Мануал на русском suzuki gsx r1000

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  GSX-R1000 9 9 5 0 0 — 3 9 3 1 0 — 0 1 E PDF processed with CutePDF evaluation edition www.CutePDF.com…

• Page 2: Table Of Contents

  FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.

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  GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE……………. 1- 2 GENERAL PRECAUTIONS …………….. 1- 2 SUZUKI GSX-R1000K7 (’07-MODEL)…………1- 4 SERIAL NUMBER LOCATION …………..1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION…… 1- 5 FUEL (FOR USA AND CANADA)…………1- 5 FUEL (FOR OTHER COUNTRIES) …………1- 5 ENGINE OIL (FOR USA)……………

• 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. Indicates a potential hazard that could result in death or injury.

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  GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

• Page 6: Suzuki Gsx-R1000K7 (’07-Model)

  1-4 GENERAL INFORMATION SUZUKI GSX-R1000K7 (’07-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head pipe.

• Page 7: Fuel, Oil And Engine Coolant Recommendation

  Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

• Page 8: Front Fork Oil

  Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

• Page 9: Break-In Procedures

  GENERAL INFORMATION 1-7 BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.

• Page 10: Information Labels

  1-8 GENERAL INFORMATION INFORMATION LABELS GSX-R1000 GSX-R1000UF Noise label A (For E-03, 24, 33) Information label A (For E-03, 28, 33) Vacuum hose routing label A (For E-33) Fuel caution label A (For E-02, 24) Fuel information label Manual notice label A (For E-03, 33) Screen label Warning steering label…

• Page 11: Specifications

  GENERAL INFORMATION 1-9 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………….2 045 mm (80.5 in) Overall width …………….720 mm (28.3 in) Overall height …………….1 130 mm (44.5 in) Wheelbase …………….1 415 mm (55.7 in) Ground clearance…………..130 mm (5.1 in) Seat height …………….

• Page 12: Chassis

  1-10 GENERAL INFORMATION CHASSIS Front suspension …………..Inverted telescopic, coil spring, oil damped Rear suspension …………..Link type, coil spring, oil damped Front fork stroke…………..125 mm (4.9 in) Rear wheel travel …………..135 mm (5.3 in) Steering angle…………….. 27° Caster ………………

• Page 13: Periodic Maintenance

  PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ………… 2- 2 PERIODIC MAINTENANCE CHART…………. 2- 2 LUBRICATION POINTS ……………. 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ……………….. 2- 4 AIR CLEANER………………2- 4 SPARK PLUG………………2- 5 VALVE CLEARANCE…………….2- 7 ENGINE OIL AND OIL FILTER ………….

• Page 14: Periodic Maintenance Schedule

  2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions.

• Page 15: Lubrication Points

  PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Brake pedal pivot and footrest pivot Clutch lever holder Side-stand pivot Footrest pivot and and spring hook…

• Page 16: Maintenance And Tune-Up Procedures

  2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months). Replace every 18 000 km (11 000 miles, 36 months). •…

• Page 17: Spark Plug

  PERIODIC MAINTENANCE 2-5 SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). Replace every 12 000 km (7 500 miles, 24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Lift and support the fuel tank. (5-3) •…

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  2-6 PERIODIC MAINTENANCE SPARK PLUG GAP • Measure the spark plug gap » with a wire gauge. • If it is not within the specification, replace the spark plug. * To prevent the damage of iridium center electrode, use a wire gauge to check the gap. * Never adjust the spark plug gap.

• Page 19: Valve Clearance

  PERIODIC MAINTENANCE 2-7 VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-14) • Disconnect the CMP sensor coupler •…

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  2-8 PERIODIC MAINTENANCE • Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches $ on the left ends of both camshafts (Ex. and In.) to the positions as shown.
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  PERIODIC MAINTENANCE 2-9 VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (3-16) • Remove the tappet and shim by fingers or magnetic hand. •…
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  2-10 PERIODIC MAINTENANCE (INTAKE SIDE)
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  PERIODIC MAINTENANCE 2-11 (EXHAUST SIDE)

• Page 24: Engine Oil And Oil Filter

  2-12 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.

• Page 25: Exhaust Control Valve

  Oil and filter change : 3.3 L (3.5/2.9 US/Imp qt) Engine overhaul : 3.6 L (3.8/3.2 US/Imp qt) ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.

• Page 26: Fuel Line

  2-14 PERIODIC MAINTENANCE • Remove the right under cowling. (8-5) • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play (6-9) and tighten them. FUEL LINE Inspect every 6 000 km (4 000 miles, 12 months). •…

• Page 27: Throttle Cable Play

  PERIODIC MAINTENANCE 2-15 THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. • Adjust the throttle cable play » as follows. • Loosen the lock-nut of the throttle pulling cable •…

• Page 28: Clutch

  2-16 PERIODIC MAINTENANCE CLUTCH (CLUTCH HOSE AND CLUTCH FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hose every 4 years. Replace fluid every 2 years. CLUTCH FLUID LEVEL • Keep the motorcycle upright and place the handlebars straight.
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  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 clutch master cylinder reservoir to the upper line. Place the reservoir cap to prevent entry of dirt.

• Page 30: Cooling System

  2-18 PERIODIC MAINTENANCE COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the upper and lower lines on the engine coolant reservoir.

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  PERIODIC MAINTENANCE 2-19 AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •…
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  2-20 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the under cowlings. (8-5) • Lift and support the fuel tank. (5-3) • Remove the sprocket cover bolts. • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one.

• Page 33: Drive Chain

  PERIODIC MAINTENANCE 2-21 DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below.

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  * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is DID530 V9. Suzuki rec- ommends to use this standard drive chain as a replacement.

• Page 35: Brake

  PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years.

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  2-24 PERIODIC MAINTENANCE BRAKE PADS Front brake The extent of brake pad wear can be checked by observing the grooved limit line » on the pads. When the wear exceeds the grooved limit line, replace the pads with the new ones. (8-66) Replace the brake pads as a set, otherwise braking performance will be adversely affected.

• Page 37: Brake Pedal Height

  PERIODIC MAINTENANCE 2-25 BRAKE PEDAL HEIGHT • Loosen the lock-nut • Turn the push rod until the brake pedal height becomes 65 – 75 mm (2.6 – 3.0 in) » below the top of the footrest. • Tighten the lock-nut securely.

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  2-26 PERIODIC MAINTENANCE FRONT BRAKE (Caliper side) • Fill the master cylinder reservoir to the upper level. Place the reservoir cap to prevent dirt from entering. • Attach a hose to the brake caliper air bleeder valve and insert the free end of the hose into a receptacle. •…

• Page 39: Tires

  PERIODIC MAINTENANCE 2-27 TIRES Inspect every 6 000 km (4 000 miles, 12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.

• Page 40: Steering

  2-28 PERIODIC MAINTENANCE STEERING Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtighten steering pre- vents smooth turning of the handlebars and too loose steering will cause poor stability.

• Page 41: Exhaust Pipe Bolt And Muffler Bolt

  PERIODIC MAINTENANCE 2-29 EXHAUST PIPE BOLT AND MUFFLER BOLT Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolts and muffler connecting bolts to the specified torque.

• Page 42: Chassis Bolts And Nuts

  2-30 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m…

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  PERIODIC MAINTENANCE 2-31…

• Page 44: Compression Pressure Check

  2-32 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit…

• Page 45: Oil Pressure Check

  PERIODIC MAINTENANCE 2-33 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 100 – 400 kPa (1.0 – 4.0 kgf/cm , 14 – 57 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) If the oil pressure is lower or higher than the specification, the following causes may be considered.

• Page 46: Sds Check

  2-34 PERIODIC MAINTENANCE SDS CHECK Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.

• Page 47: Data At The Time Of Racing

  PERIODIC MAINTENANCE 2-35 Data at 3 000 r/min under no load Approx. 3 000 r/min Check the engine coolant temperature. XX ˚C Check the manifold absolute pressure. XX kPa Data at the time of racing Secondary throttle valve opens closes in accordance with the throttle valve opening PAIR control solenoid valve OFF in accordance with…

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  2-36 PERIODIC MAINTENANCE Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. Approx. 100 ˚C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XX kPa…
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  PERIODIC MAINTENANCE 2-37 Example of trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring.
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  ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION……….3- 3 ENGINE REMOVAL …………….3- 3 ENGINE INSTALLATION …………..3-10 ENGINE DISASSEMBLY …………….3-15 ENGINE COMPONENTS INSPECTION AND SERVICE ………………… 3-29 CYLINDER HEAD COVER…………..

• Page 51: Engine Components Removable With Engine In Place

  3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION…

• Page 52: Engine Removal And Installation

  ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. •…

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  3-4 ENGINE OIL COOLER • Remove the oil cooler hose bolts. • Remove the oil cooler Be careful not to bend the oil cooler fins. RADIATOR • Remove the regulator/rectifier bracket. • Disconnect the water/air bleed hose and radiator inlet hose •…
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  ENGINE 3-5 • Remove the radiator mounting bolts. • Remove the radiator Be careful not to bend the radiator fins. • Remove the horn • Remove the front engine cover MUFFLER, CHAMBER AND EXHAUST PIPE • Remove the EXCV cables along with the bracket •…
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  3-6 ENGINE ELECTRIC PARTS AND PAIR HOSE • Disconnect the oil pressure switch lead wire • Disconnect the starter motor lead wire • Disconnect the ground lead wire • Disconnect the CKP sensor lead wire coupler • Disconnect the ECT sensor lead wire coupler •…
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  ENGINE 3-7 • Remove the ignition coils/plug caps. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage. * Be careful not to drop the ignition coil/plug cap to prevent its short or open circuit. •…
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  3-8 ENGINE • Loosen the rear axle nut • Loosen the chain adjuster lock-nuts (LH and RH). • Loosen the chain adjusters . (LH and RH) • Push the rear wheel forward and make sure that the drive chain has enough slack. •…
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  ENGINE 3-9 • Loosen the engine mounting pinch bolts • Remove the engine mounting bolts # and %. • Remove the engine mounting nut • Remove the engine mounting thrust adjuster lock-nut with the special tool. • Loosen the engine mounting thrust adjuster fully.

• Page 59: Engine Installation

  3-10 ENGINE • Remove the engine mounting nut • Loosen the engine mounting thrust adjuster lock-nut with the special tool. • Loosen the engine mounting thrust adjuster 09940-14980: Engine mounting thrust adjuster socket wrench NOTE: Do not remove the engine mounting bolts at this stage. •…

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  ENGINE 3-11 • Gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft. • Install all engine mounting bolts, spacers and tighten them temporarily. (3-12) Be careful not to catch the wiring harness between the frame and the engine.
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  3-12 ENGINE » LENGTH ITEM N·m kgf-m lb-ft ITEM «#$% «$ 40.0 1.77 54.0 Bolt 2.17 &( 16.5 8.46 16.5 Spacer 30.5 1.20 32.5 Adjuster 1.57 B LH C RH…
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  » Speed sensor rotor bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Apply grease to the clutch push rod end. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the engine sprocket cover • Install the gearshift lever .
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  3-14 ENGINE • Install the exhaust pipes, muffler chamber and mufflers. (6-16) Replace the gaskets and connectors with new ones. • Connect the EXCV cables and install the bracket » EXCV cable bracket nut: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •…

• Page 64: Engine Disassembly

  ENGINE 3-15 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 origi- nal positions. • Remove all the spark plugs. (2-5) • Remove the engine coolant reservoir bracket. STARTER MOTOR •…

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  3-16 ENGINE CAMSHAFT • Remove the valve timing inspection cap • Turn the crankshaft to bring the line » on the starter clutch to the index mark # of the valve timing inspection hole and also to bring the cams to the position as shown below. •…
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  ENGINE 3-17 • Remove the cam chain guide No.2 • Remove the intake camshaft journal holder • Remove the exhaust camshaft journal holder Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.
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  3-18 ENGINE • Remove the cylinder head gasket and dowel pins. CLUTCH • Remove the clutch cover • Remove the gasket and dowel pins. • Hold the clutch housing with the special tool. Do not damage the clutch plates by the special tool. 09920-53740: Clutch sleeve hub holder •…
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  ENGINE 3-19 • Remove the pressure plate • Remove the clutch drive plates and driven plates • Remove the clutch push piece , bearing and the thrust washer • Remove the spring washer and its seat • Remove the clutch push rod NOTE: If it is difficult to pull out the push rod , use a magnetic hand or…
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  3-20 ENGINE • Hold the clutch sleeve hub with the special tool. 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub • Remove the conical spring washer , washer and spring washer seat from the clutch sleeve hub. •…
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  3-20 ENGINE • Hold the clutch sleeve hub with the special tool. 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub #. • Remove the conical spring washer , washer and spring washer seat from the clutch sleeve hub. •…
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  ENGINE 3-21 • Remove the thrust washer • Remove the oil pump drive gear from the primary driven gear assembly OIL PUMP • Remove the snap ring . • Remove the oil pump driven gear . NOTE: Do not drop the snap ring into the crankcase. •…
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  3-22 ENGINE STARTER IDLE GEAR • Remove the starter idle gear cover . • Remove the dowel pins and gasket . • Remove the spring washer , washer and starter idle gear No.1 . • Remove the shaft , bearing and thrust washer . •…
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  ENGINE 3-23 • Remove the dowel pins and gasket . • Remove the spring washer «, starter idle gear No.2 # and shaft STARTER CLUTCH • Hold the starter clutch with the special tool. 09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. •…
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  3-24 ENGINE GENERATOR COVER • Remove the generator cover . • Remove the dowel pins and gasket . GENERATOR ROTOR • Hold the generator rotor with the special tool. 09930-44520: Rotor holder • Remove the generator rotor bolt. • Install a bolt » of suitable size to the left end of crankshaft. SUITABLE BOLT «…
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  ENGINE 3-25 WATER PUMP • Remove the water inlet cover . • Remove the water pump . Water pump servicing ( 7-13) GEAR POSITION SWITCH • Remove the gear position switch . CRANKCASE BREATHER (PCV) COVER • Remove the crankcase breather cover . •…
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  3-26 ENGINE OIL FILTER • Remove the oil filter with the special tool. 09915-40610: Oil filter wrench OIL PAN • Remove the oil pan . • Remove the gasket . • Remove the oil pipe . OIL PRESSURE SWITCH • Remove the oil pressure switch . OIL STRAINER •…
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  ENGINE 3-27 TRANSMISSION • Remove the countershaft assembly and driveshaft assem- bly . • Remove the O-rings and dowel pins. • Remove the C-rings and bearing pins . MIDDLE CRANKCASE • Remove the crankcase bolts (M6). • Remove the crankcase bolts (M6). •…
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  3-28 ENGINE CRANKSHAFT • Remove the O-ring . • Loosen the bearing cap bolts by using 10 mm, 12 point socket wrench, and tap the bearing cap bolts lightly with plastic ham- mer to remove the bearing cap. • Remove the crankshaft and thrust washers . PISTON AND CONROD •…

• Page 79: Engine Components Inspection And Service

  ENGINE 3-29 ENGINE COMPONENTS INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER •…

• Page 80: Camshaft

  3-30 ENGINE INSPECTION • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. INSTALLATION • Install the PAIR reed valves and PAIR reed valve covers. •…

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  ENGINE 3-31 CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge to read the clearance at the widest portion, which is specified as follows: Camshaft journal oil clearance: Service Limit (IN &…

• Page 82: Cam Chain Tension Adjuster

  3-32 ENGINE • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. Camshaft journal holder I.D.: Standard (IN &…

• Page 83: Cam Chain Tensioner

  ENGINE 3-33 CAM CHAIN TENSIONER INSPECTION • Check the contacting surface of the cam chain tensioner. • If it is worn or damaged, replace it with a new one. CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guides No.1 and No.2.
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  3-34 ENGINE • Remove the oil seal and spring seat . Do not reuse the removed oil seal. • Remove the other valves in the same manner as described previously. CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated.
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  ENGINE 3-35 VALVE HEAD RADIAL RUNOUT • Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. • If it measures more than the service limit, replace the valve. Valve head radial runout: Service Limit: 0.03 mm (0.001 in) 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand…
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  3-36 ENGINE VALVE STEM WEAR • If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. • If the stem is within the limit, then replace the guide. • After replacing valve or guide, be sure to recheck the deflec- tion.
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  ENGINE 3-37 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
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  3-38 ENGINE • If the seat width measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter. Valve seat width Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) If the valve seat is out of specification, re-cut the seat. VALVE SEAT SERVICING •…
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  ENGINE 3-39 VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • Check the valve spring for proper strength by measuring its free length and also by the force required to compress it.
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  3-40 ENGINE • Put on the valve spring retainer , and using the special tools, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem. 09916-14510: Valve lifter 09916-14530: Valve lifter attachment 09916-84511: Tweezers…

• Page 91: Clutch

  • Remove the water bypass union . • Apply bond to the thread part of water bypass union and tighten it to the specified torque. 99000-31140: SUZUKI BOND “1207B” or equivalent » Water bypass union: 12 N·m (1.2 kgf-m, 8.5 lb-ft) CLUTCH…

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  3-42 ENGINE • Measure the claw width of drive plates with a vernier calipers. • Replace the drive plates found to have worn down to the limit. Drive plate claw width: Service Limit: 13.05 mm (0.5138 in) 09900-20102: Vernier calipers CLUTCH DRIVEN PLATE INSPECTION NOTE: Wipe off engine oil from the clutch driven plates with a clean rag.

• Page 93: Clutch Lifter

  ENGINE 3-43 CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY • Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one. CLUTCH LIFTER CLUTCH LIFTER DRIVE CAM AND DRIVEN CAM INSPEC- TION •…

• Page 94: Oil Pump

  3-44 ENGINE • Check the height of clutch lifter adjusting pin screws at three positions using the thickness gauges. • If the measurement is out of the specification, adjust the height in the following procedures. NOTE: Each clutch lifter adjusting pin screw height should be as close as possible.

• Page 95: Starter Clutch

  ENGINE 3-45 STARTER CLUTCH INSPECTION • Install the starter driven gear onto the starter clutch . • Turn the starter driven gear by hand. • Inspect the starter clutch for a smooth movement. • Check that the gear turns only in one direction. •…

• Page 96: Water Pump

  3-46 ENGINE WATER PUMP 7-13 GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. Washer Gearshift cam drive plate Snap ring Plate return spring Gearshift shaft return spring GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION •…

• Page 97: Oil Pressure Regulator

  • If the piston does not operate, replace the oil pressure regula- tor with a new one. INSTALLATION • Apply grease to the O-ring. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent Use new O-ring to prevent oil leakage. • Press in the oil pressure regulator to the oil pan.

• Page 98: Transmission

  3-48 ENGINE TRANSMISSION DISASSEMBLY Disassemble the countershaft and driveshaft. Pay attention to the following points: • Remove the 6th drive gear snap ring from its groove and slide it towards the 3rd/4th drive gears . • Slide the 6th and 2nd drive gears toward the 3rd/4th drive gears , then remove the 2nd drive gear circlip .

• Page 99
  * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply grease to it. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent * Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.
• Page 100
  3-50 ENGINE TRANSMISSION PARTS LOCATION Countershaft Driveshaft…

• Page 101: Cylinder

  ENGINE 3-51 CYLINDER CRANKCASE SERVICING (3-55) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set.

• Page 102: Piston And Piston Ring

  3-52 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) » from the piston skirt end. • If the measurement is less than the limit, replace the piston. Piston diameter: Service Limit: 73.280 mm (2.8850 in) at 10 mm (0.39 in) from the skirt end…

• Page 103: Piston Ring Thickness

  ENGINE 3-53 PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0 –…

• Page 104: Piston Ring End Gap

  3-54 ENGINE PISTON RING FREE END GAP AND PISTON RING END GAP • Measure the piston ring free end gap using the vernier cali- pers. • Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. •…

• Page 105: Crankcase

  ENGINE 3-55 CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer screws gearshift fork shaft retainer from the lower crankcase. • Remove the gearshift fork shafts and gearshift forks from the lower crankcase. • Remove the gearshift cam and its bearing GEARSHIFT FORK-TO-GROOVE CLEARANCE •…

• Page 106
  3-56 ENGINE GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers. Shift fork thickness: Standard: 4.8 – 4.9 mm (0.189 – 0.193 in) 09900-20102: Vernier calipers GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT BEARING Bearing inspection •…
• Page 107
  • Install the oil seal with the special tool. 09913-70210: Bearing installer set (¬22) • Apply grease to the oil seal lip. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the gearshift cam with the bearing…
• Page 108
  3-58 ENGINE • Install the gearshift forks and their shafts as shown. For 3rd/4th drive gears For 5th driven gear For 6th driven gear • Apply a small quantity of thread lock to the bearing retainer screws • Tighten the bearing retainer screws and gearshift fork shaft retainer bolt to the specified torque.
• Page 109
  ENGINE 3-59 OIL JET Removal • Remove the piston cooling oil jets from the upper crank- case. • Remove the oil jet (for transmission) from the lower crank- case. • Remove the oil jet (for cam chain tension adjuster) from the cylinder head.
• Page 110
  3-60 ENGINE Installation • Fit new O-ring to each piston cooling oil jet and apply engine oil to them. Use new O-rings to prevent oil pressure leakage. • Install each piston cooling oil jet with the bolt. NOTE: Apply a small quantity of thread lock to the bolts and tighten them to the specified torque.
• Page 111
  ENGINE 3-61 • Remove the water jacket plugs • Remove the oil gallery plugs (for lower crankcase side). Installation • Apply engine coolant to the O-rings of the water jacket plugs • Apply thread lock to the oil gallery plug H 99000-32110: THREAD LOCK SUPER “1322”…

• Page 112: Balancer Shaft

  3-62 ENGINE BALANCER SHAFT DISASSEMBLY • Remove the balancer gear along with the dampers from the balancer shaft. INSPECTION • Inspect the damper for wear and damage, replace it if any defects are found. REASSEMBLY • Apply MOLYBDENUM OIL SOLUTION to each part. P MOLYBDENUM OIL SOLUTION •…

• Page 113
  ENGINE 3-63 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. Balancer shaft journal oil clearance: Standard: 0.028 –…

• Page 114: Crankshaft And Conrod

  3-64 ENGINE INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part » first and press the other end. Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.

• Page 115
  ENGINE 3-65 CONROD BIG END SIDE CLEARANCE • Inspect the conrod side clearance by using a thickness gauge. • If the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width. •…
• Page 116
  3-66 ENGINE *1: The number faces the intake side. • Remove the bearing caps and measure the width of the com- pressed plastigauge using the envelope scale. This measure- ment should be taken at the widest part of the compressed plastigauge.
• Page 117
  ENGINE 3-67 Crank pin O.D. Code O.D. specification 34.992 – 35.000 mm (1.3776 – 1.3780 in) 34.984 – 34.992 mm (1.3773 – 1.3776 in) 34.976 – 34.984 mm (1.3770 – 1.3773 in) 09900-20202: Micrometer (25 – 50 mm) Bearing thickness Color (Part No.) Thickness…

• Page 118: Crankshaft Journal Bearing

  3-68 ENGINE CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and middle crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown. 09900-22301: Plastigauge Never rotate the crankshaft when a piece of plasti- gauge is installed.

• Page 119
  ENGINE 3-69 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. Crankshaft journal oil clearance: Standard: 0.010 – 0.028 mm (0.0004 – 0.0011 in) Service Limit: 0.080 mm (0.0031 in) •…
• Page 120
  3-70 ENGINE Crankshaft journal O.D. specification Code O.D. specification 34.994 – 35.000 mm (1.3777 – 1.3780 in) 34.988 – 34.994 mm (1.3775 – 1.3777 in) 34.982 – 34.988 mm (1.3772 – 1.3775 in) 09900-20202: Micrometer (25 – 50 mm) Bearing thickness specification Color (Part No.) Thickness…

• Page 121: Crankshaft Thrust Bearing

  ENGINE 3-71 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. -: Left-side thrust bearing 3: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.

• Page 122
  3-72 ENGINE Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.570 – 2.590 mm Brown 2.480 – 2.500 mm 0.070 – 0.110 mm (0.1012 – 0.1020 in) (12228-48B00-0B0) (0.0976 – 0.0984 in) (0.0028 –…

• Page 123: Engine Reassembly

  ENGINE 3-73 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. •…

• Page 124
  3-74 ENGINE • Be sure to bring the concave side of 1st ring to the top when fitting it to the piston. • 2nd ring has letters “T” marked on the side. Be sure to bring the marked side ring to the top when fitting it to the piston. •…
• Page 125
  ENGINE 3-75 • Apply a small quantity of MOLYBDENUM OIL SOLUTION to the sliding surface of the pistons and cylinder walls. P MOLYBDENUM OIL SOLUTION NOTE: Be sure to install the pistons in the cylinders from which they were removed in disassembly, referring to the cylinder numbers, “1”…
• Page 126
  3-76 ENGINE CRANKSHAFT • Position the No.2 and No.3 conrod big ends on the same side, and the No.1 and No.4 conrod big ends on the opposite side of No.2 and No.3. • Set the crankshaft to the conrods and upper crankcase. •…
• Page 127
  ENGINE 3-77 • Apply a MOLYBDENUM OIL SOLUTION to each crankshaft journal and bearing lightly. P MOLYBDENUM OIL SOLUTION • Insert the right and left-thrust bearings with oil groove # fac- ing the crank web. NOTE: Right-thrust bearing has green painting. BALANCER SHAFT •…
• Page 128
  3-78 ENGINE • Apply bond to the mating surface of the middle crankcase. D 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: Use of 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 crankcases within few minutes.
• Page 129
  ENGINE 3-79 • Tighten the other crankcase bolts a little at a time to equalize the pressure. » Crankcase bolt: (M6) Initial: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Final : 11 N·m (1.1 kgf-m, 8.0 lb-ft) (M8) Initial : 15 N·m (1.5 kgf-m, 11.0 lb-ft) Final : 26 N·m (2.6 kgf-m, 19.0 lb-ft) NOTE: Fit a new gasket washer to the crankcase bolt «.
• Page 130
  3-80 ENGINE TRANSMISSION • Install the bearing pins and the C-rings on the middle crankcase. • Install the countershaft assembly to the middle crankcase. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. •…
• Page 131
  ENGINE 3-81 • Apply bond to the mating surface of the lower crankcase. D 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: Use of bond is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Apply to both mating surfaces of crankcases at hatched parts.
• Page 132
  • Check that the countershaft and driveshaft rotate smoothly. OIL STRAINER • Install the O-ring. • Apply grease to the O-ring. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent Use a new O-ring to prevent oil leakage. • Install the oil strainer and tighten the oil strainer bolts to the specified torque.
• Page 133
  OIL PRESSURE SWITCH • Apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. D 99000-31140: SUZUKI BOND “1207B” or equivalent » Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft) NOTE: Be careful not to apply bond to the hole of thread end.
• Page 134
  • Apply grease to the O-ring. NOTE: Align the gear position switch pin » with the gearshift cam hole X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the gear position switch. • Apply thread lock to the gear position switch bolts.
• Page 135
  ENGINE 3-85 WATER PUMP • Apply grease to the O-ring. Use a new O-ring to prevent oil leakage. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the water pump mounting bolts to the specified torque. » Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Page 136
  • Apply bond lightly to the mating surfaces at the parting line between the upper and middle crankcases as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent • Install the dowel pins and new gasket Use a new gasket to prevent oil leakage.
• Page 137
  • Install the CKP sensor • Apply bond lightly to the groove of signal generator lead wire grommet. D 99000-31140: SUZUKI BOND “1207B” or equivalent CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft. NOTE: When installing the cam chain drive sprocket, align the wide spline teeth «…
• Page 138
  • Apply bond lightly to the mating surfaces » at the parting line between the upper and middle crankcases and surface of grommet # as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent • Install a new gasket and dowel pins.
• Page 139
  ENGINE 3-89 • Install the starter clutch cover and tighten the bolts. NOTE: * Fit a new gasket washer to the bolt $. Use a new gasket washer to prevent oil leakage. » Starter clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •…
• Page 140
  3-90 ENGINE GEARSHIFT SYSTEM • Install the gearshift cam stopper , its bolt , washer return spring NOTE: Apply a small quantity of thread lock to the gearshift cam stop- per bolt and tighten it to the specified torque. H 99000-32110: THREAD LOCK SUPER “1322” or equivalent «…
• Page 141
  Use a new O-ring to prevent oil leakage. NOTE: Set the oil pump shaft end » to the water pump shaft. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the oil pump with the oil pump mounting bolts and then tighten them to the specified torque.
• Page 142
  3-92 ENGINE • Install the oil pump drive gear to the primary driven gear assembly • Install the primary driven gear assembly NOTE: * If it is difficult to install the primary driven gear, rotate the crankshaft. * Be sure to engage the oil pump driven gear with the drive gear and the primary driven gear with the drive gear.
• Page 143
  ENGINE 3-93 • Install the clutch sleeve hub assembly onto the countershaft. • Install the washer and spring washer NOTE: * Before installing the washer , visually inspect the washer surface for wear and damage. If necessary, replace it with a new one.
• Page 144
  3-94 ENGINE • Install the clutch push rod into the countershaft. • Install the clutch push piece , bearing and thrust washer to the countershaft. NOTE: Thrust washer is located between the pressure plate and bearing • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order.
• Page 145
  ENGINE 3-95 *1: Direction of outside *2: Paint DRIVE PLATE: B No. 2 Drive plate..1 pc. [No paint/Friction Piece: 48 pcs/I.D. 111 mm (4.4 in)] C No. 1 Drive plate..8 pcs. [Purple paint/Friction Piece: 36 pcs/I.D. 111 mm (4.4 in)] D No.
• Page 146
  CLUTCH COVER • Apply bond lightly to the mating surfaces at the parting line between the upper, middle and lower crankcases as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent • Install gasket and dowel pins. Use a new gasket to prevent oil leakage.
• Page 147
  ENGINE 3-97 • Install the clutch cover and tighten its bolts to the specified torque. » Clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: * Fit the clamp to the bolt «. * Fit new gasket washers to the bolts #. Use new gasket washers to prevent oil leakage.
• Page 148
  3-98 ENGINE • Tighten the cylinder head bolts to the specified torque. » Cylinder head bolt (M6): 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Fit the gasket and tighten the ECT sensor. » ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •…
• Page 149
  ENGINE 3-99 CAMSHAFT • Turn the crankshaft clockwise with the box wrench and align the line » on the starter clutch with the index mark # of valve timing inspection hole while keeping the cam chain pulled upward. Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.
• Page 150
  3-100 ENGINE • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked “1” $. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. •…
• Page 151
  ENGINE 3-101 • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust, and cam chain guide. • Have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers.
• Page 152
  3-102 ENGINE CAM CHAIN TENSION ADJUSTER • Retract the push rod by pushing the stopper • Fit a new gasket “UP” “UP” Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster with “UP” mark faced to the top side.
• Page 153
  ENGINE 3-103 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Page 154
  • Install new gaskets to the cylinder head cover. • Apply bond to the cam end caps of the gaskets as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent Use new gaskets to prevent oil leakage. • Place the cylinder head cover on the cylinder head.
• Page 155
  ENGINE 3-105 STARTER MOTOR • Apply grease to the O-ring. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the starter motor » Starter motor mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) ENGINE COOLANT RESERVOIR BRACKET • Install the engine coolant reservoir bracket…

• Page 156: Fi System Diagnosis

  FI SYSTEM DIAGNOSIS 4-1 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING …………..4- 3 ELECTRICAL PARTS …………….4- 3 FUSE…………………. 4- 4 SWITCH ………………..4- 4 ECM/VARIOUS SENSORS …………..4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE……4- 6 USING THE MULTI-CIRCUIT TESTER……….4- 9 FI SYSTEM TECHNICAL FEATURES…………

• Page 157
  4-2 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION………………4-79 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION ….4-83 “C41” (P2505) ECM/PCM POWER INPUT SIGNAL MALFUNCTION………………4-86 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION …… 4-87 “C44”…

• Page 158: Precautions In Servicing

  FI SYSTEM DIAGNOSIS 4-3 PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.

• Page 159: Fuse

  4-4 FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
• Page 160
  FI SYSTEM DIAGNOSIS 4-5 • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch , or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

• Page 161: Electrical Circuit Inspection Procedure

  4-6 FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

• Page 162
  FI SYSTEM DIAGNOSIS 4-7 Continuity check • Measure resistance across coupler (between the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals • Disconnect the coupler and measure resistance between couplers If no continuity is indicated, the circuit is open between cou- plers .
• Page 163
  4-8 FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.

• Page 164: Using The Multi-Circuit Tester

  FI SYSTEM DIAGNOSIS 4-9 USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the probes may cause the inside of the tester to burnout.

• Page 165: Fi System Technical Features

  4-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

• Page 166: Compensation Of Injection Time (Volume)

  FI SYSTEM DIAGNOSIS 4-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (volume).

• Page 167: Fi System Parts Location

  4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION Intake air temperature sensor (IATS) Throttle position sensor (TPS) Secondary throttle position sensor (STPS) Secondary throttle valve actuator (STVA) Exhaust control valve actuator (EXCVA) Fuel pump relay (FP relay) Fuel pump (FP) Crankshaft position sensor (CKPS) Heated oxygen sensor (HO2S) Driving mode selection switch (DMSS)

• Page 168
  FI SYSTEM DIAGNOSIS 4-13 — Tip-over sensor (TOS) . Atmospheric pressure sensor (APS) / Engine coolant temperature sensor (ECTS) 0 Camshaft position sensor (CMPS) 1 Gear position switch (GP switch) 2 Speed sensor 3 Cooling fan relay 4 Cooling fan 5 Primary fuel injector 6 Secondary fuel injector 7 Idle speed control valve (ISC valve)

• Page 169: Fi System Wiring Diagram

  4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM Speedometer Cooling fan motor Cooling fan relay 15 A Y/BI R/BI Br/Y *1 Immobilizer signal Fuel pump *2 Ignition switch signal Lg/W Lg/G Speed sensor Lg/BI O/BI Gr/W Camshaft position Gr/B sensor (CMPS) Gr/Y Gr/R Secondary…

• Page 170: Ecm Terminal

  FI SYSTEM DIAGNOSIS 4-15 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT EXCVA power (MO+) IAP sensor signal (IAPS) Speed sensor signal AP sensor signal (APS) STVA signal (STVA 2A) CKP sensor signal (CKPS–) STVA signal (STVA 1A) Gear position switch signal (GP) —…

• Page 171
  4-16 FI SYSTEM DIAGNOSIS TERMINAL TERMINAL CIRCUIT CIRCUIT ISC valve signal (ISC 2A) PAIR control solenoid (PAIR) ISC valve signal (ISC 1B) Secondary injector #4 (#42) ISC valve signal (ISC 1A) Secondary injector #3 (#32) Fuel pump relay (FP relay) Secondary injector #2 (#22) HO2 sensor heater (HO2H) Secondary injector #1 (#12)

• Page 172: Self-Diagnosis Function

  FI SYSTEM DIAGNOSIS 4-17 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.

• Page 173: Dealer Mode

  4-18 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

• Page 174
  FI SYSTEM DIAGNOSIS 4-19 CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air temperature sensor (IATS) Atmospheric pressure sensor (APS) Tip-over sensor (TOS) Ignition signal #1 (IG coil #1)
• Page 175
  4-18 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

• Page 176: Tps Adjustment

  FI SYSTEM DIAGNOSIS 4-21 TPS ADJUSTMENT 1. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 2. If the throttle position sensor adjustment is necessary, loosen the screw and turn the throttle position sensor and bring the line to the middle.

• Page 177: Fail-Safe Function

  4-22 FI SYSTEM DIAGNOSIS 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. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY CMP sensor When camshaft position signal has…

• Page 178
  FI SYSTEM DIAGNOSIS 4-23 STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY Secondary injection signal — “YES” — #2, #3 & #4 cylinders can run. — “YES” — #1, #3 & #4 cylinders can run. — “YES” — #1, #2 & #4 cylinders can run. —…

• Page 179: Fi System Troubleshooting

  4-24 FI SYSTEM DIAGNOSIS FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

• Page 180: Visual Inspection

  FI SYSTEM DIAGNOSIS 4-25 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (…

• Page 181: Self-Diagnostic Procedures

  4-26 FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory. Such disconnection will erase the memorized information in ECM memory.

• Page 182: Use Of Sds Diagnostic Procedures

  FI SYSTEM DIAGNOSIS 4-27 USE OF SDS DIAGNOSTIC PROCEDURES * Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory.

• Page 183: Use Of Sds Diagnosis Reset Procedure

  4-28 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.

• Page 184: Show Data When Trouble (Displaing Data At The Time Of Dtc)

  FI SYSTEM DIAGNOSIS 4-29 SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.

• Page 185: Malfunction Code And Defective Condition

  4-30 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

• Page 186
  FI SYSTEM DIAGNOSIS 4-31 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated.
• Page 187
  4-32 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated.
• Page 188
  FI SYSTEM DIAGNOSIS 4-33 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM FP relay No voltage is applied to the fuel pump, Fuel pump relay, lead wire/cou- although fuel pump relay is turned ON, pler connection, power source to C41 (P0230) or voltage is applied to fuel pump fuel pump relay and fuel injec-…
• Page 189
  4-34 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM EXCV EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- actuator lowing voltage. pler 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1675) is indicated.
• Page 190
  FI SYSTEM DIAGNOSIS 4-35 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Steering Steering damper control current does Steering damper solenoid valve damper not flow to the solenoid valve. circuit interrupter element solenoid With IG turned ON, ECM detects a fail- shorted, feedback current con- valve ure of internal circuit element.

• Page 191: C11″ (P0340) Cmp Sensor Circuit Malfunction

  4-36 FI SYSTEM DIAGNOSIS “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • CMP sensor circuit open or short after receiving the starter signal. • CMP sensor malfunction •…

• Page 192
  FI SYSTEM DIAGNOSIS 4-37 6) Under this condition, if a suitable screwdriver touching the pick-up surface of the CMP sensor is moved, the tester read- ing voltage changes (0.8 V and less ↔ 4.3 V and more). Is the voltage OK? ECM coupler (Harness side) (Black) (Gray)

• Page 193: C12″ (P0335) Ckp Sensor Circuit Malfunction

  4-38 FI SYSTEM DIAGNOSIS “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip •…
• Page 194
  FI SYSTEM DIAGNOSIS 4-39 5) If OK, then check the continuity between each terminal and ground. CKP sensor continuity: ∞ Ω (Infinity) (B – Ground) (G – Ground) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.

• Page 195: C13″ (P0105-H/L) Iap Sensor Circuit Malfunction

  4-40 FI SYSTEM DIAGNOSIS “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage < 4.85 V •…

• Page 196
  FI SYSTEM DIAGNOSIS 4-41 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Insert the needle pointed probes to the lead wire coupler. 7) Measure the voltage at the R wire and ground. If OK, then measure the voltage at the R wire and B/Br wire. IAP sensor input voltage: 4.5 –…
• Page 197
  4-42 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between G/B wire and terminal If OK, then check the continuity between B/Br wire and ter- minal IAPS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
• Page 198
  FI SYSTEM DIAGNOSIS 4-43 7) Disconnect the ECM coupler. Check the continuity between R wire and terminal 9) Also, check the continuity between G/B wire and terminal IAPS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
• Page 199
  4-44 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series (check that total — voltage is 4.5 –…

• Page 200: C14″ (P0120-H/L) Tp Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-45 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •…

• Page 201
  4-46 FI SYSTEM DIAGNOSIS TP sensor input voltage: 4.5 – 5.5 V R – Ground) R – B/Br) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal •…
• Page 202
  FI SYSTEM DIAGNOSIS 4-47 Step 1 (When indicating P0120-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
• Page 203
  4-48 FI SYSTEM DIAGNOSIS Step 2 1) Connect the special tool between TP sensor and its coupler. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the terminals (between P/B and B/Br) by turning the throttle grip. TP sensor output voltage Throttle valve is closed: Approx.

• Page 204: C15″ (P0115-H/L) Ect Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-49 “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction 0.15 V Sensor voltage < 4.85 V •…

• Page 205
  4-50 FI SYSTEM DIAGNOSIS ECT sensor voltage: 4.5 – 5.5 V B/Bl – Ground) B/Bl – B/Br) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal •…
• Page 206
  FI SYSTEM DIAGNOSIS 4-51 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 4) Disconnect the ECT sensor coupler.
• Page 207
  4-52 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance. ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Refer to page 7-7 for details.

• Page 208: C21″ (P0110-H/L) Iat Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-53 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction 0.15 V Sensor voltage < 4.85 V •…

• Page 209
  4-54 FI SYSTEM DIAGNOSIS 5) Measure the voltage between Dg wire terminal ground. 6) If OK, then measure the voltage between Dg wire terminal and B/Br wire terminal IAT sensor input voltage: 4.5 – 5.5 V Dg – Ground) Dg –…
• Page 210
  FI SYSTEM DIAGNOSIS 4-55 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
• Page 211
  4-56 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. IAT sensor resistance: Approx. 2.58 kΩ at 20 °C (68 °F) (Terminal – Terminal) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Is the resistance OK? ECM coupler (Harness side) •…

• Page 212: C22″ (P1450-H/L) Ap Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-57 “C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE AP sensor voltage is not within the fol- • Clogged air passage with dust lowing range. • AP sensor circuit open or shorted to ground • AP sensor malfunction 0.5 V Sensor voltage <…

• Page 213
  4-58 FI SYSTEM DIAGNOSIS 4) Disconnect the AP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the R wire and B/Br wire AP sensor input voltage: 4.5 –…
• Page 214
  FI SYSTEM DIAGNOSIS 4-59 6) Disconnect the ECM coupler. 7) Check the continuity between G/Y wire and terminal If OK, then check the continuity between B/Br wire and ter- minal APS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
• Page 215
  4-60 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. Check the continuity between R wire and terminal 9) If OK, then check the continuity between G/Y wire and ter- minal APS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
• Page 216
  FI SYSTEM DIAGNOSIS 4-61 Step 3 1) Remove the AP sensor. 2) Connect the vacuum pump gauge to the vacuum port of the AP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect terminal to the ground terminal terminal to the VCC terminal…

• Page 217: C23″ (P1651-H/L) To Sensor Circuit Malfunction

  4-62 FI SYSTEM DIAGNOSIS “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON.

• Page 218
  FI SYSTEM DIAGNOSIS 4-63 5) Measure the resistance between terminal and terminal TO sensor resistance: 16.5 – 22.3 kΩ (Terminal – Terminal 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Is the resistance OK? Go to Step 2. Replace the TO sensor with a new one.
• Page 219
  4-64 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.

• Page 220: C24″ (P0351), «C25» (P0352), «C26» (P0353) Or «C27» (P0354) Ignition System Malfunction

  FI SYSTEM DIAGNOSIS 4-65 Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between B and B/Br wires.

• Page 221: C28″ (P1655) Stv Actuator Circuit Malfunction

  4-66 FI SYSTEM DIAGNOSIS “C28” (P1655) 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 short the STVA. •…

• Page 222
  FI SYSTEM DIAGNOSIS 4-67 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground. STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between B wire and P wire ) and (between G wire and W/BI wire…
• Page 223
  4-68 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 4) Click each button At this time, if an operation sound is heard from the STVA, the function is normal.

• Page 224: C29″ (P1654-H/L) Stp Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-69 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short • STP sensor malfunction Difference between actual throttle open- ing and opening calculated by ECM is •…

• Page 225
  4-70 FI SYSTEM DIAGNOSIS STP sensor input voltage: 4.5 – 5.5 V R – Ground) R – B/Br) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal •…
• Page 226
  FI SYSTEM DIAGNOSIS 4-71 Step 1 (When indicating P1654-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
• Page 227
  4-72 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between Y wire and…

• Page 228: C31″ (P0705) Gp Switch Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-73 “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No GP switch voltage • GP switch circuit open or short GP switch voltage is not within the following range. • GP switch malfunction • ECM malfunction GP switch voltage 0.6 V Side-stand relay…
• Page 229
  4-74 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM coupler (Harness side) • P wire open or shorted to ground (Black) (Gray) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.

• Page 230: C32″ (P0201), «C33» (P0202), «C34» (P0203) Or «C35» (P0204) Primary Fuel Injector Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-75 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short interrupted by 4 times or more continuously. •…

• Page 231
  4-76 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground. Primary injector continuity: ∞ Ω (Infinity) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.

• Page 232: C36″ (P1764), «C37» (P1765), «C38» (P1766) Or «C39» (P1767) Secondary Fuel Injector Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-77 “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Some failure exists in the fuel injector signal in a • Injector circuit open or short high load, high revolution condition. •…

• Page 233
  4-78 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground. Secondary injector continuity: ∞ Ω (Infinity) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.

• Page 234: C40″ (P0505 Or P0506 And P0507) Isc Valve Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-79 “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground (P0505) unusual. • Power source circuit open Idle speed is lower than the desired idle •…

• Page 235
  4-80 FI SYSTEM DIAGNOSIS 4) Disconnect the ISC valve coupler and ECM couplers. 5) Check the continuity between terminals (Y) and , termi- nals (Bl) and , terminals (Br) and , terminals ISC valve continuity: Continuity (?) 09900-25008: Multi-circuit tester set ECM coupler (Harness side) (Black) (Gray)
• Page 236
  FI SYSTEM DIAGNOSIS 4-81 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control” 5) Check that the “Spec”…
• Page 237
  4-82 FI SYSTEM DIAGNOSIS Check 3 1) Click the button and increase the “Spec” to 1 500 rpm slowly. 2) Check that the “Desired idle speed” is nearly equal to the “Spec” . Also, check that the number of steps in the ISC valve position increases Check 4…

• Page 238: C41″ (P0230-H/L) Fp Relay Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-83 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump • FP relay circuit open or short although FP relay is turned ON, or volt- • FP relay malfunction age is applied to fuel pump, although FP •…

• Page 239
  4-84 FI SYSTEM DIAGNOSIS Is the FP relay OK? ECM coupler (Harness side) • Y/B or O/W wire open or short or poor con- (Black) (Gray) nection • Y/R or R/Bl wire open, shorted or poor con- nection • If wire and connection are OK, intermittent trou- ble or faulty ECM.
• Page 240
  FI SYSTEM DIAGNOSIS 4-85 Step 1 (When indicating P0230-L:) 1) Turn the ignition switch OFF. 2) Remove the front seat. (8-8) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (5-7) Is the FP relay OK? ECM coupler (Harness side) •…

• Page 241: C41″ (P2505) Ecm/Pcm Power Input Signal Malfunction

  4-86 FI SYSTEM DIAGNOSIS “C41” (P2505) ECM/PCM POWER INPUT SIGNAL MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the ECM, • Lead wire/coupler connection of ECM terminal to although the ignition switch is turned (P2505) fuel fuse • Fuel fuse No voltage is applied to the speedome- •…

• Page 242: C42″ (P01650) Ig Switch Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-87 4) Disconnect the ECM couplers. 5) Measure the voltage between terminal and ground. ECM coupler (Harness side) ECM input voltage: Battery voltage (Black) (Gray) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set W Tester knob indication: Voltage () Is the voltage OK? •…

• Page 243: C44″ (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction

  4-88 FI SYSTEM DIAGNOSIS “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open to ECM during engine operation and (P0130) running condition. (Sensor voltage < 1.0 V) In other than the above value, C44 (P0130) is indicated.

• Page 244
  FI SYSTEM DIAGNOSIS 4-89 7) Disconnect the ECM coupler. Check the continuity between W/G wire and terminal 9) Also, check the continuity between B/Br wire and terminal HO2S lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
• Page 245
  4-90 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM coupler (Harness side) • W/G wire or B/Br wire open or shorted to (Black) (Gray) ground, or poor connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •…
• Page 246
  FI SYSTEM DIAGNOSIS 4-91 Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probe to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W (O/W) wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.

• Page 247: C46″ (P1657-H/L Or P1658) Excv Actuator Circuit Malfunction

  4-92 FI SYSTEM DIAGNOSIS “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the • EXCVA maladjusted EXCV actuator. • EXCVA circuit open or short EXCVA position sensor voltage low or •…

• Page 248
  FI SYSTEM DIAGNOSIS 4-93 4) Turn the ignition switch ON. 5) Check the operation of the EXCVA (EXCVA operating order: Full close → Full open → 30% open) Is the operation OK? Go to Step 2. Go to Step 6. Step 1 (When indicating P1657-H:) 1) Turn the ignition switch OFF.
• Page 249
  4-94 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
• Page 250
  FI SYSTEM DIAGNOSIS 4-95 Step 1 (When indicating P1658:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA motor coupler for loose or poor con- tacts. Is the contacting OK? Go to Step 6. Loose or poor contacts on the EXCV motor cou- pler 4) After repairing the trouble, clear the DTC using SDS tool.
• Page 251
  4-96 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Y wire and ground. EXCVA position sensor continuity: ∞ Ω (Infinity) 3) If OK, then measure the EXCVA position sensor resistance. 4) Connect the EXCVA position sensor coupler. 5) Set the EXCVA to adjustment position.
• Page 252
  FI SYSTEM DIAGNOSIS 4-97 Step 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler 3) Measure the EXCVA position sensor output voltage at EXCV fully closed position and fully opened position. 4) Insert the needle pointed probes to the back side of the EXCVA position sensor coupler.
• Page 253
  4-98 FI SYSTEM DIAGNOSIS Step 5 1) If the EXCVA position sensor output voltage is 0.5 V and less at EXCV fully closed position, adjust the output voltage to the specified value by turning out the No.1 cable adjuster 2) Repeat the above procedure (Step 4) until the output voltage becomes specified value.
• Page 254
  FI SYSTEM DIAGNOSIS 4-99 Step 6 1) Turn the ignition switch OFF. 2) Disconnect the EXCVA motor coupler 3) Apply 12 V to the terminals and check the operation of EXCVA. 12 V 4) Then, switch the wires supplied 12 V and check the operation of EXCVA.
• Page 255
  4-100 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Exhaust valve operating control” 4) Click each button At this time, if an operation sound is heard from the EXCVA, the function is normal.

• Page 256: C49″ (P1656) Pair Control Solenoid Valve Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-101 “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction •…

• Page 257
  4-102 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground. PAIR valve voltage: Battery voltage O/W – Ground) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? ECM coupler (Harness side) •…

• Page 258: C60″ (P0480) Cooling Fan Relay Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-103 “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short • ECM malfunction Engine stop Side-stand Ignition Cooling fan switch relay switch…
• Page 259
  4-104 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 4) Click the “Operate” At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal.
• Page 260
  FI SYSTEM DIAGNOSIS 4-105 6) Click the “Off” to check the cooling fan relay and cooling fan motor operation. NOTE: This inspection should be begun from when the engine coolant temperature is below 50 °C (122 °F). Check that the cooling fan relay operates for a few seconds as the engine coolant temperature arrives each at 50 °C (122 °F), 70 °C (158 °F) and 90 °C (194 °F)/above 4 000 r/min.

• Page 261: C91″ (P0500) Vehicle Speed Sensor Circuit Malfunction

  4-106 FI SYSTEM DIAGNOSIS “C91” (P0500) VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Speedometer does not recieve signal from the vehi- • Speed sensor circuit open or short cle speed sensor for more than 6 sec. when the •…

• Page 262
  FI SYSTEM DIAGNOSIS 4-107 5) Under this condition, if a suitable screwdriver touching the pick-up surface of the speed sensor is moved, the tester reading voltage changes (0 V → 12 V or 12 V → 0 V). If the tester reading voltage does not change, replace the speed- ometer sensor with a new one.

• Page 263: C93″ (P1769) Steering Damper Solenoid Valve Circuit Malfunction

  4-108 FI SYSTEM DIAGNOSIS “C93” (P1769) STEERING DAMPER SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Steering damper control current does • Steering damper solenoid valve circuit interrupter not flow to the solenoid valve. element shorted With IG turned ON, ECM detects a fail- •…

• Page 264
  FI SYSTEM DIAGNOSIS 4-109 3) Disconnect the steering damper solenoid valve coupler. 4) Measure the steering damper solenoid valve resistance. Steering damper solenoid valve resistance: Approx 12.5 Ω at 20 °C (68 °F) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Is the resistance OK? Go to Step 2.
• Page 265
  4-110 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Raise the front wheel off the ground. 3) Turn the ignition switch ON. 4) Click “Steering damper solenoid operating control” 5) Click each button ON/OFF while turning the handlebars left and right.

• Page 266: Sensors

  FI SYSTEM DIAGNOSIS 4-111 SENSORS CMP SENSOR INSPECTION The camshaft position sensor is installed on the cylinder head cover. (4-36) CMP SENSOR REMOVAL AND INSTALLATION • Remove the CMP sensor. (3-29) • Install the CMP sensor in the reverse order of removal. CKP SENSOR INSPECTION The crankshaft position sensor is installed on the right side of middle crankcase cover.

• Page 267: Ect Sensor Inspection

  4-112 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the cylin- der head. (4-49) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor. (7-7) • Install the ECT sensor in the reverse order of removal. «…

• Page 268: Stp Sensor Inspection

  FI SYSTEM DIAGNOSIS 4-113 STP SENSOR INSPECTION The secondary throttle position sensor is installed at the right side of the No.4 throttle body. (4-69) STP SENSOR REMOVAL AND INSTALLATION • Remove the STP sensor. (5-17) • Install the STP sensor in the reverse order of removal. STP SENSOR ADJUSTMENT •…

• Page 269: Fuel System And Throttle

  FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM…………….5- 2 FUEL SYSTEM………………… 5- 3 FUEL TANK LIFT-UP …………….5- 3 FUEL TANK REMOVAL……………. 5- 4 FUEL TANK INSTALLATION …………… 5- 4 FUEL PRESSURE INSPECTION …………5- 5 FUEL PUMP INSPECTION …………..

• Page 270: Fuel Delivery System

  5-2 FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injectors installed in the fuel delivery pipe.

• Page 271: Fuel System

  FUEL SYSTEM AND THROTTLE BODY 5-3 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seats. (8-8 and -9) • Remove the fuel tank side covers. (8-8) • Take out the fuel tank prop stay • Remove the fuel tank bolt. •…

• Page 272: Fuel Tank Removal

  5-4 FUEL SYSTEM AND THROTTLE BODY FUEL TANK REMOVAL • Lift and support the fuel tank. (5-3) • Disconnect the fuel pump lead wire coupler • Disconnect the fuel tank drain hose and fuel tank breather hose (Except for E-33). •…

• Page 273: Fuel Pressure Inspection

  FUEL SYSTEM AND THROTTLE BODY 5-5 FUEL PRESSURE INSPECTION • Lift and support the fuel tank. (5-3) • Place a rag under the fuel feed hose • Remove the fuel feed hose. • Install the special tools between the fuel tank and fuel delivery pipe.

• Page 274: Fuel Pump Inspection

  5-6 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor.

• Page 275: Fuel Pump Relay Inspection

  FUEL SYSTEM AND THROTTLE BODY 5-7 • Connect proper lead wires to the fuel pump lead wire coupler (fuel pump side) and apply 12 V to the fuel pump (between Y/R wire and B/W wire) for 10 seconds and measure the amount of fuel discharged.

• Page 276: Fuel Pump And Fuel Filter Removal

  5-8 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION » Fuel level gauge Fuel pump case Fuel filter cartridge Fuel mesh filter ITEM N·m kgf-m lb-ft » Fuel outlet joint O-ring O-ring O-ring » Fuel pump mounting bolt Fuel pump…

• Page 277
  FUEL SYSTEM AND THROTTLE BODY 5-9 REMOVAL • Remove the fuel tank. (5-4) • Remove the fuel pump assembly by removing its mounting bolts diagonally. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Disconnect the lead wires (R and B). •…

• Page 278: Fuel Mesh Filter Inspection And Cleaning

  5-10 FUEL SYSTEM AND THROTTLE BODY • Remove the O-ring • Remove the nut • Remove the fuel pump plate • Remove the fuel mesh filter • Remove the fuel pump from the case. 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.

• Page 279: Fuel Pump And Fuel Mesh Filter Installation

  FUEL SYSTEM AND THROTTLE BODY 5-11 FUEL PUMP AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh filter in the reverse order of removal. Pay attention to the following points: • Replace the O-rings with new ones. Use new O-rings to prevent fuel leakage.

• Page 280
  5-12 FUEL SYSTEM AND THROTTLE BODY • Install a new O-ring and apply grease to it. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The O-ring must be replaced with a new one to prevent fuel leakage. • Install the clamp to the bolt •…

• Page 281: Throttle Body

  FUEL SYSTEM AND THROTTLE BODY 5-13 THROTTLE BODY CONSTRUCTION Only for E-33 TP sensor Cushion seal STP sensor ISC valve » STVA EVAP purge control solenoid valve Fuel delivery pipe Vacuum hose ITEM N·m kgf-m lb-ft » Fuel delivery pipe mounting screw «…

• Page 282: Air Cleaner Box Removal

  5-14 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX REMOVAL • Lift and support the fuel tank. (5-3) • Disconnect the PAIR hose , IAT sensor lead wire coupler and IAP sensor • Loosen the throttle body clamp screw (RH). •…

• Page 283: Throttle Body Removal

  FUEL SYSTEM AND THROTTLE BODY 5-15 THROTTLE BODY REMOVAL • Remove the air cleaner box. (5-14) • Disconnect the throttle cables from their drum. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body.

• Page 284: Throttle Body Disassembly

  5-16 FUEL SYSTEM AND THROTTLE BODY • Remove the fasteners on the main frame. (LH and RH) • Loosen the throttle body clamp screws at the intake pipe side. • Remove the throttle body assembly. THROTTLE BODY DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.

• Page 285
  FUEL SYSTEM AND THROTTLE BODY 5-17 • Remove the fuel pipe from the primary injectors. • Disassemble the fuel delivery pipe assembly. • Remove the ISC valve hoses • Remove the ISC valve • Remove the TP sensor and STP sensor with the special tool.
• Page 286
  5-18 FUEL SYSTEM AND THROTTLE BODY Never remove the secondary throttle valves throttle valves * These adjusting screws ( , ) are fac- tory-adjusted at the time of delivery and do not turn or remove them. * Do not separate the throttle body.

• Page 287: Throttle Body Cleaning

  FUEL SYSTEM AND THROTTLE BODY 5-19 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 passageways (except for main bore) with a spray-type carburetor cleaner and blow dry with compressed air.

• Page 288: Throttle Body Reassembly

  * Align the secondary throttle shaft end » with the groove # of STP sensor. * Apply grease to the secondary throttle shaft end » if neces- sary. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent 09930-11950: Torx wrench » STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5lb-ft)

• Page 289
  FUEL SYSTEM AND THROTTLE BODY 5-21 • Apply thin coat of engine oil to the new O-rings and cush- ion seals Replace the O-rings and cushion seals with new ones. • Assemble the fuel delivery pipes as shown. Be careful not to twist the fuel delivery pipe T-joint when installing the fuel delivery pipes, or joint part &…

• Page 290: Throttle Body Installation

  5-22 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector.

• Page 291: Stp Sensor Adjustment

  FUEL SYSTEM AND THROTTLE BODY 5-23 STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor output voltage and adjust the STP sensor position as follows: • Disconnect the STVA lead wire coupler. • Remove the air cleaner box cover. (2-4) •…

• Page 292: Fuel Injector Removal

  5-24 FUEL SYSTEM AND THROTTLE BODY FUEL INJECTOR REMOVAL • Remove the air cleaner box. (5-14) • With battery negative cable disconnected, disconnect the injector couplers. • Remove the fuel delivery pipe assemblies. (5-16) • Remove the primary and secondary fuel injectors #1, #2, #3 and #4.

• Page 293: Isc Valve Removal

  FUEL SYSTEM AND THROTTLE BODY 5-25 ISC VALVE REMOVAL • Remove the air cleaner box. (5-14) • Disconnect the ISC valve coupler Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned OFF. If the ECM coupler or ISC valve coupler is discon- nected within 5 seconds after ignition switch is turned OFF, there is a possibility of an unusual valve position…

• Page 294: Isc Valve Pre-Set

  5-26 FUEL SYSTEM AND THROTTLE BODY ISC VALVE PRE-SET When removing or replacing the ISC valve, set the ISC valve in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tool. (4-27) 3) Click “Active control”. 4) Click “ISC learned value reset”…

• Page 295: Throttle Valve Synchronization

  FUEL SYSTEM AND THROTTLE BODY 5-27 THROTTLE VALVE SYNCHRONIZATION USE OF SDS TOOL Check and adjust the throttle valve synchronization among four cylinders. Step 1 • Lift and support the fuel tank. (5-3) • Disconnect the respective vacuum hoses from each vac- uum nipple.

• Page 296
  5-28 FUEL SYSTEM AND THROTTLE BODY • Click “Active control”. • Click “ISC air volume control” • Click “ON” to fix the ISC air volume of four cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 70 – 100 °C (158 – 212 °F). «…
• Page 297
  FUEL SYSTEM AND THROTTLE BODY 5-29 • Repeat the procedures of Step 2. • Disconnect the vacuum tester and install the removed parts. • After completing the throttle valve synchronization, clear the DTC and reset the ISC learned value using SDS tool. (4-28 and 5-26) USE OF MODE SELECT SWITCH The following procedure discribes only defference between use…
• Page 298
  EXHAUST SYSTEM 6-1 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM………………6- 2 EXHAUST CONTROL SYSTEM …………6- 2 OPERATION………………6- 3 EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)…………6- 4 EXCVA REMOVAL…………….6- 4 EXCVA PULLEY INSPECTION…………. 6- 5 EXCVA INSTALLATION ……………

• Page 299: Exhaust System

  6-2 EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exhaust control system (EXCS) consists of the exhaust control valve (EXCV), exhaust control valve actuator (EXCVA) and exhaust control valve cables (EXCV cables). EXCV is installed in the exhaust pipe. EXCVA is mounted inside of the right frame. The EXCV is operated by the EXCVA via the cables.

• Page 300: Operation

  EXHAUST SYSTEM 6-3 OPERATION The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then the ECM determines the EXCV opening angle based on the engine rpm and gear positions.

• Page 301: Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)

  6-4 EXHAUST SYSTEM EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA REMOVAL • Turn the ignition switch OFF. • Lift and support the fuel tank. (5-3) • Remove the right under cowling. (8-5) • Connect the special tool (Mode select switch) to the dealer mode coupler.

• Page 302: Excva Pulley Inspection

  EXHAUST SYSTEM 6-5 • Disconnect the No.2 cable and then No.1 cable from the pulley. • Remove the EXCVA. • Hold the EXCVA pulley with an adjustable wrench, and loosen the pulley mounting bolt. * When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

• Page 303: Excva Installation

  6-6 EXHAUST SYSTEM EXCVA INSTALLATION • Install the EXCVA pulley to the shaft. NOTE: Align the shaft’s line » and cable slots # as shown. • Hold the EXCVA pulley with an adjustable wrench, and then tighten the EXCVA pulley mounting bolt to the specified torque.

• Page 304: Excva Inspection

  EXHAUST SYSTEM 6-7 in or out until the thread length $ • Turn the adjuster becomes the measured value before disconnecting the No.1 cable • Tighten the lock-nut in or out until the thread length % • Turn the adjuster becomes the measured value before disconnecting the No.2 cable •…

• Page 305
  6-8 EXHAUST SYSTEM • Connect the EXCV cables (No.1 and No.2) temporarily to the EXCV pulley. • Make the No. 1 cable (21H0CL) straight and turn the No. 1 in or out until the inner cable length » cable adjuster becomes 44 –…
• Page 306
  EXHAUST SYSTEM 6-9 44 – 45 mm (1.73 – 1.77 in) 60 – 61 mm (2.36 – 2.40 in) No.1 No.2 * When adjusting the No.1 and No.2 cables, the cable slots of EXCVA pulley must be located to adjustment position. * Do not use the adjustable wrench to turn EXCVA pulley so as not to cause damage to the internal gear of EXCVA.

• Page 307: Excva Adjustment

  6-10 EXHAUST SYSTEM EXCVA ADJUSTMENT 1st step: • Set the EXCVA to adjustment position. (6-4) 2nd step: • Turn the mode select switch OFF. • Turn the ignition switch ON to check the EXCVA operation. • Turn the mode select switch ON. •…

• Page 308
  EXHAUST SYSTEM 6-11 • Turn the ignition switch ON. • Measure the EXCVA position sensor output voltage at fully closed position. Position sensor output voltage: EXCV is fully closed: 0.45 output voltage 1.4 V ( Y – B/Br) 09900-25008: Multi circuit tester set 09900-25009: Needle pointed probe set W Tester knob indication: Voltage ()

• Page 309: Muffler, Muffler Chamber And Excv/Exhaust Pipe Removal

  6-12 EXHAUST SYSTEM If the measured voltage is more than specification, adjust the No.2 cable adjuster as follows: • Set the EXCVA to adjustment position. (6-4) Adjusting the No.2 cable with the EXCV fully opened can damage the EXCVA. Be sure to adjust the No.2 cable with the EXCV set in adjustment position.

• Page 310
  EXHAUST SYSTEM 6-13 • Remove the No.1 muffler joint cover • Separate the muffler and muffler joint • Remove the gasket and O-rings from the muffler. • Remove the under cowlings. (8-5) • Disconnect the HO2 sensor lead wire coupler •…
• Page 311
  6-14 EXHAUST SYSTEM • Remove the EXCV cable bracket nut. • Disconnect the EXCV cables from the EXCV pulley. • Remove the side cowlings. (8-6) • Move the radiator and oil cooler forward. • Disconnect one of the oil cooler hose from the oil cooler.

• Page 312: Excv Inspection

  EXHAUST SYSTEM 6-15 EXCV INSPECTION • Turn the EXCV by hand and check that it moves smoothly. • If it does not move smoothly, replace the EXCV together with the exhaust pipe assembly. • Decarbonize the EXCV if necessary. * Do not attempt to disassemble the EXCV. * The EXCV is available only as the exhaust pipe assembly.

• Page 313: Muffler, Muffler Chamber And Excv/Exhaust Pipe Installation

  6-16 EXHAUST SYSTEM MUFFLER, MUFFLER CHAMBER AND EXCV/EXHAUST PIPE INSTALLATION Install the EXCV/exhaust pipe, muffler chamber and mufflers in the reverse order of removal. Pay attention to the following points: Replace the gaskets, connectors and O-rings with new ones. • Tighten each bolt/nut to the specified torque. 25 N·m (2.5 kgf-m, 18.0 lb-ft) Clamp 25 N·m…

• Page 314: Cooling And Lubrication System

  COOLING AND LUBRICATION SYSTEM 7-1 COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ………………7- 2 COOLING CIRCUIT ………………7- 3 COOLING CIRCUIT INSPECTION…………7- 3 RADIATOR AND WATER HOSES ………….. 7- 4 RADIATOR REMOVAL …………….. 7- 4 RADIATOR CAP INSPECTION…………. 7- 4 RADIATOR INSPECTION AND CLEANING………

• Page 315: Engine Coolant

  7-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).

• Page 316: Cooling Circuit

  COOLING AND LUBRICATION SYSTEM 7-3 COOLING CIRCUIT RESERVOIR ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER RADIATOR WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the right under cowling. (8-5) •…

• Page 317: Radiator And Water Hoses

  7-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowlings. (8-5) • Drain the engine coolant. (2-18) • Remove the radiator assembly. (3-4) • Remove the cooling fan from the radiator. RADIATOR CAP INSPECTION •…

• Page 318: Radiator Installation

  COOLING AND LUBRICATION SYSTEM 7-5 RADIATOR INSTALLATION • Install the cooling fan. » Cooling fan mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) • Install the radiator. • Route the radiator hoses properly. (10-20) • Pour engine coolant. (2-18) • Bleed air from the cooling circuit. (2-19) •…

• Page 319: Cooling Fan

  7-6 COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the cooling fan. (7-4) INSPECTION • Remove the right under cowling. (8-5) • Disconnect the cooling fan coupler • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration.

• Page 320: Cooling Fan Relay Inspection

  COOLING AND LUBRICATION SYSTEM 7-7 COOLING FAN RELAY INSPECTION Cooling fan relay is located under the front seat. • Remove the front seat. (8-8) • Remove the cooling fan relay First check the insulation between » and # terminals with tester.

• Page 321: Installation

  7-8 COOLING AND LUBRICATION SYSTEM • If the ECT sensor ohmic value does not change in the propor- tion indicated, replace it with a new one. Temperature sensor specification Temperature Standard resistance 20 °C (68 °F) Approx. 2.45 kΩ 50 °C (122 °F) Approx.

• Page 322: Thermostat

  COOLING AND LUBRICATION SYSTEM 7-9 THERMOSTAT REMOVAL • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Place a rag under the thermostat cover. • Remove the thermostat cover • Remove the thermostat INSPECTION Inspect the thermostat pellet for signs of cracking.

• Page 323: Installation

  7-10 COOLING AND LUBRICATION SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in). Thermostat valve lift «: Standard: 8.0 mm and over at 95 °C (0.31 in and over at 203 °F) •…

• Page 324: Water Pump

  COOLING AND LUBRICATION SYSTEM 7-11 WATER PUMP REMOVAL AND DISASSEMBLY NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer.

• Page 325
  7-12 COOLING AND LUBRICATION SYSTEM • Remove the water pump cover and clamp • Holding the impeller with water pump pliers, remove the impeller securing bolt. • Remove the mechanical seal ring and rubber seal from the impeller. • Remove the impeller shaft and washer •…

• Page 326: Inspection

  COOLING AND LUBRICATION SYSTEM 7-13 • Remove the oil seal NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. The removed oil seal must be replaced with a new one. INSPECTION MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face.

• Page 327: Reassembly And Installation

  The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the grease to the oil seal lip. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the new mechanical seal using a suitable size socket wrench.
• Page 328
  NOTE: * Apply engine coolant to the O-ring * Apply grease to the O-ring X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the water pump cover screws to the specified torque. » Water pump cover screw: 5 N·m (0.5 kgf-m, 3.5 lb-ft) NOTE: Fit the clamp &…
• Page 329
  7-16 COOLING AND LUBRICATION SYSTEM • Install the water pump. NOTE: Set the water pump shaft end ‘ to the oil pump shaft ( as shown. 8 N·m (0.8 kgf-m, 6.0 lb-ft) • Tighten the water pump mounting bolts to the specified torque.

• Page 330: Lubrication System

  COOLING AND LUBRICATION SYSTEM 7-17 LUBRICATION SYSTEM OIL PRESSURE 2-33 OIL FILTER 2-13 OIL PRESSURE REGULATOR 3-47 OIL STRAINER 3-47 OIL JET 3-59 OIL PUMP 3-44 OIL PRESSURE SWITCH 9-34 OIL COOLER REMOVAL • Remove the under cowlings. (8-5) • Drain the engine oil. (2-12) •…

• Page 331
  7-18 COOLING AND LUBRICATION SYSTEM INSPECTION AND CLEANING • Road dirt or trash stuck to the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver.

• Page 332: Engine Lubrication System Chart

  COOLING AND LUBRICATION SYSTEM 7-19 ENGINE LUBRICATION SYSTEM CHART INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER CAM CHAIN OIL JET CAMSHAFT JOURNALS, TENSION ADJUSTER CAMFACES AND TAPPETS EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER CAMSHAFT JOURNALS, CAM DRIVE CHAIN CAMFACES AND TAPPETS STARTER CLUTCH BALANCER SHAFT BEARING…

• Page 333: Engine Lubrication System

  7-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM To sub- To sub- gallery gallery MAIN GALLERY…

• Page 334
  COOLING AND LUBRICATION SYSTEM 7-21 SUB-GALLERY VIEW OF A MAIN GALLERY To transmission…
• Page 335
  CHASSIS 8-1 CHASSIS CONTENTS EXTERIOR PARTS ………………8- 3 FASTENER REMOVAL AND INSTALLATION……..8- 3 LOWER BRACKET COVER …………..8- 5 UNDER COWLING …………….8- 5 SIDE COWLING ………………8- 6 BODY COWLING COVER…………..8- 6 SCREEN ………………..8- 7 BODY COWLING ………………
• Page 336
  8-2 CHASSIS CHASSIS CONTENTS REAR SUSPENSION ………………. 8-55 CONSTRUCTION ……………… 8-55 REMOVAL ………………… 8-56 INSPECTION AND DISASSEMBLY …………. 8-58 REASSEMBLY ………………8-61 INSTALLATION………………8-63 FINAL INSPECTION AND ADJUSTMENT ……….. 8-64 FRONT BRAKE……………….. 8-65 CONSTRUCTION ……………… 8-65 BRAKE PAD REPLACEMENT …………. 8-66 BRAKE FLUID REPLACEMENT …………

• Page 337: Exterior Parts

  CHASSIS 8-3 EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece . • Pull out the fastener Installation • Let the center piece stick out toward the head so that the pawls close.

• Page 338
  8-4 CHASSIS Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl from damage, insert the fastener all the way into the installation hole. • Push in the head of center piece.

• Page 339: Lower Bracket Cover

  CHASSIS 8-5 LOWER BRACKET COVER REMOVAL • Remove the lower bracket cover by removing the bolts. INSTALLATION • Install the lower bracket cover in the reverse order of removal. UNDER COWLING REMOVAL • Remove the fasteners and bolts. • Remove the under cowlings . (LH/RH) •…

• Page 340: Side Cowling

  8-6 CHASSIS SIDE COWLING REMOVAL NOTE: The left and right side cowlings are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. • Remove the under cowling. ( 8-5) • Remove the body cowling cover fasteners and . •…

• Page 341: Screen

  CHASSIS 8-7 SCREEN REMOVAL • Remove the screws. • Remove the combination meter . ( 9-29) • Disconnect the turnsignal lead wire couplers. • Remove the rear view mirrors/turn signals . • Remove the screen . INSTALLATION • Install the screen in the reverse order of removal. •…

• Page 342: Air Intake Pipe

  8-8 CHASSIS AIR INTAKE PIPE REMOVAL • Remove the body cowling. ( 8-7) • Remove the side cowling (-s) . ( 8-6) • Remove the air intake pipe (-s) . (LH/RH) INSTALLATION • Install the air intake pipe (-s) in the reverse order of removal. COWLING BRACE REMOVAL •…

• Page 343: Rear Seat/Seat Tail Cover

  CHASSIS 8-9 REAR SEAT/SEAT TAIL COVER REMOVAL • Remove the rear seat (seat tail cover) using the ignition key. INSTALLATION • Insert the seat hook to the guide and push down the seat (seat tail cover) firmly until the seat (seat tail cover) snaps into the locked position.

• Page 344: Front Wheel

  8-10 CHASSIS FRONT WHEEL CONSTRUCTION Brake disc Front axle » Collar Front wheel ITEM N·m kgf-m lb-ft Dust seal » Front axle bolt » 10.0 72.5 Bearing # Brake disc bolt 23.0 16.5 Spacer…

• Page 345: Removal

  CHASSIS 8-11 REMOVAL • Remove the brake calipers. (LH and RH) Do not operate the brake lever with the caliper removed. • Loosen two axle pinch bolts on the right front fork leg. • Remove the front axle bolt . •…

• Page 346: Inspection And Disassembly

  8-12 CHASSIS INSPECTION AND DISASSEMBLY • Remove the brake discs. (LH and RH) TIRE INSPECTION ( 2-27 and 8-93) BRAKE DISC INSPECTION ( 8-71) • Remove the dust seals on both sides with the special tool. 09913-50121: Oil seal remover The removed dust seals must be replaced with new ones.

• Page 347
  CHASSIS 8-13 • Remove the wheel bearings with the special tool. 09921-20240: Bearing remover set The removed bearings must be replaced with new ones. • Remove the spacer .

• Page 348: Reassembly And Installation

  100 N·m (10.0 kgf-m, 72.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 39 N·m (3.9 kgf-m, 28.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) WHEEL BEARING • Apply grease to the wheel bearings. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

• Page 349
  • Install the dust seal with the special tool. 09913-70210: Bearing installer set • Apply grease to the dust seal lip. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent BRAKE DISC • Make sure that the brake disc is clean and free of any greasy matter.
• Page 350
  8-16 CHASSIS • Install the collar to the right side of wheel. WHEEL • Install the front wheel with the front axle and hand-tighten the front axle bolt temporarily. The directional arrow mark on the tire should point to the wheel rotation, when remounting the wheel.
• Page 351
  CHASSIS 8-17 • Move the front fork up and down 4 or 5 times. • Tighten two axle pinch bolts on the left front fork leg to the specified torque. » Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Page 352: Front Fork

  8-18 CHASSIS FRONT FORK CONSTRUCTION O-ring Oil seal Spring retainer Oil seal stopper ring Spacer Dust seal Washer » Inner tube Spring » Front fork cap bolt ITEM N·m kgf-m lb-ft Adjuster rod # Lock-nut «…

• Page 353: Removal And Disassembly

  CHASSIS 8-19 REMOVAL AND DISASSEMBLY NOTE: * The left and right front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. * When the brake caliper is removed, care must be used so as not to cause stress to the brake hose.

• Page 354
  8-20 CHASSIS • Remove the front fork cap bolt from the inner rod by loosening the lock-nut. • Compress the fork spring with the special tool » and remove the special tools » and #. • Remove the front fork cap bolt , adjuster rod , spring retainer , spacer , washer and spring .
• Page 355
  CHASSIS 8-21 • Remove the inner rod/damper rod (cartridge) Do not disassemble the inner rod/damper rod (car- tridge). • Slide the outer tube to remove it from the inner tube. NOTE: Be careful not to damage the “ANTI-FRICTION” metals. • Remove the dust seal and oil seal stopper ring •…

• Page 356: Inspection

  8-22 CHASSIS INSPECTION INNER AND OUTER TUBES • Inspect the inner tube outer surface and outer tube inner sur- face for scratches. • Inspect the “ANTI-FRICTION” metal surfaces for scratches. • If any defects are found, replace them with the new ones. Do not remove the “ANTI-FRICTION”…

• Page 357: Reassembly

  CHASSIS 8-23 REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. Dust seal Oil seal stopper ring Oil seal…

• Page 358
  • Pour specified front fork oil up to the top level of the outer tube. Capacity (each leg): 512 ml (17.3/18.0 US/lmp oz) 99000-99044-L01: SUZUKI FORK OIL L01 or equivalent • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.
• Page 359
  CHASSIS 8-25 • Refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until no more bubbles come out from the oil. • Keep the front fork vertically and wait 5 – 6 minutes. NOTE: * Always keep oil level over the cartridge top end, or air may enter the cartridge during this procedure.
• Page 360
  8-26 CHASSIS FRONT FORK CAP BOLT • Pull up the inner rod with the special tool «. • Compress the spring with the special tool # and then insert the special tool $ between the lock-nut and the spacer. 09940-52841: Inner rod holder » 09940-94930: Front fork spacer holder # 09940-94922: Stopper plate $ •…

• Page 361: Installation

  CHASSIS 8-27 INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Set the upper surface of the outer tube height » at 7.0 mm (0.276 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts to the specified torque.

• Page 362: Front Suspension Setting

  8-28 CHASSIS FRONT SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and three kinds of damping force as follows. SPRING PRE-LOAD ADJUSTMENT There are five grooved lines on the side of the spring adjuster. Position 0 provides the maximum spring pre-load and position 5 provides the minimum spring pre-load.

• Page 363: Steering Damper

  CHASSIS 8-29 STEERING DAMPER CONSTRUCTION Steering damper » Convex curve side of the washer Dust seal faces down side. ITEM N·m kgf-m lb-ft Steering stem head nut » Damper rod bolt «# 16.5 # Damper rod nut 65.0…

• Page 364: Removal

  8-30 CHASSIS REMOVAL • Turn the ignition switch OFF. • Disconnect the steering damper solenoid coupler . • Remove the lower bracket cover. ( 8-5) • Remove the nut by holding the nut . • Remove the bolt . •…

• Page 365: Installation

  Install the steering damper in the reverse order of removal. Pay attention to the following points: • Apply grease to the bearings and dust seals. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the steering damper and tighten the bolt and nut .

• Page 366: Steering

  8-32 CHASSIS STEERING CONSTRUCTION Steering stem upper bracket Steering stem lower bracket » handlebars » Steering stem head nut ITEM N·m kgf-m lb-ft Steering stem nut # Steering stem lock-nut » 65.0 Dust seal cover $ Front fork upper clamp bolt 65.0 Dust seal…

• Page 367: Removal

  CHASSIS 8-33 REMOVAL • Remove the under cowlings. ( 8-5) • Support the motorcycle with a jack or a wooden block. * Do not work by using side-stand. * Do not support the motorcycle with the exhaust pipes. * Make sure that the motorcycle is supported securely. •…

• Page 368: Inspection And Disassembly

  8-34 CHASSIS • Remove the dust seal cover , dust seal , steering stem upper bearing inner race and bearing . INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebar distortion * Race wear and brinelling * Bearing wear or damage * Abnormal noise of bearing If any abnormal points are found, replace defective parts with…

• Page 369: Reassembly

  BEARING • Apply grease to the bearings and bearing races. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race.

• Page 370
  8-36 CHASSIS • Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will be 1/4 – 1/2 turn seated properly. • Loosen the stem nut by 1/4 – 1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle.

• Page 371: Steering Tension Adjustment

  CHASSIS 8-37 STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). •…

• Page 372: Handlebars

  8-38 CHASSIS HANDLEBARS CONSTRUCTION Left handle grip Handlebar (RH) Throttle grip Handlebar (LH) » Left handle switch » Handlebar clamp bolt ITEM N·m kgf-m lb-ft Right handle switch » 16.5 REMOVAL • Remove the front brake master cylinder . •…

• Page 373
  CHASSIS 8-39 • Remove the clutch master cylinder . ( 8-89) • Remove the left handle switch . • Remove the handle balancer . • Loosen the handlebar clamp bolts and front fork upper clamp bolts. (LH and RH) • Remove the steering stem head nut . •…

• Page 374: Installation

  8-40 CHASSIS INSTALLATION Install the handlebars in the reverse order of removal. Pay atten- tion to the following points: • Install the handlebars temporarily. • Install the steering stem upper bracket, washer and head nut. 8-36) • Insert the protrusion » of the handlebars into the hole # of the steering stem upper bracket.

• Page 375
  CHASSIS 8-41 • Apply grease onto the right handlebar before installing the throttle grip. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply grease to the throttle cables and cable drum. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • When remounting the right and left handle switches, engage the stopper with the handlebar hole.

• Page 376: Rear Wheel

  8-42 CHASSIS REAR WHEEL CONSTRUCTION Rear axle Wheel damper Brake disc Sprocket mounting drum Collar Sprocket » Dust seal » Brake disc bolt ITEM N·m kgf-m lb-ft Rear wheel # Rear sprocket nut «…

• Page 377: Removal

  CHASSIS 8-43 REMOVAL • Loosen the axle nut . • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. • Remove the rear wheel by disengaging the drive chain. Do not operate the brake pedal with the rear wheel removed.

• Page 378: Inspection And Disassembly

  8-44 CHASSIS • Remove the dust seal with the special tool. 09913-50121: Oil seal remover The removed dust seal must be replaced with a new one. • Remove the dust seal with the special tool. 09913-50121: Oil seal remover The removed dust seal must be replaced with a new one.

• Page 379
  CHASSIS 8-45 SPROCKET • Inspect the sprocket teeth for wear. • If they are worn as shown, replace the two sprockets and drive chain as a set. » Normal wear # Excessive wear BEARINGS • Inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place.

• Page 380: Reassembly And Installation

  8-46 CHASSIS REASSEMBLY AND INSTALLATION Reassemble and install 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) 33 N·m (3.3 kgf-m, 24.0 lb-ft) 60 N·m (6.0 kgf-m, 43.5 lb-ft) 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) 35 N·m (3.5 kgf-m, 25.5 lb-ft)

• Page 381
  CHASSIS 8-47 BEARINGS • Apply grease to the bearings before installing them. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install a new bearing to the sprocket mounting drum with the special tool. 09924-84510: Bearing installer set • First install the right wheel bearing, then install the left one with the special tools.
• Page 382
  • Install new dust seal with the special tool. 09913-70210: Bearing installer set • Apply grease to the dust seal lip before assembling rear wheel. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent REAR SPROCKET AND SPROCKET MOUNTING DRUM • Install the rear sprocket mounting drum spacer .
• Page 383
  CHASSIS 8-49 • Tighten the sprocket mounting nuts to the specified torque. » Rear sprocket nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) NOTE: Stamped mark » on the sprocket should face outside. • Install the collar . BRAKE DISC • Apply THREAD LOCK to the disc bolts and tighten them to the specified torque.

• Page 384: Rear Shock Absorber

  8-50 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION Right Left » Rear shock absorber mount- Rear shock absorber » ing bolt/nut ITEM N·m kgf-m lb-ft » Rear shock absorber bracket 36.0 Rear shock absorber bracket 11.5 83.0…

• Page 385: Removal

  CHASSIS 8-51 REMOVAL • Remove the mufflers and muffler chamber. ( 6-12) • Support the motorcycle with a jack to relieve load on the rear shock absorber. • Remove the muffler chamber brackets . • Remove the rear shock absorber upper and lower mounting bolts and nuts.

• Page 386: Rear Shock Absorber Disposal

  8-52 CHASSIS REAR SHOCK ABSORBER DISPOSAL * The rear shock absorber unit contains high-pressure nitrogen gas. * Mishandling can cause explosion. * Keep away from fire and heat. High gas pressure caused by heat can cause an explosion. * Release gas pressure before disposing. GAS PRESSURE RELEASE The rear cushion damper unit contains high-pressure nitrogen gas.

• Page 387: Installation

  CHASSIS 8-53 INSTALLATION Remount the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber upper/lower mounting bolts and nuts. » Rear shock absorber mounting nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •…

• Page 388
  8-54 CHASSIS Compression damping force (High speed) Fully turn the compression damping force (High speed) adjuster clockwise. From that position (stiffest), turn it out to the stan- dard setting position. STD position: 3 turns out from stiffest position Compression damping force (Low speed) Fully turn the compression damping force (Low speed) adjuster clockwise.

• Page 389: Rear Suspension

  CHASSIS 8-55 REAR SUSPENSION CONSTRUCTION Rear shock absorber » Swingarm pivot boss (LH) Rear cushion rod » Rear shock absorber mounting » Rear cushion lever bolt/nut ITEM N·m kgf-m lb-ft Spacer # Rear cushion lever bolt/nut «…

• Page 390: Removal

  8-56 CHASSIS REMOVAL • Cut the drive chain. ( 8-97) NOTE: It is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • Remove the rear wheel. ( 8-43) • Remove the brake hose guide . •…

• Page 391
  CHASSIS 8-57 • Remove the rear fender (lower) . • Remove the chain case . • Remove the chain buffer . SWINGARM PIVOT BOSS REMOVAL AND INSTALLATION • Remove the swingarm. ( 8-56) • Remove the swingarm pivot boss nut . NOTE: Remove the swingarm pivot boss when only replacing it.

• Page 392: Inspection And Disassembly

  8-58 CHASSIS INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm. • Remove the spacers from the cushion lever and cushion rod. • Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones. SWINGARM BEARING •…
• Page 393
  CHASSIS 8-59 CUSHION LEVER BEARING • Insert the spacer into bearing and check the play when mov- ing the spacer up and down. • If excessive play is noted, replace the bearing with a new one. • Remove the cushion lever bearings with the special tool. 09921-20240: Bearing remover set ( 20 mm) ( 17 mm) The removed bearings must be replaced with new…
• Page 394
  8-60 CHASSIS CHAIN BUFFER • Inspect the chain buffer for wear and damage. • If any defects are found, replace the chain buffer with a new one. PLATE • Inspect the plate for damage and excessive bend.

• Page 395: Reassembly

  (0.02 in) 1 mm 1 mm (0.04 in) (0.04 in) Apply SUZUKI SUPER 115 N·m (11.5 kgf-m, 83.0 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) GREASE “A” or equiva- 50 N·m (5.0 kgf-m, 36.0 lb-ft) 65 N·m (6.5 kgf-m, 47.0 lb-ft) lent one to the bearings, 50 N·m (5.0 kgf-m, 36.0 lb-ft)

• Page 396
  $ from the cushion rod surface with the special tool and suitable size socket wrench. ( 8-61) 09924-84521: Bearing installer set NOTE: When installing the bearing, stamped mark on the bearing must face outside. • Apply grease to the bearings, spacers. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

• Page 397: Installation

  CHASSIS 8-63 • Install the chain case chain buffer and rear fender . INSTALLATION Install the swingarm in the reverse order of disassembly and removal, and pay attention to the following points: SWINGARM PIVOT THRUST CLEARANCE ADJUSTMENT Adjust swingarm pivot thrust clearance in the following procedure. •…

• Page 398: Final Inspection And Adjustment

  8-64 CHASSIS CUSHION LEVER, CUSHION ROD AND REAR SHOCK ABSORBER • Install the cushion lever and washers. • Install the cushion rod and washers. • Tighten each nut to the specified torque. » Cushion lever mounting nut : 98 N·m (9.8 kgf-m, 71.0 lb-ft) Cushion rod mounting nut (Front side): 98 N·m (9.8 kgf-m, 71.0 lb-ft) (Rear side):…

• Page 399: Front Brake

  CHASSIS 8-65 FRONT BRAKE CONSTRUCTION Front brake lever Front brake hose » Dust boot » Master cylinder mounting bolt ITEM N·m kgf-m lb-ft Piston set # Brake hose union bolt » Piston seal $ Caliper mounting bolt 16.5 Dust seal % Caliper air bleeder valve…

• Page 400: Brake Pad Replacement

  8-66 CHASSIS * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use 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 fluid left over from the last servicing or stored for long periods.

• Page 401: Brake Fluid Replacement

  CHASSIS 8-67 • Install the spring to the caliper, bring its wider side of pawl » facing top. • Install the new brake pads. • Install the brake caliper. • Tighten each bolt to the specified torque. » Pad mounting pin : 16 N·m (1.6 kgf-m, 11.5 lb-ft) Front brake caliper mounting bolt : 39 N·m (3.9 kgf-m, 28.0 lb-ft) NOTE:…

• Page 402: Caliper Removal

  8-68 CHASSIS CALIPER REMOVAL NOTE: * The left and right front brake calipers are installed symmetri- cally and therefore the removal procedure for one side is the same as that for the other side. * Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid.

• Page 403: Caliper Inspection

  CHASSIS 8-69 • Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air. Avoid using high pressure air to prevent piston dam- age. • Remove the dust seals and piston seals . Avoid reusing the dust seals and piston seals to pre- vent fluid leakage.

• Page 404: Caliper Reassembly

  8-70 CHASSIS CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves. Specification and classification: DOT 4 * Clean the caliper components with fresh brake fluid before reassembly.

• Page 405: Caliper Installation

  CHASSIS 8-71 • Temporarily tighten the air bleeder valve . • Tighten each bolt to the specified torque. » Front brake caliper housing bolt : 22 N·m (2.2 kgf-m, 16.0 lb-ft) 09930-11920: Torx bit JT40H 09930-11940: Bit holder CALIPER INSTALLATION Install the caliper in the reverse order of removal.

• Page 406: Master Cylinder Removal And Disassembly

  8-72 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain the brake fluid. ( 8-67) • Disconnect the front brake light switch lead wires . • Place a rag underneath the union bolt on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose.

• Page 407: Master Cylinder Inspection

  CHASSIS 8-73 • Remove the dust boot push rod and snap ring «. • Remove the following parts. Secondary cup Piston Primary cup Return spring Return spring guide Air bleeder valve • Remove the dust rubber and snap ring •…

• Page 408: Master Cylinder Reassembly

  Specification and classification: DOT 4 • Install the O-ring to the brake hose connector. Use a new O-ring to prevent the fluid leakage. • Apply SUZUKI SILICONE GREASE to the push rod. 99500-25100: SUZUKI SILICONE GREASE or equivalent…

• Page 409: Master Cylinder Installation

  CHASSIS 8-75 • Apply SUZUKI SILICONE GREASE to the brake lever pivot bolt. 99000-25100: SUZUKI SILICONE GREASE or equivalent » Brake lever pivot bolt: 1.0 N·m (0.1 kgf-m, 0.7 lb-ft) Brake lever lock-nut: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft) • Align the convex part » of brake light switch with the hole # of master cylinder when installing the brake light switch.

• Page 410: Rear Brake

  8-76 CHASSIS REAR BRAKE CONSTRUCTION Brake pedal » Caliper air bleeder valve » Piston/Cup set # Brake hose union bolt ITEM N·m kgf-m lb-ft Reservoir hose $ Brake caliper mounting bolt » 0.75 Brake hose % Brake master cylinder mounting bolt 16.5 Brake pad &…

• Page 411: Brake Pad Replacement

  CHASSIS 8-77 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use 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 fluid left over from the last servicing or stored for long periods.

• Page 412: Brake Fluid Replacement

  8-78 CHASSIS BRAKE FLUID REPLACEMENT • Remove the brake fluid reservoir mounting bolt . • Place a rag underneath the brake fluid reservoir to catch any split brake fluid. Remove the brake fluid reservoir cap . • Replace the brake fluid in the same manner as the front brake.

• Page 413
  CHASSIS 8-79 • Remove the brake pad spring. • Remove the caliper air bleeder valve . • Remove the spacer and rubber boot from the caliper. • Place a rag over the piston to prevent it from popping out and then force out the pistons using compressed air.

• Page 414: Caliper Inspection

  8-80 CHASSIS CALIPER INSPECTION BRAKE CALIPER AND BRAKE CALIPER PISTON • Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. • Inspect the brake caliper piston surface for any scratches and other damage.

• Page 415: Caliper Reassembly

  Caliper body Piston seal SLIDING PIN • Install the rubber boot . • Apply SUZUKI SILICONE GREASE to the inside of the boot. 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the spacer . • Install the caliper air bleeder valve.

• Page 416: Caliper Installation

  8-82 CHASSIS CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Tighten each bolt to the specified torque. » Brake hose union bolt : 23 N·m (2.3 kgf-m, 16.5 lb-ft) Brake caliper mounting bolt : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Brake caliper sliding pin : 33 N·m (3.3 kgf-m, 24.0 lb-ft) •…

• Page 417: Master Cylinder Disassembly

  CHASSIS 8-83 MASTER CYLINDER DISASSEMBLY • Remove the reservoir cap, insulator , diaphragm and reservoir tank . • Remove the connector by removing the screw. • Remove the O-ring . Replace the O-ring with a new one. • Pull out the dust boot , then remove the snap ring . 09900-06108: Snap ring pliers •…

• Page 418: Master Cylinder Reassembly

  * Apply brake fluid to the cylinder bore and all the component to be inserted into the bore. Specification and classification: DOT 4 • Apply SUZUKI SILICONE GREASE to the push rod end. 99000-25100: SUZUKI SILICONE GREASE or equivalent MASTER CYLINDER INSTALLATION Install the master cylinder in the reverse order of removal.

• Page 419: Clutch Release Cylinder And Master Cylinder

  CHASSIS 8-85 CLUTCH RELEASE CYLINDER AND MASTER CYLINDER CONSTRUCTION Diaphragm Spring » Push rod Clutch release cylinder ITEM N·m kgf-m lb-ft Dust boot » Clutch master cylinder mounting bolt » Piston/cup set # Clutch hose union bolt 16.5 Clutch hose $ Air bleeder valve…

• Page 420: Clutch Fluid Replacement

  8-86 CHASSIS * 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 containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

• Page 421: Clutch Release Cylinder Removal And Disassembly

  CHASSIS 8-87 CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY • Drain the clutch fluid. ( 8-86) • Disconnect the clutch hose by removing the union bolt . NOTE: Place a rag underneath the union bolt on the release cylinder to catch any spilled brake fluid. •…

• Page 422: Clutch Release Cylinder Reassembly And Remounting

  Air bleeder valve Bleeder cap Clutch release cylinder body • Apply grease to the clutch push rod end. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Remove the clutch release cylinder. • Tighten each bolt to the specified torque.

• Page 423: Clutch Master Cylinder Removal And Disassembly

  CHASSIS 8-89 CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain clutch fluid. ( 8-86) • Disconnect the clutch lever position switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt and disconnect the clutch hose from the master cylinder.

• Page 424: Clutch Master Cylinder Inspection

  8-90 CHASSIS • Remove the dust boot and push rod . • Remove the snap ring . 09900-06108: Snap ring pliers • Remove the piston/cup set. » Secondary cup Piston Primary cup Spring CLUTCH MASTER CYLINDER INSPECTION • Inspect the piston surface for any scratches or other damage. •…

• Page 425: Clutch Master Cylinder Reassembly And Remounting

  • Install O-rings to the master cylinder and reservoir tank . • Install the reservoir tank . Use new O-rings to prevent fluid leakage. • Apply SUZUKI SILICONE GREASE to the push rod. • Install the push rod and dust boot. 99500-25100: SUZUKI SILICONE GREASE…

• Page 426
  8-92 CHASSIS • Apply SUZUKI SILICONE GREASE to the bushing and clutch lever pivot bolt. 99000-25100: SUZUKI SILICONE GREASE or equivalent » Clutch lever pivot bolt: 1.0 N·m (0.1 kgf-m, 0.7 lb-ft) Clutch lever lock-nut: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft) •…

• Page 427: Tire And Wheel

  CHASSIS 8-93 TIRE AND WHEEL TIRE REMOVAL The most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

• Page 428: Valve Inspection

  8-94 CHASSIS VALVE INSPECTION • Inspect the valve after the tire is removed from the rim. • Replace the valve with a new one if the seal » rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.

• Page 429: Tire Installation

  CHASSIS 8-95 TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points. * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant.

• Page 430: Balancer Weight Installation

  8-96 CHASSIS • In this condition, check the “rim line” # cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.

• Page 431: Drive Chain

  CHASSIS 8-97 DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain. 09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.

• Page 432: Drive Chain Connecting

  8-98 CHASSIS • Place the drive chain link being disjointed on the holder part of the tool. • Turn in both the adjuster bolt and pressure bolt “A” so that each of their end hole fits over the chain joint pin properly. •…

• Page 433
  CHASSIS 8-99 • Apply grease on the recessed portion of the joint plate holder and set the joint plate . NOTE: When positioning the joint plate on the tool, its stamp mark must face the joint plate holder side. •…
• Page 434
  8-100 CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “A” with the bar until the pin end diameter becomes the specified dimension. Pin end diameter specification % 5.50 – 5.80 mm (0.217 – 0.228 in) * After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.
• Page 435
  ELECTRICAL SYSTEM 9-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING …………….. 9- 3 CONNECTOR ………………9- 3 COUPLER………………..9- 3 CLAMP ………………..9- 3 FUSE…………………. 9- 3 SWITCH ………………..9- 3 SEMI-CONDUCTOR EQUIPPED PART ……….9- 4 BATTERY ………………..9- 4 CONNECTING THE BATTERY………….
• Page 436
  9-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS RELAYS …………………. 9-37 TURN SIGNAL/SIDE-STAND RELAY ……….9-37 STARTER RELAY …………….. 9-37 FUEL PUMP RELAY …………….9-37 COOLING FAN RELAY…………….. 9-37 SWITCH ………………….. 9-38 IGNITION SWITCH REMOVAL …………. 9-38 IGNITION SWITCH INSTALLATION…………. 9-38 DRIVING MODE SWITCH …………..9-39 SWITCH INSPECTION …………….

• Page 437: Cautions In Servicing

  ELECTRICAL SYSTEM 9-3 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

• Page 438: Semi-Conductor Equipped Part

  9-4 ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •…

• Page 439: Using The Multi-Circuit Tester

  ELECTRICAL SYSTEM 9-5 USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester and probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •…

• Page 440: Location Of Electrical Components

  9-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS EXCVA ( 6-10) CMP sensor ( 4-36) IAP sensor ( 4-40) Ignition coil STV actuator ( 4-66) ISC valve ( 4-79) STP sensor ( 4-69) EVAP system purge control solenoid valve TP sensor ( 4-45) (E-33 only)

• Page 441
  ELECTRICAL SYSTEM 9-7 Steering damper solenoid valve ( 4-108) Mode select switch coupler Secondary fuel injector ( 4-77) Primary fuel injector ( 4-75) Starter relay/Main fuse Fuel pump Generator Fuel level gauge Fuse box Regulator/Rectifier Turn signal/Side-stand relay Horn Speed sensor…

• Page 442: Charging System

  9-8 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier IG. switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. ( 9-9) Is the battery for current leaks OK? Go to Step 3.

• Page 443: Inspection

  ELECTRICAL SYSTEM 9-9 Step 5 1) Measure the generator no-load performance. ( 9-11) Is the generator no-load performance OK? Go to Step 6. Faulty generator Step 6 1) Inspect the regulator/rectifier. ( 9-11) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier Step 7 1) Inspect wirings.

• Page 444
  9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. ( 8-8) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the and battery termi- nals using the multi-circuit tester.
• Page 445
  ELECTRICAL SYSTEM 9-11 GENERATOR NO-LOAD PERFORMANCE • Lift and support the fuel tank. ( 5-3) • Disconnect the generator coupler. • Start the engine and keep it running at 5 000 r/min. • Using the multi-circuit tester, measure the voltage between three lead wires.

• Page 446: Starter System And Side-Stand/Ignition Interlock System

  9-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To Ignition coil Starter motor Fuse GP switch (Neutral) (10 A) Battery Starter relay Starter Turn signal/ button side-stand relay Clutch switch side-stand switch TROUBLESHOOTING Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.

• Page 447: Starter Motor Removal

  ELECTRICAL SYSTEM 9-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G and B/Y ) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch •…

• Page 448: Starter Motor Disassembly

  9-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. O-ring Armature Housing end (inside) Housing end (outside) ITEM N·m kgf-m lb-ft Starter motor case » Lead wire mounting bolt «…

• Page 449: Starter Motor Reassembly

  • Apply grease to the lip of the oil seal. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. 99000-25140: SUZUKI MOLY PASTE or equivalent • Fit the projection of the starter motor case to the depression of the housing end.

• Page 450: Starter Relay Inspection

  9-16 ELECTRICAL SYSTEM • Install the starter motor to the engine. • Tighten the starter motor mounting bolts and lead wire bolt. 10-16) Starter motor mounting bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Starter motor lead wire bolt: 5 N·m (0.5 kgf-m, 3.5 lb-ft) STARTER RELAY INSPECTION •…

• Page 451: Side Stand/Ignition Interlock System Parts Inspection

  ELECTRICAL SYSTEM 9-17 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH The side-stand switch coupler is located above the crankcase.

• Page 452
  9-18 ELECTRICAL SYSTEM GEAR POSITION SENSOR • Lift and support the fuel tank. ( 5-3) • Disconnect the gear position switch coupler and check the continuity between Bl and B/W with the transmission in “NEU- TRAL”. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test ( ON (Neutral) OFF (Except neutral)
• Page 453
  ELECTRICAL SYSTEM 9-19 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the turn signal/side-stand relay . SIDE-STAND RELAY INSPECTION First check the insulation between % and & terminals with the tester.

• Page 454: Ignition System

  9-20 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Side- stand Power source relay circuit Fuse sensor Waveform arrangement Ignition circuit switch Fuse Waveform arrangement circuit Battery sensor sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 13 500 r/min, this circuit cuts off fuel at the fuel injector.

• Page 455: Immobilizer (Except For E-03, 28, 33)

  ELECTRICAL SYSTEM 9-21 IMMOBILIZER (Except for E-03, 28, 33) DESCRIPTION The immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start. Immobilizer antenna Indicator light Transponder…

• Page 456
  9-22 ELECTRICAL SYSTEM Operation When the ignition switch is turned ON with the engine stop switch in ON, the immobi-antenna and ECM are powered ON. The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID.

• Page 457: Troubleshooting

  ELECTRICAL SYSTEM 9-23 TROUBLESHOOTING No spark or poor spark NOTE: * Check that the transmission is in neutral and the engine stop switch is in the RUN position. Grasp the clutch lever. * Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.
• Page 458
  9-24 ELECTRICAL SYSTEM Step 5 1) Inspect the ignition coil/plug caps. ( 9-25) Is the ignition coil/plug cap OK? Go to Step 6. • Poor connection of the ignition coil/plug cap(-s). • Faulty ignition coil/plug cap(-s). Step 6 1) Measure the crankshaft position sensor peak voltage and its resistance. ( 9-27) NOTE: The crankshaft position sensor peak voltage inspection is applicable only with the multi circuit tester and…

• Page 459: Inspection

  ELECTRICAL SYSTEM 9-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. ( 5-14) • Disconnect all the ignition coil/plug cap lead wire couplers before removing the ignition coil/plug caps. • Remove all of the ignition coil/plug caps. * Do not remove the ignition coil/plug cap before dis- connecting the lead wire coupler, or the lead wire will be damaged.

• Page 460
  9-26 ELECTRICAL SYSTEM NOTE: Use the special tool, to prevent the rubber of the water proof coupler from damage. • Shift the transmission into neutral and turn the ignition switch • Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage.
• Page 461
  ELECTRICAL SYSTEM 9-27 CKP SENSOR PEAK VOLTAGE NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Lift and support the fuel tank. ( 5-3) • Disconnect the CKP sensor lead wire coupler and connect the multi-circuit tester with the peak volt adaptor as follows.

• Page 462: Combination Meter

  9-28 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition. The rpm pointer is driven by the stepping motor.

• Page 463: Removal And Disassembly

  ELECTRICAL SYSTEM 9-29 REMOVAL AND DISASSEMBLY • Remove the screw . • With the hooked parts behind the combination meter pulled from the cowling brace, disconnect the combination meter lead wire coupler. • Remove the combination meter. When disconnecting and reconnecting the combina- tion meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

• Page 464: Inspection

  9-30 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights [FI light, Fuel level indicator light, Engine revolution indicator lamp and immobilizer indicator light (For E-02, 19, 24)] immediately after turning the ignition switch ON. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depend- ing on each switch position.

• Page 465
  ELECTRICAL SYSTEM 9-31 ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection ( 7-7 to -8) • Lift and support the fuel tank. ( 5-3) • Disconnect the ECT sensor coupler . When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
• Page 466
  9-32 ELECTRICAL SYSTEM FUEL LEVEL GAUGE INSPECTION • Remove the fuel pump assembly. ( 5-9) • 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 Resistance 245.4 mm…
• Page 467
  ELECTRICAL SYSTEM 9-33 SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. SPEED SENSOR •…
• Page 468
  9-34 ELECTRICAL SYSTEM OIL PRESSURE INDICATOR NOTE: Before inspecting the oil pressure switch, check if the engine oil level is correct. ( 2-12) • Remove the right under cowling. ( 8-5) • Disconnect the oil pressure switch lead wire from the oil pres- sure switch.

• Page 469: Lamps

  ELECTRICAL SYSTEM 9-35 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 55 W H7 12 V 65 W H9 POSITION LIGHT 12 V 5 W BRAKE LIGHT/TAILLIGHT LICENCE PLATE LIGHT 12 V 5 W TURN SIGNAL LIGHT 12 V 21 W ×…

• Page 470
  9-36 ELECTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. NOTE: * Use a screw driver for adjuster » and #. * To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. «: Horizontal adjuster #: Vertical adjuster…

• Page 471: Relays

  ELECTRICAL SYSTEM 9-37 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

• Page 472: Switch

  9-38 ELECTRICAL SYSTEM SWITCH IGNITION SWITCH REMOVAL • Remove the air cleaner box. ( 5-14) • Disconnect the ignition switch lead wire coupler (Green) . • Disconnect the immobilizer lead wire coupler (Black) . (For E-02, 19, 24) • Remove the cable guide . •…

• Page 473: Driving Mode Switch

  ELECTRICAL SYSTEM 9-39 DRIVING MODE SWITCH DESCRIPTION Engine power characteristics can be changed in 3 modes by operating the driving mode switch to meet various riding condi- tions and rider’s preference. MODE OPERATION Driving mode is preset at A-mode when the ignition switch and engine stop switch are turned ON.

• Page 474
  9-40 ELECTRICAL SYSTEM INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Data monitor”. 4) Make sure each of “Driving mode selection” on the monitor is indicated “Open”.

• Page 475: Switch Inspection

  ELECTRICAL SYSTEM 9-41 SWITCH INSPECTION Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. PUSH HAZARD SWITCH HORN BUTTON Color Position Color B/Bl (OFF) Position (ON) PUSH…

• Page 476: Battery

  9-42 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation FT12A-BS Capacity 12 V, 36 kC (10 Ah)/10 HR Upper cover breather Terminal Cathode plates Safety valve Stopper Anode plates Filter Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •…
• Page 477
  ELECTRICAL SYSTEM 9-43 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.

• Page 478: Servicing

  9-44 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.

• Page 479: Servicing Information

  SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING …………….10- 3 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION…………..10- 3 ENGINE ………………..10- 3 RADIATOR (COOLING SYSTEM) …………10- 9 CHASSIS ………………..10-10 BRAKES ………………..10-11 ELECTRICAL ………………10-12 BATTERY ………………… 10-13 WIRING HARNESS, CABLE AND HOSE ROUTING………

• Page 480
  10-2 SERVICING INFORMATION SERVICING INFORMATION CONTENTS REAR VIEW MIRROR INSTALLATION……….10-37 REAR COMBINATION LIGHT INSTALLATION ……..10-38 REAR COMBINATION LIGHT CUSHION/FASTENER INSTALLATION………………10-39 REGULATOR/RECTIFIER INSTALLATION ……..10-40 SPECIAL TOOLS …………….. 10-41 TIGHTENING TORQUE …………….10-45 ENGINE ………………..10-45 FI SYSTEM AND INTAKE AIR SYSTEM ……….10-46 COOLING SYSTEM…………….

• Page 481: Troubleshooting

  SERVICING INFORMATION 10-3 TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION (4-30 to -35) ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of adjustment Adjust. 2.

• Page 482
  10-4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace.
• Page 483
  SERVICING INFORMATION 10-5 Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace.
• Page 484
  10-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust.
• Page 485
  SERVICING INFORMATION 10-7 Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinders Replace.
• Page 486
  10-8 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.

• Page 487: Radiator (Cooling System)

  SERVICING INFORMATION 10-9 Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn shifting gears on driveshaft or Replace. out of gear. countershaft 2. Distorted or worn gearshift forks Replace. 3. Weakened stopper spring on gearshift stopper Replace. 4. Worn gearshift cam plate Replace.

• Page 488: Chassis

  10-10 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. 5. Defective steering damper solenoid Replace.

• Page 489: Brakes

  SERVICING INFORMATION 10-11 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.

• Page 490: Electrical

  10-12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective spark plugs Replace. 3. Defective CKP sensor Replace. 4. Defective ECM Replace. 5. Defective TO sensor Replace. 6. Open-circuited wiring connections Check and repair.

• Page 491: Battery

  SERVICING INFORMATION 10-13 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 Battery runs down…

• Page 492: Wiring Harness, Cable And Hose Routing

  10-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING PAIR control solenoid valve Clamp Fixed clamp Fixed clamp Clamp Fixed clamp Clamp Clamp Fixed clamp Fixed clamp Secondary fuel injector White tape 5 – 10 mm (0.2 – 0.4 in) Immobilizer label Primary fuel injector (For E-02, 19, 24)

• Page 493
  SERVICING INFORMATION 10-15 ECM cushion Clamp Clamp Backside of the headlight Fixed clamp Guide Clamp Guide Clutch hose Side-stand switch HO2 sensor lead wire…
• Page 494
  10-16 SERVICING INFORMATION Grommet 120 N . m 12.0 kgf-m 87 lb-ft Make slack to the gear position switch lead wire at this point. Gear position sensor Oil pressure switch 14 N . m 1.4 kgf-m 6.5 N . m 10.0 lb-ft (0.65 kgf-m, 4.7 lb-ft) 1.5 N .

• Page 495: Throttle Cable Routing

  SERVICING INFORMATION 10-17 THROTTLE CABLE ROUTING 0 mm (0 in) 0 mm (0 in) Throttle cable No.1 Brake hose Pass the throttle cables along the air cleaner Throttle cable No.2 box.

• Page 496: Throttle Body Hose Routing

  10-18 SERVICING INFORMATION THROTTLE BODY HOSE ROUTING Fuel feed hose EVAP purge hose (E-33 only) EVAP system purge control solenoid valve PCV (breather) hose (E-33 only) ISC valve hose EVAP system purge control solenoid valve hose » To IAP sensor EVAP surge hose (E-33 only) # To EVAP system purge control solenoid valve EVAP canister (E-33 only)

• Page 497: Fuel Tank Drain Hose Routing

  SERVICING INFORMATION 10-19 FUEL TANK DRAIN HOSE ROUTING Pass the breather hose and drain hose Fuel feed hose through over the wiring harness. Bend the hose clamp at the white painted mark Breather hose (Except for E-33) on the breather hose .

• Page 498: Cooling System Hose Routing

  10-20 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING “A” : Backward. Marking (White) “A” : Top side. “B” : Backward. “A” : Right side. “B” : Right side. “A” “B” : Backward. Left side. Marking (Green) “B” : Left side. “A” : Left side.

• Page 499: Front Brake Hose Routing

  SERVICING INFORMATION 10-21 FRONT BRAKE HOSE ROUTING 1 – 2 mm (0.04 – 0.08 in) 14˚ 42˚ 42˚ Clamp ends should face downward. The green paint is right side and face upside. Clamp ends should face backward. Brake hose guide. After the brake hose union has contacted the 23 N·m (2.3 kgf-m, 16.5 lb-ft) stopper, tighten the union bolt.

• Page 500: Rear Brake Hose Routing

  10-22 SERVICING INFORMATION REAR BRAKE HOSE ROUTING 21˚ 28˚ Clamp ends should face backward. 23 N·m (2.3 kgf-m, 16.5 lb-ft) Clamp ends should face inside. 33 N·m (3.3 kgf-m, 24.0 lb-ft) White paint faces outside. 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) After the brake hose union has contacted the 18 N·m (1.8 kgf-m, 13.0 lb-ft) stopper, tighten the union bolt.

• Page 501: Clutch Hose Routing

  SERVICING INFORMATION 10-23 CLUTCH HOSE ROUTING 14˚ 28˚ Clutch hose guide. 6 N·m (0.6 kgf-m, 4.3 lb-ft) Stopper: After the clutch hose union has con- 23 N·m (2.3 kgf-m, 16.5 lb-ft) tacted the stopper, tighten the union bolt. Grommet: Install the grommet of the clutch 10 N·m (1.0 kgf-m, 7.0 lb-ft) hose to the clutch.

• Page 502: Pair (Air Supply) System Hose Routing

  10-24 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 0˚ Approx. 45˚ Approx. 25˚ 0˚ PAIR control solenoid valve Air cleaner box PAIR reed valve *1 To air cleaner box…

• Page 503: Fuel Tank Installation

  SERVICING INFORMATION 10-25 FUEL TANK INSTALLATION “A” “A” “A” “A” “A” “B” “C” Fuel tank cover Apply adhesive agent. “A” Velcro fastening View from bottom. “B” Frame cover cushion Align the fuel tank cushion with the dent mark “C”…

• Page 504: Fuel Tank Lower Side Cover Cushion Rubber/ Fastener Installation

  10-26 SERVICING INFORMATION FUEL TANK LOWER SIDE COVER CUSHION RUBBER/ FASTENER INSTALLATION 3 mm (0.12 in) Cushion Protective tape Cushion Align the velcro fastening to the aligned mark. Clean an adhesive surface before adhering the cushion and Velcro fastening velcro fastening.

• Page 505: Body Cowling Cushion Rubber Installation

  SERVICING INFORMATION 10-27 BODY COWLING CUSHION RUBBER INSTALLATION Align the cushion rubber to the aligning mark. NOTE: Clean the adhesive surface before adhering the cushion rubber. UNDER COWLING HEAT SHIELD INSTALLATION Heat shield (RH) Clean the adhesive surface before adhering the heat shield. NOTE: Clean an adhesive surface before adhering the heat shield.

• Page 506: Fuel Tank Heat Shield And Fuel Tank Bracket Cushion Installation

  10-28 SERVICING INFORMATION FUEL TANK HEAT SHIELD AND FUEL TANK BRACKET CUSHION INSTALLATION The ends of the clamp should face forward. FUEL TANK COVER CUSHION/VELCRO FASTENING INSTALLATION Fuel tank cover cushion Velcro fastening…

• Page 507: Cowling Installation

  SERVICING INFORMATION 10-29 COWLING INSTALLATION “A1” “B” To “A” To Radiator heat shield “A” To “B” To “A1”…

• Page 508: Frame Cover Installation

  10-30 SERVICING INFORMATION FRAME COVER INSTALLATION SEAT LOCK CABLE ROUTING…

• Page 509: Front Fender Installation

  SERVICING INFORMATION 10-31 FRONT FENDER INSTALLATION (For E-03, 24, 28, 33) 1 Reflex reflector 1.8 N·m (0.18 kgf-m, 1.3 lb-ft) 4.5 N·m (0.45 kgf-m, 3.25 lb-ft)

• Page 510: Rear Fender Installation

  10-32 SERVICING INFORMATION REAR FENDER INSTALLATION Rear fender (front) Rear fender (lower) Rear fender cover (front) Swingarm Rear fender (rear)

• Page 511: Side-Stand Installation

  SERVICING INFORMATION 10-33 SIDE-STAND INSTALLATION 50 N·m (5.0 kgf-m, 36.0 lb-ft) 95 N·m (9.5 kgf-m, 68.5 lb-ft) X Apply grease to sliding surface. 40 N·m (4.0 kgf-m, 29.0 lb-ft)

• Page 512: Gearshift Pedal Installation

  10-34 SERVICING INFORMATION GEARSHIFT PEDAL INSTALLATION “A” “C” 2˚ “B” * When adjusting the footrest position to the backside, the optional gearshift rod must be used. Adjust the thread of each rod end b to “A” “STD” footrest top position A: 195.65 mm (7.70 in) equal length.

• Page 513: Front Footrest Installation

  SERVICING INFORMATION 10-35 FRONT FOOTREST INSTALLATION “A” 39 N·m (3.9 kgf-m, 28.0 lb-ft) 18 N·m (1.8 kgf-m, 13.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) Align the cutaway when installing. “A” 10 N·m (1.0 kgf-m, 9.0 lb-ft)

• Page 514: Pillion Footrest Installation

  10-36 SERVICING INFORMATION PILLION FOOTREST INSTALLATION Footrest X Apply grease to sliding surface.

• Page 515: Rear View Mirror Installation

  SERVICING INFORMATION 10-37 REAR VIEW MIRROR INSTALLATION “A” Body cowling Mirror cover Cowling brace Mirror body Cushion 10 N·m (1.0 kgf-m, 7.0 lb-ft) Turn signal lead wire Locate the turn signal lead wire coupler between “A” the mirror cover and mirror body Turn signal lead wire coupler…

• Page 516: Rear Combination Light Installation

  10-38 SERVICING INFORMATION REAR COMBINATION LIGHT INSTALLATION 5 N·m (0.5 kgf-m, 3.5 lb-ft) 2.75 N·m (0.275 kgf-m, 2.0 lb-ft) 2.75 N·m (0.275 kgf-m, 2.0 lb-ft)

• Page 517: Rear Combination Light Cushion/Fastener Installation

  SERVICING INFORMATION 10-39 REAR COMBINATION LIGHT CUSHION/FASTENER INSTALLATION Rear combination light Align the corner of cushions and fasteners with the root of the rib. Fastener 25 mm (0.98 in) 30 mm (1.18 in) Cushion 33 mm (1.30 in) 40 mm (1.58 in) 4 mm (0.16 in) or more…

• Page 518: Regulator/Rectifier Installation

  10-40 SERVICING INFORMATION REGULATOR/RECTIFIER INSTALLATION 1 Regulator/Rectifier 3 Clamp 2 Bracket 4 Radiator NOTE: To remove or install the regulator/rectifier easily, hold its bolt head with an open-end wrench.

• Page 519: Special Tools

  SERVICING INFORMATION 10-41 SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-20203 09900-06108 Hexagon socket 09900-20102 Micrometer Micrometer Snap ring pliers (24 mm) Vernier calipers (25 – 50 mm) (50 – 75 mm) 09900-20205 09900-20602 09900-20605 09900-20607 Micrometer 09900-20530 Dial gauge Dial calipers Dial gauge (0 –…

• Page 520
  10-42 SERVICING INFORMATION 09915-64512 09915-74521 09913-50121 09913-70210 09915-40610 Compression gauge Oil pressure gauge Oil seal remover Bearing installer set Oil filter wrench hose 09915-74540 09915-77331 09916-14530 Oil pressure gauge Meter 09916-10911 09916-14510 Valve lifter attach- attachment (for high pressure) Valve lapper set Valve lifter ment 09916-33210…
• Page 521
  SERVICING INFORMATION 10-43 09920-53740 09922-22711 Clutch sleeve hub 09921-20210 09921-20240 Drive chain cutting 09923-74511 holder Bearing remover Bearing remover set and joining tool Bearing remover 09925-18011 09924-84510 09924-84521 Steering bearing 09930-11920 09930-11940 Bearing installer set Bearing installer set installer Torx bit JT40H Bit holder 09930-82720 09930-11950…
• Page 522
  10-44 SERVICING INFORMATION 09940-40211 09940-40220 09940-52841 09940-52861 Fuel pressure Fuel pressure gauge Front fork inner Front fork oil seal 09940-92720 gauge adaptor hose attachment rod holder installer Spring scale 09940-94922 09940-94930 09941-34513 09944-28320 Front fork spring Front fork spacer Steering race 09943-74111 Hexagon socket stopper plate…

• Page 523: Tightening Torque

  SERVICING INFORMATION 10-45 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Exhaust pipe bolt 16.5 Muffler connecting bolt 16.5 Muffler mounting bolt 18.0 Muffler chamber bracket bolt 18.0 Muffler chamber mounting bolt 16.5 Muffler joint nut 18.0 Speed sensor rotor bolt 18.0 Speed sensor bolt 0.65…

• Page 524: Fi System And Intake Air System

  10-46 SERVICING INFORMATION ITEM N·m kgf-m lb-ft Crankcase bolt (Initial) (M: 6) (Final) (Initial) 11.0 (M: (Final) 19.0 Crankshaft journal bolt (Initial) 13.0 (M: 9) 50° (Final) Oil gallery plug (M: 6) (M: 13.0 (M: 10) 13.0 (M: 16) 25.5 Oil drain plug 16.5…

• Page 525: Chassis

  SERVICING INFORMATION 10-47 CHASSIS N·m kgf-m lb-ft ITEM Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt and nut 16.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork inner rod lock-nut 11.0 Front fork damper rod bolt…

• Page 526: Tightening Torque Chart

  10-48 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt » (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55…

• Page 527: Service Data

  SERVICING INFORMATION 10-49 SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (0.94) Valve clearance (when cold) 0.08 – 0.18 — (0.003 – 0.007) 0.18 – 0.28 — (0.007 – 0.011) Valve guide to valve stem 0.010 –…

• Page 528
  10-50 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 000 kPa (13 – 17 kgf/cm², 185 – 242 psi) (10 kgf/cm , 142 psi) Compression pressure difference 200 kPa —…
• Page 529
  SERVICING INFORMATION 10-51 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5909 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –…
• Page 530
  10-52 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.72 – 2.88 2.42 No. 1, 2 and 3 (0.107 – 0.113) (0.095) Drive plate claw width 13.85 – 13.96 13.05 No. 1, 2 and 3 (0.5453 – 0.5496) (0.5138) Driven plate distortion 0.10…
• Page 531
  SERVICING INFORMATION 10-53 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 82 °C (180 °F) — ature Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) — ECT sensor resistance 20 °C Approx.
• Page 532
  10-54 SERVICING INFORMATION FI SENSORS ITEM SPECIFICATION NOTE 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.6 V at idle speed TP sensor input voltage 4.5 –…
• Page 533
  SERVICING INFORMATION 10-55 THROTTLE BODY ITEM SPECIFICATION Bore size 44 mm (1.73 in) I.D. No. 21G1 (For E-33), 21G0 (For the others) Idle r/min 1 150 ± 100 r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) ELECTRICAL Unit: mm (in) ITEM…
• Page 534
  10-56 SERVICING INFORMATION WATTAGE Unit: W STANDARD/SPECIFICATION ITEM E-03, 28, 33 Others ← Headlight ← ← Position/Parking light ← Brake light/Taillight ← Turn signal light 21 × 4 ← License plate light ← Combination meter light ← Turn signal indicator light ←…
• Page 535
  SERVICING INFORMATION 10-57 ITEM STANDARD LIMIT Wheel rim runout Axial — (0.08) Radial — (0.08) Wheel rim size Front 17 M/C × MT 3.50 — Rear 17 M/C × MT 6.00 — Wheel axle runout 0.25 Front — (0.010) 0.25 Rear —…
• Page 536
  Front fork oil level (without spring, 124 (4.88) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (each leg) 512 ml (17.3/18.0 US/Imp oz) — Front fork inner tube O.D.
• Page 537
  SERVICING INFORMATION 10-59 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.

• Page 538: Emission Control Information

  EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ………….. 11- 2 FUEL INJECTION SYSTEM…………..11- 2 CRANKCASE EMISSION CONTROL SYSTEM……..11- 3 EXHAUST EMISSION CONTROL SYSTEM……..11- 4 HO2 SENSOR INSPECTION …………… 11- 5 HO2 SENSOR REMOVAL AND INSTALLATION ……. 11- 5 NOISE EMISSION CONTROL SYSTEM……….

• Page 539: Emission Control Systems

  11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM GSX-R1000 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.

• Page 540: Crankcase Emission Control System

  EMISSION CONTROL INFORMATION 11-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atomo- sphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combus- tion chamber through the PCV (breather) hose, air cleaner and throttle body.

• Page 541: Exhaust Emission Control System

  11-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of the PAIR system, exhaust control system, three-way catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control sole- noid valve and PAIR reed valve.

• Page 542: Ho2 Sensor Inspection

  EMISSION CONTROL INFORMATION 11-5 HO2 SENSOR INSPECTION (4-88) HO2 SENSOR REMOVAL AND INSTALLATION (4-113) NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.

• Page 543: Pair (Air Supply) System And Emission Control System Inspection

  11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses for secure connection. PAIR REED VALVE • Lift and support the fuel tank. (5-3) •…

• Page 544
  EMISSION CONTROL INFORMATION 11-7 • Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow. • If air does not flow out, the solenoid valve is in normal condi- tion. • Check the resistance between the terminals of the PAIR con- trol solenoid valve.

• Page 545: Pair (Air Supply) System Diagram

  11-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM DIAGRAM PAIR control solenoid valve *1 From air cleaner PAIR reed valve *2 To #1 and #2 cylinders » FRESH AIR *3 To #3 and #4 cylinders # EXHAUST GAS PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (10-24)

• Page 546: Wiring Diagram

  WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. PAIR ISC VALVE HANDLEBAR SWITCH (RH) IGNITION IGNITION IGNITION IGNITION CONTROL COIL #1 COIL #2 COIL #3 COIL #4 DRIVING SOLENOID MODE ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH BUTTON…

• Page 547
  E-03, 28, 33 PURGE CONTROL SOLENOID (E33 only) PAIR ISC VALVE HANDLEBAR SWITCH (RH) IGNITION IGNITION IGNITION IGNITION CONTROL COIL #1 COIL #2 COIL #3 COIL #4 DRIVING SOLENOID MODE ENGINE STOP FRONT BRAKE STARTER SWITCH SWITCH BUTTON SWITCH DOWN PUSH SIDE-STAND SWITCH…
• Page 548
  Prepared by January, 2007 Part No. 99500-39310-01E Printed in Japan…
• Page 549
  Printed in Japan…

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