distortion • check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. • if the largest reading at any position of the straightedge ex- ceeds th...

  • Page 99

    Engine 3-51 piston and piston ring piston diameter • using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) from the piston skirt end. • if the measurement is less than the limit, replace the piston. Piston diameter: service limit: 71.880 mm (2.8230 in) at 15 mm (0.6 in) from the ...

  • Page 100

    3-52 engine piston ring to groove clearance • measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • if any of the clearances exceed the limit, replace both the pis- ton and piston rings. [ 09900-20803: thickness gauge 09900-20205: micrometer (0 – 25 mm) piston ring...

  • Page 101

    Engine 3-53 piston ring reassembly • install the piston rings in the order of oil ring, 2nd ring and 1st ring. • the first member to go into the oil ring groove is a spacer 1 . After placing the spacer, fit the two side rails 2 . Note: side designations, top and bottom, are not applied to the spacer...

  • Page 102

    3-54 engine crankcase lower crankcase gearshift fork and gearshift cam removal • remove the gearshift cam bearing retainer 1 and gearshift fork retainer 2 from the lower crankcase. • remove the gearshift fork shafts and gearshift forks from the lower crankcase. • remove the gear shift cam and its be...

  • Page 103

    Engine 3-55 • inspect the gearshift cam bearing for abnormal noise and smooth rotation. • replace the bearings if there is anything unusual. • inspect the gearshift cam bearing 1 , gearshift fork bearing 2 and gearshift shaft bearing 3 for abnormal noise and smooth rotation while they are in the cra...

  • Page 104

    3-56 engine installation • install the bearings using the special tool. [ 09913-70210: bearing installer set note: the stamped mark side of the gearshift shaft bearing faces outside. • install the oil seal. • install the gearshift cam with the bearing. Note: the stamped mark side of the gearshift ca...

  • Page 105

    Engine 3-57 • install the gearshift forks and their shafts as shown. 1 for 3rd/4th drive gears 2 for 6th driven gear 3 for 5th driven gear • apply a small quantity of thread lock “1342” to the bearing retainer screws and the shift fork shaft retainer bolt. • tighten them to the specified torque. I 9...

  • Page 106

    3-58 engine oil jet removal • remove the piston cooling oil jets 1 from the upper crank- case. • remove the oil jet (for transmission) from the lower crankcase. Inspection and cleaning • check the oil jets for clogging. • if they are clogged, clean their oil passage with a proper wire and compressed...

  • Page 107

    Engine 3-59 installation • fit the new o-rings 1 to each piston cooling oil jet as shown and apply engine oil to them. # use the new o-rings to prevent oil pressure down. Note: be sure to face the oil holes a on each piston cooling oil jet to the top when installing them. • install each piston cooli...

  • Page 108

    3-60 engine crankshaft and conrod crankshaft runout • support the crankshaft with “v” blocks as shown, with the two end journals resting on the blocks. • set up the dial gauge, as shown. • rotate the crankshaft slowly to read the runout. • replace the crankshaft if the runout is greater than the lim...

  • Page 109

    Engine 3-61 conrod-crank pin bearing inspection • inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. Conrod-crank pin bearing selection • place the plastigauge axially along the crank pin, avoiding the oil hole, as sho...

  • Page 110

    3-62 engine • check the corresponding conrod i.D. Code number (“1” or “2”) a . • check the corresponding crank pin o.D. Code number (“1” , “2” or “3”) b . Bearing selection table conrod i.D. Code i.D. Specification 1 36.000 – 36.008 mm (1.4173 – 1.4176 in) 2 36.008 – 36.016 mm (1.4176 – 1.4179 in) c...

  • Page 111

    Engine 3-63 crankshaft journal bearing inspection • inspect each bearing of upper and lower crankcases for any damage. Selection • place the plastigauge axially along the crankshaft journal, avoid- ing the oil hole, as shown. [ 09900-22301: plastigauge # never rotate the crankshaft when a piece of p...

  • Page 112

    3-64 engine • check the corresponding crankcase journal i.D. Code number a , “a” or “b” which are stamped on the rear of upper crank- case. • check the corresponding crankshaft journal o.D. Code number b , “a”, “b” or “c” which are stamped on the crankshaft. Bearing selection table crankcase i.D. Sp...

  • Page 113

    Engine 3-65 crankshaft thrust bearing • with the crankshaft right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. R : right-side thrust bearing l : left-side thrust bearing note: pull the cr...

  • Page 114

    3-66 engine thrust bearing selection table clearance before color thrust bearing inserting left-side (part no.) thickness thrust clearance thrust bearing 2.560 – 2.585 mm white 2.475 – 2.500 mm 0.060 – 0.110 mm (0.1008 – 0.1018 in) (12228-17e00-0f0) (0.0974 – 0.0984 in) (0.0024 – 0.0043 in) 2.535 – ...

  • Page 115: Engine Reassembly

    Engine 3-67 engine reassembly • reassemble the engine in the reverse order of disassembly. • the following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reassem- bling. • be sure to install the following item...

  • Page 116

    3-68 engine der walls. • install the pistons and conrods into the cylinders from upside. Note: when installing the pistons, the indent a of the piston head must be faced to each exhaust side. # be carefull not to damage the cylinder wall by the conrod. • check that id code b on the each conrods face...

  • Page 117

    Engine 3-69 crankshaft • position the no.2 and no.3 conrod big ends toward same side, and position the no.1 and no.4 conrod big ends toward oppo- site side of no.2 and no.3. • set the crankshaft to the conrods and upper crankcase. • apply molybdenum oil solution to the crank pin and bearing sur- fac...

  • Page 118

    3-70 engine ing lightly. O o o o o molybdenum oil solution • insert the right and left-thrust bearings with oil groove b facing the crank web.. Note: right-thrust bearing has green painting. Crankcase • clean the mating surfaces of the crankcases. • install the dowel pins 1 and o-ring 2 to the upper...

  • Page 119

    Engine 3-71 case. C c c c c 99104-31140: suzuki bond “1207b” (for usa) d d d d d 99000-31110: suzuki bond “1215” (for the others) note: use of suzuki bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * spread on surfaces thinly to form an even layer, and ...

  • Page 120

    3-72 engine • tighten the other crankcase bolts a little at a time to equalize the pressure. ! Crankcase bolt: (m6) initial: 6 n.M (0.6 kgf.M, 4.5 lb-ft) final: 11 n.M (1.1 kgf.M, 8.0 lb-ft) note: fit the clamp to the crankcase bolt a . Note: after the crankcase bolts have been tightened, check if t...

  • Page 121

    Engine 3-73 transmission • install the bearing pins 1 and the c-ring 2 on the upper crank- case. • install the countershaft assembly on the upper crankcase. Note: align the c-ring with the groove on the bearing and the bearing pin with the indent on the bearing. • install the driveshaft assembly on ...

  • Page 122

    3-74 engine • apply suzuki bond to the mating surface of the lower crank- case. C c c c c 99104-31140: suzuki bond “1207b” (for usa) d d d d d 99000-31110: suzuki bond “1215” (for the others) note: use of suzuki bond is as follows: * make surfaces free from moisture, oil, dust and other foreign mate...

  • Page 123

    Engine 3-75 • tighten the crankcase bolts a little at a time to equalize the pres- sure. ! Crankcase bolt: (m6) initial: 6 n.M (0.6 kgf.M, 4.5 lb-ft) final : 11 n.M (1.1 kgf.M, 8.0 lb-ft) (m8) initial: 15 n.M (1.5 kgf.M, 10.8 lb-ft) final : 26 n.M (2.6 kgf.M, 19.0 lb-ft) note: * fit the copper washe...

  • Page 124

    3-76 engine oil pressure regulator • apply grease to the o-ring and press in the oil pressure regula- tor to the crankcase. W w w w w 99000-25030: suzuki super grease “a” # use the new o-ring to prevent oil leakage. Oil pan • install the gasket 1 . # use the new gasket to prevent oil leakage. • inst...

  • Page 125

    Engine 3-77 oil pressure switch • apply suzuki bond “1207b” to the thread part of the oil pres- sure switch 1 and tighten it to the specified torque. C 99104-31140: suzuki bond “1207b” ! Oil pressure switch: 14 n.M (1.4 kgf.M, 10.0 lb-ft) note: be careful not to apply suzuki bond “1207b” to the hole...

  • Page 126

    3-78 engine • install the gasket. • install the breather cover. ! Breather cover bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) gear position switch • install the gear position switch contacts 1 and the springs 2 . • apply the grease to the o-ring. W 99000-25030: suzuki super grease “a” • apply the thread lock...

  • Page 127

    Engine 3-79 water pump • apply grease to the o-ring. # use the new o-ring to prevent oil leakage. W w w w w 99000-25030: suzuki super grease “a” • tighten the water pump mounting bolts to the specified torque. ! ! ! ! ! Water pump mounting bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) note: pass through the g...

  • Page 128

    3-80 engine generator rotor • degrease the tapered portion of the generator rotor and also the crankshaft. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. • install the generator rotor onto the crankshaft. • install the rotor bolt with the ...

  • Page 129

    Engine 3-81 • install the ckp sensor. • apply suzuki bond “1207b” light to the groove of the signal generator lead wire gromet. C 99104-31140: suzuki bond “1207b” cam chain drive sprocket • install the cam chain drive sprocket onto the crankshaft. Note: align the punched mark a on the cam chain driv...

  • Page 130

    3-82 engine starter clutch • install the washer 1 . • install the starter clutch assembly onto the crankshaft. Note: align the engraved line a on the starter clutch with the punched mark b on the crankshaft. • install the starter clutch bolt with the washer. • hold the starter clutch with special to...

  • Page 131

    Engine 3-83 • install the new gasket 1 and the dowel pins. # use a new gasket to prevent oil leakage. • install the starter clutch cover and tighten its bolt as shown. Note: * fit the wire clamp to the starter clutch cover bolt a as shown. * fit the new gasket washer to the starter clutch cover bolt...

  • Page 132

    3-84 engine gearshift system • install the gearshift cam stopper 1 , its bolt 2 , the washer 3 and the return spring 4 . Note: apply a small quantity of thread lock “1342” to the gearshift cam stopper bolt 2 and tighten it to the specified torque. I 99000-32050: thread lock “1342” ! Gearshift cam st...

  • Page 133

    Engine 3-85 • install the gearshift shaft/gearshift arm 1 with the washers as shown. Note: pinch the gearshift arm stopper 2 with return spring ends a . • install the washer 3 and circlip 4 . Oil pump • install the o-ring to the oil pump and apply grease to it. # use the new o-ring to prevent oil le...

  • Page 134

    3-86 engine clutch • install the thrust washer onto the countershaft. Note: the chamfer side a of the thrust washer faces crankcase side. • install the oil pump drive gear 1 to the primary driven gear assembly. Note: rotate the crankshaft so as not to contact the primary driven gear and crankshaft b...

  • Page 135

    Engine 3-87 • install the clutch sleeve hub 2 onto the countershaft. • install the washer 3 and spring washer 4 . Note: the convex side of the washer 4 faces outside. • install the clutch sleeve hub nut. • hold the clutch sleeve hub using the special tool. [ [ [ [ [ 09920-53740: clutch sleeve hub ho...

  • Page 136

    3-88 engine the clutch sleeve hub in the prescribed order. Note: insert the outermost no.1 drive plate claws a to the other slits b of clutch housing as shown. Drive plate: • install the clutch push piece 2 , the bearing 3 and the thrust washer 4 to the countershaft. Note: thrust washer 4 is located...

  • Page 137

    Engine 3-89 • install the clutch springs. • hold the clutch housing using the special tool. # be careful not to damage the clutch housing or clutch plates. [ 09920-53740: clutch sleeve hub holder • tighten the clutch spring set bolts to the specified torque. ! Clutch spring set bolt: 10 n.M (1.0 kgf...

  • Page 138

    3-90 engine cylinder. # use the new gasket to prevent gas leakage. • place the cylinder head on the cylinder. • install the cylinder head side bolt 2 and gasket 3 and tighten it to the specified torque. When installing the cylinder head, keep the cam chain taut. • tighten the cylinder head bolts (m1...

  • Page 139

    Engine 3-91 • fit the gasket 1 and tighten the water temp. Gauge. ! ! ! ! ! Water temp. Gauge: 18 n.M (1.8 kgf.M, 13.0 lb-ft) • install the thermostat. ( 5-10) • install the thermostat cover. ! ! ! ! ! Thermostat cover bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) note: fit the clamp to the bolt a . • install...

  • Page 140

    3-92 engine camshaft • turn the crankshaft clockwise with the box wrench and align the line a on the starter clutch with the index mark b of the valve timing inspection hole while keeping the cam chain pulled up- ward. # pull the cam chain upward, or the chain will be caught between crankcase and ca...

  • Page 141

    Engine 3-93 • engage the 14 roller pin c on the cam chain with the arrow marked “3” on the intake sprocket. • bind the cam chain and the sprocket with a proper wire clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders. Note: the cam chain should now be on all ...

  • Page 142

    3-94 engine • install the dowel pins. • install the camshaft journal holders, intake and exhaust and cam chain guide. • fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. Note: * damage to head or camshaft journal holder thrust sur...

  • Page 143

    Engine 3-95 cam chain tension adjuster • retract the push rod by pushing the stopper. • install the ball 1 to the cam chain tension adjuster. • install the new gasket 2 . # use the new gasket to prevent oil leakage. • install the cam chain tension adjuster and tighten the mounting bolts. ! Cam chain...

  • Page 144

    3-96 engine 3 2 35f 1 3 2 35f 35f 35f 1 10 n . M (1.0 kgf . M, 7.0 lb-ft) align the center of cam chain tension adjuster mounting bolt with the left side face of oil hose union pipe . White mar k oil hose 20 ˚ 12 n . M (1.2 kgf . M, 8.7 lb-ft) 23 n . M (2.3 kgf . M, 16.5 lb-ft) 90 ˚ 90 ˚ 14 13 12 11...

  • Page 145

    Engine 3-97 • tighten the valve timing inspection plug 1 to the specified torque. ! Valve timing inspection plug: 11 n.M (1.1 kgf.M, 8.0 lb-ft) cylinder head cover • pour engine oil in each oil pocket in the cylinder head. Note: be sure to check the valve clearance. ( 2-8) • install the dowel pins. ...

  • Page 146

    3-98 engine pair valve • install the pair reed valve 1 . ( 8-22) • apply thread lock to the bolts, install the pair valve and hose. ( 8-22) i 99000-32050: thread lock “1342” ! ! ! ! ! Pair reed valve cover bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) starter motor • apply the grease to the o-ring. W 99000-25...

  • Page 147

    Fi system and intake air system contents precautions in servicing ....................................................... 4- 2 fi system technical features ............................................. 4- 8 injection time ........................................................................... 4-...

  • Page 148

    Fi system and intake air system 4-1 4 fuel system ................................................................................. 4-51 fuel tank lift-up .................................................................... 4-51 fuel tank removal ........................................................

  • Page 149: Precautions In Servicing

    4-2 fi system and intake air system click click coupler probe coupler probe where male terminal fits precautions in servicing when handling the fi component parts or servicing the fi sys- tem, observe the following points for the safety of the system. Connector/coupler • when connecting a connector,...

  • Page 150

    Fi system and intake air system 4-3 incorrect ignition s/w incorrect fuse • when a fuse blows, always investigate the cause, correct it and then replace the fuse. • do not use a fuse of a different capacity. • do not use wire or any other substitute for the fuse. Ecm/various sensors • since each com...

  • Page 151

    4-4 fi system and intake air system • removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electro- motive force will be applied to the ecm which may result in serious damage. • before measuring voltage at each terminal, check to...

  • Page 152

    Fi system and intake air system 4-5 ecm ' sensor check for loose connection ecm check contact tension by inserting and removing. Check each terminal for bend and proper alignment. Looseness of crimping open thin wire (a few strands left) ecm • disconnect the negative cable from the battery. • check ...

  • Page 153

    4-6 fi system and intake air system 0v 5v 5v 5v to other parts other parts 5v voltage check if voltage is supplied to the circuit being checked, voltage check can be used as circuit check. • with all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage betw...

  • Page 154

    Fi system and intake air system 4-7 to other parts ecm multi-circuit tester • 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 the ground between terminals a and b . Usin...

  • Page 155

    4-8 fi system and intake air system fi system technical features injection time (injection volume) the factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compe...

  • Page 156

    Fi system and intake air system 4-9 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal atmospheric pressure sensor sig- nal engine coolant temperature sen- sor signal intake air t...

  • Page 157

    4-10 fi system and intake air system fuel delivery system the fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by th...

  • Page 158

    Fi system and intake air system 4-11 relief valve brush outlet port check valve armature magnet impeller inlet port outlet blade groove inlet flow clearance turning direction motor shaft vortex flow impeller fuel pump the electric fuel pump is located under the fuel tank, which consists of the armat...

  • Page 159

    4-12 fi system and intake air system needle valve plunger solenoid coil filter fuel pressure regulator the fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kpa (3.0 kgf/cm 2 , 43 psi) applied to the injector at all times. When the fuel pressure rises m...

  • Page 160

    Fi system and intake air system 4-13 tos 30a ig switch 15a 10a fp relay side-stand relay engine stop switch to starter button side-stand switch fi #1 #2 #3 #4 fuel pump ecm battery ckps fuel pump control system when the ignition switch is turned on, current from the battery flows to the fuel pump mo...

  • Page 161

    4-14 fi system and intake air system engine r/min throttle opening injection time engine r/min throttle opening injection time injection time intake air pressure engine r/min injection time intake air pressure engine r/min injection time intake air pressure engine r/min injection time intake air pre...

  • Page 162

    Fi system and intake air system 4-15 injection timing the system employs a sequential, four-cylinder independent injection type, using the crankshaft position sensor (signal generator) to determine the piston position (injection timing and ignition timing) and the cam- shaft position sensor to ident...

  • Page 163

    4-16 fi system and intake air system output voltage (v) lo w high low high (high vacuum) (low vacuum) intake air pressure(mmhg) output voltage (v) lo w high small large throttle valve opening(degree) sensors intake air pressure sensor (iap sensor) the intake air pressure sensor is located at the rea...

  • Page 164

    Fi system and intake air system 4-17 cmp sensor signal rotor crankshaft position sensor (ckp sensor) the signal rotor is mounted on the right end of the crankshaft, and the crankshaft position sensor (pick-up coil) is installed on the right side of the middle crankcase. The sensor generates the pick...

  • Page 165

    4-18 fi system and intake air system output voltage (v) lo w high low high (high vacuum) (low vacuum) atmospheric pressure(mmhg) resistance value lo w high temperature low high thermistor engine coolant temperature sensor (ect sensor) the thermistor resistance value increases when the engine cool- a...

  • Page 166

    Fi system and intake air system 4-19 tip over sensor (to sensor) the tip over sensor is located in ahead of the rear fender. The sensor detects the leaning of the motorcycle. When it leans more than 43°, the mechanical switch turns on and a signal is sent to the ecm. At the same time, this signal cu...

  • Page 167: Intake Air System

    4-20 fi system and intake air system intake air system secondary throttle control system the secondary throttle control system (stc system) consists of the secondary throttle valve (st valve), secondary throttle valve actuator (stv actuator) and st valve control cables. St valve is installed in each...

  • Page 168

    Fi system and intake air system 4-21 secondary throttle valve secondary throttle valve actuator operation the secondary throttle control system (stc system) operates on the signal supplied from the ecm. The open/close operation of the secondary throttle valve (st valve) is performed by the secondary...

  • Page 169: Fi System Parts Location

    4-22 fi system and intake air system a speedometer b engine coolant temperature sensor (ects) c ignition coil (ig coil) d speed sensor e atmospheric pressure sensor (aps) f camshaft position sensor (cmps) ecm g intake air pressure sensor (iaps) h fuel injector (fi) i tip over sensor (tos) fi system ...

  • Page 170

    Fi system and intake air system 4-23 ecm j intak e air temper ature sensor (ia ts) k throttle position sensor (tps) l crankshaft position sensor (ckps) m secondar y throttle v alv e actuator (stv a) n fuel pump (fp) o fuel pump rela y (fp rela y).

  • Page 171

    4-24 fi system and intake air system fp relay fi #1 fi #2 fi #3 fi #4 #1 #2 #3 #4 iats tps stva aps iaps ig cmps ects starter motor speed sensor ckps gps ecm battery ts tos fp clp switch fi system diagram.

  • Page 172

    Fi system and intake air system 4-25 fi system wiring diagram.

  • Page 173: Self-Diagnosis Function

    4-26 fi system and intake air system self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi light). To check the function of the individual fi syst...

  • Page 174

    Fi system and intake air system 4-27 dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive signal from ...

  • Page 175

    4-28 fi system and intake air system code malfunction part remarks c00 none no defective part c11 camshaft position sensor (cmp sensor) c12 crankshaft position sensor (ckp sensor) pick-up coil signal, signal generator c13 intake air pressure sensor (iap sensor) c14 throttle position sensor (tp senso...

  • Page 176: Fail-Safe Function

    Fi system and intake air system 4-29 fail-safe function 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 camshaft position sensor crankshaft position sensor intake air pressu...

  • Page 177: Fi System Troubleshooting

    4-30 fi system and intake air system fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point require...

  • Page 178

    Fi system and intake air system 4-31 09930-82710 : mode select switch self-diagnostic procedures • don’t disconnect couplers from ecm, battery cable from bat- tery, ecm ground wire harness from engine or main fuse be- fore confirming malfunction code (self-diagnostic trouble code) stored in memory. ...

  • Page 179

    4-32 fi system and intake air system malfunction code and defective condition malfunction code c00 c11 c12 c13 c14 c15 c21 c22 c23 c24, c25, c26 or c27 detected item no fault camshaft position sensor crankshaft position sensor intake air pressure sensor throttle position sensor engine coolant temper...

  • Page 180

    Fi system and intake air system 4-33 stva position sensor produces following voltage. (0.1 sensor voltage without the above value, c28 is indicated. Stva motor can not move. Stv actuator, stv actuator adjustment, lead wire/coupler. Gear position signal voltage should be higher than the follow- ing f...

  • Page 181

    4-34 fi system and intake air system peak volt adaptor v “c11” cmp sensor circuit malfunction detected condition possible cause no cmp sensor signal for 4 seconds at engine • metal particles or foreign material being cranking. Attached on the cmp sensor and rotor tip. • cmp sensor circuit open or sh...

  • Page 182

    Fi system and intake air system 4-35 v peak volt adaptor peak volt adaptor grees green black black “c12” ckp sensor circuit malfunction detected condition possible cause no ckp sensor signal for 4 seconds at engine • metal particles or foreign material being cranking. Attached on the ckp sensor and ...

  • Page 183

    4-36 fi system and intake air system b/br red v v red inspection • lift and support the fuel tank with its prop stay. ( 4-51) turn the ignition switch off. Check the iap sensor coupler for loose or poor contacts. If ok, then measure the iap sensor input voltage. Disconnect the iap sensor coupler. Tu...

  • Page 184

    Fi system and intake air system 4-37 ground vout vcc 1.5v battery (4.5v in total) remove the iap sensor. Connect the vacuum pump gauge to the vacuum port of the iap sensor. Arrange 3 new 1.5 v batteries in series (check that total voltage is 4.5 – 5.0 v) and connect - terminal to the ground terminal...

  • Page 185

    4-38 fi system and intake air system v b/br red v red ground “c14” tp sensor circuit malfunction detected condition possible cause signal voltage low or high. • tp sensor maladjusted. Difference between actual throttle opening and • tp sensor circuit open or short. Opening calculated by ecm in large...

  • Page 186

    Fi system and intake air system 4-39 connect the tp sensor coupler. Insert the copper wires to the lead wire coupler. Turn the ignition switch on. Measure the tp sensor output voltage at the coupler (be- tween yellow and black wires) by turning the throttle grip. Tp sensor output voltage throttle va...

  • Page 187

    4-40 fi system and intake air system b/br b/bl v engine coolant resistance temp. 20°c ( 68 °f) approx. 2.45 k Ω 50°c ( 122 °f) approx. 0.811 k Ω 80°c ( 176 °f) approx. 0.318 k Ω 110°c ( 230 °f) approx. 0.142 k Ω inspection • lift and support the fuel tank with its prop stay. ( 4-51) turn the ignitio...

  • Page 188

    Fi system and intake air system 4-41 b/br dg v “c21” iat sensor circuit malfunction detected condition possible cause high intake air temp. (low voltage – low • dg circuit shorted to ground. Resistance) • b/br circuit open. Low intake air temp. (high voltage – high • iat sensor malfunction. Resistan...

  • Page 189

    4-42 fi system and intake air system “c22” ap sensor circuit malfunction detected condition possible cause low pressure and low voltage. • clogged air passage with dust. High pressure and high voltage. • red wire circuit open or shorted to ground. 0.5 v sensor voltage • b/br or g/y wire circuit shor...

  • Page 190

    Fi system and intake air system 4-43 1.5v battery (4.5v in total) vcc vout ground v remove the ap sensor. Connect the vacuum pump gauge to the air passage port of the ap sensor. Arrange 3 new 1.5 v batteries in series (check that total voltage is 4.5 – 5.0 v) and connect - terminal to the ground ter...

  • Page 191

    4-44 fi system and intake air system inspection • lift and support the fuel tank with its prop stay. ( 4-51) turn the ignition switch off. Check the to sensor coupler for loose or poor contacts. If ok, then measure the to sensor resistance. Disconnect the to sensor coupler. Measure the resistance be...

  • Page 192

    Fi system and intake air system 4-45 inspection • lift and support the fuel tank with its prop stay. ( 4-51) turn the ignition switch off. Check the stv actuator lead wire coupler for loose or poor contacts. Turn the ignition switch on. Check the movement of the stv actuator. No to 2-b ( 4-47) yes c...

  • Page 193

    4-46 fi system and intake air system ground ground white white yellow yellow 4-a turn the ignition switch off. Check the continuity between yellow wire and ground. Position sensor continuity: ∞Ω ∞Ω ∞Ω ∞Ω ∞Ω (infinity) if ok, then measure the position sensor resistance. Connect the position sensor co...

  • Page 194

    Fi system and intake air system 4-47 if the position sensor output voltage is less than 0.2 v at fully close position, adjust the output voltage to specified by turning out the no.2 cable adjuster 1 . Adjusting the cable with the st valve fully opened or fully closed can damage the stv actuator. Be ...

  • Page 195

    4-48 fi system and intake air system ecm couplers v pink pink ground ground 1 “c31” gear position (gp) switch circuit malfunction detected condition possible cause no gear position switch voltage • gear position switch circuit open or short. Switch voltage low. • gear position switch malfunction. Se...

  • Page 196

    Fi system and intake air system 4-49 “c32”, “c33”, “c34” or “c35” fuel injection malfunction detected condition possible cause no injector current. • injector circuit open or short. • injector malfunction. • ecm malfunction. Inspection • lift and support the fuel tank with its prop stay. ( 4-51) tur...

  • Page 197

    4-50 fi system and intake air system “c41” fp relay circuit malfunction detected condition possible cause no signal from fuel pump relay. • fuel pump relay circuit open or short. • fuel pump relay malfunction. • ecm malfunction. Inspection • remove the front and rear seats. • lift and support the fu...

  • Page 198: Fuel System

    Fi system and intake air system 4-51 fuel system fuel tank lift-up • remove the front and rear seats. • remove the fuel tank mounting bolts. Fuel tank removal • lift and support the fuel tank with the fuel tank prop stay. (see above) • disconnect the fuel pump lead wire coupler 1 . • place a rag und...

  • Page 199

    4-52 fi system and intake air system fuel pressure inspection • lift and support the fuel tank with its prop stay. ( 4-51) • place a rag under the fuel pressure check bolt 1 and slowly loosen it and catch the remaining fuel using a suitable con- tainer. • remove the fuel pressure check bolt 1 and in...

  • Page 200

    Fi system and intake air system 4-53 fuel pump inspection turn the ignition switch on and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor. Fuel discharge amoun...

  • Page 201

    4-54 fi system and intake air system • pull out the power source lead wire 1 (yellow with red tracer). • place the measuring cylinder and insert the fuel hose end into the measuring cylinder. • apply 12 volts to the fuel pump for 30 seconds and measure the amount of fuel discharged. Battery + termin...

  • Page 202

    Fi system and intake air system 4-55 fwd fuel pump relay inspection fuel pump relay is located in ahead of the rear fender. • remove the front and rear seats. • lift and support the fuel tank with its prop stay. ( 4-51) • remove the fuel pump relay. First, check the insulation between 1 and 2 termin...

  • Page 203

    4-56 fi system and intake air system removal • remove the fuel tank. ( 4-51) • remove the fuel pump assembly by removing its mounting bolts diagonally. " gasoline is highly flammable and explosive. Keep heat, spark and flame away. • remove the nuts. • remove the screws. • remove the fuel pump assy f...

  • Page 204

    Fi system and intake air system 4-57 • remove the fuel pressure regulator holder 1 and the fuel pres- sure regulator 2 . Fuel filter inspection and cleaning if the fuel filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel filter with...

  • Page 205

    4-58 fi system and intake air system • be sure to connect the wires to the proper terminals. A .......... + terminal for fuel pump b .......... Thermistor for low level c .......... Thermistor for high level • pass through the wires behind the thermistors. Thermistor f mistor for high level thermist...

  • Page 206

    Fi system and intake air system 4-59 • install the o-ring and apply grease to it. W 99000-25030: suzuki super grease “a” " the o-ring must be replaced with a new one to prevent fuel leakage. • when installing the fuel pump assembly, lightly tighten all the fuel pump assembly mounting bolts in the as...

  • Page 207

    4-60 fi system and intake air system fwd fwd throttle body and stv actuator construction 1 tp sensor 2 throttle stop screw 3 fast idle adjusting screw 4 fuel delivery pipe 5 o-ring 6 dust seal 7 ignitor 8 cusion seal 9 vacuum hose 0 stv actuator bracket a stv actuator b stva control cable (no.1) c s...

  • Page 208

    Fi system and intake air system 4-61 throttle body and stv actuator removal adjustment position setting procedure • turn the ignition switch off. • remove the rear seat. • connect the special tool to the dealer mode coupler. • after turning the special tool’s switch on, turn the ignition switch on. ...

  • Page 209

    4-62 fi system and intake air system • loosen the throttle body clamp screws. • remove the air cleaner box mounting bolt. • remove the air cleaner box. Throttle body • disconnect the throttle cables from their drum. • disconnect the fast idle cable from its cam. # after disconnecting the throttle ca...

  • Page 210

    Fi system and intake air system 4-63 • disconnect the vacuum hose 1 from the no.4 throttle body. • disconnect the fuel injector lead wire coupler 2 . • loosen the throttle body clamp screws at the intake pipe side. • remove the throttle stop screw 3 from the cable guide. • remove the throttle body a...

  • Page 211

    4-64 fi system and intake air system secondary throttle valve actuator • disconnect the stv actuator lead wire couplers 1 . • hold the actuator pulley 3 with an adjustable wrench, and loosen the pulley mounting bolt 4 . # when loosening or tightening the pulley bolt, be sure to fix the pulley with a...

  • Page 212

    Fi system and intake air system 4-65 • remove the stv actuator. • remove the actuator bracket 1 . # a little portion of the st valve is visible from the top of the throttle body. Don’t put the secondary valve’s side of the throttle body down, for it may damage the st valve..

  • Page 213

    4-66 fi system and intake air system throttle body disassembly • disconnect the tp sensor lead wire coupler 1 . • disconnect the fuel injector lead wire couplers 2 . • remove the fuel delivery pipe assembly 3 by removing its mounting screws. • remove the fuel injectors. • disconnect the respective v...

  • Page 214

    Fi system and intake air system 4-67 throttle body cleaning " some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • clean all passagewa...

  • Page 215

    4-68 fi system and intake air system fuel pressure check bolt to fuel feed hose throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attension to the following points: • when installing the tp sensor, align the groove 1 with the lib 2 . Tp sensor setting p...

  • Page 216

    Fi system and intake air system 4-69 • apply thin coat of the engine oil to the new fuel injector cushion seals 1 , and install them to each fuel injector. # replace the cushion seal with a new one. • install the seals 2 and o-rings 3 to each fuel injector. • apply thin coat of the engine oil to the...

  • Page 217

    4-70 fi system and intake air system throttle body and stv actuator installation stv actuator installation • install the stv actuator bracket 1 to the throttle body. • fit the clamp to the bolt a . • install the stv actuator to the bracket. ! ! ! ! ! Stv actuator mounting bolt: 5 n.M (0.5 kgf.M, 3.5...

  • Page 218

    Fi system and intake air system 4-71 • connect the two cables temporarily to the throttle body. • connect the cables to the inside slots 1 of the stv actuator pulley. • install the pulley to the shaft by aligning the groove 2 with the line 3 . # the slot of the pulley must be facing to downward. • h...

  • Page 219

    4-72 fi system and intake air system stv actuator adjustment 1st step: • set the stv actuator to adjustment position. ( 4-61) 2nd step: • turn out the no.2 cable adjuster 1 until the outer cable play a becomes zero. Note: make sure that outer cable end is fixed into the rubber stopper b . 3rd step: ...

  • Page 220

    Fi system and intake air system 4-73 4th step: • turn the mode select switch off. • turn the ignition switch on to check the stv actuator opera- tion. • turn the mode select switch on. • if c28 is not indicated on the lcd (display), the adjustment is correctly completed. In this case, it is unnecess...

  • Page 221

    4-74 fi system and intake air system v yellow yellow b/br b/br 12 v gray gray pink pink 5th step: this procedure is only required when c28 is indicated. • turn the ignition switch off. • insert the two copper wires into the back side of the position sensor lead wire coupler 1 . • disconnect the stva...

  • Page 222

    Fi system and intake air system 4-75 to set the st valve to fully open position, apply 12 volts to a and b terminals. Positive wire ––– b (gray wire) terminal negative wire ––– a (pink wire) terminal to prevent the motor damage, stop to apply 12v as soon as the st valve reaches to fully open positio...

  • Page 223

    4-76 fi system and intake air system fuel injector installation • apply thin coat of the engine oil to new injector cushion seals and o-rings. • install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. ( 4-68) fast idle adjustment the fast idle syst...

  • Page 224

    Fi system and intake air system 4-77 throttle valve synchronization check and adjust the throttle valve synchronization among four cylinders. Calibrating each gauge • lift and support the fuel tank. ( 4-51) • start up the engine and run it in idling condition for warming up. • stop the warmed-up eng...

  • Page 225

    4-78 fi system and intake air system • connect one of the four rubber hoses of the vacuum balancer gauge to the nipple 1 on the no.1 throttle body. 09913-13121: vacuum balancer gauge • connect a tachometer. • start up the engine and keep it running at 1 200 rpm by turning throttle stop screw 2 . Avo...

  • Page 226

    Fi system and intake air system 4-79 throttle valve synchronization • to synchronize throttle valves, remove the rubber caps 1 from each vacuum nipple and connect the vacuum balancer gauge hoses to the vacuum nipples respectively. 09913-13121: vacuum balancer gauge • connect a tachometer and start u...

  • Page 227

    4-80 fi system and intake air system throttle position sensor (tps) setting after all adjustments are completed, check or adjust the tps set- ting condition. (refer to page 4-28 for tps setting procedure.) throttle cable adjustment note: minor adjustment can be made by the throttle grip side adjuste...

  • Page 228: Sensors

    Fi system and intake air system 4-81 sensors iap sensor inspection the intake air pressure sensor is located at the rear side of the air cleaner box. ( 4-36) iap sensor removal/installation • lift and support the fuel tank. ( 4-51) • remove the iap sensor mounting screw 1 and disconnect the coupler ...

  • Page 229

    4-82 fi system and intake air system ect sensor inspection the engine coolant temperature sensor is installed at the rear side of the cylinder head. ( 4-40 and 5-8) ect sensor removal/installation ( 5-8 and -9) ap sensor inspection the atmospheric pressure sensor is located beneath the left side of ...

  • Page 230

    Cooling and lubrication system 5-1 5 cooling and lubrication system engine coolant .......................................................................... 5- 2 cooling circuit .......................................................................... 5- 3 cooling circuit inspection .................

  • Page 231: Engine Coolant

    5-2 cooling and lubrication system gauge pressure (kgf/cm 2 ) engine coolant at the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat protectio...

  • Page 232: Cooling Circuit

    Cooling and lubrication system 5-3 water pump radiator oil cooler cooling fan thermo switch engine coolant temperature sensor thermostat cylinder head cylinder reserve tank cooling circuit cooling circuit inspection before removing the radiator and draining the engine coolant, inspect the cooling ci...

  • Page 233: Radiator And Water Hoses

    5-4 cooling and lubrication system radiator and water hoses radiator removal • remove the under cowling. ( 6-5) • drain engine coolant. ( 2-18) • remove the radiator. ( 3-4 and -5) radiator cap inspection • fit the cap 1 to the radiator cap tester 2 . • build up pressure slowly by operating the test...

  • Page 234

    Cooling and lubrication system 5-5 water hose inspection • remove the under cowling. ( 6-5) • any water hose found in a cracked condition or flattened must be replaced. • any leakage from the connecting section should be corrected by proper tightening. Radiator remounting • install the radiator. • r...

  • Page 235: Cooling Fan Thermo-Switch

    5-6 cooling and lubrication system inspection • remove the under cowling. ( 6-5) • disconnect the cooling fan lead wire coupler 1 . • test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • the voltmeter is for making sure that the battery applies 12 vol...

  • Page 236

    Cooling and lubrication system 5-7 oil inspection • check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure. Connect the thermo-switch to a circuit tester and place it in the oil contained in a pan, which is placed on a stove. • heat the oil to raise...

  • Page 237: Engine Coolant Temperature

    5-8 cooling and lubrication system oil engine coolant temperature sensor removal • remove the under cowling. ( 6-5) • drain engine coolant. ( 2-18) • remove the front and rear seats. ( 6-8) • lift and support the fuel tank. ( 4-51) • remove the air cleaner box. ( 4-60 and -61) • remove the throttle ...

  • Page 238: Thermostat

    Cooling and lubrication system 5-9 installation • tighten the engine coolant temperature sensor to the specified torque. ! Engine coolant temperature sensor: 18 n.M (1.8 kgf.M, 13.0 lb-ft) # take special care when handling the temperature sen- sor. It may cause damage if it gets a sharp impact. • in...

  • Page 239

    5-10 cooling and lubrication system inspection inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner. • pass a string between flange, as shown in the illustration. • immerse the thermostat in the water contained in a beake...

  • Page 240: Water Pump

    Cooling and lubrication system 5-11 • install the thermostat case. Note: fit the clamp to the thermostat case bolt a . • tighten the thermostat case bolt to the specified torque. ! Thermostat case bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) • install the throttle body. • install the air cleaner box. • insta...

  • Page 241

    5-12 cooling and lubrication system • remove the engine sprocket cover 1 . • disconnect the water hoses. • remove the water pump. • remove the water pump cover. • remove the impeller securing bolt 2 by holding the impeller shaft with a water pump pliers..

  • Page 242

    Cooling and lubrication system 5-13 • remove the mechanical seal ring 1 and the rubber seal 2 from the impeller. • remove the impeller shaft 3 . • remove the bearing using the special tool. [ 09921-20220: bearing remover set ( φ 10) note: if no abnormal noise, bearing removal is not necessary. # the...

  • Page 243

    5-14 cooling and lubrication system inspection bearing • inspect the play of the bearing by hand while it is in the water pump case. • rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • replace the bearing if there is anything unusual. Mechanical seal • visually inspe...

  • Page 244

    Cooling and lubrication system 5-15 reassembly and installation • install the oil seal using the special tool. [ 09913-70210: bearing installer set ( φ 20) note: the stamped mark on the oil seal faces outside. • apply a small quantity of the suzuki super grease “a” to the oil seal lip. W 99000-25030...

  • Page 245

    5-16 cooling and lubrication system • apply grease to the impeller shaft. W 99000-25030: suzuki super grease “a” • install the impeller shaft to the water pump body. • install the rubber seal 1 into the impeller. • after wiping off the oily or greasy matter from the mechanical seal ring, install it ...

  • Page 246

    Cooling and lubrication system 5-17 • install the new o-rings, 1 and 2 . # use the new o-rings to prevent engine coolant leakage. Note: * apply engine coolant to the o-ring 1 . * apply grease to the o-ring 2 . W 99000-25030: suzuki super grease “a” • tighten the water pump cover screws to the specif...

  • Page 247: Lubrication System

    5-18 cooling and lubrication system lubrication system oil pressure 2-31 oil filter 2-13 oil pressure regulator 3-46 oil strainer 3-46 oil jet 3-58 oil pump 3-44 oil pressure switch 7-39 water pump oil pump.

  • Page 248: Sub-Gallery

    Cooling and lubrication system 5-19 intake camshaft intake camshaft journal holder cam drive chain starter clutch oil hose cam chain tension adjuster #1 piston cooling oil jet #1 piston and cylinder wall #1 crank pin bearing #1 crankshaft journal bearing orifice generator #2 crankshaft journal beari...

  • Page 249

    5-20 cooling and lubrication system engine lubrication system main gallery to sub-gallery.

  • Page 250

    Cooling and lubrication system 5-21.

  • Page 251: Chassis

    Chassis contents exterior parts ........................................................................... 6- 2 construction .......................................................................... 6- 2 fastener removal and reinstallation ....................... 6- 4 screen .........................

  • Page 252

    Chassis 6-1 6 rear suspension ....................................................................... 6-50 construction .......................................................................... 6-50 removal ..................................................................................... 6-52 i...

  • Page 253: Exterior Parts

    6-2 chassis exterior parts construction right air intake pipe cowling brace 23 n . M (2.3 kgf . M, 16.5 lb-ft) wind screen body cowling cover right under inner cowling right under cowling center under cowling body cowling left air intake pipe left under inner cowling left under cowling.

  • Page 254

    Chassis 6-3 front seat 23 n.M (2.3 kgf.M, 16.5 lb-ft) frame cover left under cowling right under cowling left under cowling heat shield no.1 left under cowling heat shield no.2 center under cowling heat shield no.1 center under cowling heat shield no.2 left under cowling heat shield no.3 center unde...

  • Page 255

    6-4 chassis fastener removal and reinstallation fastener a removal • depress the head of fasteners center piece 1 . • pull out the fastener. Installation • let the center piece stick out toward the head so that the pawls 2 close. • insert the fastener into the installation hole. Note: to prevent the...

  • Page 256

    Chassis 6-5 right and left under cowlings • remove the fastener. • remove the fastener. • with the bolts removed, remove the right under cowling. • disconnect the turn signal light coupler. • with the bolts removed, remove the left under cowling. • disconnect the turn signal light coupler. Body cowl...

  • Page 257

    6-6 chassis body cowling • remove the rear view mirrors, right and left, by removing the bolts. • remove the fasteners. • remove all the bolts. • disconnect the headlight coupler. Remounting note: when remounting the body cowling, install the hooks a to the cowling brace holes..

  • Page 258

    Chassis 6-7 right and left air intake pipes • remove the body cowling. • with the fastener removed, remove the right air intake pipe 1 . • with the fastener removed, remove the left air intake pipe 2 . Cowling brace removal • remove the body cowling. ( 6-6) • remove the cowling brace bolts and nut, ...

  • Page 259

    6-8 chassis front seat • with the bolts removed, remove the front seat. Rear seat and seat tail cover • remove the rear seat (seat tail cover) with the ignition key. Frame cover • remove the seats. • remove the bolts. • remove the fasteners. • disconnect the rear combination light coupler. • remove ...

  • Page 260: Front Wheel

    Chassis 6-9 front wheel construction 1 brake disc 2 dust seal 3 bearing 4 spacer 5 spacer nut 6 front wheel a front axle b brake disc bolt (front) ! Item n.M kgf.M lb-ft a 100 10.0 72.5 b 23 2.3 16.5.

  • Page 261

    6-10 chassis left right 25 n.M (2.5 kgf.M, 18.1 lb-ft) 25 n.M (2.5 kgf.M, 18.1 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 100 n.M (10.0 kgf.M, 72.5 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) left right left right clearance spacer.

  • Page 262

    Chassis 6-11 removal • remove the brake calipers, left and right. # do not operate the brake lever while removing the cali- pers. • loosen two axle pinch bolts 1 on the right front fork leg. • loosen the front axle 2 . • raise the front wheel off the ground and support the motor- cycle with a jack o...

  • Page 263

    6-12 chassis inspection and disassembly tire inspection: 6-71 • remove the brake disc. Brake disc inspection: 6-62 • remove both side dust seals by using the oil seal remover. [ [ [ [ [ 09913-50121: oil seal remover # the removed dust seals must be replaced with new ones. Axle shaft using a dial gau...

  • Page 264

    Chassis 6-13 • remove the wheel bearings by using the special tool a or b . [ 09921-20220: a bearing remover set or 09944-60210: b wheel bearing remover # the removed bearings should be replaced with new ones..

  • Page 265

    6-14 chassis reassembly and remounting reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: left right 25 n.M (2.5 kgf.M, 18.1 lb-ft) 25 n.M (2.5 kgf.M, 18.1 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 100 n.M (10.0 kgf.M, 72.5 lb-f...

  • Page 266

    Chassis 6-15 left right left right clearance spacer wheel bearing • apply grease to the wheel bearings. W 99000-25030: suzuki super grease “a” • install the wheel bearings as follows by using the special tools. [ 09941-34513: bearing/steering race installer set # first install the left wheel bearing...

  • Page 267

    6-16 chassis spacer nut after touching the flange of spacer nut being contact with the left front fork leg, tighten the two axle pinch bolts on the left front fork leg to the specified torque. ! Front axle pinch bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) wheel install the front wheel with the front axle a...

  • Page 268: Front Fork

    Chassis 6-17 front fork construction ! Item n.M kgf.M lb-ft a 35 3.5 25.5 b 20 2.0 14.5 c 23 2.3 16.5 d 35 3.5 25.5 e 18 1.8 13.0 1 spring adjuster bolt 2 o-ring 3 spring adjuster 4 rebound damping force adjuster 5 rubber seat 6 spacer 7 spring 8 oil flow pipe 9 inner rod/damper rod (cartridge) 0 ou...

  • Page 269

    6-18 chassis removal and disassembly • remove the body cowling. ( 6-6) • remove the front wheel. ( 6-11) • disconnect the brake hose from the brake hose guides on the front fender. • remove the front fender. • loosen the front fork upper clamp bolts 1 , left and right. • loosen the handlebar clamp b...

  • Page 270

    Chassis 6-19 • remove the damper rod bolt with a hexagon wrench. Note: if the damper rod turns with the damper rod bolt, hold the damper rod with the special tool. [ 09940-30221: front fork assembling tool • remove the front fork cap bolt from the inner rod by loosening the lock nut. • compress the ...

  • Page 271

    6-20 chassis • remove the inner rod/damper rod (cartridge) 1 and plate 2 . # do not disassemble the inner rod/damper rod (cartridge). • remove the dust seal 3 and the oil seal stopper ring 4 . • extract the outer tube from the inner tube. Note: be careful not to damage the inner tube. # the “anti-fr...

  • Page 272

    Chassis 6-21 front fork cap bolt disassembly • remove the spring adjuster stopper ring. • remove the spring adjuster bolt 1 and adjuster 2 . • remove the rebound damping force adjuster 3 . Inspection inner and outer tubes inspect the inner tube outer surface and outer tube inner sur- face for scratc...

  • Page 273

    6-22 chassis reassembly and remounting reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: tube metals and seals • hold the inner tube vertically and clean the metal groove and install the anti-friction metal by hand as shown....

  • Page 274

    Chassis 6-23 compression damping force adjuster • tighten the compression damping force adjuster to the speci- fied torque. ! Compression damping force adjuster: 18 n.M (1.8 kgf.M, 13.0 lb-ft) # the removed o-ring must be replaced with a new one. Damper rod bolt insert the inner rod/damper rod (cart...

  • Page 275

    6-24 chassis fork oil • place the front fork vertically without spring. • compress it fully. • pour specified front fork oil up to the top level of the outer tube. • refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until no ...

  • Page 276

    Chassis 6-25 fork spring • install the fork spring as shown in the illustration. Front fork cap bolt • adjust the height a of the rebound damping force adjuster at 1.5 mm (0.06 in). • install the rebound damping force adjuster housing to the cap bolt. • install the spring adjuster bolt and its stopp...

  • Page 277

    6-26 chassis • install the front fork cap bolt to the outer tube temporarily. • set the upper surface of the outer tube at 4.0 mm (0.16 in) height a from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts to the speci- fied torque. ! Front fork lower cl...

  • Page 278

    Chassis 6-27 suspension setting after installing the front fork, adjust the spring pre-load and damp- ing force as follows. Spring pre-load adjustment there are seven grooved lines on the side of the spring ad- juster. Position 0 provides the maximum spring pre-load and position 7 provides the minim...

  • Page 279: Steering Damper

    6-28 chassis steering damper construction 1 steering damper 2 dust seal ! Item n.M kgf.M lb-ft a 23 2.3 16.5 b 23 2.3 16.5 removal • remove the body cowling cover. ( 6-6) • with the nut a held immovable, remove the nut 1 . • with the bolt 2 removed, remove the steering damper. Inspection inspect the...

  • Page 280: Steering

    Chassis 6-29 steering construction removal and disassembly • remove the right and left under cowlings. ( 6-5) • remove the front wheel. ( 6-11) • remove the front fork. ( 6-18) ! Item n.M kgf.M lb-ft a 90 9.0 65.0 b 80 8.0 58.0 c 23 2.3 16.5 d 23 2.3 16.5 e 10 1.0 7.0 f 23 2.3 16.5 1 steering stem u...

  • Page 281

    6-30 chassis • remove the left and right handlebars by removing its set bolts. • remove the left and right handlebar switch lead wires from the guide. Note: place the rags under each handlebar to prevent scratching the upper fairing and the air intake pipes. • remove the steering stem upper bracket ...

  • Page 282

    Chassis 6-31 inspection and disassembly inspect the removed parts for the following abnormalities. * handlebars distortion * race wear and brinelling * bearing wear or damage * abnormal noise of bearing if any abnormal points are found, replace defective parts with the new ones. • remove the steerin...

  • Page 283

    6-32 chassis bearing • apply grease to the bearings and bearing races. W w w w w 99000-25030: suzuki super grease “a” • install the lower bearing to the steering stem lower bracket. • install the upper bearing and bearing inner race. 1/4 – 1/2 turn stem nut • install the dust seal. • tighten the ste...

  • Page 284

    Chassis 6-33 front fork and steering stem upper bracket install the front fork and steering stem upper bracket following steps: 1) install the upper bracket, washer 1 and steering stem head nut 2 temporarily. 2) set the front forks and tighten the steering stem head nut 2 . ! ! ! ! ! Steering stem h...

  • Page 285: Handlebar

    6-34 chassis handlebar construction removal and disassembly right handlebar • remove the brake master cylinder 1 . ( 6-63) • remove the right handle switch 2 . • with the screw removed, remove the handle balancer 3 . • remove the right handle grip 4 . Left handlebar • remove the clutch cable 1 . • r...

  • Page 286

    Chassis 6-35 • remove the handlebar set bolts. • with the handlebar clamp bolts and steering stem head nut loosened, remove the steering stem upper bracket. • with the handlebar clamp bolts loosened, draw out the handle- bars to upward. Reassembly and remounting reassemble and remount the handlebar ...

  • Page 287

    6-36 chassis • tighten the handlebar set bolts and handlebar clamp bolts. ! Handlebar set bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) handlebar clamp bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) • when remounting the clutch lever holder, align the holder’s mating surface with punch mark a on the handlebar. • when r...

  • Page 288: Rear Wheel

    Chassis 6-37 rear wheel construction 1 rear axle 2 caliper bracket 3 brake disc 4 collar 5 bearing 6 rear wheel 7 spacer 8 bearing 9 cushion 0 spacer a sprocket drum b sprocket c bearing d dust seal e collar a brake disc bolt b rear sprocket nut c rear axle nut ! Item n.M kgf.M lb-ft a 35 3.5 25.5 b...

  • Page 289

    6-38 chassis 120 n.M (12.0 kgf.M, 86.8 lb-ft) left right 110 n.M (11.0 kgf.M, 79.6 lb-ft) 35 n.M (3.5 kgf.M, 25.5 lb-ft) 26 n.M (2.6 kgf.M, 19.0 lb-ft) 7.5 n.M (0.75 kgf.M, 5.5 lb-ft) for e-03, 28, 33 for the others left right left right spacer clearance bearing installer.

  • Page 290

    Chassis 6-39 removal • remove the cotter pin. (for canada and usa) • loosen the axle nut. • raise the rear wheel off the ground and support the motor- cycle with a jack or wooden block. • remove the axle nut and draw out the rear axle. • remove the rear wheel by disengaging the drive chain. # do not...

  • Page 291

    6-40 chassis • remove the collar 1 . • remove the brake disc. Inspection and disassembly tire inspection: 2-25 and 6-71 wheel inspection: 6-11 and 71 rear axle using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. Axle shaft runout: service limit...

  • Page 292

    Chassis 6-41 bearings inspect the play of the wheel and sprocket mounting drum bear- ings by hand while they are in the wheel and drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. • remove the sprocket mounting dr...

  • Page 293

    6-42 chassis reassembly and remounting reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: 120 n.M (12.0 kgf.M, 86.8 lb-ft) left right 110 n.M (11.0 kgf.M, 79.6 lb-ft) 35 n.M (3.5 kgf.M, 25.5 lb-ft) 26 n.M (2.6 kgf.M, 19.0 lb-...

  • Page 294

    Chassis 6-43 left right left right spacer clearance bearing installer bearings • apply grease to the bearings before installing. W w w w w 99000-25030: suzuki super grease “a” • install the new bearing to the sprocket mounting drum using the special tool. [ [ [ [ [ 09924-84510: bearing installer set...

  • Page 295

    6-44 chassis dust seals • install the new dust seal using proper drift. • apply grease to the dust seal lip before assembling rear wheel. W w w w w 99000-25030: suzuki super grease “a” brake disc • apply thread lock super “1360” to the disc bolts and tighten them to the specified torque. Note: make ...

  • Page 296

    Chassis 6-45 rear axle • remount the rear wheel and rear axle shaft, install the washer 1 and rear axle nut 2 . • adjust the chain slack after rear wheel installation. ( 2-20) • tighten the rear axle nut 2 to the specified torque. ! ! ! ! ! Rear axle nut: 110 n.M (11.0 kgf.M, 79.6 lb-ft) [for e-03, ...

  • Page 297: Rear Shock Absorber

    6-46 chassis rear shock absorber construction 1 rear shock absorber 2 height adjuster a rear shock absorber mounting bolt/nut b height adjuster nut ! Item n.M kgf.M lb-ft a 50 5.0 36.0 b 115 11.5 83.2 left right.

  • Page 298

    Chassis 6-47 removal • support the motorcycle with a jack to be no load for the rear shock absorber. • remove the rear cushion lever bolt and nut. • remove the rear shock absorber lower mounting bolt and nut. • take out the rear shock absorber to downward. Inspection inspect the shock absorber body ...

  • Page 299

    6-48 chassis rear shock absorber scrapping procedure " * handle the rear shock absorber with caution since a high pressure nitrogen gas is contained. * avoid incineration, exposure to high pressure or over- hauling. * in the case of scrapping the rear shock absorber, evacuate gas in the following pr...

  • Page 300

    Chassis 6-49 suspension setting after installing the rear suspension, adjust the spring pre-load and damping force as follows. Spring pre-load adjustment the set length 186.5 mm provides the maximum spring pre- load. The set length 196.5 mm provides the minimum spring pre-load. (std length: 191.5 mm...

  • Page 301

    6-50 chassis rear suspension construction ! Item n.M kgf.M lb-ft a 50 5.0 36.0 b 78 7.8 56.5 c 78 7.8 56.5 d 15 1.5 11.0 e 90 9.0 65.0 f 100 10.0 72.5 g 34 3.4 24.6 h 28 2.8 20.0 1 rear shock absorber 2 rear cushion rod 3 rear cushion lever 4 spacer 5 bearing 6 dust seal 7 torque link 8 chain cover ...

  • Page 302

    Chassis 6-51 left right 50 n.M (5.0 kgf.M, 36.0 lb-ft) 78 n.M (7.8 kgf.M, 56.5 lb-ft) 100 n.M 10.0 kgf.M 72.5 lb-ft ( ( 90 n.M 9.0 kgf.M 65.0 lb-ft ( ( 15 n.M 1.5 kgf.M 11.0 lb-ft ( (.

  • Page 303

    6-52 chassis removal • raise the rear wheel off the ground and support the motor- cycle with a jack or a wooden block. • remove the rear wheel. ( 6-39) • remove the side-stand. ( 8-26) • remove the brake hose from the brake hose guides at inside of swingarm. • cut the drive chain. ( 6-76) note: it i...

  • Page 304

    Chassis 6-53 • remove the swingarm pivot shaft lock nut by using the special tool. [ [ [ [ [ 09940-14970: swingarm pivot thrust adjuster socket wrench • hold the swingarm pivot shaft 1 with a 27 mm socket wrench and remove the swingarm pivot nut 2 with a 36 mm socket wrench. • remove the swingarm pi...

  • Page 305

    6-54 chassis inspection and disassembly spacer • remove the spacers from swingarm. • remove the spacers from the cushion lever. • inspect the spacers for any flaws or other damage. If any de- fects are found, replace the spacers with new ones. Swingarm bearing insert the spacer into bearing and chec...

  • Page 306

    Chassis 6-55 cushion lever bearing insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • draw out the cushion lever bearings with the special tool. [ [ [ [ [ 09921-20220: bearing remover set # the remov...

  • Page 307

    6-56 chassis left right 50 n.M (5.0 kgf.M, 36.0 lb-ft) 78 n.M (7.8 kgf.M, 56.5 lb-ft) 100 n.M 10.0 kgf.M 72.5 lb-ft ( ( 90 n.M 9.0 kgf.M 65.0 lb-ft ( ( 15 n.M 1.5 kgf.M 11.0 lb-ft ( ( reassembly reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following p...

  • Page 308

    Chassis 6-57 swingarm bearing • press the bearing into the swingarm pivot by using the special tool. [ 09941-34513: steering race installer • press the swingarm cushion rod upper side bearing with the special tool. [ 09941-34513: steering race installer note: when reinstalling the bearing, stamped m...

  • Page 309

    6-58 chassis • assemble the cushion rod onto the swingarm. ( 6-58) ! ! ! ! ! Cushion rod mounting nut: 78 n.M (7.8 kgf.M, 56.5 lb-ft) • install the torque link and tighten the rear torque link nut. ! Torque link nut (front): 28 n.M (2.8 kgf.M, 20.0 lb-ft) remounting remount the swingarm in the rever...

  • Page 310

    Chassis 6-59 shock absorber and cushion lever mounting nut • install the washers a and cushion lever. ! ! ! ! ! Cushion lever mounting nut: 78 n.M (7.8 kgf.M, 56.5 lb-ft) drive chain • connect the drive chain. ( 6-78) torque link • tighten the rear torque link nuts to the specified torque. ! ! ! ! !...

  • Page 311: Front Brake

    6-60 chassis front brake construction 1 front brake lever 2 dust boot 3 piston set 4 piston set (trailing) 5 piston set (leading) 6 brake pad 7 brake pad spring 8 pad mounting pin 9 brake hose 0 brake hose a front master cylinder mounting bolt b brake hose union bolt c caliper mounting bolt d calipe...

  • Page 312

    Chassis 6-61 brake pad replacement • remove the spring 1 . • remove the brake pads by removing the clip 2 and pad mount- ing pin 3 . # * do not operate the brake lever while dismounting the pads. * replace the brake pads as a set, otherwise braking performance will be adversely affected. • install t...

  • Page 313

    6-62 chassis caliper removal and disassembly • remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle. Note: place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. • remove the brake caliper by removi...

  • Page 314

    Chassis 6-63 dust seal piston seal caliper body • remove the dust seals and piston seals. # do not reuse the dust seals and piston seals to pre- vent fluid leakage. Caliper inspection brake caliper inspect the brake caliper cylinder wall for nicks, scratches or other damage. Brake caliper piston ins...

  • Page 315

    6-64 chassis • tighten each bolt to the specified torque. ! ! ! ! ! Front brake caliper housing bolt 1 : 21 n.M (2.1 kgf.M, 15.1 lb-ft) front brake caliper mounting bolt 2 : 25 n.M (2.5 kgf.M, 18.1 lb-ft) front brake hose union bolt 3 : 23 n.M (2.3 kgf.M, 16.5 lb-ft) note: before remounting the cali...

  • Page 316

    Chassis 6-65 master cylinder removal and disassembly • disconnect the front brake light switch lead wires. • place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid. Remove the union bolt and dis- connect the brake hose. # immediately and completely wipe off any b...

  • Page 317

    6-66 chassis • pull out the dust boot 1 and remove the circlip 2 . [ [ [ [ [ 09900-06108: snap ring pliers. • remove the piston/secondary cup, primary cup and return spring. 3 secondary cup 4 piston 5 primary cup 6 return spring • remove the circlip 7 , connector 8 and o-ring 9 . Master cylinder ins...

  • Page 318

    Chassis 6-67 master cylinder handlebars upper clamp bolt "up"mark clearance punched mark • when remounting the brake master cylinder onto the handle- bar, align the master cylinder holder’s mating surface with punched mark a on the handlebar and tighten the upper clamp bolt first as shown. ! ! ! ! !...

  • Page 319: Rear Brake

    6-68 chassis rear brake construction ! Item n.M kgf.M lb-ft a 8 0.8 6.0 b 23 2.3 16.5 c 25 2.5 18.1 d 10 1.0 7.0 e 18 1.8 13.0 f 30 3.0 21.5 " * this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum...

  • Page 320

    Chassis 6-69 brake pad replacement • remove the brake pad cover. • remove the clip 1 . • remove the brake pads along with the shims by removing the brake pad mounting pins 2 and springs 3 . # * do not operate the brake pedal while dismounting the pads. * replace the brake pads as a set, otherwise br...

  • Page 321

    6-70 chassis caliper removal and disassembly • remove the union bolt 1 and catch the brake fluid in a suitable receptacle. # never reuse the brake fluid left over from previous ser- vicing and stored for long periods. " brake fluid, if it leaks, will interfere with safe running and discolor painted ...

  • Page 322

    Chassis 6-71 dust seal piston seal caliper body caliper inspection caliper inspection: 6-63 piston: 6-63 disc: 6-64 service limit: rear disc thickness: 4.5 mm (0.18 in) rear disc runout: 0.30 mm (0.012 in) caliper reassembly and remounting reassemble and remount the caliper in the reverse order of r...

  • Page 323

    6-72 chassis master cylinder removal and disassembly • remove the frame cover. ( 6-8) • remove the brake fluid reservoir tank mounting bolt 1 . • remove the reservoir cap and diaphragm. • remove the connector by removing the screw. • remove the o-ring 6 . # replace the o-ring with a new one. • pull ...

  • Page 324

    Chassis 6-73 master cylinder inspection cylinder, piston and cup set inspect the cylinder bore wall for any scratches or other damage. Inspect the cup set and each rubber part for damage. Master cylinder reassembly and remounting reassemble and remount the master cylinder in the reverse or- der of r...

  • Page 325: Tire And Wheel

    6-74 chassis tire and wheel tire 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 efficient as well as functional. For...

  • Page 326

    Chassis 6-75 seal valve hole wheel valve lip valve valve inspection inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal rubber is peeling or has dam- age. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the v...

  • Page 327

    6-76 chassis rim line • when installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the time of removal with the valve position. • for installation procedure of tire onto the wheel, follow the instructions given by...

  • Page 328: Drive Chain

    Chassis 6-77 drive chain use the special tool in the following procedures, to cut and re- join the drive chain. [ [ [ [ [ 09922-22711: drive chain cutting and joining tool set note: when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Drive chain c...

  • Page 329

    6-78 chassis (f520) rear wheel side • place the drive chain link being disjointed on the holder part 8 of the tool. • turn in both the adjuster bolt 6 and pressure bolt “a” 3 so that each of their end hole fits over the chain joint pin properly. • tighten the pressure bolt “a” 3 with the bar. • turn...

  • Page 330

    Chassis 6-79 • apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0 . Note: when positioning the joint plate 0 on the tool, face its stamp mark on the joint plate holder 3 side. • set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 to ...

  • Page 331

    6-80 chassis • stake the joint pin by turning (approximately 7/8 turn) the pres- sure bolt “a” 3 with the bar until the pin end diameter becomes the specified dimension. Pin end diameter specification d rk 5.45 – 5.85 mm (0.215–0.230 in) # * after joining of the chain has been completed, check to ma...

  • Page 332: Electrical System

    Electrical system 7-1 7 electrical system contents cautions in servicing ............................................................... 7- 2 location of electrical components ................................ 7- 4 charging system .........................................................................

  • Page 333: Cautions In Servicing

    7-2 electrical system cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock before disconnecting it ...

  • Page 334

    Electrical system 7-3 battery • the mf battery used in this vehicle does not require mainte- nance as inspection of electrolyte level and replenishment of water. • no hydrogen gas is produced during normal charging of the battery, but such gas may be produced when it is overcharged. Therefore, do no...

  • Page 335

    7-4 electrical system location of electrical components 1 battery 2 ecm (engine control module) 3 tip over sensor ( 4-44) 4 fuel pump relay 5 secondary valve actuator 6 throttle position sensor 7 intake air temp. Sensor 8 ignition switch 9 front brake switch 0 handlebar switch (r) a rear brake switc...

  • Page 336

    Electrical system 7-5 b cooling fan thermo-switch ( 5-6) c cooling fan ( 5-5) d intake air pressure sensor ( 4-36) e engine coolant temp. Sensor ( 5-8) f injection g generator h speedometer sensor i gear position switch j side-stand switch 1 clutch lever position switch 2 handlebar switch (l) 3 cams...

  • Page 337: Charging System

    7-6 electrical system generator regulator / rectifier scr ic ig.Switch load batter y generator regulator / rectifier ic scr ig.Switch load batter y charging system description the circuit of the charging system is indicated in the figure, which is composed of the generator, regulator/ rectifier unit...

  • Page 338

    Electrical system 7-7 generator regulator / rectifier ig.Switch scr ic load batter y when the engine r/min becomes higher, the generated voltage of the generator also becomes higher and the voltage between the battery terminals becomes high accordingly. When it reaches the adjusted voltage of the i....

  • Page 339

    7-8 electrical system troubleshooting battery runs down quickly. Check accessories which use excessive accessories • remove accessories. Amounts of electricity. Are installed no accessories check the battery for current current leaks • short circuit of wire harness leaks. ( 7-9) • loose or disconnec...

  • Page 340

    Electrical system 7-9 inspection battery current leak inspection • remove the front seat. ( 6-8) • turn the ignition switch to the off position. • disconnect the battery _ lead wire. • connect the multi circuit tester between the _ terminal and _ lead wire of the battery. Note: leakage is evident if...

  • Page 341

    7-10 electrical system b/w b 1 b 1 b 3 b 2 b/r generator coil resistance inspection • remove the frame cover. ( 6-8) • disconnect the generator coupler. Measure the resistance between the three lead wires. Also check that the stator core is insulated. If the resistance is not specified value, replac...

  • Page 342

    Electrical system 7-11 gear position switch side-stand switch to ecm and ignition coils engine stop switch o/b o/w turn signal/ side-stand relay bi g b/o fuse o ignition switch r fuse fuse r battery neutral indicator light bi/b starter motor starter relay b/y to ecm and ignition coil o/w y/g clutch ...

  • Page 343

    7-12 electrical system the circuit consists of the turn signal/side-stand relay, neutral indicator light, gear position switch and side- stand switch. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side-stand is either up or down...

  • Page 344

    Electrical system 7-13 trouble shooting starter motor will not run. The transmission is in neutral. Grasp the check if the starter motor runs clutch lever, turn on the ignition switch when its terminal is connected with the engine stop switch in the “run” clicks to the battery + terminal (do positio...

  • Page 345

    7-14 electrical system 10 n.M (1.0 kgf.M, 7.0 lb-ft) starter motor removal and disassembly • disconnect the starter motor lead wire. ( 3-6) • remove the starter motor. ( 3-16) • disassemble the starter motor as shown in the illustration. Starter motor inspection carbon brush inspect the brushes for ...

  • Page 346

    Electrical system 7-15 commutator inspect the commutator for discoloration, abnormal wear or un- dercut a . If the commutator is abnormally worn, replace the armature. When surface is discolored, polish it with #400 sand paper and clean it with dry cloth. If there is no undercut, scrape out the insu...

  • Page 347

    7-16 electrical system starter relay inspection • remove the front seat and frame cover. ( 6-8) • disconnect the battery _ lead wire, and starter relay cover 1 . Apply 12 volts to a and b terminals, inspect the continuity be- tween the terminals, positive and negative. If continuity is found, the st...

  • Page 348

    Electrical system 7-17 side-stand/ignition interlock system part inspection if the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one. Side-stand switch the side-stand switch coupler is located behind the left upper fai...

  • Page 349

    7-18 electrical system gear position switch • lift the fuel tank. ( 4-51) • disconnect the gear position switch lead wire and check the continuity between blue and black/white with the transmission in “neutral”. 09900-25008: multi circuit tester set tester knob indication: continuity test ( ) when d...

  • Page 350

    Electrical system 7-19 turn signal/side-stand relay removal the turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode. • remove the turn signal/side-stand relay. Side-stand relay inspection first check the insulation between d and e terminals with the ...

  • Page 351: Ignition System

    7-20 electrical system ignition system description the ignition system is controlled by the ecm. The system is called fully transistorized ignition system which decides accurate ignition timing according to the engine rpm, gear position and throttle position. The ignition system has four ignition co...

  • Page 352

    Electrical system 7-21 ecm throttle position sensor engine coolant temp. Sensor gear position switch engine stop switch side- stand relay fuse ignition switch battery wave form arrangement circuit wave form arrangement circuit cpu power source circuit ckp sensor cam position sensor #1 #2 #3 #4 note:...

  • Page 353

    7-22 electrical system troubleshooting * check that the transmission is in neutral and the no spark or poor spark 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. Check the ignition system couple...

  • Page 354

    Electrical system 7-23 new spark plug contact to the cylinder head inspection ignition coil primary peak voltage • remove the air cleaner box. ( 4-61) • disconnect all the ignition coil/plug cap lead wire couplers be- fore removing the ignition coil/plug caps. • remove all of the ignition coil/plug ...

  • Page 355

    7-24 electrical system peak volt adaptor ecm ig coil to engine stop switch inspect each ignition coil primary peak voltage at the ignition coil/plug cap coupler. • connect the multi circuit tester with peak voltage adaptor as follows. No.1 ignition coil/plug cap: w/bl terminal ( + probe) – ground ( ...

  • Page 356

    Electrical system 7-25 ignition coil/plug cap resistance • check the ignition coil/plug cap for resistance in both primary and secondary windings. If the resistance is not within the stan- dard range, replace the ignition coil/plug cap with a new one. 09900-25008: multi circuit tester set tester kno...

  • Page 357

    7-26 electrical system ckp sensor ckp sensor coupler ecm coupler peak volt adaptor ckp sensor peak voltage • remove the front seat. ( 6-8) note: be sure that all couplers are connected properly and the battery used is in fully-charged condition. • connect the multi circuit tester with peak volt adap...

  • Page 358

    Electrical system 7-27 ckp sensor peak volt adaptor ckp sensor coupler ckp sensor ckp sensor coupler • lift up the fuel tank. ( 4-51) • disconnect the ckp sensor lead wire coupler and connect the multi circuit tester with the peak volt adaptor. Green ( + probe) – blue ( - probe) • measure the ckp se...

  • Page 359: Combination Meter

    7-28 electrical system adjust switch tachometer speedometer engine coolant temp. /fi odo/trip 1/trip 2/clock select switch led : led (speedometer light) led stepping motor lcd combination meter description this combination meter mainly consists of the stepping motor, lcd (liquid crystal display) and...

  • Page 360

    Electrical system 7-29 crank position sensor ecm stator rotor distribution circuit exciter circuit angle position sensor coil stepping motor the following contents and illustration shows the explanation of stepping motor’s basic principle by using a simple structure. Tachometer is driven by stepping...

  • Page 361

    7-30 electrical system stepping motor operation step.1) when current is sent only through circuit b , the magnetic force is equilibrated and causes the rotor to stay at position b . Step.2) when the same amount of current as circuit b is sent also through circuit a , the rotor turns 15° counterclock...

  • Page 362

    Electrical system 7-31 removal • remove the screw 1 . • draw out the hook 2 from the body cowling. • disconnect the lead wire coupler. • remove the combination meter. When disconnecting and connecting the combination meter coupler, make sure to turn off the ignition switch, or electronic parts may g...

  • Page 363

    7-32 electrical system pointer inspection led (light emitting diode) check that the led lights immediately after turning the ignition switch on. If the led fails in operation, replace the combination meter unit with a new one after checking its wire harness/coupler. Stepping motor check that the poi...

  • Page 364

    Electrical system 7-33 variable resister engine coolant temp. Sensor engine coolant temperature meter and indicator engine coolant temp. Sensor inspection: 5-8 • lift up the fuel tank. ( 4-51) • disconnect the engine coolant temp. Sensor coupler 1 . When connecting and disconnecting the engine cool-...

  • Page 365

    7-34 electrical system on test bulb battery on test bulb battery off test bulb water battery off test bulb water battery fuel level indicator switch inspection • remove and disassemble the fuel pump assembly. ( 4- 55) • connect 12 v battery and test bulb (12 v, 3.4 w) to the fuel level indicator swi...

  • Page 366

    Electrical system 7-35 to oil pressure switch b b/r speedometer if the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of cou- plers. If the speedometer sensor and connection are all right, replace the meter with a new one. Speedometer se...

  • Page 367: Lamps

    7-36 electrical system lamps headlight bulb replacement • disconnect the socket 1 and the rubber cap 2 . • remove the bulb by removing the bulb holder spring. • reassemble the headlight bulb in the reverse order of removal. Headlight bulb 1 : 55w (h7) 2 : 55w (h7) lo: 1 hi: 1 + 2 position light bulb...

  • Page 368

    Electrical system 7-37 brake light/taillight and turn signal light bulb replacement • remove the lens. • remove the brake light/taillight bulb by turning it counterclock- wise. • reassemble the brake light/taillight bulb in the reverse order of removal. • remove the screw and take off the lens. • re...

  • Page 369

    7-38 electrical system turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Inspection before removing the turn signal/side-stand relay, check the op- eration of the turn signal light. If the turn signal light does not illumi...

  • Page 370

    Electrical system 7-39 inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Ignition switch (for e-24) o/w r o o/y b/w on off lock color position (for others) o/w r o o/y b/w gr br on off lock p color position lighting...

  • Page 371: Battery

    7-40 electrical system battery specifications type designation yt12a-bs capacity 12v, 36 kc (10 ah)/10hr initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes. • remove the caps 2 . Note: * after filling the electrolyte completely, use the rem...

  • Page 372

    Electrical system 7-41 correct incorrect note: if no air bubbles are coming up from a filler port, tap the bottom of the two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from...

  • Page 373

    7-42 electrical system recharging operation • using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0v (dc), recharge the bat- tery with a battery charger. * when recharging the battery, remove the battery from the motorcycle. * do not remove the caps ...

  • Page 374: Servicing Information

    Servicing information 8-1 8 troubleshooting ...................................................................... 8- 2 fi system malfunction code and defective condition .............................................................. 8- 2 engine .........................................................

  • Page 375: Troubleshooting

    8-2 servicing information troubleshooting fi system malfunction code and defective condition malfunction code c00 c11 c12 c13 c14 c15 c21 c22 c23 c24, c25, c26 or c27 detected item no fault camshaft position sensor crankshaft position sensor intake air pressure sensor throttle position sensor engine...

  • Page 376

    Servicing information 8-3 the position sensor of the stv actuator produces following voltage. (0.1 sensor voltage 4.9) without the above value, c28 is indicated. Stva motor can not move. Stv actuator, stv actuator adjustment, lead wire/coupler. Gear position signal voltage should be higher than the ...

  • Page 377

    8-4 servicing information engine complaint symptom and possible causes remedy engine will not start, compression too low or is hard to start. 1. Out of adjustment valve clearance. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3. Mistiming valves. Adjust. 4. Excessively w...

  • Page 378

    Servicing information 8-5 complaint symptom and possible causes remedy engine idles poorly. 1. Out of adjustment valve clearance. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn down camshaft. Replace. 5. Too wide spark plug gaps. Adjust or replace. ...

  • Page 379

    8-6 servicing information complaint symptom and possible causes remedy noisy engine. Excessive valve chatter 1. Too large valve clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace. Noise seems to come fr...

  • Page 380

    Servicing information 8-7 complaint symptom and possible causes remedy engine runs poorly defective air flow system in high speed range. 1. Clogged air cleaner element. Clean or replace. 2. Defective throttle valve. Adjust or replace. 3. Defective secondary throttle valve. Adjust or replace. 4. Suck...

  • Page 381

    8-8 servicing information complaint symptom and possible causes remedy engine overheats. Defective engine internal parts 1. Heavy carbon deposit on piston crowns. Clean. 2. Not enough oil in the engine. Add oil. 3. Defective oil pump or clogged oil circuit. Replace or clean. 4. Sucking air from inta...

  • Page 382

    Servicing information 8-9 radiator (cooling system) complaint symptom and possible causes remedy engine overheats. 1. Not enough engine coolant. Add coolant. 2. Clogged with dirt or trashes radiator core. Clean. 3. Faulty cooling fan. Repair or replace. 4. Defective cooling fan thermo-switch. Replac...

  • Page 383

    8-10 servicing information chassis complaint symptom and possible causes remedy heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance...

  • Page 384

    Servicing information 8-11 brakes complaint symptom and possible causes remedy insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace. Power. 2. Worn pads. Replace. 3. Oil adhesion of engaging surface of pads/shoe. Clean disc and pads. 4. Worn disc. Replace. 5. Air in ...

  • Page 385

    8-12 servicing information electrical complaint symptom and possible causes remedy no sparking or poor 1. Defective ignition coil/plug cap or camshaft replace. Sparking. Position sensor. 2. Defective spark plugs. Replace. 3. Defective crankshaft position sensor. Replace. 4. Defective ecm. Replace. 5...

  • Page 386

    Servicing information 8-13 battery complaint symptom and possible causes remedy “sulfation”, acidic 1. Cracked battery case. Replace the battery. White powdery sub- 2. Battery has been left in a run-down condition for replace the battery. Stance or spots on a long time. Surface of cell plates. Batte...

  • Page 387

    8-14 servicing information wiring harness, cable and hose routing wiring harness routing install the wiring harness to left side of headlight, and not to be loosely. Clamp clamp clamp to the frame. Inside of the body cowling inside of the under cowling wiring harness wiring harness handle switch (l,...

  • Page 388

    Servicing information 8-15 clamp clamp to the frame. Clamp handle switch (l, r) ignition switch handle switch (l, r) clamp handle switch (l, r) ignition switch clamp guide wiring harness fan motor clamp wiring harness fan motor clamp to the frame clamp clamp clamp clamp wiring harness clamp fan moto...

  • Page 389

    8-16 servicing information clamp gear position sensor gear position sensor star ter motor ground lead wire 90° 45° 5 n . M (0.5 kgf . M, 3.6 lb-ft) 10 n . M (1.0 kgf . M, 7.0 lb-ft) gener ator gener ator clamp 45° clamp ckp sensor ckp sensor oil pressure s witch oil pressure s witch clamp 1.5 n . M ...

  • Page 390

    Servicing information 8-17 throttle no .2 cab le (retur n) throttle no .2 cab le (retur n) throttle no .2 cab le (retur n) throttle no .2 cab le (retur n) throttle no .1 cab le throttle no .1 cab le throttle no .1 cab le throttle no .1 cab le f ast idle cab le f ast idle cab le f ast idle cab le f a...

  • Page 391

    8-18 servicing information fuel tank drain hose routing f ace the clamp to do wnside . Fuel tank dr ain hose.

  • Page 392

    Servicing information 8-19 cooling system hose routing : the ends of the clamp f ace .... : the clamp bolt head f ace .... Do wn side mar king align the mar king with the lib of pipe . Left side rear side left side right side rear side left side rear side left side rear side rear side f ront side f ...

  • Page 393

    8-20 servicing information front brake hose routing clamp the br ak e hose fir mly . 42˚ 42˚ 42˚ after touching the br ak e hose unions to the stopper , tighten the union bolts . After touching the br ak e hose unions to the stopper , tighten the union bolts . Clamp the br ak e hose fir mly . After ...

  • Page 394

    Servicing information 8-21 rear brake hose routing after touching the br ak e hose union to the stopper , tighten the union bolt. After touching the br ak e hose union to the stopper , tighten the union bolt. After touching the br ak e hose union to the stopper , tighten the union bolt. F ace the cl...

  • Page 395

    8-22 servicing information pair (air supply) system hose routing pair valve vacuum hose (530 mm) pair valve 10 n.M (1.0 kgf.M, 7.5 lb-ft) pair reed valve pair valve hose l (30 mm) matching mark pair cleaner hose pair valve hose r (50 mm) to throttle body (no.4 cylinder) air cleaner box 1.

  • Page 396: Fuel Tank  Set-Up

    Servicing information 8-23 fuel tank set-up 23 n . M (2.3 kgf . M, 16.5 lb-ft) heat shield align the front end of the heat shield with rear end of the br ac k et. Inner side 13 n . M (1.3 kgf . M, 9.5 lb-ft) adhere adhere adhere.

  • Page 397: Cowling Set-Up

    8-24 servicing information cowling set-up right air intak e pipe co wling br ace 23 n . M (2.3 kgf . M, 16.5 lb-ft) wind screen body co wling co v e r right under inner co wling right under co wling center under co wling body co wling left air intak e pipe left under inner co wling left under co wli...

  • Page 398: Frame Cover Set-Up

    Servicing information 8-25 left under cowling right under cowling left under cowling heat shield no.1 left under cowling heat shield no.2 center under cowling heat shield no.1 center under cowling heat shield no.2 left under cowling heat shield no.3 center under cowling right under cowling heat shie...

  • Page 399: Side-Stand Set-Up

    8-26 servicing information 40 n.M (4.0 kgf.M, 28.9 lb-ft) 50 n.M (5.0 kgf.M, 36.2 lb-ft) side-stand set-up gearshift pedal set-up footrest 52 – 62 mm (2.05 – 2.44 in).

  • Page 400: Special Tools

    Servicing information 8-27 special tools 09900-06104 snap ring pliers 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25–50 mm) 09900-20204 micrometer (75–100 mm) 09900-20205 micrometer (0–25 mm) 09900-20508 cylinder gauge se...

  • Page 401

    8-28 servicing information 09915-74540 oil pressure gauge adaptor 09915-77330 meter (for high pressure) 09916-10911 valve lapper set 09916-14510 valve spring compressor 09916-14521 valve spring compressor attachment 09916-21111 valve seat cutter set 09916-20630 valve seat cutter head (n-126) 09916-2...

  • Page 402

    Servicing information 8-29 09930-11960 torx wrench 09930-30450 rotor remover 09930-44520 rotor holder 09930-82710 mode selection switch 09940-14911 steering stem nut wrench 09940-14960 steering nut wrench socket 09940-14970 swingarm pivot shaft lock nut socket wrench 09940-14990 engine mounting thru...

  • Page 403: Tightening Torque

    8-30 servicing information tightening torque engine item n.M kgf.M lb-ft exhaust pipe bolt 23 2.3 16.5 muffler mounting nut 23 2.3 16.5 speed sensor rotor bolt 20 2.0 14.4 engine sprocket nut 115 11.5 83.2 engine mounting bolt and nut (m:12) 75 7.5 54.0 (m:10) 55 5.5 39.8 engine mounting thrust adju...

  • Page 404

    Servicing information 8-31 item n.M kgf.M lb-ft piston cooling oil jet bolt 10 1.0 7.0 oil pump mounting bolt 10 1.0 7.0 conrod bearing cap bolt (initial) 15 1.5 11.0 (final) 90° ( µ turn) bearing retainer screw 10 1.0 7.0 breather cover bolt 10 1.0 7.0 oil strainer bolt 10 1.0 7.0 oil pan bolt 10 1...

  • Page 405

    8-32 servicing information chassis item n.M kgf.M lb-ft steering stem head nut 90 9.0 65.0 steering stem lock nut 80 8.0 58.0 steering damper bolt and nut 23 2.3 16.6 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 23 2.3 16.5 front fork cap bolt 35 3.5 25.5 front fork inner rod ...

  • Page 406

    Servicing information 8-33 tightening torque chart for other bolts and nuts listed previously, refer to this chart: bolt diameter conventional or “4” marked bolt “7” marked bolt a (mm) 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 1.0 7.0 8 13...

  • Page 407: Service Data

    8-34 servicing information item std/spec. Limit in. Ex. 29 (1.14) 24 (0.94) valve diam. ——— ——— ——— in. Ex. 0.010 – 0.037 (0.0004 – 0.0015) 0.030 – 0.057 (0.0012 – 0.0022) valve guide to valve stem clearance ——— ——— valve clearance (when cold) in. & ex. Valve guide i.D. 0.35 (0.014) in. 3.975 – 3.99...

  • Page 408

    Servicing information 8-35 item std/spec. Limit ——— camshaft journal o.D. 23.959 – 23.980 (0.9433 – 0.9441) ——— camshaft runout 0.10 (0.004) 14th pin cam chain pin (at arrow “3”) cylinder head distortion ——— ——— cylinder + piston + piston ring item std/spec. Limit compression pressure compression pr...

  • Page 409

    8-36 servicing information conrod + crankshaft item std/spec. Limit conrod small end i.D. 15.010 – 15.018 (0.5910 – 0.5913) 15.040 (0.5921) conrod big end side clearance 0.10 – 0.20 (0.004 – 0.008) 0.30 (0.012) conrod big end width 19.95 – 20.00 (0.7854 – 0.7874) crank pin width 20.10 – 20.15 (0.791...

  • Page 410

    Servicing information 8-37 transmission + drive chain item std/spec. Limit primary reduction ratio 1.857 (78/42) drive chain shift fork to groove clearance 0.10 – 0.30 (0.004 – 0.012) shift fork groove width 5.0 – 5.1 (0.197 – 0.201) shift fork thickness 4.8 – 4.9 (0.189 – 0.193) ——— unit: mm (in) e...

  • Page 411

    8-38 servicing information item std/spec. Limit engine coolant type engine coolant use an antifreeze/coolant compatible with alumi- num radiator, mixed with distilled water only, at the ratio of 50:50. ——— ——— approx. 250 ml (0.3/0.2 us/imp qt) reserve tank side approx. 2 150 ml (2.3/1.9 us/imp qt) ...

  • Page 412

    Servicing information 8-39 throttle body item std/spec. Bore size 42 mm i.D. No. 35 f1 (for e-33), 35 f0 (for the others) idle r/min. 1 200 ± 100 r/min. Fast idle r/min. 3 500 r/min. (after warming up) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) electrical item std/spec. Note unit: mm (in) fir...

  • Page 413

    8-40 servicing information wattage item std/spec. E-03, -24, -28, -33 e-02, -19 headlight 55 + 55 w ← 55 w parking or position light brake light / taillight 21/5 w × 2 ← ← 5 w hi lo turn signal light 21 w × 4 ← speedometer light led ← ← ← turn signal indicator light led high beam indicator light led...

  • Page 414

    Servicing information 8-41 item std/spec. Limit wheel rim runout ——— axial ——— radial 2.0 (0.08) 2.0 (0.08) wheel rim size ——— front ——— rear 0.25 (0.010) 0.25 (0.010) wheel axle runout 17 × mt3.50 front ——— 17 × mt5.50 rear ——— tire item std/spec. Limit cold inflation tire pressure (solo riding) ——...

  • Page 415

    8-42 servicing information item std/spec. Limit 130 (5.1) rear wheel travel ——— swingarm pivot shaft runout 0.3 (0.01) ——— fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 90 pump octane ( ). Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol...

  • Page 416: Emission Control Information

    9 emission control information 9-1 emission control information contents fuel injection system ............................................................. 9- 2 evaporative emission control system ........................... 9- 2 canister hose routing ..................................................

  • Page 417: Fuel Injection System

    9-2 emission contorol information fuel tank fuel pump fuel hose throttle body purge port fuel shut-off valve tank pressure control valve canister fuel hc vapor fresh air breather pipe fuel-vapor separator fuel injection system gsx-r750 motorcycles are equipped with a fuel injection system for emissi...

  • Page 418

    Emission control information 9-3 canister hose routing (only for e-33) chacoal canister surge hose (red tr acer) surge hose (red tr acer) purge hose purge hose t o carb uretor tpc v alv e fuel shut-off v alv e a view a.

  • Page 419: (Only For E-33)

    9-4 emission contorol information evaporative emission control system inspection (only for e-33) • remove the seats and frame cover. • remove the fuel tank. ( 4-51) note: when connecting the tank pressure control valve to the hose, the side b should face toward the fuel shut-off valve side, and the ...

  • Page 420

    Emission control information 9-5 negative pressure throttle body air cleaner box fresh air exhaust gas pair control valve pair reed valve pair control valve open close pair (air supply) system diagram.

  • Page 421

    9-6 emission contorol information pair (air supply) system hose routing pair valve vacuum hose (530 mm) pair valve 10 n.M (1.0 kgf.M, 7.5 lb-ft) pair reed valve pair valve hose l (30 mm) matching mark pair cleaner hose pair valve hose r (50 mm) to throttle body (n0.4 cylinder) air cleaner box 1.

  • Page 422

    Emission control information 9-7 pair (air supply) system inspection hoses • inspect the hoses for wear or damage. • inspect that the hoses and pipes are securely connected. Pair control valve • inspect that air flows through the pair control valve air inlet port to the air outlet ports. • if air do...

  • Page 423: Gsx-R750K1 (’01-Model)

    Gsx-r750k1 (’01-model) 10-1 10 gsx-r750k1 (’01-model) contents specifications ............................................................................. 10- 2 service data ................................................................................. 10- 3 clutch .................................

  • Page 424: Specifications

    10-2 gsx-r750k1 (’01-model) specifications dimensions and dry mass overall length .......................................................................... 2 040 mm (80.3 in) overall width ............................................................................ 715 mm (28.1 in) overall height ....

  • Page 425: Service Data

    Gsx-r750k1 (’01-model) 10-3 service data valve + guide unit: mm (in) item std/spec. Limit valve diam. In. 29 (1.14) ——— ex. 24 (0.94) ——— valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ——— ex. 0.20 – 0.30 (0.008 – 0.012) ——— valve guide to valve stem in. 0.010 – 0.037 clearance (0.0004 ...

  • Page 426

    10-4 gsx-r750k1 (’01-model) item std/spec. Limit camshaft journal o.D. In. & ex. 23.959 – 23.980 (0.9433 – 0.9441) ——— camshaft runout 0.10 ——— (0.004) cam chain pin (at arrow “3”) 14th pin ——— cylinder head distortion 0.20 ——— (0.008) cylinder + piston + piston ring unit: mm (in) item std/spec. Lim...

  • Page 427

    Gsx-r750k1 (’01-model) 10-5 conrod + crankshaft unit: mm (in) item std/spec. Limit conrod small end i.D. 15.010 – 15.018 15.040 (0.5910 – 0.5913) (0.5921) conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) conrod big end width 19.95 – 20.00 (0.7854 – 0.7874) ——— crank pin width 2...

  • Page 428

    10-6 gsx-r750k1 (’01-model) transmission + drive chain unit: mm (in) except ratio item std/spec. Limit primary reduction ratio 1.857 (78/42) ——— final reduction ratio 2.470 (42/17) ——— gear ratios low 2.785 (39/14) ——— 2nd 2.052 (39/19) ——— 3rd 1.681 (37/22) ——— 4th 1.450 (29/20) ——— 5th 1.304 (30/2...

  • Page 429

    Gsx-r750k1 (’01-model) 10-7 injector + fuel pump + fuel pressure regulator item std/spec. Note injector resistance 11 – 16 Ω at 20°c (68°f) fuel pump discharge amount approx. 1.2 l (1.3/1.1 us/imp qt) /30 sec. Fuel pressure regulator operating approx. 300 kpa (3.0 kgf/cm 2 , 43 psi) set pressure fi ...

  • Page 430

    10-8 gsx-r750k1 (’01-model) throttle body item std/spec. Bore size 42 mm i.D. No. 35 f1 (for e-33), 35 f0 (for the others) idle r/min. 1 200 ± 100 r/min. Fast idle r/min. 3 500 r/min. (after warming up) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) electrical unit: mm (in) item std/spec. Note fi...

  • Page 431

    Gsx-r750k1 (’01-model) 10-9 wattage item std/spec. E-03, 24, 28, 33 the others headlight hi 55 + 55 w ← lo 55 w ← parking or position light ——— 5 w brake light/taillight 21/5 w × 2 ← turn signal light 21 w × 4 ← speedometer light led ← turn signal indicator light led ← high beam indicator light led ...

  • Page 432

    10-10 gsx-r750k1 (’01-model) item std/spec. Limit wheel rim runout axial 2.0 ——— (0.08) radial 2.0 ——— (0.08) wheel rim size front 17 × mt 3.50 ——— rear 17 × mt 5.50 ——— wheel axle runout front ——— 0.25 (0.010) rear ——— 0.25 (0.010) tire unit: mm (in) item std/spec. Limit cold inflation tire pressur...

  • Page 433

    Gsx-r750k1 (’01-model) 10-11 use only unleaded gasoline of at least 90 pump octane ( ). Gasoline containing mtbe (methyi tertiary butyi ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible. Gasoline used should be graded 95 octa...

  • Page 434: Clutch

    10-12 gsx-r750k1 (’01-model) clutch clutch reassembly drive plate: identify drive plates, no. 1, no. 2 and no. 3 according to the fol- lowing table. Drive plate part no. Identification no.1 21441-31e50 purple paint no.2 21441-31e60 green paint no.3 21440-35f00 dampers • no.3 drive plate claws have d...

  • Page 435

    Gsx-r750k1 (’01-model) 10-13 clutch drive plates inspection note: * wipe off engine oil from the clutch drive plates with a clean rag. * clutch drive plate no.1: purple paint no.2: green paint no.3: dampers on claws • measure the drive plates with a vernier calipers. • if the thickness is not within...

  • Page 436: Fuel Pressure Inspection

    10-14 gsx-r750k1 (’01-model) fuel pressure inspection • lift and support the fuel tank with its prop stay. • place a rag under the fuel feed hose. • remove the fuel feed hose 1 and install the special tools be- tween the fuel tank and fuel delivery pipe. [ 09940-40211: fuel pressure gauge adaptor 09...

  • Page 437: Throttle Stop Screw

    Gsx-r750k1 (’01-model) 10-15 throttle stop screw the throttle stop screw a is installed on the no.1 throttle body. • remove the front seat. • lift and support the fuel tank. • ajust the engine idle speed. ( 2-15) ap sensor the ap sensor b (atmospheric pressure sensor) is located over the ecm. Ap sen...

  • Page 438: Engine Mounting Bolt and Nut

    10-16 gsx-r750k1 (’01-model) item n.M kgf.M lb-ft abc 55 5.5 39.8 36 75 7.5 54.0 147 23 2.3 16.5 58 45 4.5 32.5 ! Length item mm in ac 45 1.77 bolt b 55 2.17 de 215 8.46 spacer 2 30.5 1.20 adjuster 47 40 1.57 left right engine mounting bolt and nut.

  • Page 439

    Gsx-r750k1 (’01-model) 10-17 chacoal canister surge hose (red tr acer) surge hose (red tr acer) purge hose purge hose t o carb uretor tpc v alv e fuel shut-off v alv e a view a clamp clamp canister hose routing (for e-33).

  • Page 440: Gsx-R750K2 (’02-Model)

    Gsx-r750k2 (’02-model) 11-1 contents specifications ............................................................................. 11- 2 engine ............................................................................................. 11- 4 clutch .....................................................

  • Page 441: Specifications

    11-2 gsx-r750k2 (’02-model) specifications dimensions and dry mass overall length ................................................................ 2 040 mm (80.3 in) overall width ................................................................. 715 mm (28.1 in) overall height .........................

  • Page 442

    Gsx-r750k2 (’02-model) 11-3 chassis front suspension .......................................................... Inverted telescopic, coil spring, spring pre-load fully adjustable, rebound and compression damping force fully adjustable. Rear suspension ...................................................

  • Page 443: Engine

    11-4 gsx-r750k2 (’02-model) engine clutch the spring washer 1 and its seat 2 have been equipped and no. 3 drive plate 3 has been changed as follows. Tightening torque for cam chain tension adjuster cap k2-model dry torque: 35 n.M (3.5 kgf.M, 25.5 lb-ft) (part no.: 09168-12019) note: when using late ...

  • Page 444

    Gsx-r750k2 (’02-model) 11-5 fi system and intake air system malfunction code and defective condition malfunction code c00 c11 c12 c13 c14 c15 c21 c22 c23 c24, c25, c26 or c27 detected item no fault camshaft position sensor crankshaft position sensor intake air pressure sensor throttle position senso...

  • Page 445

    11-6 gsx-r750k2 (’02-model) when no actuator control signal is supplied from the ecm or communication signal does not reach ecm or operation voltage does not reach stva motor, c28 is indicated. Stva can not operate. Stva lead wire/coupler. The sensor should produce following voltage. (0.2 v sensor v...

  • Page 446

    Gsx-r750k2 (’02-model) 11-7 inspection • lift and support the fuel tank with its prop stay. • remove the air cleaner element. Turn the ignition switch on and off. Check the stva lead wire coupler for loose or poor con- tacts. Turn the ignition switch on to check the stva operation. (stv operating or...

  • Page 447

    11-8 gsx-r750k2 (’02-model) “c29” stp sensor circuit malfunction detected condition possible cause signal voltage low or high. • stp sensor maladjusted. Difference between actual throttle opening and • stp sensor circuit open or short. Opening calculated by ecm in larger than specified • stp sensor ...

  • Page 448

    Gsx-r750k2 (’02-model) 11-9 turn the ignision switch off. Connect the stp sensor coupler. Insert the copper wires to the lead wire coupler. Disconnect the stva lead wire coupler 1 . Turn the ignition switch on. Measure the stp sensor output voltage at the coupler (be- tween yellow and black wires) b...

  • Page 449

    11-10 gsx-r750k2 (’02-model) fuel pump construction reassembly • pass through the wires behind the thermistor. 1 fuel pressure regulator 2 o-ring 3 fuel pump case/fuel filter cartridge (for high pressure) 4 thermistor 5 fuel pump 6 fuel mesh filter (for low pressure) item n.M kgf.M lb-ft a 10 1.0 7....

  • Page 450

    Gsx-r750k2 (’02-model) 11-11 • be sure to connecft the wires to the proper terminals. A .............. + terminal for fuel pump b .............. For thermistor c .............. - terminal for fuel pump pass through the wires behind the thermistor..

  • Page 451

    11-12 gsx-r750k2 (’02-model) throttle body construction 1 vacuum hose 2 tp sensor 3 stp sensor 4 throttle body (nos. 3, 4) 5 throttle body (nos. 1, 2) 6 synchronizing screw 7 stay plate 8 fast idle adjusting screw 9 throttle stop screw 0 fuel delivery pipe a o-ring b dust seal c fuel injection d cus...

  • Page 452

    Gsx-r750k2 (’02-model) 11-13 throttle body removal • lift and support the fuel tank with its prop stay. • disconnect the iat sensor coupler 1 and pair hose 2 . • disconnect the iap sensor coupler 3 and vacuum hose 4 . • disconnect the crankcase breather hose 5 . • loosen the throttle body clamp scre...

  • Page 453

    11-14 gsx-r750k2 (’02-model) • disconnect the throttle cables from their drum. • place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank. • disconnect the vacuum hose 1 from the pair valve. • disconnect the fuel injector lead wire coupler 2 . • loosen the throttle b...

  • Page 454

    Gsx-r750k2 (’02-model) 11-15 throttle body disassembly • disconnect the following parts. 1 fuel feed hose 2 vacuum hose 3 vacuum hose 4 purge hose (only for e-33) • disconnect the lead wire couplers. • remove the fuel delivery pipe assembly 5 by removing its mounting screws. • remove the fuel inject...

  • Page 455

    11-16 gsx-r750k2 (’02-model) • remove the nut 1 . • separate the throttle body assembly to a pair of two bodies (nos. 1.2 and nos. 3.4) by removing their connecting bolts. Note: be careful not to lose the springs. Never remove the secondary throttle valve and throttle valve..

  • Page 456

    Gsx-r750k2 (’02-model) 11-17 throttle body cleaning some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • clean all passageways with a ...

  • Page 457

    11-18 gsx-r750k2 (’02-model) • install the stay plate 1 . • place the throttle body assembly on the surface plate and tighten the connecting bolts. Throttle body connecting bolt: 6 n.M (0.6 kgf.M, 4.5 lb-ft) • install the fast idle link levers properly. • set the st valve to fully open position, ins...

  • Page 458

    Gsx-r750k2 (’02-model) 11-19 white color stps 6 n.M (0.6 kgf.M, 4.5 lb-ft) 3.5 n.M (0.35 kgf.M, 2.5 lb-ft) 6 n.M (0.6 kgf.M, 4.5 lb-ft) 3.5 n.M (0.35 kgf.M, 2.5 lb-ft) tps black color 3.5 n.M (0.35 kgf.M, 2.5 lb-ft) stva ! Tps and stps resemble each other very closely in external appearance. Make su...

  • Page 459

    11-20 gsx-r750k2 (’02-model) clamp clamp clamp no. 1: gr/w & y/r no. 2: gr/b & y/r no. 3: gr/y & y/r no. 4: gr/r & y/r 90˚ to fuel feed hose purge hose (only for e-33) • assemble the fuel delivery pipes. • install the fuel delivery pipe assembly to the throttle body as- sembly. Never turn the fuel i...

  • Page 460

    Gsx-r750k2 (’02-model) 11-21 forward #1 #2 #3 #4 r 25˚ ± 10˚ 10˚ ± 10˚ 10˚ ± 10˚ l view of top throttle body clamp position stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor resistance and adjust the stp sensor positioning as follows: • disconnect the stp sensor cou...

  • Page 461

    11-22 gsx-r750k2 (’02-model) ← incorrect ← correct position ← incorrect the lcd indicates 0.4 sec./time, and two times show the correct position, where it is fixed. Throttle position sensor adjustment 1. Adjust the engine rpm to 1 200 rpm. 2. Stop the engine and connect the special tool (mode select...

  • Page 462

    Gsx-r750k2 (’02-model) 11-23 throttle valve synchronization check and adjust the throttle valve synchronization among four cylinders. Calibrating each gauge • lift and support the fuel tank. • start up the engine and run it in idling condition for warming up. • stop the warmed-up engine. • disconnec...

  • Page 463

    11-24 gsx-r750k2 (’02-model) • remove the vacuum hose 1 from the no. 1 throttle body. • connect one of the four rubber hoses of the vacuum balancer gauge to the nipple 2 on the no.1 throttle body. 09913-13121: vacuum balancer gauge • connect a tachometer. • start up the engine and keep it running at...

  • Page 464

    Gsx-r750k2 (’02-model) 11-25 throttle valve synchronization • remove the pair vacuum hose 1 and connect a proper rub- ber cap to the nipple. • to synchronize throttle valves, remove the respective vacuum hoses 2 from each vacuum nipple and connect the vacuum balancer gauge hoses to the vacuum nipple...

  • Page 465: Chassis

    11-26 gsx-r750k2 (’02-model) chassis front axle when loosening and tightening the front axle, use the special tool. 09900-18740: hexagon wrench 24 mm • tighten the front axle to the specified torque. Front axle: 100 n.M (10.0 kgf.M, 72.5 lb-ft) swingarm pivot boss removal • remove the swingarm. ( 6-...

  • Page 466

    Gsx-r750k2 (’02-model) 11-27 installation • set the swingarm pivot boss by its set screws. • tighten the swingarm boss nut to the specified torque. Swingarm pivot boss nut: 65 n.M (6.5 kgf.M, 47.0 lb-ft) 100 n.M 10.0 kgf.M 72.5 lb-ft 65 n.M 6.5 kgf.M 47.0 lb-ft 15 n.M 1.5 kgf.M 11.0 lb-ft 90 n.M 9.0...

  • Page 467

    11-28 gsx-r750k2 (’02-model) torque link front side of the torque link washer has been eliminated. In accor- dance with this elimination, the torque link mounting bolt has been changed. K2-model a 19 mm (0.7 in) b 34.5 mm (1.36 in).

  • Page 468: Servicing Information

    Gsx-r750k2 (’02-model) 11-29 servicing information wire harness routing clamp clamp clamp wire har ness ignition s witch clamp wire har ness oil pressure s witch side-stand s witch star ter motor speed sensor clamp wire har ness f an motor wire har ness wire har ness batter y - lead wire handlebar s...

  • Page 469

    11-30 gsx-r750k2 (’02-model) clamp radiator horn set the wire harness to the groove of the headlight correctly. Fix the wire harness clamp to the frame. Fix the wire harness clamp to the frame. Set the injector coupler to the optimurn position after connecting the injector lead wire coupler. Pass th...

  • Page 470

    Gsx-r750k2 (’02-model) 11-31 a a f f view a view f w ater hose gear position s witch star ter motor gear position s witch 45 ˚ 45 ˚ 90 ˚ w ater b ypass hose star ter motor ground lead wire 5 n . M (0.5 kgf . M, 3.6 lb-ft) clamp ckp sensor ckp sensor oil pressure s witch oil pressure s witch clamp 1....

  • Page 471

    11-32 gsx-r750k2 (’02-model) cooling system hose routing a : f ace the tip of clip to the bottom b : f ace the tip of clip to the left c : f ace the tip of clip to the bac k d : f ace the head of scre w to the r ight e : f ace the head of scre w to the bac k f : f ace the head of scre w to the left ...

  • Page 472

    Gsx-r750k2 (’02-model) 11-33 front brake hose routing clamp the br ak e hose fir mly . 42 ˚ 42 ˚ after touching the br ak e hose unions to the stopper , tighten the union bolts . After touching the br ak e hose unions to the stopper tighten the union bolts . Inser t the clamp to the hole of the fron...

  • Page 473

    11-34 gsx-r750k2 (’02-model) rear brake hose routing after touching the br ak e hose union to the stopper , tighten the union bolt. After touching the br ak e hose union to the stopper , tighten the union bolt. F ace the clamp ends bac kw ard. F ace the clamp ends forw ard. F ace the clamp ends forw...

  • Page 474

    Gsx-r750k2 (’02-model) 11-35 canister hose routing (only for e-33) chacoal canister surge hose (red tr acer) surge hose (red tr acer) purge hose purge hose t o carb uretor tpc v alv e fuel shut-off v alv e a view a.

  • Page 475: Service Data

    11-36 gsx-r750k2 (’02-model) service data valve + guide unit: mm (in) item std/spec. Limit valve diam. In. 29 (1.14) ——— ex. 24 (0.94) ——— valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ——— ex. 0.20 – 0.30 (0.008 – 0.012) ——— valve guide to valve stem in. 0.010 – 0.037 clearance (0.0004...

  • Page 476

    Gsx-r750k2 (’02-model) 11-37 item std/spec. Limit camshaft journal o.D. In. & ex. 23.959 – 23.980 (0.9433 – 0.9441) ——— camshaft runout 0.10 ——— (0.004) cam chain pin (at arrow “3”) 14th pin ——— cylinder head distortion 0.20 ——— (0.008) cylinder + piston + piston ring unit: mm (in) item std/spec. Li...

  • Page 477

    11-38 gsx-r750k2 (’02-model) conrod + crankshaft unit: mm (in) item std/spec. Limit conrod small end i.D. 15.010 – 15.018 15.040 (0.5910 – 0.5913) (0.5921) conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) conrod big end width 19.95 – 20.00 (0.7854 – 0.7874) ——— crank pin width ...

  • Page 478

    Gsx-r750k2 (’02-model) 11-39 transmission + drive chain unit: mm (in) except ratio item std/spec. Limit primary reduction ratio 1.857 (78/42) ——— final reduction ratio 2.470 (42/17) ——— gear ratios low 2.785 (39/14) ——— 2nd 2.052 (39/19) ——— 3rd 1.681 (37/22) ——— 4th 1.450 (29/20) ——— 5th 1.304 (30/...

  • Page 479

    11-40 gsx-r750k2 (’02-model) injector + fuel pump + fuel pressure regulator item std/spec. Note injector resistance 11 – 16 Ω at 20°c (68°f) fuel pump discharge amount approx. 1.2 l (1.3/1.1 us/imp qt) /30 sec. Fuel pressure regulator operating approx. 300 kpa (3.0 kgf/cm 2 , 43 psi) set pressure fi...

  • Page 480

    Gsx-r750k2 (’02-model) 11-41 throttle body item std/spec. Bore size 42 mm i.D. No. * 35 f3 (for e-33), 35 f2 (the others) idle r/min. 1 200 ± 100 r/min. Fast idle r/min. *1 800 r/min. (when engine is cold) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) electrical unit: mm (in) item std/spec. Note...

  • Page 481

    11-42 gsx-r750k2 (’02-model) wattage item std/spec. E-03, 24, 28, 33 the others headlight hi * 60 w × 2 55 + 55 w lo * 55 w × 2 55 w parking or position light ——— 5 w brake light/taillight 21/5 w × 2 ← turn signal light 21 w × 4 ← speedometer light led ← turn signal indicator light led ← high beam i...

  • Page 482

    Gsx-r750k2 (’02-model) 11-43 item std/spec. Limit wheel rim runout axial 2.0 ——— (0.08) radial 2.0 ——— (0.08) wheel rim size front 17 × mt 3.50, 17m/c × mt 3.50 ——— rear 17 × mt 5.50, 17m/c × mt 5.50 ——— wheel axle runout front ——— 0.25 (0.010) rear ——— 0.25 (0.010) tire unit: mm (in) item std/spec....

  • Page 483

    11-44 gsx-r750k2 (’02-model) item std/spec. Limit rear wheel travel 130 (5.1) ——— swingarm pivot shaft runout 0.3 ——— (0.01) fuel + oil item std/spec. Note fuel type e-03, 28, 33 the others fuel tank capacity including 18 l reserve (4.8/4.0 us/lmp gal) fuel level * approx. 4 l indicator light (1.1/0...

  • Page 484

    12 wire color b : black bl : blue br : brown dbr : dark brown dg : dark green g : green gr : gray lbl : light blue lg : light green o : orange p : pink r : red v : violet w : white y : yellow b/bl : black with blue tracer b/br : black with brown tracer b/g : black with green tracer b/lg : black with...

  • Page 485

    Wiring diagram (y-model) for e-03, 28, 33 1 3 2 4 5 6 1. Fan 10a 2. Fuel 10a 3. Head hi 15a 4. Ignition 15a 5. Signal 15a 6. Head lo 15a push free 12v on off on off lock p on off off run off on push l push r hi lo push on off on off speedometer headlight (lo) headlight (hi) front turn signal light (...

  • Page 486

    1 3 2 4 5 6 1. Fan 10a 2. Fuel 10a 3. Head hi 15a 4. Ignition 15a 5. Signal 15a 6. Head lo 15a push free 12v on off on off off run off on push on off on off speedometer headlight (lo) headlight (hi) front turn signal light (r) front turn signal light (l) t b n f speed sensor handle switch (r) engine...

  • Page 487

    For e-02, 19 (y-model) 1 3 2 4 5 6 1. Fan 10a 2. Fuel 10a 3. Head hi 15a 4. Ignition 15a 5. Signal 15a 6. Head lo 15a push free 12v on off on off on off on off speedometer headlight (lo) headlight (hi) front turn signal light (r) front turn signal light (l) position light t b n f speed sensor handle...

  • Page 488

    Wiring diagram (k1-model) for e-03, 28, 33 1 3 2 4 5 6 1. Fan 10a 2. Fuel 10a 3. Head hi 15a 4. Ignition 15a 5. Signal 15a 6. Head lo 15a push free 12v on off on off lock p on off off run off on push l push r hi lo push on off on off speedometer headlight (lo) headlight (hi) front turn signal light ...

  • Page 489

    1 3 2 4 5 6 1. Fan 10a 2. Fuel 10a 3. Head hi 15a 4. Ignition 15a 5. Signal 15a 6. Head lo 15a push free 12v on off on off off run off on push on off on off speedometer headlight (lo) headlight (hi) front turn signal light (r) front turn signal light (l) t b n f speed sensor handle switch (r) engine...

  • Page 490

    The others (k1-model) 1 3 2 4 5 6 1. Fan 10a 2. Fuel 10a 3. Head hi 15a 4. Ignition 15a 5. Signal 15a 6. Head lo 15a push free 12v on off on off on off on off speedometer headlight (lo) headlight (hi) front turn signal light (r) front turn signal light (l) position light t b n f speed sensor handle ...

  • Page 491

    B bl br dg g gr lbl lg o p r w y b/bl b/br b/g b/lg b/r b/w b/y bl/b bl/g bl/r bl/w bl/y g/b g/w g/y gr/b gr/r gr/w gr/y o/b o/bl o/g o/r o/w o/y p/b p/w r/b r/bl r/w w/b w/bl w/g w/r y/b y/bl y/g y/r y/w : black : blue : brown : dark green : green : gray : light blue : light green : orange : pink :...

  • Page 492

    For e-02, 19, 54 (k2-model) headlight (lo) headlight (hi) front turn signal light (r) front turn signal light (l) position light speedometer t b n f t b n f oil : turn signal indicator light : high beam indicator light : neutral indicator light : fuel indicator light : oil pressure/engine coolant te...

  • Page 493

    For e-24 (k2-model) headlight (r) headlight (l) front turn signal light (r) front turn signal light (l) speedometer t b n f t b n f oil : turn signal indicator light : high beam indicator light : neutral indicator light : fuel indicator light : oil pressure/engine coolant temp./fi indicator light oi...

  • Page 494

    For e-03, 28, 33 (k2-model) headlight (r) headlight (l) front turn signal light (r) front turn signal light (l) speedometer t b n f t b n f oil : turn signal indicator light : high beam indicator light : neutral indicator light : fuel indicator light : oil pressure/engine coolant temp./fi indicator ...

  • Page 495

    Prepared by 3rd ed. August, 2002 1st ed. February, 2000 part no. 99500-37112-03e printed in japan 488.