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Suzuki GSX1400 Service Manual

Other manuals for GSX1400: Owner's Manual, Service Manual, Owner's Manual, Manual

Summary of GSX1400

  • Page 1

    9 9 5 0 0 - 3 9 2 2 2 - 0 1 e gsx1400 www.Gsx1400fe.Com.

  • Page 2: Group Index

    Group index 1 foreword this manual contains an introductory description on the suzuki gsx1400 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 yourse...

  • Page 3: General Information

    General information 1-1 1 general information contents warning/caution/note ............................................................. 1- 2 general precautions .............................................................. 1- 2 suzuki gsx1400k2 (2002-model) ..........................................

  • Page 4: Warning/caution/note

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

  • Page 5

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

  • Page 6: 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 7: Fuel and Oil Recommendation

    General information 1-5 fuel and oil recommendation fuel gasoline used should be graded 91 octane (research method) or higher. An unleaded gasoline is recom- mended. Engine oil use a premium quality 4-stroke motor oil to ensure longer ser- vice life of your motorcycle. Use only oils which are rated ...

  • Page 8: Break-In Procedures

    1-6 general information break-in procedures during manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performa...

  • Page 9: Information Labels

    General information 1-7 information labels gsx1400 gsx1400ud 1 noise label for e-24 2 fuel caution label for e-02, 24 3 tire pressure label 4 warning safety label 5 id plate for e-02, 19, 24 6 loading capacitiy rear fender unit: mm www.Gsx1400fe.Com.

  • Page 10: Specifications

    1-8 general information specifications dimensions and dry mass overall length ................................................................ 2 160 mm (85.0 in) overall width ................................................................. 810 mm (31.9 in) overall height .............................

  • Page 11

    General information 1-9 chassis front suspension .......................................................... Telescopic, coil spring, oil damped rear suspension ........................................................... Swingarm, coil spring, oil damped front suspension stroke .........................

  • Page 12: 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. Gsx1400 e-19 eu e-24 australia gsx1400ud e-19 eu www.Gsx1400fe.Com.

  • Page 13: Periodic Maintenance

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

  • Page 14

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

  • Page 15

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

  • Page 16: Maintenance And Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item mentioned in the periodic maintenance chart. Air cleaner • remove the fuel tank. • remove the fuel tank bracket. • remove the air cleaner element by removing the screws. • carefu...

  • Page 17

    Periodic maintenance 2-5 spark plug spark plug and spark plug cap removal • remove the seat. • remove the fuel tank. ( 4-48) • remove all spark plug caps. • remove the spark plugs with a spark plug wrench. Heat range • check to see the heat range of the plug. If the electrode of the plug is wet appe...

  • Page 18

    2-6 periodic maintenance electrode’s condition • check the condition of the electrode. • if it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc. Check the thread size and reach when replacing the spark plug. If the reach is ...

  • Page 19

    Periodic maintenance 2-7 • remove the engine oil cooler bolts. • remove the engine oil cooler hose clamp. • move the engine oil cooler forward. • disconnect the cooling fan lead wire coupler. • remove the oil hose clamp bolts. • remove the cylinder head cover bolts. • remove the cylinder head cover....

  • Page 20

    2-8 periodic maintenance the valve clearance specification is different for intake and ex- haust valves. Valve clearance must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are disturbed by removing them for servicin...

  • Page 21: 170

    Periodic maintenance 2-9 ex ex in in 1 2 3 4 ex ex in in 1 2 3 4 • when the lines face each other, measure • marked valve clear- ances. • turn the crankshaft 360° and measure • marked valve clear- ances. • measure the valve clearances with a thickness gauge. \ 09900-20803: thickness gauge valve clea...

  • Page 22

    2-10 periodic maintenance note: * be sure to apply engine oil to tappet shim top and bottom faces. * when seating the tappet shim, be sure to face figure printed surface to the tappet. Reinstall the camshafts as the specified manner. ( 3-74) • after replacing the tappet shim and camshafts, rotate th...

  • Page 23

    Periodic maintenance 2-11 (intake side) t appet shim selection t able [int ake] t appet shim no . (12892-05c00-xxx) h o w t o use this char t : i. Measure v alv e clearance . “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 24

    2-12 periodic maintenance (exhaust side) t appet shim selection t able [exha ust] t appet shim no . (12892-05c00-xxx) h o 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 ...

  • Page 25

    Periodic maintenance 2-13 engine oil and oil filter oil should be changed while the engine is warm. Oil filter replace- ment at the specified intervals, should be done together with the engine oil change. Engine oil replacement • keep the motorcycle upright. • place an oil pan below the engine, and ...

  • Page 26

    2-14 periodic maintenance • install the new oil filter. Turn it by hand until you feel that the oil filter gasket has contacted the oil filter mounting surface. Then, tighten the oil filter two full turns using the special tool. Note: to properly tighten the oil filter, use the special tool. Never t...

  • Page 27

    Periodic maintenance 2-15 throttle valve synchronization inspect throttle valve synchronization periodically. ( 4-66) throttle cable play 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 the adjuster 3....

  • Page 28

    2-16 periodic maintenance major adjustment • lift and support the fuel tank with its prop stay. ( 4-48) • 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 the ...

  • Page 29

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

  • Page 30

    2-18 periodic maintenance 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 reference marks a on both sides of the swingarm and the edge of each chain adjuster must...

  • Page 31

    Periodic maintenance 2-19 cleaning and lubricating • clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. Do not use trichloroethylene, gasoline or any similar solvent. These fluids have too great a dissolving power for this chain and they c...

  • Page 32

    2-20 periodic maintenance 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. ( 6-58) replace the brake pads as a set, otherwise braking per- formance will be adversel...

  • Page 33

    Periodic maintenance 2-21 brake light switch • adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. Air bleeding the brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large pro...

  • Page 34

    2-22 periodic maintenance 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 tire tread condition operating the motorcycle with excess...

  • Page 35

    Periodic maintenance 2-23 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 36

    2-24 periodic maintenance front fork inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( 6-13) rear suspension inspect the rear shock absorbers for oil leakage and check that there is no play in the swing...

  • Page 37

    Periodic maintenance 2-25 chassis bolts and nuts check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle.: 2-26 item n.M kgf.M ib-ft 1 steering stem head nut 65 6.5 47.0 2 steering stem lock nut 80 8.0 58.0 3 fron...

  • Page 38

    2-26 periodic maintenance www.Gsx1400fe.Com.

  • Page 39: Compression Pressure Check

    Periodic maintenance 2-27 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 40: Oil Pressure Check

    2-28 periodic maintenance 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 300 – 600 kpa (3.0 – 6.0 kgf/cm 2 , 43 – 85 psi) at 3 000 r/min., oil temp. At 60°c (140°f) if the oil pressure i...

  • Page 41: Engine

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

  • Page 42

    3-2 engine engine center item removal inspection reinstallation oil cooler 3-4 ––––– 3-10 exhaust pipe and muffler 3-4 ––––– 3-9 pair valve 3-11 3-22 3-78 cylinder head cover 3-11 3-23 3-78 cam chain tension adjuster 3-12 3-25 3-76 camshaft 3-12 3-23 3-74 cylinder head 3-12 3-26 3-72 cylinder 3-13 3...

  • Page 43

    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 seat. ( 6-3) • remove t...

  • Page 44

    3-4 engine oil cooler • remove the cooling fan coupler (2p). • with the oil cooler bolts removed,detach the oil cooler and cool- ing fan. • remove the oil hose union and oil hose guide. Exhaust pipe and muffler • loosen the muffler connecting bolts, 1 and 2. • with the muffler mounting nuts (3 and 4...

  • Page 45

    Engine 3-5 • disconnect the breather hose. • remove the throttle body assembly. ( 4-55) ignition coil • with the ignition coil couplers and plug caps disconnected, re- move the ignition coil brackets (r, l). Electric parts • disconnect the oil temperature sensor coupler (2p)1. • disconnect the signa...

  • Page 46

    3-6 engine gearshift lever • disconnect the gearshift lever linkage. Engine sprocket • remove the engine sprocket cover. • disconnect the generator coupler (3p) 1. • remove the clutch release cylinder housing. Do not operate the clutch lever after removing the clutch release housing. • disconnect th...

  • Page 47

    Engine 3-7 engine mounting • support the engine using an engine jack. • with each engine mounting bolts and nuts removed,detach the frame down tube . • remove the clutch push rod 1. • remove the speed sensor rotor 2. • remove the engine sprocket nut 3 and the washer. • remove the cotter pin. (for e-...

  • Page 48

    3-8 engine bolt length item mm in 1 35 1.4 2 25 0.98 3 14 0.55 4 60 2.4 5 50 2.0 6 14 0.55 7 140 5.5 8 155 6.1 engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: note: hang the drive chain on the driveshaft when installing the engine...

  • Page 49

    Engine 3-9 • apply a small quantity of thread lock to the drive shaft thread portion and tighten the engine sprocket nut 1 to the specified torque. J 99000-32050: thread lock “1342” " engine sprocket nut: 115 n.M (11.5 kgf.M, 83.2 lb-ft) • tighten the speed sensor rotor bolt 2 to the specified torqu...

  • Page 50

    3-10 engine • install and adjust the following items. * engine oil ( 2-13) * throttle valve synchronization ( 4-66) * throttle cable play ( 2-15) * idling adjustment ( 2-14) * drive chain slack ( 2-17) * wiring harness, cables and hoses ( 8-16 – 29) oil cooler • fit a new o-ring. • install the oil c...

  • Page 51: Engine Disassembly

    Engine 3-11 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 positions. Cylinder head cover • remove the pair reed valve cover and reed valve. • remove the oil hoses....

  • Page 52

    3-12 engine • set the #1 cylinder at tdc. Turn the crankshaft to bring the “t” line on the rotor to the tip of signal generator, and the lines on camshaft facing outside. • remove the cam chain tension adjuster cap, the washer, the spring and the steel ball. • remove the cam chain tension adjuster. ...

  • Page 53

    Engine 3-13 cylinder head • remove the oil hose. • loosen the cylinder nut a. • remove the cylinder head bolts (m6). • remove the cylinder head bolts and nuts. Note: when loosening the cylinder head bolts and nuts, loosen each bolt little by little diagonally. • remove the cylinder head. Cylinder • ...

  • Page 54

    3-14 engine • remove the cylinder head gasket and dowel pins. • with both end of cylinder evenly rised, remove the cylinder. Piston • put the rag under the piston so as not to drop the parts into the crankcase, remove the piston pin circlip. • draw out the piston pin, remove the piston. • remove the...

  • Page 55

    Engine 3-15 signal generator • with the rotor held, remove the signal generator rotor bolt. • remove the signal generator. • remove the oil pressure switch 1. Oil filter • remove the oil filter. \ 09915-40610: oil filter wrench cooling fan switch • remove the cooling fan switch. Www.Gsx1400fe.Com.

  • Page 56

    3-16 engine clutch • remove the clutch cover. • with the clutch spring bolts removed, detach the clutch springs and clutch pressure plate. • remove the clutch push piece 1, the bearing 2 and the thrust washer 3. • remove the clutch push rod 4. Note: if it is difficult to pull out the push rod 4, use...

  • Page 57

    Engine 3-17 • remove the wave washer 1, the back torque limiter 2 and the clutch sleeve hub. • remove the washer 3 and the primary driven gear assembly. • remove the spacer, the bearing and the washer. Oil pump driven gear • remove the circlip 1 and the washer 2. • remove the oil pump driven gear. N...

  • Page 58

    3-18 engine generator cover • remove the generator cover. • remove the starter idle gear and its shaft. Generator rotor/starter clutch • hold the generator rotor with the special tool and remove the generator rotor bolt. \ 09930-44530: rotor holder • remove the generator rotor with the special tool....

  • Page 59

    Engine 3-19 oil pan • remove the oil pan. • remove the oil pressure regulator. • remove the oil pipes, 1 and 2. • remove the crank balancer guard 3. • remove the oil strainer 4 and its o-ring. Crank balancer • with the balancer lever bolt removed, draw out the crank bal- ancer shaft and remove the c...

  • Page 60

    3-20 engine oil pump • remove the oil pump. Crank case • remove the lower crankcase bolts, (6 mm) and (8 mm). • remove the upper crankcase bolts, (6 mm) and (8 mm). • remove the crank journal bolts (9 mm). Note: loosen the crank journal bolts in the descending order of the number on crankcase. • rem...

  • Page 61

    Engine 3-21 • remove the o-rings and the dowel pins. Crankshaft • remove the crankshaft thrust bearings 1. • remove the crankshaft together with the cam chain. Transmission • remove the countershaft and the driveshaft. • remove the c-ring 2 and the dowel pins 3. Www.Gsx1400fe.Com.

  • Page 62: Engine Components Inspection

    3-22 engine 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 removal and installation • remove the fuel tank.(...

  • Page 63

    Engine 3-23 cylinder head cover cam position sensor • inspect the cam position sensor for abnormal condition. • with the grease applied to the o-ring, install the cam position sensor. " cam position sensor bolt: 10 n.M (1.0 kgf.M, 7.4 lb-ft) x 99000-25010: suzuki super grease “a” oil gallery plug • ...

  • Page 64

    3-24 engine 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 65

    Engine 3-25 cam sprocket • inspect the sprocket teeth for wear. • if they are worn, replace the sprocket/camshaft assembly and cam chain as a set. • install the cam sprocket to the camshaft. ( 3-75) • apply a small quantity of thread lock to the cam sprocket bolt and tighten it to the specified torq...

  • Page 66

    3-26 engine cylinder head and valve valve and valve spring disassembly • remove the tappets and shims 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 1 from valve stem. \ 09916-14510: valve li...

  • Page 67

    Engine 3-27 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 68

    3-28 engine valve spring the force of the coil springs keeps the valve seat tight. Weakened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism. • check the valve springs for proper strength by measuring their free length and also...

  • Page 69

    Engine 3-29 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 as replacement pa...

  • Page 70

    3-30 engine 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 71

    Engine 3-31 45° 15° (ex) 30° (in) initial seat cut • install the 45° cutter 2, attachment 3 and t-handle 4. • 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...

  • Page 72

    3-32 engine bottom narrowing cut (in.) • if the contact area w is too wide or too low, use the 60° cutter to narrow and raise the contact area. 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° an...

  • Page 73

    Engine 3-33 valve and valve spring reassembly • apply molybdenum oil solution to each oil seal, and press-fit them into position with the valve guide installer. \ 09916-43210: valve guide remover/installer p molybdenum oil solution do not reuse the removed oil seals. • insert the valves, with their ...

  • Page 74

    3-34 engine oil gallery • install the washer and the oil gallery plug. " oil gallery plug: 20 n.M (2.0 kgf.M, 15 lb-ft) intake pipe • install the intake pipes. Cylinder cylinder distortion • check the gasket surface of the cylinder for distortion with a straightedge and thickness gauge, taking a cle...

  • Page 75

    Engine 3-35 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: standard: 80.980 – 80.995 mm (3.1882 – 3.1888 in) service limit:...

  • Page 76

    3-36 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 77

    Engine 3-37 clutch clutch drive plates inspection note: wipe off engine oil from the clutch drive plates with a clean rag. • measure the thickness of drive plates with a vernier calipers. • if each drive plate thickness is less than the limit, replace it with a new one. Drive plate thickness: servic...

  • Page 78

    3-38 engine 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 79

    Engine 3-39 back torque limiter • inspect the back torque limiter for wear or damage. If any de- fects are found, replace it with a new one. • apply a small quantity of thread lock to the clutch spring guide bolt and tighten it. J 99000-32050: thread lock “1342” " clutch spring guide bolt: 23 n.M (2...

  • Page 80

    3-40 engine generator inspection: 7-8 reassembly • when installing the generator stator set bolts, tighten them to the specified torque. " generator stator set bolt: 10 n.M (1.0 kgf.M, 7.4 lb-ft) note: be sure to install the grommet to the generator cover. Starter clutch inspection • inspect the sta...

  • Page 81

    Engine 3-41 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 82

    3-42 engine transmission • disassemble the countershaft and driveshaft. Pay attention to the following points: \ 09900-06104: snap ring pliers • slide the 6th (top) drive gear circlip b from its groove towards the 3rd/4th drive gears. • slide the 2nd drive gear towards the 6th (top) drive gear, then...

  • Page 83

    Engine 3-43 gear • inspect the teeth of gear for wear, scratch or damage. • inspect the dock of gear for wear or damage. • if there are anything unusual, replace them with new ones. Gearshift fork to groove clearance • using a thickness gauge, check the gearshift fork clearance in the groove of its ...

  • Page 84

    3-44 engine * never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. * when installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft. * after installing a circlip, make sure ...

  • Page 85

    Engine 3-45 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 86

    3-46 engine 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. • if the oil clearance exceeds the service limit, select the speci- fied bearings from the bearing selection table. C...

  • Page 87

    Engine 3-47 • check the corresponding conrod i.D. Code number a stamped on the conrod. • check the corresponding crank pin o.D. Code number b stamped on the crankshaft. Bearing selection table crank pin o.D. B code 1 2 3 conrod 1 green black brown i.D. A 2 black brown yellow conrod i.D. Code i.D. Sp...

  • Page 88

    3-48 engine installation • when fitting the bearing to the bearing cap and conrod, be sure to fix the stopper part a first and press in the other end. Be sure to clean the conrod big end. • apply molybdenum oil solution to the crank pin and bearing surface. P molybdenum oil • when fitting the conrod...

  • Page 89

    Engine 3-49 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 pla...

  • Page 90

    3-50 engine • check the corresponding crankcase journal i.D.Code number a stamped on the upper crankcase. • check the corresponding crankshaft journal o.D.Code number b stamped on the crankshaft. Bearing selection table crankshaft journal o.D. B code a b c crankcase a green black brown i.D. A b blac...

  • Page 91

    Engine 3-51 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. 1: right-side thrust bearing 2: left-side thrust bearing note: pull the cra...

  • Page 92

    3-52 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) (12228-24f00-0f0) (0.0974 – 0.0984 in) (0.0024 – 0.0043 in) 2.535 – ...

  • Page 93

    Engine 3-53 crankcase/oil pan oil check valve • install the oil check valve. " oil check valve: 35 n.M (3.5 kgf.M, 26 lb-ft) lower crankcase • inspect the gearshift shaft bearings (1 and 2) and the gear- shift cam bearing 3 for abnormal noise and smooth rotation while they are in the crankcase. • re...

  • Page 94

    3-54 engine • remove the gearshift cam bearing using the special tools. \ 09923-74510: bearing remover 09930-30102: sliding shaft • install the bearing using the special tool. \ 09913-70210: bearing installer set (30 mm) oil jet removal • remove the piston cooling oil jets 1 from the upper crankcase...

  • Page 95

    Engine 3-55 oil gallery plug • install each plug. " 1main gallery plug: 35 n.M (3.5 kgf.M, 26 lb-ft) 2main gallery plug: 21 n.M (2.1 kgf.M, 15 lb-ft) 3sub gallery plug: 35 n.M (3.5 kgf.M, 26 lb-ft) 4sub gallery plug: 10 n.M (1.0 kgf.M, 7.4 lb-ft) www.Gsx1400fe.Com.

  • Page 96: Engine Reassembly

    3-56 engine engine reassembly • reassemble the engine in the reverse order of disassembly. • the following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. Oil pump • install the dowel pins. • ap...

  • Page 97

    Engine 3-57 • apply a small quantity of thread lock to the bearing re- tainer screws and the shift fork shaft retainer screw and tighten them. J 99000-32050: thread lock “1342” • tighten the gearshift shaft spring stopper. " gearshift shaft spring stopper: 10 n.M (1.0 kgf.M, 7.4 lb-ft) crankshaft • ...

  • Page 98

    3-58 engine 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 99

    Engine 3-59 • apply suzuki bond to the mating surface of the lower crank- case. D 99000-31140: suzuki bond “1207b” 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 assemble the cr...

  • Page 100

    3-60 engine • match the upper and lower crankcases. • tighten the crank journal bolt (9 mm) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure as following two steps. " crank journal bolt: (m9) initial: 18 n.M (1.8 kgf.M, 13 lb-ft) fi...

  • Page 101

    Engine 3-61 • from this position, turn the balancer shaft counterclockwise by 1.5 – 2 graduations and tighten the lock bolt. " balancer lever lock bolt: 10 n.M (1.0 kgf.M, 7.4 lb-ft) • apply engine oil to the balancer shaft and insert it. • apply a small quantity of thread lock to the balancer lever...

  • Page 102

    3-62 engine • apply grease to the o-ring and install it with the shim. X 99000-25010: suzuki super grease “a” oil pan • install the gasket. • set the stopper of oil return pipe in the convex on crankcase. Oil strainer • with grease applied to the o-ring, install the oil strainer. X 99000-25010: suzu...

  • Page 103

    Engine 3-63 gear position switch • install the gear position switch contacts and the springs. • apply grease to the o-ring. X 99000-25010: suzuki super grease “a” • install the gear position switch as shown. Generator • degrease the tapered portion of the generator rotor and also the crankshaft. Use...

  • Page 104

    3-64 engine generator cover • apply suzuki bond lightly to the mating surfaces at the part- ing line between the upper and lower crankcases as shown. D 99000-31140: suzuki bond “1207b” • install the dowel pins and new gasket. • install the generator cover and tighten the generator cover bolts to the...

  • Page 105

    Engine 3-65 • confirm the gearshift cam stopper movement. • check the neutral position. • install the gearshift cam stopper plate after aligning the gear- shift cam pin with the gearshift cam stopper plate hole. • apply a small quantity of thread lock to the gearshift cam stopper plate bolt and tigh...

  • Page 106

    3-66 engine • install the primary driven gear assembly and apply engine oil to the needle bearing. • install the thrust washer 1. Note: be sure to engage the oil pump drive and driven gears, primary drive and driven gears. • align the punched mark on back torque limiter driven with punched mark on d...

  • Page 107

    Engine 3-67 • insert the spring washer seat 1 and the spring washer 2. • insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order as shown in the illustration. Note: insert the outermost no.2 drive plate claws to the other slits of clutch housing...

  • Page 108

    3-68 engine • 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.M...

  • Page 109

    Engine 3-69 oil filter • install the oil filter using the special tool. ( 2-13) \ 09915-40610: oil filter wrench oil pressure switch • install the oil pressure switch and tighten it to the specified torque. " oil pressure switch: 14 n.M (1.4 kgf.M, 10.0 lb-ft) signal generator • install the signal g...

  • Page 110

    3-70 engine breather cover • install the gasket. • install the breather cover. " breather cover bolt: 10 n.M (1.0 kgf.M, 7.4 lb-ft) note: install the engine ground lead wire and clamp to the bolt a. Starter motor • apply grease to the o-ring and install the starter motor. X 99000-25010: suzuki super...

  • Page 111

    Engine 3-71 piston • 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 and side rails: y...

  • Page 112

    3-72 engine cylinder • install the dowel pins and gasket. • apply engine oil to the sliding surface of the pistons and cylin- der walls. • set the special tools to the no.2 and no.3 pistons, and insert them into the cylinder block. ! 09916-74521: holder body 09916-54550: band note: do not over tight...

  • Page 113

    Engine 3-73 • place the cylinder head on the cylinder. • apply engine oil to the threads of cylinder head bolt and the copper washers. • tighten the cylinder head bolts (m6) and the cylinder nut b. " cylinder head bolt (m6): 10 n.M (10 kgf.M, 7.4 lb-ft) cylinder nut: 10 n.M (1.0 kgf.M, 7.4 lb-ft) • ...

  • Page 114

    3-74 engine • install the cylinder head oil hose. " cylinder head oil hose union bolt: 20 n.M (2.0 kgf.M, 15 lb-ft) • install the oil pipe with the white paint facing exhaust side. • install and tighten the oil pipe bolts with the washers. " oil pipe bolt: 10 n.M (1.0 kgf.M, 7.4 lb-ft) camshaft • tu...

  • Page 115

    Engine 3-75 position of camshafts and cam sprockets www.Gsx1400fe.Com.

  • Page 116

    3-76 engine • apply molybdenum oil solution to journals and cam faces. P molybdenum oil solution • install each dowel pin. • install the camshaft journal holders by aligning the embossed letters on the camshaft journal holders with the embossed let- ters on the cylinder head. • fasten the camshaft j...

  • Page 117

    Engine 3-77 • after installing the cam chain tension adjuster, check to be sure that the adjuster work properly by checking the slack of cam chain. • after installing the cam chain tension adjuster, rotate the crank- shaft (some turns), and recheck the positions of the camshafts. ( 3-75) • install t...

  • Page 118

    3-78 engine cylinder head cover • pour engine oil in each oil pocket in the cylinder head. Note: be sure to check the valve clearance. ( 2-6) • install the new gaskets to the cylinder head cover. • apply suzuki bond to the cam end caps of the gaskets as shown. 99000-31230: suzuki bond “1216b” • plac...

  • Page 119: Fi System

    Fi system contents precautions in servicing ....................................................... 4- 2 fi system technical features .............................................. 4- 8 injection time ........................................................................... 4- 8 compensation of in...

  • Page 120

    Fi system 4-1 4 fuel system .................................................................................. 4-48 fuel tank removal ................................................................. 4-48 fuel tank installation ......................................................... 4-48 fuel pres...

  • Page 121: Precautions In Servicing

    4-2 fi 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, be sure to push it in...

  • Page 122

    Fi 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 component is a high-preci...

  • Page 123

    4-4 fi 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 make sure that batter...

  • Page 124

    Fi 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 each connector/coupler...

  • Page 125

    4-6 fi 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 between each ter- minal an...

  • Page 126

    Fi 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. Using testers • use the suzu...

  • Page 127

    4-8 fi 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 compensations which are det...

  • Page 128

    Fi 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 oil temperature sensor signal intake air temperature sensor sig- nal b...

  • Page 129

    4-10 fi 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 the fuel pump and pressu...

  • Page 130

    Fi 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 mounted at the bottom of the fuel tank, which consists of the armature, magnet...

  • Page 131

    4-12 fi system filter solenoid coil plunger needle valve 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 more than 300 kpa (3.0 ...

  • Page 132

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

  • Page 133

    4-14 fi system ecm (fi control unit) the ecm is located under the seat. The ecm consists of cpu (central processing unit), memory (rom) and i/o (input/output) sections. The signal from each sensor is sent to the input section and then sent to cpu. On the basis of signal information received, cpu cal...

  • Page 134

    Fi system 4-15 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 upper frame be- tween the...

  • Page 135

    4-16 fi system 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 crankcase. The sensor generates the pick-up signal to be supplied to the ecm. The ecm calcula...

  • Page 136

    Fi system 4-17 output voltage (v) lo w high low high (high vacuum) (low vacuum) atmospheric pressure(mmhg) resistance value lo w high temperature low high engine oil temperature sensor (eot sensor) the thermistor resistance value increases when the engine oil temperature is low, and decreases when t...

  • Page 137

    4-18 fi system tip over sensor (to sensor) the tip over sensor is located in ahead of the battery holder. 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 cuts off current supp...

  • Page 138: Fi System Parts Location

    Fi system 4-19 a speedometer b speed sensor c ignition coil (ig coil) d camshaft position sensor (cmps) e throttle position sensor (tps) f fuel pump (fp) g fuel pump rela y (fp rela y ) h gear position s witch (gp switch) fi system parts location ecm www.Gsx1400fe.Com.

  • Page 139

    4-20 fi system i intak e air pressure sensor (iaps) j intak e air temperature sensor (ia ts) k atmospher ic pressure sensor (aps) l tip o v er sensor (t os) ecm m secondar y throttle position sensor (stps) n secondar y throttle v alv e actuator (stv a ) o engine oil temper ature sensor (eo ts) p c r...

  • Page 140: Fi System Diagram

    Fi system 4-21 fi # 4 fi # 3 fi # 2 fi # 1 clp switch fp relay tos stps stva # 4 # 3 # 2 # 1 aps iats ig coil cmps ckps sps starter motor starter motor gp switch gp switch tps iaps battery fp fp ts ecm ecm eots eots fi system diagram www.Gsx1400fe.Com.

  • Page 141: Fi System Wiring Diagram

    4-22 fi system fi system wiring diagram speedometer fuel pump clp switch ecm ba tter y mode selection switch iaps st ar ter b utt on ignition coil tip o ver sensor fuel pump rela y gp switch side- st and rela y side-st and switch st ar ter rela y main switch 1&4 2&3 iaps : int ake air pressure senso...

  • Page 142: Self-Diagnosis Function

    Fi system 4-23 self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi light). To check the function of the individual fi system devices, the dealer...

  • Page 143

    4-24 fi system dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive signal from the devices. These aff...

  • Page 144

    Fi system 4-25 code malfunction part remarks c00 none no defective part c11 camshaft position sensor (cmps) c12 crankshaft position sensor (ckps) pick-up coil signal, signal generator c13 intake air pressure sensor (iaps) c14 throttle position sensor (tps) c15 engine oil temp. Sensor (eots) c21 inta...

  • Page 145: Fail-Safe Function

    4-26 fi system fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. Item fail-safe mode starting ability running ability camshaft position ecm determines cylinder...

  • Page 146: Fi System Troubleshooting

    Fi system 4-27 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 required for proper analysis ...

  • Page 147

    4-28 fi system 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. Such disconnection wil...

  • Page 148

    Fi system 4-29 malfunction code and defective condition malfunction code c00 c11 c12 c13 c14 c15 c21 c22 c23 c24 or c25 detected item no fault camshaft position sensor crankshaft position sensor intake air pressure sensor throttle position sensor engine oil temperature sensor intake air temperature ...

  • Page 149

    4-30 fi system 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. (0.20 v sensor voltage witho...

  • Page 150

    Fi system 4-31 “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 short. • cmp sensor malfunction. • ecm malfu...

  • Page 151

    4-32 fi system “c12” ckp sensor circuit malfunction detected condition possible cause no ckp sensor signal for 3 seconds at engine • metal particles or foreign material being cranking. Attached on the ckp sensor and rotor tips. • ckp sensor circuit open or short. • ckp sensor malfunction. • ecm malf...

  • Page 152

    Fi system 4-33 inspection • lift and support the fuel tank with a proper stay. ( 4-48) 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. Turn the ignition switch on. Measure the ...

  • Page 153

    4-34 fi system 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 and + terminal to the vcc terminal. Check the voltage between vout...

  • Page 154

    Fi system 4-35 “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 larger than specified • tp sensor malfunction. Valu...

  • Page 155

    4-36 fi system 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 valve is closed: approx....

  • Page 156

    Fi system 4-37 b/br b/bl v engine oil resistance temp. 20°c ( 68 °f) approx. 61.3 k Ω 50°c ( 122 °f) approx. 17.8 k Ω 80°c ( 176 °f) approx. 6.2 k Ω 110°c ( 230 °f) approx. 2.5 k Ω inspection • remove the right frame side cover. ( 6-3) turn the ignition switch off. Check the eot sensor coupler for l...

  • Page 157

    4-38 fi system 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. Resistance) • ecm malfunction....

  • Page 158

    Fi system 4-39 v red “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. 0.20 v sensor voltage • b/br or g/y wire circuit shorted to ground. ...

  • Page 159

    4-40 fi system 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 terminal and + terminal to the vcc terminal. Check the voltage between v...

  • Page 160

    Fi system 4-41 inspection • remove the right frame side cover. ( 6-3) 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 between black and b/w wire ter- minals. T...

  • Page 161

    4-42 fi system inspection • lift and support the fuel tank with a proper stay. ( 4-48) “c28” stv actuator circuit malfunction detected condition possible cause the operation voltage does not reach the stva. • stva malfunction. Ecm does not receive communication signal from • stva circuit open or sho...

  • Page 162

    Fi system 4-43 “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 malfunction. ...

  • Page 163

    4-44 fi system 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. Turn the ignition switch on. Measure the stp sensor output voltage at the coupler (be- tween yellow and black wires) by turning the se...

  • Page 164

    Fi system 4-45 ecm coupler “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. Switch voltage > 0.6 v • ecm malfunction. ( without t...

  • Page 165

    4-46 fi system “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 a proper stay. ( 4-48) turn the ignition switch ...

  • Page 166

    Fi system 4-47 “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 left frame side cover. ( 6-3) turn the ignition switch off. Check the...

  • Page 167: Fuel System

    4-48 fi system fuel system fuel tank removal • remove the seat and frame side covers, left and right. ( 6- 3) • remove the fuel tank mounting bolts. • lift and support the fuel tank with a proper stay. • place a rag under the fuel feed hose and remove the fuel feed hose 1. • disconnect the fuel pump...

  • Page 168

    Fi system 4-49 fuel pressure inspection • remove the seat and frame side covers, left and right. ( 6- 3) • lift and support the fuel tank with a proper stay. ( 4-48) • place a rag under the fuel feed hose. ( 4-48) • remove the fuel feed hose and install the special tools be- tween the fuel tank and ...

  • Page 169

    4-50 fi system • apply 12 volts to the fuel pump for 30 seconds and measure the amount of fuel discharged. Battery + terminal –––– power source lead wire 1 (yellow with red tracer) if the discharge amount is not specified it means that the fuel pump is defective or that the fuel filter is clogged. F...

  • Page 170

    Fi system 4-51 fuel pump relay inspection fuel pump relay is located behind the left frame side cover. • remove the seat and left frame side cover. ( 6-3) • remove the fuel pump relay. First, check the insulation between 1 and 2 terminals with pocket tester. Then apply 12 volts to 3 and 4 terminals,...

  • Page 171

    4-52 fi system • remove the fuel pressure regulator holder 1 and the fuel pres- sure regulator 2. Fuel mesh filter inspection and cleaning if the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compres...

  • Page 172

    Fi system 4-53 fuel pump and fuel mesh filter installation install the fuel pump and fuel mesh filter in the reverse order of removal, and pay attention to the following points: • install the new o-rings to the fuel pressure regulator and fuel pipe. • apply thin coat of the engine oil to the o-rings...

  • Page 173

    4-54 fi system 5 n.M (0.5 kgf.M, 3.7 lb-ft) 3.5 n.M (0.35 kgf.M, 2.5 lb-ft) 2 n.M (0.2 kgf.M, 1.5 lb-ft) 5 n.M (0.5 kgf.M, 3.7 lb-ft) 2 n.M 0.2 kgf.M 1.5 lb-ft 3.5 n.M 0.35 kgf.M 2.5 lb-ft 3.5 n.M (0.35 kgf.M) 3.5 n.M (0.35 kgf.M, 2.5 lb-ft) 5 n.M (0.5 kgf.M, 3.7 lb-ft) 3.5 n.M (0.35 kgf.M) 3.5 n.M ...

  • Page 174

    Fi system 4-55 throttle body removal • remove the fuel tank. ( 4-48) • disconnect the fuel injector/sensor lead wire coupler 1. • loosen the respective throttle body clamp screws. • remove the air cleaner box mounting bolts, left and right. • slightly move the air cleaner box backward. Www.Gsx1400fe...

  • Page 175

    4-56 fi system • disconnect the throttle cables from their drum. • disconnect the vacuum hose 1 from the iap sensor. • dismount the throttle body assembly. * be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly. * after dis...

  • Page 176

    Fi system 4-57 • remove the fuel injectors. • separate the throttle body assembly to a pair of two bodies (no.1/no.2 and no.3/no.4) by removing their connecting bolts. • remove the tp sensor with the special tool. \ 09930-11960: torx wrench note: prior to disassembly, mark the tp sensor’s original p...

  • Page 177

    4-58 fi system • remove the stva motor lead wire connector 1 by removing the screw. Never remove the stva motor yoke and motor. Avoid removing the stv adjuster a unless absolutely necessary. Never remove the throttle valve and secondary throttle valve. Www.Gsx1400fe.Com.

  • Page 178

    Fi system 4-59 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 spray-type c...

  • Page 179

    4-60 fi system • apply thread lock “1342” to the actuator cover nuts and tighten them. J 99000-32050: thread lock “1342” " stva cover nut: 2.0 n.M (0.2 kgf.M, 1.5 lb-ft) • install the fast idle cam and tighten its mounting nut. " fast idle cam mounting nut: 4.0 n.M (0.4 kgf.M, 3.0 lb-ft) • position ...

  • Page 180

    Fi system 4-61 • place the throttle body assembly on the surface plate and tighten the connecting bolts. " throttle body connecting bolt: 5 n.M (0.5 kgf.M, 3.7 lb-ft) • apply thin coat of the engine oil to the new fuel injector cushion seals 1, and install them to each fuel injector. Replace the cus...

  • Page 181

    4-62 fi system w • set the no.3 and no.4 stv’s to the same opening by turning the balance screw 1. Then, set the no.1/no.2 valves and no.3/ no.4 valves to the same opening by turning the balance screw 2. • install the tp sensor to the no.1 throttle body and stp sensor to the no.4 throttle body respe...

  • Page 182

    Fi system 4-63 tp sensor clamp p ass through the lead wire betw een the fuel injector co v er and fuel injector . Tp sensor tp sensor actuator lead wire actuator coupler clamp clamp clamp clamp clamp clamp stp sensor coupler (white color) stp sensor tp sensor coupler (blac k color) www.Gsx1400fe.Com.

  • Page 183

    4-64 fi system w tp sensor adjustment • after checking or adjusting the throttle valve synchronization, measure the tp sensor resistance and adjust the tp sensor positioning as follows: • after warming up engine, adjust the idling speed to 1 100 ± 100 rpm. • stop the warmed-up engine and disconnect ...

  • Page 184

    Fi system 4-65 fast idle cam stv actuator throttle valve lever the throttle valve lever opens throttle valve a little to increase the engine speed. Fast idle inspection the fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes t...

  • Page 185

    4-66 fi system throttle valve synchronization check and adjust the throttle valve synchronization among four cylinders. To synchronize throttle valves, disconnect the iap sensor’s vacuum hoses from the vacuum nipples on the respec- tive throttle bodies and connect the vacuum balancer gauge hoses to ...

  • Page 186: Sensors

    Fi system 4-67 sensors iap sensor inspection the intake air pressure sensor is located at the upper frame be- tween the tubes. ( 4-33) iap sensor removal/installation • lift and support the fuel tank. ( 4-48) • remove the iap sensor 1 and disconnect the coupler 2 and vacuum hose 3. • installation is...

  • Page 187

    4-68 fi system cmp sensor inspection the signal rotor is installed on the intake camshaft, and the cam- shaft position sensor (pick-up coil) is installed on the cylinder head cover. ( 4-31) cmp sensor removal/installation • lift and support the fuel tank. ( 4-48) • disconnect the coupler and remove ...

  • Page 188

    Oil cooling and lubrication system 5-1 5 oil cooling and lubrication system oil cooling system/lubrication system ......................... 5- 2 cylinder head oil cooling circuit ................................. 5- 2 cylinder head cooling system chart .......................... 5- 3 engine lubricat...

  • Page 189

    5-2 oil cooling and lubrication system oil cooling system/lubrication system cylinder head oil cooling circuit www.Gsx1400fe.Com.

  • Page 190: Cylinder Head Cover

    Oil cooling and lubrication system 5-3 oil return pipe oil return pipe cylinder head (oil pool) cylinder head (oil pool) cylinder head cover oil hoses oil gallery oil temp. Sensor oil pump oil sump filter oil pan cylinder head cooling system chart www.Gsx1400fe.Com.

  • Page 191

    5-4 oil cooling and lubrication system engine lubrication circuit www.Gsx1400fe.Com.

  • Page 192

    Oil cooling and lubrication system 5-5 www.Gsx1400fe.Com.

  • Page 193

    5-6 oil cooling and lubrication system engine lubrication system chart www.Gsx1400fe.Com.

  • Page 194: Oil Cooler and Oil Hose

    Oil cooling and lubrication system 5-7 oil cooler and oil hose oil cooler removal • drain engine oil. ( 2-13) • remove the oil cooler hoses. • disconnect the cooling fan lead wire coupler. • remove the oil cooler. Oil cooler inspection and cleaning • inspect the oil cooler and hose joints for oil le...

  • Page 195: Cooling Fan

    5-8 oil cooling and lubrication system oil hose/oil pipe inspection • any oil hose/oil pipe found in a cracked condition or flattened must be replaced. • any leakage from the connecting section should be corrected by proper tightening. Oil cooler installation • install the oil cooler. • use a new o-...

  • Page 196: Cooling Fan Thermo-Switch

    Oil cooling and lubrication system 5-9 inspection • disconnect the cooling fan lead wire coupler. • 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 volts to the motor. With the motor wi...

  • Page 197

    5-10 oil cooling and lubrication system 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 rais...

  • Page 198: Oil Temperature Sensor

    Oil cooling and lubrication system 5-11 oil temperature sensor removal • remove the right frame side cover. ( 6-3) • disconnect the oil temperature sensor lead wire coupler. • remove the oil temperature sensor. Inspection • check the oil temperature sensor by testing it at the bench as shown in the ...

  • Page 199: Oil Pressure

    5-12 oil cooling and lubrication system oil pressure ( 2-28) oil filter ( 2-13, 2-14) oil strainer ( 3-19, 3-62) oil pressure regulator ( 3-19) oil jet ( 3-54) oil pump ( 3-20, 3-56) oil pressure switch ( 3-15, 3-69, 7-25, 7-30) www.Gsx1400fe.Com.

  • Page 200: Chassis

    Chassis contents exterior parts ............................................................................ 6- 2 construction........................................................................... 6- 2 removal ........................................................................................

  • Page 201

    Chassis 6-1 6 front brake ................................................................................. 6-49 construction........................................................................... 6-49 brake pad replacement ...................................................... 6-50 brake fluid ...

  • Page 202: Exterior Parts

    6-2 chassis exterior parts construction 1 seat 2 seat support 3 seat lock cable 4 seat lock set 5 pillion rider handle 6 fastener 7 seat tail cover 8 frame cover (rh) 9 frame cover (lh) www.Gsx1400fe.Com.

  • Page 203

    Chassis 6-3 removal seat • remove the seat with the ignition key. Fram covers • remove the seat. ( above) • remove the frame cover mounting secrews (left and right sides). • remove the frame covers by pulling on the hooked parts. Pillion rider handle • remove the pillion rider handle by removing the...

  • Page 204

    6-4 chassis • remove the fasteners.( 6-5) • disconnect the seat lock cable a. • disconnect the brake light/taillight lead wire coupler. • remove the seat tail cover. Remounting • remount the seat, frame covers, pillion rider handle and seat tail cover in the reverse order of removal. Www.Gsx1400fe.C...

  • Page 205

    Chassis 6-5 fastener removal and reinstallation fastener 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 pa...

  • Page 206: Front Wheel

    6-6 chassis front wheel construction 1 brake disc 2 dust seal 3 bearing 4 spacer 5 spacer nut 6 front wheel 7 tire valve 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 www.Gsx1400fe.Com.

  • Page 207

    Chassis 6-7 inspection and disassembly tire ( 6-70) • remove the brake disc. Brake disc ( 6-53) removal • remove the brake calipers 1. Do not operate the brake lever while removing the cali- pers. • loosen two axle pinch bolts 2 on the right front fork leg. • loosen the front axle 3. \ 09900-18740: ...

  • Page 208

    6-8 chassis • remove both dust seals by using the oil seal remover. \ 09913-50121: oil seal remover never reuse the removed dust seals. Front axle using a dial gauge, check the front axle for runout and replace it if the runout exceeds the limit. \ 09900-20607: dial gauge (1/100) 09900-20701: magnet...

  • Page 209

    Chassis 6-9 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, 18.0 lb-ft) 25 n.M (2.5 kgf.M, 18.0 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) ...

  • Page 210

    6-10 chassis wheel bearing • apply grease to the wheel bearings. X 99000-25010: suzuki super grease “a” • first install the left wheel bearing, then install the right wheel bearing and spacer by using the special tools. \ 09941-34513: bearing/steering race installer set the sealed cover of the beari...

  • Page 211

    Chassis 6-11 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 212: Front Fork

    6-12 chassis front fork construction 1 o-ring 2 washer 3 spacer 4 spring 5 inner rod/damper rod (cartridge) 6 inner tube 7 slide metal 8 protecter 9 dust seal 0 oil seal stopper ring a oil seal b oil seal retainer c guide metal d oil lock piece e outer tube f gasket a front fork cap bolt b inner rod...

  • Page 213

    Chassis 6-13 removal and disassembly • remove the front wheel. ( 6-7) • disconnect the brake hoses. • remove the front fender and brake hose guides. • loosen the front fork upper clamp bolts 1. Note: slightly loosen the front fork cap bolts 2 before loosening the lower clamp bolts to facilitate late...

  • Page 214

    6-14 chassis • invert the fork and drain the fork oil out of the fork by stroking. • hold the fork inverted for a few minutes to drain oil. • remove the dust seal. • remove the adjuster rod. • remove the spacer 1, washers 2 and spring 3. • loosen and remove the front fork cap bolt. Www.Gsx1400fe.Com.

  • Page 215

    Chassis 6-15 • remove the oil seal stopper ring. • remove the front axle pinch bolts. • pull the inner tube out of the outer tube. Note: be careful not to damage the inner tube. The slide metals, oil seal and dust seal must be replaced with the new ones when reassembling the front fork. • remove the...

  • Page 216

    6-16 chassis inspection inner and outer tubes • inspect the inner tube outer surface and the outer tube inner surface for scratches. • if any defects are found, replace them with the new ones. Fork spring • measure the fork spring free length. • if it is shorter than the service limit, replace it wi...

  • Page 217

    Chassis 6-17 reassembly and remounting reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attension to the following points: tube metals and seals • hold the inner tube vertically and clean the metal groove and install the guide metal 1 by hand as shown. Use s...

  • Page 218

    6-18 chassis fork oil • place the front fork vertically without spring. • compress it fully. • pour the specified front fork oil into the front fork up to the top of the inner rod. • move the inner tube up and down several strokes until no more bubbles come out from the oil. • keep the front fork ve...

  • Page 219

    Chassis 6-19 • hold the front fork vertically and adjust the fork oil level with the special tool. Note: when adjusting the fork oil level, remove the fork spring and com- press the inner tube fully. \ 09943-74111: front fork oil level gauge fork oil level: 108.0 mm (4.25 in) 99000-99044-l01: suzuki...

  • Page 220

    6-20 chassis front fork cap bolt • install the washers 1 and spacer 2. • adjust the height a of the inner rod threads by turning the lock nut 3 as shown. A: 11 mm (0.43 in) • install the front fork protecter. Note: fit the projection of the front fork protecter to the depression of the front fork ou...

  • Page 221

    Chassis 6-21 • fix the front fork to the front fork lower bracket temporarily as shown. • tighten the front fork cap bolt to the specified torque. " front fork cap bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) • align the top of the inner tube to the upper surface of the steer- ing stem upper bracket. • tigh...

  • Page 222

    6-22 chassis suspension setting after installing the front fork, adjust the spring pre-load and damp- ing force as follows. Spring pre-load adjustment there are eight grooves on the spring adjuster. Position 1 pro- vides the maximum spring pre-load and position 8 provides the minimum spring pre-load...

  • Page 223: Steering and Handlebar

    Chassis 6-23 steering and handlebar construction " item n.M kgf.M lb-ft a 23 2.3 16.5 b 65 6.5 47.0 c 45 4.5 32.5 d 23 2.3 16.5 e 45 4.5 32.5 f 23 2.3 16.5 1 handlebars 2 steering stem upper bracket 3 dust seal 4 bearing upper 5 bearing lower 6 steering stem lower bracket 7 headlight housing bracket...

  • Page 224

    6-24 chassis removal and disassembly • remove the front wheel. ( 6-7) • remove the front forks. ( 6-13) • remove the headlight. • disconnect all the lead wire couplers in the headlight housing. • remove the headlight housing bolts. • remove the brake hose joint mounting bolt. • remove the headlight ...

  • Page 225

    Chassis 6-25 • remove the rear view mirrors. • disconnect the front brake light switch lead wire coupler 1. • remove the front brake master cylinder along with brake hose and calipers. • remove the right handlebar switch box 2 and throttle case 3. • remove the handlebar balancers. Note: the handleba...

  • Page 226

    6-26 chassis • loosen the handlebar holder nuts. • remove the handlebar clamp bolt caps. • remove the handlebar by removing the handlebar clamp bolts. • remove the steering stem upper bracket by removing the steer- ing stem head nut. • remove the steering stem nut with the steering stem nut wrench. ...

  • Page 227

    Chassis 6-27 • remove the ignition switch. ( 7-29) • remove the handlebar holder. Inspection and disassembly inspect the removed parts for the following abnormalities. * handlebars distriction * race wear and brinelling * bearing wear or damage * abnormal bearing noise * distortion of the steering s...

  • Page 228

    6-28 chassis reassembly and remounting reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points: outer races • press in the upper and lower outer races using the special tool. \ 09941-34513: steering outer race installer bearings...

  • Page 229

    Chassis 6-29 • install the ignition switch. ( 7-29) • install the handlebar holders to the steering stem upper bracket. Note: tighten the handlebar holder nuts 1 lightly. After installing handlebars, it should be tightend to the specified torque. • install the steering stem upper bracket and tighten...

  • Page 230

    6-30 chassis • set the punched mark on the handlebar clamp forward. • tighten the handlebar clamp bolts. " handlebar clamp bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) • tighten the handlebar holder nuts to the specified torque. " handlebar holder nut: 45 n.M (4.5 kgf.M, 32.5 lb-ft) handlebar switch box • i...

  • Page 231

    Chassis 6-31 • install the left handlebar switch box to the handlebars by en- gaging the stopper 1 with the handlebars hole 2. • install the clutch master cylinder with the proper clutch hose routing. (clutch hose routing: 8-19) • install the handlebar barancers and the rear view mirrors. • install ...

  • Page 232: Rear Wheel

    6-32 chassis rear wheel construction 1 rear axle 2 caliper bracket 3 brake disc 4 collar 5 bearing 6 rear wheel 7 tire valve 8 damper 9 spacer 0 bearing a retainer b sproket mounting drum c rear sproket d bearing e dust seal f collar g washer a brake disc bolt (rear) b rear sprocket nut c rear axle ...

  • Page 233

    Chassis 6-33 removal • loosen the rear axle nut 1. • raise the rear wheel off the ground and support the motor- cycle with the center stand. • remove the axle nut and draw out the rear axle. Do not operate the brake pedal while removing the rear wheel. • remove the collar 2. • draw out the rear spro...

  • Page 234

    6-34 chassis bearing 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. Inspection and disassembly tire in...

  • Page 235

    Chassis 6-35 • remove the sprocket mounting drum bearing and wheel bear- ings by using the special tool. \ 09921-20240: bearing remover set the removed bearings must be replaced with the new ones. Www.Gsx1400fe.Com.

  • Page 236

    6-36 chassis reassembly and remounting reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: 100 n.M (10.0 kgf.M, 72.5 lb-ft) 102 n.M (10.2 kgf.M, 74.0 lb-ft) left right 23 n.M (2.3 kgf.M, 16.5 lb-ft) 26 n.M 2.6 kgf.M 19.0 lb-ft...

  • Page 237

    Chassis 6-37 left right left right spacer clearance bearing installer bearing • apply grease to the bearings before installing. X 99000-25010: suzuki super grease “a” • install the new bearing to the sprocket mounting drum using the special tool. \ 09924-84510: bearing installer set • first install ...

  • Page 238

    6-38 chassis dust seal • install the new dust seal using proper drift. • apply grease to the dust seal lip before assembling rear wheel. X 99000-25010: suzuki super grease “a” brake disc • apply thread lock super “1360” to the disc bolts and tighten them to the specified torque. Note: make sure that...

  • Page 239

    Chassis 6-39 rear axle • remount the rear wheel and rear axle, install the washer and rear axle nut. • tighten the rear axle nut 1 to the specified torque. • adjust the chain slack after rear wheel installation. ( 2-17) " rear axle nut: 100 n.M (10.0 kgf.M, 72.5 lb-ft) www.Gsx1400fe.Com.

  • Page 240: Rear Shock Absorber

    6-40 chassis rear shock absorber construction " item n.M kgf.M lb-ft a 23 2.3 16.5 b 34 3.4 24.5 1 hook 2 washer 3 rear shock absorber 4 spacer 5 rear shock absorber lower mounting bolt 6 swingarm a rear shock absorber upper mounting bolt b rear shock absorber lower mounting nut www.Gsx1400fe.Com.

  • Page 241

    Chassis 6-41 removal • raise the rear wheel off the ground and support the motor- cycle with the center stand. • remove the left muffler. ( 3-4) • loosen the rear shock absorber lower mounting bolt. • remove the rear shock absorber upper mounting bolt. • dismount the rear shock absorber’s upper side...

  • Page 242

    6-42 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 243

    Chassis 6-43 suspension setting after installing the rear suspension, adjust the spring pre-load and damping force as follows. Spring pre-load adjustment position “1” provides the softest spring pre-load. Position “5” provides the stiffest spring pre-load. Std position: “1.5” damping force adjustmen...

  • Page 244

    6-44 chassis rear swingarm construction 1 swingarm 2 bearing 3 spacer 4 chain buffer 5 dust seal 6 washer 7 bearing spacer 8 pivot shaft a swingarm pivot nut " item n.M kgf.M lb-ft a 120 12.0 87.0 www.Gsx1400fe.Com.

  • Page 245

    Chassis 6-45 removal • raise the rear wheel off the ground and support the motor- cycle with the center stand. • remove the rear wheel. ( 6-33) • remove the rear shock absorbers. ( 6-41) • remove the rear brake hose guide 1. • remove the pivot shaft cap. • remove the swingarm by removing the pivot s...

  • Page 246

    6-46 chassis swingarm pivot shaft using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. \ 09900-20607: dial gauge (1/100 mm, 10 mm) 09900-20701: magnetic stand 09900-21304: v-block (100 mm) swingarm pivot shaft runout: service limit: 0.3 mm (0.01 in) inspec...

  • Page 247

    Chassis 6-47 reassembly reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: swingarm bearing • install the bearings and spacer into the swingarm pivot by us- ing the special tool. \ 09941-34513: steering race installer • apply grease to the...

  • Page 248

    6-48 chassis • install the rear brake hose with the proper brake hose routing. (rear brake hose routing: 8-23) " brake hose union bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) bleed air from the brake system. ( 2-22) final inspection and adjustment after installing the rear suspension and wheel, the followin...

  • Page 249: Front Brake

    Chassis 6-49 front brake construction 1 diaphragm 2 dust boot 3 piston/cup set 4 brake hose #1 5 brake hose #2 (rh) 6 brake hose #2 (lh) 7 brake pad spring 8 brake pad 9 o-ring 0 piston seal a dust seal b piston a front brake master cylinder mounting bolt b brake hose union bolt c pad mounting pin d...

  • Page 250

    6-50 chassis brake pad replacement • remove the pad spring 1. • remove the brake pads by removing the pad mounting pin 2. * do not operate the brake lever while dismounting the pads. * replace the brake pads as a set, otherwise braking performance will be adversely affected. • clean up the caliper e...

  • Page 251

    Chassis 6-51 caliper removal and disassembly • drain the brake fluid. ( 6-50) • remove the brake pads. ( 6-50) • disconnect the brake hoses by removing the brake hose union bolts. Note: place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. • remove the brake cali...

  • Page 252

    6-52 chassis • remove the dust seals and piston seals. Never reuse the removed dust seals and piston seals to prevent fluid leakage. Caliper inspection brake caliper inspect the brake caliper cylinder wall for nicks, scratches or other damage. Brake caliper piston inspect the brake caliper piston su...

  • Page 253

    Chassis 6-53 • tighten each bolt to the specified torque. (front brake hose routing: 8-22) " front brake caliper housing bolt 1: 21 n.M (2.1 kgf.M, 15.0 lb-ft) front brake caliper mounting bolt 2: 25 n.M (2.5 kgf.M, 18.0 lb-ft) front brake hose union bolt 3: 23 n.M (2.3 kgf.M, 16.5 lb-ft) • install ...

  • Page 254

    6-54 chassis • pull out the dust boot 4 and remove the circlip 5. \ 09900-06108: snap ring pliers master cylinder removal and disassembly • drain the brake fluid. ( 6-50) • remove the rear view mirror. • disconnect the front brake light switch lead wire coupler 1. • place a rag underneath the union ...

  • Page 255

    Chassis 6-55 master cylinder inspection inspect the master cylinder bore for any scratches or other dam- age. Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage. Master cylinder reassembly and remounting reassemble th...

  • Page 256

    6-56 chassis • apply brake fluid to the piston and cups. • install the following parts to the master cylinder. 1 dust boot 2 circlip 3 secondary cup 4 piston 5 primary cup 6 return spring \ 09900-06108: snap ring plires • when remounting the brake master cylinder onto the handle- bar, align the mast...

  • Page 257: Rear Brake

    Chassis 6-57 rear brake construction # * 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-based. * do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake flui...

  • Page 258

    6-58 chassis brake pad replacement • remove the pad mounting pin 1. • remove the brake pad spring 2. • remove the brake pads along with the pad shims. * do not operate the brake pedal while dismounting the pads. * replace the brake pads as a set, otherwise braking performance will be adversely affec...

  • Page 259

    Chassis 6-59 caliper removal and disassembly • drain the brake fluid. ( 6-58) • remove the brake pads. ( 6-58) • disconnect the brake hose by removing the brake hose union bolt. Never reuse the brake fluid left over from previous ser- vicing and stored for long periods. # brake fluid, if it leaks, w...

  • Page 260

    6-60 chassis caliper inspection caliper inspection: 6-52 brake disc inspection: 6-53 service limit rear disc thickness: 5.0 mm (0.20 in) rear disc runout: 0.30 mm (0.012 in) caliper reassembly and remounting reassemble and remount the caliper in the reverse order of re- moval and disassembly. Pay at...

  • Page 261

    Chassis 6-61 • place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 2 and disconnect the brake hose. • disconnect the reservoir tank hose. Immediately and completely wipe off any brake fluid con- tacting any parts of the motorcycle...

  • Page 262

    6-62 chassis 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 263

    Chassis 6-63 • apply brake fluid to the piston/cup set. • install the following parts. 1 piston/primary cup 2 push rod 3 circlip 4 dust boot • apply the suzuki moly paste to the push rod. Z 99000-25140: suzuki moly paste \ 09900-06108: snap ring pliers • install the master cylinder. • tighten the lo...

  • Page 264

    6-64 chassis clutch release cylinder and master cylinder construction # * this clutch 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-based. * do not use any brake fluid taken from old, used or unsealed ...

  • Page 265

    Chassis 6-65 clutch fluid replacement • place the motorcycle on a level surface and keep the handle- bars straight. • remove the engine sprocket cover. ( 3-6) • remove the master cylinder reservoir cap and diaphragm. • suck up the old clutch fluid as much as possible from the reser- voir tank. • fil...

  • Page 266

    6-66 chassis • place a rag over the piston to prevent it from popping out. Force out the piston by using compressed air. Do not use high pressure air to prevent piston damage. Clutch release cylinder inspection inspect the clutch release cylinder bore wall for nicks, scratches or other damage. Inspe...

  • Page 267

    Chassis 6-67 • tighten each bolts to the specified torque. " clutch hose union bolt 1: 23 n.M (2.3 kgf.M, 16.5 lb-ft) air bleeder valve 2: 8.0 n.M (0.8 kgf.M, 6.0 lb-ft) * the seal washers should be replaced by the new ones to prevent fluid leakage. * bleed air from the system after reassembling the...

  • Page 268

    6-68 chassis • remove the clutch lever 1 and clutch lever position switch. • remove the boot 2 and push rod 3. • remove the circlip 4 with snap ring pliers. \ 09900-06108: snap ring pliers • remove the piston/cup set 5 secondary cup 6 piston 7 primary cup 8 spring clutch master cylinder inspection i...

  • Page 269

    Chassis 6-69 clutch master cylinder reassembly and remounting reassemble the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: * wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline ...

  • Page 270: Tire And Wheel

    6-70 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 271

    Chassis 6-71 seal valve hole wheel valve lip valve valve • 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 damage. • inspect the valve core. If the seal has abnormal deformation, replace the valve with a new one. Tire in...

  • Page 272

    6-72 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 in- structions given ...

  • Page 273: Electrical System

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

  • Page 274: 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 275

    Electrical system 7-3 battery • the mf battery used in this motorcycle does not require main- tenance (e.G., electrolyte level inspection, distilled water replen- ishment). • during normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced...

  • Page 276

    7-4 electrical system location of electrical components 1 ecm (engine control module) 2 battery 3 fuel injector ( 4-46) 4 actuator ( 4-42) 5 intake air pressure sensor ( 4-33) 6 cam position sensor ( 4-31) 7 fuel pump ( 4-50) 8 fuel level gauge 9 ignition coil (no. 2 & 3) 0 secondary throttle positi...

  • Page 277

    Electrical system 7-5 0 generator a side-stand switch b gear position switch c speedometer sensor 1 cooling fan 2 ignition coil (no. 1 & 4) 3 throttle position sensor 4 fuse box 5 side-stand/turn signal relay 6 starter relay 7 fuel pump relay 8 regulator/rectifier 9 mode selection switch coupler www...

  • Page 278: Charging System

    7-6 electrical system generator regulator / rectifier scr ic ig.Switch load batter y charging 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 c...

  • Page 279

    Electrical system 7-7 measure the generator no-load voltage. ( 7-8) incorrect • faulty generator correct inspect the regulator/rectifier. Incorrect • faulty regulator/rectifier ( 7-10) correct inspect wirings. Incorrect • short circuit of wire harness • poor contact of couplers correct • faulty batt...

  • Page 280

    7-8 electrical system y y y y y y generator coil resistance • remove the engine sprocket outer cover. • disconnect the generator coupler. Measure the resistance between the three lead wires. If the resistance is not specified value, replace the stator with a new one. Also, check that the generator c...

  • Page 281

    Electrical system 7-9 regulator/rectifier • remove the seat. ( 6-3) • remove the tray. • remove the battery. • disconnect the seat lock cable 1 and brake light/taillight cou- pler 2. • remove the pillion rider gripe 3 and seat tail cover 4. • disconnect the rear turn signal light couplers (right and...

  • Page 282

    7-10 electrical system measure the voltage between the terminals using the multi circuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. \ 09900-25008: multi circuit tester set tester knob indication: diode tes...

  • Page 283: System

    Electrical system 7-11 starter motor starter relay b/y to ecm and ignition coil o/w y/g clutch lever position switch b/w starter button engine stop switch o/b turn signal/ side-stand relay g ignition switch r fuse(30a) gear position switch fuse (15a) batter y bl side-stand switch starter system and ...

  • Page 284

    7-12 electrical system check the starter relay. ( 7-14) incorrect • faulty starter relay correct • poor contact of the starter relay the starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up. Check...

  • Page 285

    Electrical system 7-13 commutator inspect the commutator for discoloration, abnormal wear or un- dercut a. If abnormal wear is found, replace the armature with a new one. If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth. If there is no under...

  • Page 286

    7-14 electrical system • apply a small quantity of suzuki moly paste to the arma- ture shaft. Z 99000-25140: suzuki moly paste • apply a small quantity of thread lock super “1322” to the starter motor housing bolts. H 99000-32110: thread lock super “1322” • apply suzuki super grease “a” to the o-rin...

  • Page 287

    Electrical system 7-15 measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. \ 09900-25008: multi circuit tester set v tester knob indication: resistance ( Ω Ω Ω Ω Ω ) sta...

  • Page 288

    7-16 electrical system when disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. • connect the gear position switch coupler to the wiring harness. • turn the ignition switch to “on” position and side-stand to u...

  • Page 289

    Electrical system 7-17 side-stand relay inspection first check the insulation between d and e terminals with the tester. Then apply 12v to terminals d and c (+ to d and - to c) and check the continuity between d and e. If there is no continuity, replace the turn signal/side-stand relay with a new on...

  • Page 290: Ignition System

    7-18 electrical system ecm throttle position sensor engine oil temp. Sensor gear position switch engine stop switch side- stand relay fuse fuse ignition switch ignition coil spark plug battery wave form arrangement circuit wave form arrangement circuit cpu power source circuit ckp sensor cam positio...

  • Page 291

    Electrical system 7-19 measure the battery voltage between input lead wires (o/w and b/w) at the ecm with the ignition switch in the incorrect • faulty ignition switch “on” position. • faulty turn signal/side-stand relay • faulty engine stop switch correct • broken wire harness or poor connection of...

  • Page 292

    7-20 electrical system inspection ignition coil primary peak voltage • remove the fuel tank. ( 4-48) • disconnect the four spark plug caps. • connect new four spark plugs to each spark plug cap and ground them to the ignition coil brackets. Note: make sure that all couplers and spark plugs are conne...

  • Page 293

    Electrical system 7-21 ignition coil resistance • remove the fuel tank. ( 4-48) • disconnect the spark plug caps and coupler, and remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings. If the resistance is not within the standard range, replace t...

  • Page 294

    7-22 electrical system ckp sensor ckp sensor coupler ckp sensor peak volt adaptor ckp sensor coupler g b bl y if the peak voltage on the ckp sensor lead wire coupler is ok but on the ecm coupler is out of specification, the wire harness must be replaced. If both peak voltages are out of specificatio...

  • Page 295: Combination Meter

    Electrical system 7-23 combination meter removal and disassembly • remove the headlight. ( 6-24) • remove the headlight housing. • remove the combination meter. When disconnecting and connecting the combination meter coupler, make sure to turn off the ignition switch, or electronic parts may get dam...

  • Page 296

    7-24 electrical system 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. Note: the pointer may not return to the p...

  • Page 297

    Electrical system 7-25 e f flicker e f to oil pressure switch fuel level meter • remove the fuel tank. ( 4-48) • connect each resistor between the yellow/black and black/ white lead wires at the wire harness. • turn the ignition switch “on” position and wait for approx. 13 seconds. Check the display...

  • Page 298

    7-26 electrical system fuel level gauge inspection • remove the fuel tank. ( 4-48) • disconnect the hose 1. • remove the fuel level gauge 2. Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. Float position res...

  • Page 299

    Electrical system 7-27 b b/r speedometer sensor speedometer if the speedometer, odometer or trip meter does not function prop- erly, inspect the speedometer sensor and connection of couplers. If the speedometer sensor and connection are all right, replace the meter with a new one. Speedometer sensor...

  • Page 300: Lamps

    7-28 electrical system lamps headlight, brake light/taillight and turn signal light if you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol or soapy water to prevent early failure. Headlight beam adjustment • adjust the headlight beam, both vertical and horizontal. A...

  • Page 301: Relays

    Electrical system 7-29 relays turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Inspection before removing the turn signal/side-stand relay, check the op- eration of the turn signal light. If the turn signal light does not...

  • Page 302

    7-30 electrical system 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) r o o/y b/w on off lock color position (for others) r o o/y b/w gr br on off lock p color position lighting switch ...

  • Page 303: Battery

    Electrical system 7-31 battery specifications type designation ftx14-bs capacity 12v, 43.2 kc (12 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 re...

  • Page 304

    7-32 electrical system correct incorrect note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the elect...

  • Page 305

    Electrical system 7-33 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 306: Servicing Information

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

  • Page 307: 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 or c25 detected item no fault camshaft position sensor crankshaft position sensor intake air pressure sensor throttle position sensor engine oil tempe...

  • Page 308

    Servicing information 8-3 when no actuator control signal is supplied from ecm or com- munication 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. (0.20 v sensor volt...

  • Page 309

    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 310

    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 311

    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 312

    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 secoundary throttle valve. Adjust or replace. 4. Suc...

  • Page 313

    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 314

    Servicing information 8-9 cooling system complaint symptom and possible causes remedy engine overheats. 1. Not enough engine oil. Add oil. 2. Clogged with dirt or trashes oil cooler core. Clean. 3. Faulty cooling fan. Repair or replace. 4. Defective cooling fan thermo-switch. Replace. 5. Clogged oil...

  • Page 315

    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 316

    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 317

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

  • Page 318

    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 319

    8-14 ser vicing informa tion o/lo/l o/ro/r o/bo/b o/wo/w b/rb/r b/lb/l y/gy/g o/l o/r o/b o/w b/r b/l y/g grgr gr only for e-24 stp sensor b/gb/g r o/ro/r p/bp/b g/yg/y br/bbr/b b/wb/w b lglg o/go/g y bl/bbl/b grgr b/wb/w y/by/b r o o/yo/y b/wb/w grgr brbr o/go/g grgr o y/wy/w o/bo/b o/wo/w o/go/g w...

  • Page 320

    Servicing information 8-15 speedometer fuel pump clp switch ecm battery mode selection switch iaps starter button ignition coil tip over sensor fuel pump relay gp switch side- stand relay side-stand switch starter relay main switch 1&4 2&3 iaps : intake air pressure sensor cmps : camshaft position s...

  • Page 321

    8-16 servicing information wiring harness, cable and hose routing wiring harness routing clamp (after binding the lead wires, cut the projection of the clamp.) clamp (after binding the lead wires, cut the projection of the clamp.) clamp clamp (after binding the lead wires, cut the projection of the ...

  • Page 322

    Servicing information 8-17 inside of the headlight housing high-tension cord routing www.Gsx1400fe.Com.

  • Page 323

    8-18 servicing information engine electrical parts set-up 8 n.M (0.8 kgf.M, 5.7 lb-ft) 160 n.M (16.0 kgf.M, 115.5 lb-ft) 10 n.M (1.0 kgf.M, 7.3 lb-ft) 10 n.M (1.0 kgf.M, 7.3 lb-ft) 11 n.M (1.1 kgf.M, 8 lb-ft) 14 n.M (1.4 kgf.M, 10 lb-ft) 25 n.M (2.5 kgf.M, 18.0 lb-ft) 6 n.M (0.6 kgf.M, 4.3 lb-ft) cm...

  • Page 324

    Servicing information 8-19 after touching the hose union to the stopper, tighten the union bolt. After touching the hose union to the stopper, tighten the union bolt. Approx. 21˚ approx. 21˚ approx. 14˚ approx. 35˚ clamp frame pipe wiring harness clutch hose pass through the clutch hose behind the i...

  • Page 325

    8-20 servicing information more than 2 mm (0.08 in) squeeze the brake lever fully and check or adjust the clearance between the lever and throttle cable case to provide more than 2 mm (0.08 in). The end of the clip face to the left side. Pass through the throttle cables between the front fork and fr...

  • Page 326

    Servicing information 8-21 10 n.M (1.0 kgf.M, 7.3 lb-ft) fuel pump fuel tank drain hose fuel level gauge * tighten the bolts in ascending order of numbers to the specified torque. 1.6 1.5 3 3 5 2 2 4 4 1.6 1.5 3 2 4 4 fuel pump/fuel level gauge set-up www.Gsx1400fe.Com.

  • Page 327

    8-22 servicing information approx. 35˚ approx. 14˚ approx. 14˚ approx. 35˚ approx. 14˚ approx. 28˚ approx. 35˚ approx. 14˚ approx. 14˚ approx. 14˚ approx. 28˚ approx. 21˚ approx. 35˚ approx. 7˚ approx. 7˚ after touching the hose union to the stopper, tighten the union bolt. After touching the hose u...

  • Page 328

    Servicing information 8-23 after touching the hose union to the stopper, tighten the union bolt. The clamp ends face to backward. After touching the hose union to the stopper, tighten the union bolt. Approx. 28˚ clamp pass through the brake hose inside the guide. Rear brake hose routing www.Gsx1400f...

  • Page 329

    8-24 servicing information side-stand set-up center stand set-up 40 n.M (4.0 kgf.M, 29 lb-ft) 50 n.M (5.0 kgf.M, 36 lb-ft) to muffler cushion www.Gsx1400fe.Com.

  • Page 330

    Servicing information 8-25 seat lock cable routing and luggage hook set-up fix the circlip securely. Apply grease to the groove. Brake pedal set-up www.Gsx1400fe.Com.

  • Page 331

    8-26 servicing information fuel hose routing clip clip fuel connecting hose fuel connecting hose fuel feed hose water drain hose fuel pump a view of a air cleaner box swingarm water drain hose fuel feed hose wiring harness water drain hose fuel pump www.Gsx1400fe.Com.

  • Page 332

    Servicing information 8-27 fuel tank set-up cushion rubber cushion rubber cushion rubber align the hole of the cushion with the protrusion on the frame tube. Hole protrusion protrusion before installing the cushion rubber, apply adhesive agent to its bottom. Outside inside face the clamp end to insi...

  • Page 333

    8-28 servicing information throttle body set-up 10 n.M (1.0 kgf.M, 7.0 lb-ft) 18 n.M (1.8 kgf.M, 13.0 lb-ft) view of a view of b crankcase breather hose engine oil temp. Sensor intake air temp. Sensor air cleaner water drain hose a b a b www.Gsx1400fe.Com.

  • Page 334

    Servicing information 8-29 pair (air supply) system hose routing 10 n.M (1.0 kgf.M, 7.3 lb-ft) pair hose (r) pair hose (l) pair hose iap sensor iap sensor pair valve vacuum hose (to no.3 throttle body) pair valve pair valve vacuum hose (to no.3 throttle body) pair cleaner hose pair cleaner hose to a...

  • Page 335: Special Tools

    8-30 servicing information special tools 09900-06104 snap ring pliers 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-18740 hexagon socket (24 mm) 09900-20101 09900-20102 vernier calipers 09900-20203 micrometer (50 – 75 mm) 09900-20204 micrometer (75 – 100 mm) 09900-20205 micrometer ...

  • Page 336

    Servicing information 8-31 09915-74520 oil pressure gauge hose 09915-74540 oil pressure gauge adaptor 09915-77330 meter (for high pressure) 09916-10911 valve lapper set 09916-14510 valve spring compressor 09916-20610 valve seat cutter head (n-121) 09916-20620 valve seat cutter head (n-122) 09916-206...

  • Page 337

    8-32 servicing information 09930-11940 bit holder 09930-11960 torx wrench 09930-30102 sliding shaft 09930-30450 rotor remover 09930-44530 generator rotor holder 09930-82710 mode selection switch 09940-14911 steering stem nut wrench 09940-30250 front fork assembling tool 09940-40211 fuel pressure gau...

  • Page 338: Tightening Torque

    Servicing information 8-33 tightening torque engine item n.M kgf.M lb-ft exhaust pipe bolt 23 2.3 16.5 exhaust pipe connecting bolt 20 2.0 14.5 muffler connecting bolt 24 2.4 17.5 muffler mounting bolt 23 2.3 16.5 speed sensor rotor bolt 20 2.0 14.5 engine sprocket nut 115 11.5 83.0 cylinder head co...

  • Page 339

    8-34 servicing information item n.M kgf.M lb-ft balancer lever bolt 10 1.0 7.3 balancer cover bolt 10 1.0 7.3 piston cooling oil jet bolt 10 1.0 7.3 oil pump mounting bolt 10 1.0 7.3 conrod bearing cap bolt (initial) 21 2.1 15.5 (final) 90° (¼ turn) bearing retainer screw 10 1.0 7.3 breather cover b...

  • Page 340

    Servicing information 8-35 chassis item n.M kgf.M lb-ft steering stem head nut 65 6.5 47.0 steering stem nut 45 4.5 32.5 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 23 2.3 16.5 front fork cap bolt 23 2.3 16.5 front fork inner rod lock nut 15 1.5 11.0 front fork damper rod bol...

  • Page 341

    8-36 servicing information 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 342: Service Data

    Servicing information 8-37 service data valve + guide unit: mm (in) item std/spec. Limit valve diam. In. 28.5 (1.12) ——— ex. 25 (0.98) ——— 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 343

    8-38 servicing information 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”) 24th pin ——— cylinder head distortion 0.20 ——— (0.008) cylinder + piston + piston ring unit: mm (in) item std/spec. Limi...

  • Page 344

    Servicing information 8-39 conrod + crankshaft unit: mm (in) item std/spec. Limit conrod small end i.D. 18.010 – 18.018 18.040 (0.7091 – 0.7094) (0.7102) conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) conrod big end width 20.950 – 21.000 (0.8248 – 0.8268) ——— crank pin width ...

  • Page 345

    8-40 servicing information transmission + drive chain unit: mm (in) except ratio item std/spec. Limit primary reduction ratio 1.509 (83/55) ——— final reduction ratio 2.277 (41/18) ——— gear ratios low 2.916 (35/12) ——— 2nd 1.937 (31/16) ——— 3rd 1.526 (29/19) ——— 4th 1.285 (27/21) ——— 5th 1.136 (25/22...

  • Page 346

    Servicing information 8-41 fi sensors + secondary throttle valve actuator item std/spec. Note cmp sensor output voltage more than 3.7 v ckp sensor resistance 134 – 202 Ω ckp sensor peak voltage more than 2.7 v iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.5 v at idle speed...

  • Page 347

    8-42 servicing information throttle body item std/spec. Bore size 34 mm i.D. No. 42f0 idle r/min. 1 100 ± 100 r/min. Fast idle r/min. 1 500 – 1 700 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 firing order 1.2.4.3 spark p...

  • Page 348

    Servicing information 8-43 wattage item std/spec. Headlight hi 60 w lo 55 w parking or position light 5 w (except for e-24) brake light/taillight 21/5 w × 2 turn signal light 21 w × 4 speedometer light led tachometer light led turn signal indicator light led high beam indicator light led neutral ind...

  • Page 349

    8-44 servicing information 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, 17 m/c × mt 3.50 ——— rear 17 × mt 6.00, 17 m/c × mt 6.00 ——— wheel axle runout front ——— 0.25 (0.010) rear ——— 0.25 (0.010) tire unit: mm (in) item std/spec....

  • Page 350

    Servicing information 8-45 item std/spec. Limit rear wheel travel 123 (4.8) ——— swingarm pivot shaft runout 0.3 ——— (0.01) fuel + oil item std/spec. Note fuel type fuel tank capacity including 22 l reserve (5.8/4.8 us/lmp gal) engine oil type sae 10w/40, api, sf or sg engine oil capacity change 4 20...

  • Page 351: Gsx1400K3 (’03-Model)

    Gsx1400k3 (’03-model) 9-1 contents gsx1400k3 (’03-model) 9 this chapter describes service specifications, service data and servicing procedurers which dif- fer from those of the gsx1400k2 (’02-model). Note: * any differences between the gsx1400k2 (’02-model) and gsx1400k3 (’03-model) in specificatio...

  • Page 352: Specifications

    9-2 gsx1400k3 (’03-model) specifications dimensions and dry mass overall length ......................................................................... 2 160 mm (85.0 in) overall width........................................................................... 810 mm (31.9 in) overall height .........

  • Page 353: Engine

    Gsx1400k3 (’03-model) 9-3 engine gearshift cam ! Gearshift cam stopper plate bolt: 13 n·m (1.3 kgf-m, 9.5 lb-ft) chassis steering steering stem bearings have been changed from ball type to taper-roller type. Gearshift cam stopper plate bolt taper-roller bearing www.Gsx1400fe.Com.

  • Page 354

    9-4 gs x 14 00k 3 (’0 3-mo d e l ) w ir ing di agram o/lo/l o/ro/r o/bo/b o/wo/w b/rb/r b/lb/l y/gy/g o/l o/r o/b o/w b/r b/l y/g grgr gr only for e-24 stp sensor b/gb/g r o/ro/r p/bp/b g/yg/y br/bbr/b b/wb/w b lglg o/go/g y bl/bbl/b grgr b/wb/w y/by/b r o o/yo/y b/wb/w grgr brbr o/go/g grgr o y/wy/...

  • Page 355: Wire Harness Routing

    Gsx1400k3 (’03-model) 9-5 wire harness routing clamp clamp (after binding the lead wires, cut the projection of the clamp.) clamp (after binding the lead wires, cut the projection of the clamp.) clamp clamp (after binding the lead wires, cut the projection of the clamp.) clamp clamp clamp clamp clam...

  • Page 356: Service Data

    9-6 gsx1400k3 (’03-model) service data valve + guide unit: mm (in) item std/spec. Limit valve diam. In. 28.5 (1.12) — ex. 25 (0.98) — 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 clearance in. 0.010 – 0.037 (0.0004 – 0.0015...

  • Page 357

    Gsx1400k3 (’03-model) 9-7 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item std/spec. Limit cam height in. 35.28 – 35.33 (1.389 – 1.391) 34.98 (1.377) ex. 34.18 – 34.22 (1.346 – 1.347) 33.88 (1.334) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.001...

  • Page 358

    9-8 gsx1400k3 (’03-model) conrod + crankshaft unit: mm (in) oil pump item std/spec. Limit piston ring thickness 1st 1.175 – 1.190 (0.0463 – 0.0469) — 2nd 0.970 – 0.990 (0.0382 – 0.0390) — piston pin bore 18.002 – 18.008 (0.7087 – 0.7090) 18.030 (0.7098) piston pin o.D. 17.996 – 18.000 (0.7085 – 0.70...

  • Page 359

    Gsx1400k3 (’03-model) 9-9 clutch unit: mm (in) drive train unit: mm (in) except ratio injector + fuel pump + fuel pressure regulator item std/spec. Limit drive plate thickness no. 1, 2 and 3 3.22 – 3.38 (0.127 – 0.133) 2.92 (0.115) drive plate claw width no. 1, 2 and 3 13.7 – 13.8 (0.5394 – 0.5433) ...

  • Page 360

    9-10 gsx1400k3 (’03-model) fi sensors + secondary throttle valve actuator throttle body item std/spec. Note cmp sensor peak voltage more than 3.7 v ckp sensor resistance 134 – 202 Ω ckp sensor peak voltage more than 2.7 v iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.5 v a...

  • Page 361

    Gsx1400k3 (’03-model) 9-11 electrical unit: mm (in) item std/spec. Note firing order 1·2·4·3 spark plug type ngk: cr8ek denso: u24etr gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 (0.3) at 1 atm. Ckp sensor resistance 134 – 202 Ω ckp sensor peak voltage more than 2.7 v +: y -: bl ignition c...

  • Page 362

    9-12 gsx1400k3 (’03-model) wattage unit: w brake + wheel unit: mm (in) item std/spec. Headlight hi 60 w lo 55 w parking or position light 5 w (except for e-24) brake light/taillight 21/5 w × 2 turn signal light 21 w × 4 speedometer light led tachometer light led turn signal indicator light led high ...

  • Page 363

    Gsx1400k3 (’03-model) 9-13 tire unit: mm (in) 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, 17 m/c × mt 3.50 — rear 17 × mt 6.00, 17 m/c × mt 6.00 — wheel axle runout front — 0.25 (0.010) rear — 0.25 (0.010) item std/spec. Limit cold ...

  • Page 364

    9-14 gsx1400k3 (’03-model) suspension unit: mm (in) fuel + oil item std/spec. Limit front fork stroke 130 (5.12) — front fork spring free length 322.6 (12.70) 316 (12.44) front fork oil level (without spring, outer tube fully compressed) 108 (4.25) — front fork oil type suzuki fork oil l01 or an equ...

  • Page 365: Gsx1400K4 (’04-Model)

    Gsx1400k4 (’04-model) 10-1 contents gsx1400k4 (’04-model) 10 this chapter describes service specifications, service data and servicing procedurers which dif- fer from those of the gsx1400k3 (’03-model). Note: * any differences between the gsx1400k3 (’03-model) and gsx1400k4 (’04-model) in specificat...

  • Page 366: Specifications

    10-2 gsx1400k4 (’04-model) specifications dimensions and dry mass overall length ...................................................................................... 2 160 mm (85.0 in) overall width ....................................................................................... 810 mm (31....

  • Page 367: Service Data

    Gsx1400k4 (’04-model) 10-3 service data valve + guide unit: mm (in) item std/spec. Limit valve diam. In. 28.5 (1.12) — ex. 25 (0.98) — 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 clearance in. 0.010 – 0.037 (0.0004 – 0.001...

  • Page 368

    10-4 gsx1400k4 (’04-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item std/spec. Limit cam height in. 35.28 – 35.33 (1.389 – 1.391) 34.98 (1.377) ex. 34.18 – 34.22 (1.346 – 1.347) 33.88 (1.334) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.00...

  • Page 369

    Gsx1400k4 (’04-model) 10-5 conrod + crankshaft unit: mm (in) oil pump item std/spec. Limit piston ring thickness 1st 1.175 – 1.190 (0.0463 – 0.0469) — 2nd 0.970 – 0.990 (0.0382 – 0.0390) — piston pin bore 18.002 – 18.008 (0.7087 – 0.7090) 18.030 (0.7098) piston pin o.D. 17.996 – 18.000 (0.7085 – 0.7...

  • Page 370

    10-6 gsx1400k4 (’04-model) clutch unit: mm (in) drive train unit: mm (in) except ratio injector + fuel pump + fuel pressure regulator item std/spec. Limit drive plate thickness no. 1, 2 and 3 3.22 – 3.38 (0.127 – 0.133) 2.92 (0.115) drive plate claw width no. 1, 2 and 3 13.7 – 13.8 (0.5394 – 0.5433)...

  • Page 371

    Gsx1400k4 (’04-model) 10-7 fi sensors + secondary throttle valve actuator throttle body item std/spec. Note cmp sensor peak voltage more than 3.7 v ckp sensor resistance 134 – 202 Ω ckp sensor peak voltage more than 2.7 v iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.5 v a...

  • Page 372

    10-8 gsx1400k4 (’04-model) electrical unit: mm (in) item std/spec. Note firing order 1·2·4·3 spark plug type ngk: cr8ek denso: u24etr gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 (0.3) at 1 atm. Ckp sensor resistance 134 – 202 Ω ckp sensor peak voltage more than 2.7 v +: y -: bl ignition c...

  • Page 373

    Gsx1400k4 (’04-model) 10-9 wattage unit: w brake + wheel unit: mm (in) item std/spec. Headlight hi 60 w lo 55 w parking or position light 5 w (except for e-24) brake light/taillight 21/5 w × 2 turn signal light 21 w × 4 speedometer light led tachometer light led turn signal indicator light led high ...

  • Page 374

    10-10 gsx1400k4 (’04-model) tire unit: mm (in) item std/spec. Limit wheel rim runout axial — 2.0 (0.08) radial — 2.0 (0.08) wheel rim size front 17 m/c × mt 3.50 — rear 17 m/c × mt 6.00 — wheel axle runout front — 0.25 (0.010) rear — 0.25 (0.010) item std/spec. Limit cold inflation tire pressure (so...

  • Page 375

    Gsx1400k4 (’04-model) 10-11 suspension unit: mm (in) fuel + oil item std/spec. Limit front fork stroke 130 (5.12) — front fork spring free length 322.6 (12.70) 316 (12.44) front fork oil level (without spring, outer tube fully compressed) 108 (4.25) — front fork oil type suzuki fork oil l01 or an eq...

  • Page 376: Periodic Maintenance Chart

    10-12 gsx1400k4 (’04-model) periodic maintenance chart i = inspect and adjust, clean, lubricate or replace as necessary r= replace t= tighten interval item km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 15 000 months 2 12 24 36 48 air cleaner element — i i r i spark plugs — i r i r...

  • Page 377

    G s x 1400k 4 (’ 04-mo d e l ) 10-13 wi ri ng d iagr am push push l push r hi lo free on off on off free push on off on off off on off on off run push on off lock p speedometer ignition switch sp ta n h o r l : speedometer light : tachometer light : neutral indicator light : high beam indicator ligh...

  • Page 378: Gsx1400K5/udk5 (’05-Model)

    Gsx1400k5/udk5 (’05-model) 11-1 contents gsx1400k5/udk5 (’05-model) 11 this chapter describes service specifications, service data and servicing procedurers which dif- fer from those of the gsx1400k4 (’04-model). Note: * any differences between the gsx1400k4 (’04-model) and gsx1400k5/udk5 (’05-model...

  • Page 379: Specifications

    11-2 gsx1400k5/udk5 (’05-model) specifications imensions and dry mass overall length ...................................................................................... 2 160 mm (85.0 in) overall width ....................................................................................... 810 mm ...

  • Page 380: Service Data

    Gsx1400k5/udk5 (’05-model) 11-3 service data valve + guide unit: mm (in) item std/spec. Limit valve diam. In. 28.5 (1.12) — ex. 25 (0.98) — 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 clear- ance in. 0.010 – 0.037 (0.0004 ...

  • Page 381

    11-4 gsx1400k5/udk5 (’05-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item std/spec. Limit cam height in. 35.28 – 35.33 (1.389 – 1.391) 34.98 (1.377) ex. 34.18 – 34.22 (1.346 – 1.347) 33.88 (1.334) camshaft journal oil clearance in. & ex. 0.032 – 0.066 ...

  • Page 382

    Gsx1400k5/udk5 (’05-model) 11-5 conrod + crankshaft unit: mm (in) oil pump item std/spec. Limit piston ring thickness 1st 1.175 – 1.190 (0.0463 – 0.0469) — 2nd 0.970 – 0.990 (0.0382 – 0.0390) — piston pin bore 18.002 – 18.008 (0.7087 – 0.7090) 18.030 (0.7098) piston pin o.D. 17.996 – 18.000 (0.7085 ...

  • Page 383

    11-6 gsx1400k5/udk5 (’05-model) clutch unit: mm (in) drive train unit: mm (in) except ratio item std/spec. Limit drive plate thickness no. 1, 2 and 3 3.22 – 3.38 (0.127 – 0.133) 2.92 (0.115) drive plate claw width no. 1, 2 and 3 13.7 – 13.8 (0.5394 – 0.5433) 12.9 (0.5079) driven plate distortion — 0...

  • Page 384

    Gsx1400k5/udk5 (’05-model) 11-7 injector + fuel pump + fuel pressure regulator fi sensors + secondary throttle valve actuator throttle body item std/spec. Note injector resistance 12 – 18 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...

  • Page 385

    11-8 gsx1400k5/udk5 (’05-model) electrical unit: mm (in) item std/spec. Note firing order 1·2·4·3 spark plug type ngk: cr8ek denso: u24etr gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 (0.3) at 1 atm. Ckp sensor resistance 134 – 202 Ω ckp sensor peak voltage more than 2.7 v +: y -: bl ignit...

  • Page 386

    Gsx1400k5/udk5 (’05-model) 11-9 wattage unit: w brake + wheel unit: mm (in) item std/spec. Headlight hi 60 w lo 55 w parking or position light 5 w (except for e-24) brake light/taillight 21/5 w × 2 turn signal light 21 w × 4 speedometer light led tachometer light led turn signal indicator light led ...

  • Page 387

    11-10 gsx1400k5/udk5 (’05-model) tire unit: mm (in) item std/spec. Limit wheel rim runout axial — 2.0 (0.08) radial — 2.0 (0.08) wheel rim size front 17 m/c × mt 3.50 — rear 17 m/c × mt 6.00 — wheel axle runout front — 0.25 (0.010) rear — 0.25 (0.010) item std/spec. Limit cold inflation tire pressur...

  • Page 388

    Gsx1400k5/udk5 (’05-model) 11-11 suspension unit: mm (in) fuel + oil item std/spec. Limit front fork stroke 130 (5.12) — front fork spring free length 322.6 (12.70) 316 (12.44) front fork oil level (without spring, outer tube fully compressed) 108 (4.25) — front fork oil type suzuki fork oil l01 or ...

  • Page 389: Immobilizer

    11-12 gsx1400k5/udk5 (’05-model) immobilizer • the immobilizer, an anti-theft system, is installed as a standard equipment. • the immobilizer verifies that the key id agrees with ecm id by means of radio communication through the immobilizer antenna. When the id agreement is verified, the system mak...

  • Page 390

    Gsx1400k5/udk5 (’05-model) 11-13 operation • when the ignition switch is turned on with the engine stop switch in on, the immobi-antenna and ecm are powered on. The ecm transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key id and ecm id. With th...

  • Page 391

    11-14 gsx1400k5/udk5 (’05-model) exhaust pipe/muffler installation 23 n·m (2.3 kgf-m, 16.5 lb-ft) use a new connector. Apply permatex 1372. Use a new gasket. 23 n·m (2.3 kgf-m, 16.5 lb-ft) 24 n·m (2.4 kgf-m, 17.5 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) 20 n·m (2.0 kgf-m, 14.4 lb-ft) use a new connecto...

  • Page 392: Center Stand Installation

    Gsx1400k5/udk5 (’05-model) 11-15 center stand installation www.Gsx1400fe.Com.

  • Page 393: Wire Harness Routing

    11-16 gsx1400k5/udk5 (’05-model) wire harness routing clamp (after binding the lead wires, cut the projection of the clamp.) to the right horn to the left horn clamp (after binding the lead wires, cut the projection of the clamp.) clamp clamp clamp fuel injector lead wire/wiring harness clamp (after...

  • Page 394: Wiring Diagram

    Gsx1400k5/udk5 (’05-model) 11-17 wiring diagram push push l push r hi lo free on off on off free push on off on off off on off on off ru n push on off lock p speedometer ignition switch sp ta n h o r l : speedometer light : t a chometer light : neutral indica t or light : high beam indica t or light...

  • Page 395

    Prepared by 2nd ed. May, 2005 1st ed. March, 2001 part no. 99500-39222-01e printed in japan 404 www.Gsx1400fe.Com.

  • Page 396

    Printed in japan k2 k3 k4 k5 www.Gsx1400fe.Com.