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GSX-R1000

SERVICE MANUAL

Printed in Japan

K9

No. 1298 GSX-R1000 S/M 99500-39380-01E For PS printing 2009.3.3 (Back: 23 mm) 5/0

BOTTOM

email: [email protected] / www.motomatrix.co.uk

DIC255

9 9 5 0 0 — 3 9 3 8 0 — 0 1 E

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

FOREWORD

This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/ service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.

This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized

SUZUKI motorcycle dealer to help you.

!

WARNING

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2009

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

TABLE OF CONTENTS

Precautions……………………………………………………… 00-i

Precautions …………………………………………………… 00-1

General Information …………………………………………… 0-i

General Information ……………………………………….. 0A-1

Maintenance and Lubrication …………………………… 0B-1

Service Data…………………………………………………..0C-1

Engine ………………………………………………………………. 1-i

Precautions …………………………………………………….. 1-1

Engine General Information and Diagnosis ……….. 1A-1

Emission Control Devices ……………………………….. 1B-1

Engine Electrical Devices…………………………………1C-1

Engine Mechanical………………………………………….1D-1

Engine Lubrication System ……………………………… 1E-1

Engine Cooling System…………………………………… 1F-1

Fuel System …………………………………………………..1G-1

Ignition System……………………………………………….1H-1

Starting System………………………………………………. 1I-1

Charging System……………………………………………..1J-1

Exhaust System …………………………………………….. 1K-1

Suspension ……………………………………………………….. 2-i

Precautions …………………………………………………….. 2-1

Suspension General Diagnosis………………………… 2A-1

Front Suspension …………………………………………… 2B-1

Rear Suspension…………………………………………….2C-1

Wheels and Tires ……………………………………………2D-1

Driveline / Axle ………………………………………………….. 3-i

Precautions …………………………………………………….. 3-1

Drive Chain / Drive Train / Drive Shaft ………………. 3A-1

Brake ………………………………………………………………… 4-i

Precautions …………………………………………………….. 4-1

Brake Control System and Diagnosis ……………….. 4A-1

Front Brakes………………………………………………….. 4B-1

Rear Brakes …………………………………………………..4C-1

Transmission / Transaxle …………………………………… 5-i

Precautions …………………………………………………….. 5-1

Manual Transmission ……………………………………… 5B-1

Clutch ……………………………………………………………5C-1

Steering…………………………………………………………….. 6-i

Precautions …………………………………………………….. 6-1

Steering General Diagnosis …………………………….. 6A-1

Steering / Handlebar ………………………………………. 6B-1

Body and Accessories……………………………………….. 9-i

Precautions …………………………………………………….. 9-1

Wiring Systems ……………………………………………… 9A-1

Lighting Systems……………………………………………. 9B-1

Combination Meter / Fuel Meter / Horn………………9C-1

Exterior Parts …………………………………………………9D-1

Body Structure ………………………………………………. 9E-1 email: [email protected] / www.motomatrix.co.uk

4

5

6

7

2

3

00

0

1

10

11

8

9

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 00- i

Section 00

Precautions

00

CONTENTS

Precautions ………………………………………..00-1

Precautions………………………………………………….. 00-1

Warning / Caution / Note………………………………. 00-1

General Precautions ……………………………………. 00-1

Precautions for Electrical Circuit Service ………… 00-2 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

00-1 Precautions:

Precautions

Precautions

Precautions

Warning / Caution / Note

B947H10000001

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

!

WARNING

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

!

CAUTION

Indicates a potential hazard that could result in motorcycle damage.

NOTE

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the

WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

General Precautions

!

WARNING

B947H10000002

• Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.

• When 2 or more persons work together, pay attention to the safety of each other.

• When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.

• When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the material manufacturer’s instructions.

• Never use gasoline as cleaning solvent.

• To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled.

• After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks.

!

CAUTION

• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.

• 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.

• Be sure to use special tools when instructed.

• Make sure that all parts used in reassembly are clean. Lubricate them when specified.

• Use the specified lubricant, bond or sealant.

• When removing the battery, disconnect the negative (–) cable first and then the positive (+) cable.

• When reconnecting the battery, connect the positive (+) cable first and then the negative (–) cable, and replace the terminal cover on the positive (+) terminal.

• When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative (–) cable the battery.

• When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.

• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, selflocking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.

• Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.

• After reassembling, check parts for tightness and proper operation.

• To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires.

• To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

Precautions for Electrical Circuit Service

B947H10000003

When handling the electrical parts or servicing FI system, observe the following points for the safety of the systems.

Precautions: 00-2

• Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material which could impede proper terminal contact.

• Before refitting the sealed coupler, make sure its seal rubber is positioned properly. The seal rubber may possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber improperly positioned, it may result in poor water sealing.

I310G1000002-01

• Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.

Electrical Parts

Connector / Coupler

• Faulty FI system is often related to poor electrical contact of connector/coupler. Before servicing individual electronic part, check electrical contact of the connector/coupler.

• When connecting a connector, be sure to push it in until a click is felt.

I310G1000003-02

• When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (rear) of the connector/coupler.

2

I823H1000002-01

• With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully to engage the lock when connecting.

• When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.

• Inspect each terminal on the connector/coupler for looseness or bending.

• Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed, possibly resulting in poor electrical contact.

1. Coupler 2. Probe

1

I649G1000013-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

00-3 Precautions:

• When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female terminal. Never push in the probe where male terminal is supposed to fit.

• Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.

Fuse

• When a fuse is blown, always investigate the cause to correct it and then replace the fuse.

• Do not use a fuse of different capacity.

• Do not use wire or any other substitute for the fuse.

4

“A”

3

3. Coupler 4. Probe

4

I649G1000030-02

“A”: Where male terminal fits

• Avoid applying grease or other similar material to connector/coupler terminals to prevent electric trouble.

Clamp

• Clamp the wire harness at such positions as indicated in “Wiring Harness Routing Diagram” in Section 9A

(Page 9A-7).

• Bend the clamp properly so that the wire harness is clamped securely.

• In clamping the wire harness, use care not to allow it to hang down.

• Do not use wire or any other substitute for the band type clamp.

I649G1000001-02

Switch

Never apply grease material to switch contact points to prevent damage.

ECM / Various sensors

• Since each component is a high-precision part, great care should be taken not to apply any severe impacts during removal and installation.

I310G1000007-01

• Be careful not to touch the electrical terminals of the electronic parts (ECM, etc.). The static electricity from your body may damage them.

CORRECT INCORRECT

I718H1000001-02

I310G1000008-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

• When disconnecting and connecting the coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

Precautions: 00-4

• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher.

Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.

1

I837H1000001-01

1. Ignition switch

Battery

• 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.

I718H1000004-01

• Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the electronic unit which may result in serious damage.

I310G1000012-02

• Never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its coupler is disconnected. Otherwise, damage to electronic unit may result.

• Never connect an ohmmeter to the electronic unit with its coupler connected. If attempted, damage to ECM or sensors may result.

• Be sure to use a specified voltmeter/ohmmeter.

Otherwise, accurate measurements may not be obtained and personal injury may result.

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 circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

• Loose connection of connector/coupler.

• Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.).

• Wire harness being open.

• Poor terminal-to-wire connection.

When checking system circuits including an electronic control unit such as ECM, etc., it is important to perform careful check, starting with items which are easier to check.

1) Disconnect the negative (–) cable from the battery.

I310G1000011-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

00-5 Precautions:

2) Check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock if equipped.

Continuity check

1) Measure resistance across coupler “B” (between “A” and “C” in figure).

If no continuity is indicated (infinity or over limit), the circuit is open between terminals “A” and “C”.

“A”

“A”

“A”

1

ECM

“B”

ECM

1. Sensor

I718H1000005-02

“A”: Check for loose connection

3) Using a test male terminal, check the female terminals of the circuit being checked for contact tension.

Check each terminal visually for poor contact

(possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the coupler and locked.

If contact tension is not enough, rectify the contact to increase tension or replace. The terminals must be clean and free of any foreign material which could impede proper terminal contact.

“C”

I705H1000006-02

2) Disconnect the coupler “B” and measure resistance between couplers “A” and “B-1”.

If no continuity is indicated, the circuit is open between couplers “A” and “B-1”. If continuity is indicated, there is an open circuit between couplers

“B-2” and “C” or an abnormality in coupler “B-2” or coupler “C”.

“A”

“B-2”

ECM

“B”

“C”

I649G1000027-02

“B”: Check contact tension by inserting and removing

“C”: Check each terminal for bend and proper alignment

4) Using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection.

Locate abnormality, if any.

“D”

“E”

“F”

“B”

“B-1”

“C”

I705H1000010-02

Voltage check

If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.

1) With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.

2) If measurements were taken as shown in the figure and results were listed in the following, it means that the circuit is open between terminals “A” and “B”.

Voltage between

“A” and body ground: Approx. 5 V

“B” and body ground: Approx. 5 V

“C” and body ground: 0 V

I649G1000028-02

“D”: Looseness of crimping

“E”: Open

“F”: Thin wire (A few strands left) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3) Also, if measured values are as listed following, a resistance (abnormality) exists which causes the voltage drop in the circuit between terminals “A” and

“B”.

Voltage between

“A” and body ground: Approx. 5 V

“B” and body ground: Approx. 5 V – 2 V voltage drop

“C” and body ground: 3 V – 2 V voltage drop

“A”

Precautions: 00-6

Short circuit check (Wire harness to ground)

1) Disconnect the negative (–) cable from the battery.

2) 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. Otherwise, diagnosis will be wrong.

3) Measure resistance between terminal at one end of circuit (“A” terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals “A” and “C”.

ECM

“A”

“B”

“C”

“D”

“B”

ECM

“C”

“E”

5V

“A”

0V

5V

5V

“B” “C”

5V

I705H1000007-01

“A” “C”

“D”: To other parts “E”: Other parts

I705H1000008-01 email: [email protected] / www.motomatrix.co.uk

“A”

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

00-7 Precautions:

4) Disconnect the connector/coupler included in circuit

(coupler “B”) and measure resistance between terminal “A” and body ground. If continuity is indicated, the circuit is shorted to ground between terminals “A” and “B”.

“B”

“D”

“C”

ECM

Using the testers

• Incorrectly connecting the (+) and (–) probes may cause the inside of the tester to be burned.

• If the voltage and current are not known, make measurements using the highest range.

• When measuring the resistance with the multi-circuit tester (1),

∞

will be shown as 10.00 M

Ω

and “1” flashes in the display.

• Check that no voltage is applied before making the measurement. If voltage is applied the tester may be damaged.

• After using the tester, turn the power off.

Special tool

: 09900–25008 (Multi circuit tester set)

I705H1000009-02

“D”: To other parts

Using The Multi-Circuit Testers

• Use the Suzuki multi-circuit tester set.

• Use well-charged batteries in the tester.

• Be sure to set the tester to the correct testing range.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(A)

I649G1000024-03

I649G1000002-02

NOTE

• When connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them.

• Use the needle pointed probe to prevent the rubber of the water proof coupler from damage.

• When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

Special tool

(A): 09900–25009 (Needle-point probe set)

(A)

I649G1000025-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 0- i

Section 0

General Information

CONTENTS

0

General Information ………………………….. 0A-1

General Description ………………………………………0A-1

Symbols …………………………………………………….. 0A-1

Abbreviations ……………………………………………… 0A-1

Vehicle Side View ……………………………………….. 0A-2

Vehicle Identification Number ……………………….. 0A-3

Fuel and Oil Recommendation ……………………… 0A-3

Engine Coolant Recommendation …………………. 0A-4

BREAK-IN Procedures…………………………………. 0A-4

Cylinder Identification…………………………………… 0A-4

Country and Area Codes ……………………………… 0A-5

Wire Color Symbols …………………………………….. 0A-5

Warning, Caution and Information Labels

Location …………………………………………………… 0A-6

Component Location …………………………………….0A-7

Electrical Components Location ……………………. 0A-7

Specifications……………………………………………….0A-9

Specifications ……………………………………………… 0A-9

Special Tools and Equipment ………………………0A-11

Special Tool ……………………………………………… 0A-11

Maintenance and Lubrication…………….. 0B-1

Precautions…………………………………………………..0B-1

Precautions for Maintenance ………………………… 0B-1

General Description ………………………………………0B-1

Recommended Fluids and Lubricants…………….. 0B-1

Scheduled Maintenance ………………………………..0B-2

Periodic Maintenance Schedule Chart……………. 0B-2

Lubrication Points ……………………………………….. 0B-3

Repair Instructions ……………………………………….0B-3

Air Cleaner Element Replacement…………………. 0B-3

Air Cleaner Element Inspection …………………….. 0B-3

Exhaust Pipe Bolt and Muffler Bolt Inspection …. 0B-4

Exhaust Control Valve Inspection ………………….. 0B-4

Valve Clearance Inspection and Adjustment ……0B-5

Spark Plug Replacement ………………………………0B-9

Spark Plug Inspection and Cleaning ……………….0B-9

Fuel Line Inspection ……………………………………0B-10

Evaporative Emission Control System

Inspection (E-33 only) ……………………………….0B-10

Engine Oil and Filter Replacement ……………….0B-10

Throttle Cable Play Inspection and

Adjustment ………………………………………………0B-12

PAIR System Inspection ……………………………..0B-12

Throttle Valve Synchronization …………………….0B-12

Cooling System Inspection…………………………..0B-12

Clutch Cable Play Inspection and Adjustment ..0B-14

Drive Chain Inspection and Adjustment …………0B-14

Drive Chain Cleaning and Lubricating……………0B-16

Brake System Inspection …………………………….0B-16

Tire Inspection……………………………………………0B-18

Steering System Inspection …………………………0B-18

Front Fork Inspection ………………………………….0B-19

Rear Suspension Inspection ………………………..0B-19

Chassis Bolt and Nut Inspection …………………..0B-19

Compression Pressure Check ……………………..0B-21

Oil Pressure Check …………………………………….0B-21

SDS Check………………………………………………..0B-21

Specifications ……………………………………………..0B-21

Tightening Torque Specifications………………….0B-21

Special Tools and Equipment ………………………0B-22

Recommended Service Material …………………..0B-22

Special Tool ………………………………………………0B-22

Service Data ……………………………………… 0C-1

Specifications ……………………………………………….0C-1

Service Data………………………………………………..0C-1

Tightening Torque List ………………………………….0C-9 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0A-1 General Information:

General Information

General Information

General Description

Symbols

B947H10101001

Listed in the table below are the symbols indicating instructions and other information necessary for servicing.

The meaning of each symbol is also included in the table.

Symbol Definition

Torque control required.

Data beside it indicate specified torque.

Apply oil.

Use engine oil unless otherwise specified.

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1).

Apply SUZUKI SUPER GREASE “A” or equivalent.

99000-25010

Apply SUZUKI MOLY PASTE or equivalent.

99000-25140

Apply SUZUKI SILICONE GREASE or equivalent.

99000-25100

Apply SUZUKI BOND “1207B” or equivalent.

99000-31140

Apply THREAD LOCK CEMENT SUPER “1303” or equivalent.

99000-32030

Apply THREAD LOCK CEMENT SUPER “1322” or equivalent.

99000-32110

Apply THREAD LOCK CEMENT SUPER “1360” or equivalent.

99000-32130

Use engine coolant or equivalent.

99000-99032-11X

Use fork oil or equivalent.

99000-99001-SS5

Apply MUFFLER SEAL LOCTITE “5920” (commercially available) or equivalent.

Apply or use brake fluid.

Use special tool.

Do not reuse.

Note on reassembly.

Abbreviations

B947H10101002

A:

ABDC:

After Bottom Dead Center

AC:

Alternating Current

ACL:

Air Cleaner, Air Cleaner Box

API:

American Petroleum Institute

ATDC:

After Top Dead Center

ATM Pressure:

Atmospheric Pressure, Atmospheric

Pressure Sensor (APS, AP Sensor)

A/F:

Air Fuel Mixture

B:

BARO:

Barometric pressure (Atmospheric pressure)

BBDC:

Before Bottom Dead Center

BTDC:

Before Top Dead Center

B+:

Battery Positive Voltage

C:

CKP Sensor:

Crankshaft Position Sensor (CKPS)

CKT:

Circuit

CLP Switch:

Clutch Lever Position Switch (Clutch

Switch)

CMP Sensor:

Camshaft Position Sensor (CMPS)

CO:

Carbon Monoxide

CPU:

Central Processing Unit

D:

DC:

Direct Current

DMC:

Dealer Mode Coupler

DOHC:

Double Over Head Camshaft

DRL:

Daytime Running Light

DTC:

Diagnostic Trouble code email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

General Information: 0A-2

E:

ECM:

Engine Control Module Engine Control Unit

(ECU) (FI Control Unit)

ECT Sensor:

Engine Coolant Temperature Sensor

(ECTS)

Water Temp. Sensor (WTS)

EVAP:

Evaporative Emission

EXC System:

Exhaust Control System (EXCS)

EXC Valve:

Exhaust Control Valve (EXCV)

EXCV Actuator:

Exhaust Control Valve Actuator

(EXCVA)

F:

FI:

Fuel Injection, Fuel Injector

FP:

Fuel pump

FPR:

Fuel Pressure Regulator

FP Relay:

Fuel Pump Relay

G:

GEN:

Generator

GND:

Ground

GP Switch:

Gear Position Switch

H:

HC:

Hydrocarbons

HO2 sensor:

Heated Oxygen Sensor (HO2S)

I:

IAP Sensor:

Intake Air Pressure Sensor (IAPS)

IAT Sensor:

Intake Air Temperature Sensor (IATS)

IG:

Ignition

ISC Valve:

Idle Speed Control Valve (ISCV)

J:

JASO:

Japanese Automobile Standards Organization

L:

LCD:

Liquid Crystal Display

LED:

Light Emitting Diode (Malfunction Indicator Lamp)

LH:

Left Hand

M:

MAL-CODE:

Malfunction Code (Diagnostic Code)

Max:

Maximum

MIL:

Malfunction Indicator Lamp (LED)

Min:

Minimum

N:

NOx:

Nitrogen Oxides

O:

OHC:

Over Head Camshaft

OPS:

Oil Pressure Switch

P:

PAIR:

Pulsed Secondary Air Injection

PCM:

Power Control Module

PCV:

Positive Crankcase Ventilation (Crankcase

Breather)

R:

RH:

Right Hand

ROM:

Read Only Memory

S:

SAE:

Society of Automotive Engineers

SDS:

Suzuki Diagnosis System

SRAD:

Suzuki Ram Air Direct

STC System:

Secondary Throttle Control System

(STCS)

STP Sensor:

Secondary Throttle Position Sensor

(STPS)

ST Valve:

Secondary Throttle Valve (STV)

STV Actuator:

Secondary Throttle Valve Actuator

(STVA)

T:

TO Sensor:

Tip-over Sensor (TOS)

TP Sensor:

Throttle Position Sensor (TPS)

Vehicle Side View

B947H10101003

NOTE

Difference between illustrations and actual motorcycles may exist depending on the markets.

SUZUKI GSX-R1000 (2009-model)

Right Side

Left Side

I947H1010002-02

I947H1010003-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0A-3 General Information:

Vehicle Identification Number

B947H10101004

The frame serial number or V.I.N. (Vehicle Identification

Number) “A” is stamped on the right side of the steering head tube. The engine serial number “B” is located on the lower crankcase. These numbers are required especially for registering the machine and ordering spare parts.

Engine Oil (For USA)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil.

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 and alternative according to the chart.

“A”

I947H1010004-02

Engine Oil (For Other Countries)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality 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 chart.

“B”

I947H1010005-01

Fuel and Oil Recommendation

B947H10101005

Fuel (For USA and Canada)

Use only unleaded gasoline of at least 90 pump octane

(R/2 + M/2).

Gasoline containing MTBE (Meltyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Fuel (For Other Countries)

Gasoline used should be graded 95 octane (Research

Method) or higher. Unleaded gasoline is recommended.

I310G1010005-01

Brake Fluid

Specification and classification: DOT 4

!

WARNING

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never reuse brake fluid left over from a previous servicing, which has been stored for a long period.

Front Fork Oil

Use fork oil SS-05 or equivalent fork oil.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

General Information: 0A-4

Engine Coolant Recommendation

B947H10101006

Engine Coolant

Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.

Water for mixing

Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.

Anti-freeze / Engine coolant

The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point.

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

BREAK-IN Procedures

B947H10101007

During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.

1) Keep to these break-in engine speed limits:

Speed limits

Initial 800 km (500 miles): Below 7 000 r/min

Up to 1 600 km (1 000 miles): Below 10 500 r/min

Over 1 600 km (1 000 miles): Below 13 750 r/min

2) Upon reaching an odometer reading of 1 600 km (1

000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 13 750 r/ min at any time.

Cylinder Identification

B947H10101008

The four cylinders of this engine are identified as #1, 2, 3 and #4 cylinder, as counted from left to right (as viewed by the rider on the seat).

Liquid amount of water / Engine coolant

Solution capacity (total)

2 750 ml (2.9/2.4 US/Imp qt)

For engine coolant mixture information, refer to “Engine

Coolant Description” in Section 1F (Page 1F-1).

!

CAUTION

Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced.

Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing point.

#1

#2

#3

#4

I947H1010001-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0A-5 General Information:

Country and Area Codes

The following codes stand for the applicable country(-ies) and area(-s).

Code

GSX-R1000 K9 (E-02)

GSX-R1000 K9 (E-14)

GSX-R1000 K9 (E-19)

GSX-R1000UF K9 (E-19)

GSX-R1000 K9 (E-03)

GSX-R1000 K9 (E-24)

GSX-R1000 K9 (E-28)

GSX-R1000 K9 (E-33)

GSX-R1000 K9 (E-51)

Country or Area

U.K.

Thailand

E.U.

E.U.

U.S.A. (Except for California)

Australia

Canada

California (U.S.A.)

Korea

B947H10101009

Effective Frame No.

JS1CY111100100001 –

JS1CY121400100001 –

JS1CY111100100001 –

JS1CY211100100001 –

JS1GT78A 92100001 –

JS1CY111200100001 –

JS1GT78A 92100001 –

JS1GT78A 92100001 –

JS1CY111390100001 –

Wire Color Symbols

Bl/G

Bl/W

Bl/Y

Br/B

Br/Y

G/B

G/Bl

G/R

B/Br

B/G

B/Lg

B/O

B/R

B/W

B/Y

Bl/B

Lbl

Lg

O

P

R

W

Y

B/Bl

Symbol

B

Bl

Br

Dbr

Dg

G

Gr

Wire Color

Black

Blue

Brown

Dark brown

Dark green

Green

Gray

Light blue

Light green

Orange

Pink

Red

White

Yellow

Black with Blue tracer

Black with Brown tracer

Black with Green tracer

Black with Light green tracer

Black with Orange tracer

Black with Red tracer

Black with White tracer

Black with Yellow tracer

Blue with Black tracer

Blue with Green tracer

Blue with White tracer

Blue with Yellow tracer

Brown with Black tracer

Brown with Yellow tracer

Green with Black tracer

Green with Blue tracer

Green with Red tracer

W/R

W/Y

Y/B

Y/Bl

Y/G

Y/R

Y/W

P/B

P/W

R/B

R/Bl

R/Y

W/B

W/Bl

W/G

Symbol

G/W

G/Y

Gr/B

Gr/R

Gr/W

Gr/Y

Lg/Bl

Lg/G

Lg/W

O/B

O/Bl

O/G

O/R

O/W

O/Y

Wire Color

Green with White tracer

Green with Yellow tracer

Gray with Black tracer

Gray with Red tracer

Gray with White tracer

Gray with Yellow tracer

Light green with Blue tracer

Light green with Green tracer

Light green with White tracer

Orange with Black tracer

Orange with Blue tracer

Orange with Green tracer

Orange with Red tracer

Orange with White tracer

Orange with Yellow tracer

Pink with Black tracer

Pink with White tracer

Red with Black tracer

Red with Blue tracer

Red with Yellow tracer

White with Black tracer

White with Blue tracer

White with Green tracer

White with Red tracer

White with Yellow tracer

Yellow with Black tracer

Yellow with Blue tracer

Yellow with Green tracer

Yellow with Red tracer

Yellow with White tracer

B947H10101010 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

General Information: 0A-6

Warning, Caution and Information Labels Location

B947H10101011

[C]

6 (E-28)

6, 7, 8, 9

[A]

1 (E-24), 2

1 (E-03, 33)

3, 21, 23

[B]

5

10, 11, 12

16, 17, 18, 19, 20

4

[D]

13, 14, 15

[E]

22, 24

1. Noise label (For E-03, 24, 33)

2. Information label (For E-03, 28, 33, 51)

3. Vacuum hose routing label (For E-33)

4. Fuel information label (For E-02, 03, 19, 24, 28, 33, 51, GSX-R1000UF E-19)

5. Manual notice label (For E-03, 33)

6. Screen label (English) (For E-02, 03, 24, 28, 33)

7. Screen label (French) (For E-28, GSX-R1000UF E-19)

8. Screen label (French/German/Italian/Swedish) (For E-19)

9. Screen label (Korean) (For E-51)

10. Steering warning label (English) (For E-03, 33)

11. Steering warning label (French/German/English) (For E-02, 19, 24, 28, GSX-

R1000UF E-19)

12. Steering warning label (Korean) (For E-51)

13. Tire information label (English) (For E-03, 33)

14. Tire information label (French/German/English) (For E-02, 19, 24, 28, GSX-

R1000UF E-19)

15. Tire information label (Korean) (For E-51)

I947H1010008-04

16. General warning label (English) (For E-02, 03, 24, 33)

17. General warning label (French) (For GSX-R1000UF E-19)

18. General warning label (English/French) (For E-28)

19. General warning label (French/German/Italian/Swedish) (For E-19)

20. General warning label (Korean) (For E-51)

21. ICES Canada label (For E-28)

22. I.D. plate (For E-02, 19, 24, GSX-R1000UF E-19)

23. I.D. label (For GSX-R1000UF E-19)

24. Safety plate (For E-03, 28, 33, 51)

[A]: Frame (LH)

[B]: Rear fender, front

[C]: Intake cover

[D]: Chain case

[E]: Frame (RH) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0A-7 General Information:

Component Location

Electrical Components Location

2

7

3

1

B947H10103001

5

8

6

4

9

10

14

11

12

13

16

17

15

18

21

22

20

19

1. Steering damper solenoid valve

2. PAIR control solenoid valve

3. CMP sensor

4. Ignition coil

5. ISC valve

6. TP sensor

7. STP sensor

8. STV actuator

9. Fuel level gauge

10. Fuel pump

11. Mode select switch/SDS coupler

12. ECM

13. Fuse box

14. Starter relay/Main fuse

15. Battery

16. AP sensor

17. TO sensor

18. CKP sensor

19. HO2 sensor

20. Regulator/Rectifier

21. Cooling fan

22. Lap time counter switch

I947H1010006-06 email: [email protected] / www.motomatrix.co.uk

23

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

General Information: 0A-8

27

25

28

24

26

29

30

31

33

32

34

35

36

37

38

41

23. Ignition switch/Immobilizer antenna (E-02, 19, 24, 51)

24. IAT sensor

25. Secondary fuel injector

26. Primary fuel injector

27. IAP sensor

28. EVAP system purge control solenoid valve (E-33 only)

29. Fuel pump relay

39

40

30. Turn signal/Side-stand relay

31. Cooling fan relay

32. ECT sensor

33. Generator

34. Starter motor

35. GP switch

36. Speed sensor

37. Horn

38. EXCV actuator

39. Oil pressure switch

40. Side-stand switch

41. Drive mode selector

I947H1010007-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0A-9 General Information:

Specifications

Specifications

NOTE

These specifications are subject to change without notice.

Dimensions and dry mass

Item

Overall length

Overall width

Overall height

Wheelbase

Ground clearance

Seat height

Curb mass

Specification

2 045 mm (80.5 in)

720 mm (28.3 in)

1 130 mm (44.5 in)

1 405 mm (55.3 in)

130 mm (5.1 in)

810 mm (31.9 in)

205 kg (452 lbs)

Engine

Item

Type

Number of cylinders

Bore

Stroke

Displacement

Compression ratio

Fuel system

Air cleaner

Starter system

Lubrication system

Idle speed

Specification

4-stroke, Liquid-cooled, DOHC

4

74.5 mm (2.933 in)

57.3 mm (2.256 in)

999 cm

3

(61.0 cu. in)

12.8 : 1

Fuel injection system

Paper element

Electric

Wet sump

1 150

±

100 r/min

Drive train

Item

Clutch

Transmission

Gearshift pattern

Primary reduction ratio

Gear ratios

Low

2nd

3rd

4th

5th

Top

Final reduction ratio

Drive chain

Specification

Wet multi-plate type

6-speed constant mesh

1-down, 5-up

1.617 (76/47)

2.562 (41/16)

2.052 (39/19)

1.714 (36/21)

1.500 (36/24)

1.360 (34/25)

1.269 (33/26)

2.470 (42/17)

DID50VAZ, 114 links

B947H10107001

Remark

Remark

Remark

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

General Information: 0A-10

Chassis

Item

Front suspension

Rear suspension

Front suspension stroke

Rear wheel travel

Caster

Trail

Steering angle

Turning radius

Front brake

Rear brake

Front tire size

Rear tire size

Specification

Inverted telescopic, coil spring, oil damped

Link type, coil spring, oil damped

125 mm (4.9 in)

130 mm (5.1 in)

23

°

50’

98 mm (3.86 in)

27

°

(right & left)

3.4 m (11.2 ft)

Disc brake, twin

Disc brake

120/70ZR17M/C (58W), tubeless

190/50ZR17M/C (73W), tubeless

Remark

Electrical

Item

Ignition type

Ignition timing

Spark plug

Battery

Generator

Main fuse

Fuse

Headlight

High

Low

Position light

Brake light/Taillight

License plate light

Turn signal light

Speedometer light

Tachometer light

Fuel level indicator light

Turn signal indicator light

Neutral indicator light

High beam indicator light

Oil pressure/Coolant temperature indicator light

FI indicator light/Sd indicator light

Engine R.P.M. indicator light

Immobilizer indicator light

Capacities

Item

Fuel tank

Engine oil

Engine coolant

Oil change

With filter change

Overhaul

Specification

Electronic ignition (Transistorized)

4

°

B.T.D.C. at 1 150 r/min

NGK CR9EIA-9 or DENSO IU27D

12 V 36.0 kC (10 Ah)/10 HR

Three-phase A.C. generator

30 A

30/10/10/15/10/10/15 A

12 V 65 W (H9)

12 V 55 W (H11)

12 V 5 W

LED

12 V 5 W

12 V 21 W

LED

LED

LED

LED

LED

LED

LED

LED

LED

LED

Specification

16.5 L (4.4/3.6 US/lmp gal)

17.5 L (4.6/3.8 US/lmp gal)

2 800 ml (3.0/2.5 US/lmp qt)

3 300 ml (3.5/3.0 US/lmp qt)

3 600 ml (3.8/3.2 US/lmp qt)

2 750 ml (2.8/2.4 US/lmp qt)

Remark

E-02, 19, 24, 51

Remark

E-33

Others

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0A-11 General Information:

Special Tools and Equipment

Special Tool

B947H10108002

09900–06104

Snap ring remover

(Open type)

09900–06107

Snap ring remover

(Open type)

09900–06108

Snap ring remover

(Close type)

09900–18740

Hexagon socket (24 mm)

09900–20102

Vernier calipers (200 mm)

09900–20202

Micrometer (25 – 50 mm)

09900–20203

Micrometer (50 – 75 mm)

09900–20205

Micrometer (0 – 25 mm)

09900–20530

Cylinder gauge set

09900–20602

Dial gauge

09900–20605

Dial calipers (10 – 34 mm)

09900–20607

Dial gauge

09900–20701

Dial gauge chuck

09900–20803

Thickness gauge

09900–20805

Tire depth gauge

09900–21304

V blocks

09900–22301

Plastigage (0.025 –

0.076 mm)

09900–22302

Plastigage (0.051 –

0.152 mm)

09900–22401

Small bore gauge (10

– 18 mm)

09900–22403

Small bore gauge (18

– 35 mm)

09900–25008

Multi circuit tester set

09900–25009

Needle-point probe set

09904–41010

SUZUKI Diagnostic system set

09913–50121

Oil seal remover

09913–70210

Bearing installing set

(10 – 75

Φ

) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

General Information: 0A-12

09915–17410

Oil pressure gauge adapter

09915–40610

Oil filter wrench

09915–63311

Compression gauge attachment

09915–64512

Compression gauge

09915–74521

Adapter hose

09915–77331

Oil pressure gauge

(1000 kPa)

09916–10911

Valve lapper set

09916–14510

Valve lifter

09916–14522

Valve lifter attachment

09916–33210

Valve guide reamer

(4.5 mm)

09916–33320

Valve guide reamer

(9.8 mm)

09916–34542

Reamer handle

09916–43211

Valve guide installer & remover

09916–53380

Valve guide installer attachment

09916–77310

Piston ring compressor

09916–84511

Tweezer

09917–47011

Vacuum pump gauge set

09919–28620

Sleeve protector

09920–53740

Clutch sleeve hub holder

09921–20210

Bearing remover (12 mm)

09921–20240

Bearing remover set

09922–22711

Drive chain cutting and joint tool set

09923–74511

Bearing remover

09924–84510

Bearing installer set

09924–84521

Bearing installer set email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0A-13 General Information:

09925–18011

Bearing installer

09930–10121

Spark plug wrench set

09930–11920

Torx bit (JT40H)

09930–11940

Torx bit holder

09930–11950

Torx wrench (5 mm)

09930–11960

Torx wrench (4 mm)

09930–30104

Rotor remover sliding shaft

09930–30460

Rotor remover bolt

09930–34970

Rotor remover

09930–40113

Flywheel rotor holder

09930–44530

Rotor holder

09930–73170

Starter torque limiter holder

09930–73181

Starter torque limiter socket

09930–82720

Mode selection switch

09940–14911

Steering stem nut socket wrench

09940–14940

Swingarm pivot thrust adjuster wrench

09940–14960

Steering stem nut socket wrench

09940–14990

Engine mounting adjust wrench

09940–40211

Fuel pressure gauge adapter

09940–40220

Fuel pressure gauge attachment

09940–52861

Front fork oil seal installer set

09940–84710

Rod guide case wrench

09940–92720

Spring scale

09941–34513

Bearing installer

09941–53670

Front fork cap socket wrench (45 mm) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

General Information: 0A-14

09943–74111

Front fork oil level gauge

09943–88211

Pinion bearing installer

09944–28321

Hexagon socket (19 mm)

99565–01010–020

CD-ROM Ver.20

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-1 Maintenance and Lubrication:

General Information

Maintenance and Lubrication

Precautions

Precautions for Maintenance

B947H10200001

The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.

NOTE

More frequent servicing may be required on motorcycles that are used under severe conditions.

General Description

Recommended Fluids and Lubricants

B947H10201001

Refer to “Fuel and Oil Recommendation” in Section 0A (Page 0A-3) and “Engine Coolant Recommendation” in

Section 0A (Page 0A-4).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-2

Scheduled Maintenance

Periodic Maintenance Schedule Chart

B947H10205001

NOTE

I = Inspect and clean, adjust, replace or lubricate as necessary.

R = Replace.

T = Tighten.

Air cleaner element

Exhaust pipe bolts and muffler bolts

Exhaust control valve

Valve clearance

Spark plugs

Fuel line

Evaporative emission control system

(E-33 only)

Engine oil

Engine oil filter

Throttle cable play

PAIR (air supply) system

Throttle valve synchronization

Engine coolant

Radiator hose

Clutch cable play

Drive chain

Brakes

Brake fluid

Brake hoses

Tires

Steering

Front fork

Rear suspension

Item

Chassis bolts and nuts

km miles months

1 000

600

2

—

T

I

—

—

—

—

Interval

6 000 12 000

4 000

12

7 500

24

I

I

I

—

—

—

I

T

I

—

R

I

— I

18 000

11 000

36

R

—

—

—

I

I

—

R

R

I

—

I

(E-33 only)

— I —

—

—

I

I

I

I

Replace every 2 years.

I

I

I

I

I

I

Clean and lubricate every 1 000 km (600 miles).

I

I

I

I

I

—

—

R

—

I

—

I

I

R

—

I

I

I

I

I

Replace every 2 years.

I I

I

I

R

R

I

—

R

—

I

I

I

I

I

—

I

—

—

T

I

Replace every 4 years.

I I

—

—

I

I

—

—

—

T

I

T

—

T

I

I

I

I

T

24 000

14 500

48

I

T

I

I

R

I

I email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-3 Maintenance and Lubrication:

Lubrication Points

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Major lubrication points are indicated as follows.

B947H10205002

NOTE

• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

• Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions.

1

5

3

2

4

1. Clutch lever holder

2. Side stand pivot and spring hook

3. Gearshift lever pivot and footrest pivot

4. Drive chain

6

5. Brake lever holder

6. Brake pedal pivot and footrest pivot

: Apply grease.

: Apply oil.

I947H1020033-02

Repair Instructions

Air Cleaner Element Replacement

B947H10206001

Replace air cleaner element

Every 18 000 km (11 000 miles, 36 months)

Refer to “Air Cleaner Element Removal and Installation” in Section 1D (Page 1D-6).

NOTE

If driving under dusty conditions, replace the air cleaner element more frequently. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component.

Air Cleaner Element Inspection

B947H10206002

Inspect air cleaner element

Every 6 000 km (4 000 miles, 12 months)

Inspection

1) Remove the air cleaner element. Refer to “Air

Cleaner Element Removal and Installation” in

Section 1D (Page 1D-6).

2) Inspect the air cleaner element for clogging. If it is clogged with dirt, replace it with a new one.

!

CAUTION

Do not blow the air cleaner element with compressed air.

I947H1020001-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-4

3) Drain water from the air cleaner box by removing the drain plug (1).

1

4) Reinstall the removed parts.

I947H1020002-01

Exhaust Control Valve Inspection

B947H10206004

Inspect exhaust control valve

Initially at 1 000 km (600 miles, 2 months) and every

12 000 km (7 500 miles, 24 months) thereafter

Inspect exhaust control valve as follows:

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Check the exhaust control valve actuator (1) for its smooth movement when the ignition switch is turned on. If the exhaust valve actuator does not move smoothly, check exhaust valve actuator electrical circuit. Refer to “EXCVA Inspection” in Section 1K

(Page 1K-9).

Exhaust Pipe Bolt and Muffler Bolt Inspection

B947H10206003

Tighten exhaust pipe bolts and muffler bolts

Initially at 1 000 km (600 miles, 2 months) and every

12 000 km (7 500 miles, 24 months) thereafter

Check the exhaust pipe bolts and muffler bolts to the specified torque.

Tightening torque

Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

Muffler chamber connecting bolt (b): 30 N·m (3.0 kgf-m, 21.5 lbf-ft)

Muffler chamber bracket bolt (c): 25 N·m (2.5 kgf-m,

18.0 lbf-ft)

Muffler chamber mounting bolt (d): 23 N·m (2.3 kgfm, 16.5 lbf-ft)

Muffler connecting bolt (e): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

Muffler mounting bolt (f): 25 N·m (2.5 kgf-m, 18.0 lbf-ft)

1

I947H1020003-02

3) Check the lock-nuts (2) for tightness. If the lock-nuts

(2) are loose, tighten them after adjusting the cable length. Refer to “EXCV Cable Removal and

Installation” in Section 1K (Page 1K-6).

(f)

(e)

(e)

(d)

(c)

(b)

(a)

I947H1020053-01 email: [email protected] / www.motomatrix.co.uk

2

I947H1020004-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-5 Maintenance and Lubrication:

Valve Clearance Inspection and Adjustment

B947H10206005

Inspect valve clearance

Initially every 24 000 km (14 500 miles, 48 months)

Inspection

Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

3) Remove the cylinder head cover. Refer to “Engine

Top Side Disassembly” in Section 1D (Page 1D-26).

4) Remove the spark plugs. Refer to “Ignition Coil and

Spark Plug Removal and Installation” in Section 1H

(Page 1H-6).

Valve clearance (When cold)

IN: 0.08 – 0.18 mm (0.003 – 0.007 in)

EX: 0.18 – 0.28 mm (0.007 – 0.011 in)

5) Remove the valve timing inspection cap (1).

“B”

“A”

EX IN

“B”

I823H1020007-01

6) Turn the crankshaft to bring the line “C” on the CKP sensor rotor to the slit “D” of cap hole thread and also to bring the notches “E” on the left ends of both camshafts (EX and IN) to the positions as shown.

“C”

“D”

“A”

I947H1020006-02

1

“E”

FWD

I947H1020005-01

NOTE

• The cam must be at positions, “A” or “B”, when checking the valve clearance.

Clearance readings should not be taken with the cam in any other position than these two positions.

• The valve clearance should be taken when each cylinder is at Top Dead Center (TDC) of compression stroke.

• The clearance specification is for COLD state.

• To turn the crankshaft for valve clearance checking, be sure to use a wrench, and rotate in the normal running direction.

I947H1020036-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-6

7) In this condition, read the valve clearance at the valves “F” (IN and EX of No. 4 cylinder, EX of No. 3 and IN of No. 2). If the clearance is out of specification, adjust the clearance.

Special tool

: 09900–20803 (Thickness gauge)

FWD

“F”

“F”

Adjustment

The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner shim.

1) Remove the intake or exhaust camshaft. Refer to

“Engine Top Side Disassembly” in Section 1D

(Page 1D-26).

2) Remove the tappet (1) and shim (2) by fingers or magnetic hand.

1

2

“F”

“F”

I947H1020050-01

Turn the crankshaft 360

°

degrees (one rotation) to bring the line on the CKP sensor rotor to the rib behind the clutch cover and also to bring the notches

“E” to the position as shown.

I947H1020034-01

3) Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated.

FWD

“E”

I947H1020037-01

9) Read the clearance at the rest of the valves “G” and adjust the clearance if necessary.

FWD

“G”

“G”

1.70 mm

I837H1020014-01

4) Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 21 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm.

5) Fit the selected shim (2) to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure its size.

NOTE

• Be sure to apply engine oil to tappet shim top and bottom faces.

• When seating the tappet shim, be sure the figure printed surface faces the tappet.

2

“G”

“G”

I947H1020051-01

Cam position

“F”

“G”

Notch “E” position

Exhaust camshaft Intake camshaft

FWD FWD

FWD FWD

I837H1020013-01 email: [email protected] / www.motomatrix.co.uk

I947H1020007-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-7 Maintenance and Lubrication:

(INTAKE SIDE)

email: [email protected] / www.motomatrix.co.uk

I837H1020015-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-8

(EXHAUST SIDE)

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I837H1020016-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-9 Maintenance and Lubrication:

6) Install the camshafts and cam chain tension adjuster.

Refer to “Engine Top Side Assembly” in Section 1D

(Page 1D-28).

7) Rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then check the clearance again to confirm that it is within the specified range.

After finishing the tappet clearance adjustment, reinstall the removed parts. Refer to “Engine Top

Side Assembly” in Section 1D (Page 1D-28).

2) Measure the spark plug gap using a wire gauge. If it is not within the specification, replace the spark plug.

!

CAUTION

• To prevent the damage of iridium center electrode, use a wire gauge to check the gap.

• Never adjust the spark plug gap.

Spark plug gap

0.8 – 0.9 mm (0.031 – 0.035 in)

Spark Plug Replacement

Replace spark plug

Every 12 000 km (7 500 miles, 24 months)

B947H10206006

Refer to “Ignition Coil and Spark Plug Removal and

Installation” in Section 1H (Page 1H-6).

Spark Plug Inspection and Cleaning

B947H10206007

Inspect spark plug

Every 6 000 km (4 000 miles, 12 months)

Heat Range

1) Remove the spark plugs. Refer to “Ignition Coil and

Spark Plug Removal and Installation” in Section 1H

(Page 1H-6).

2) Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one.

Heat range

NGK

ND

Hot type

CR8EIA-9

IU24D

Standard

CR9EIA-9

IU27D

Cold type

CR10EIA-9

IU31D

3) After finishing the spark plug inspection, reinstall the removed parts.

Tightening torque

Spark plug: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

Spark Plug Gap

1) Remove the spark plugs. Refer to “Ignition Coil and

Spark Plug Removal and Installation” in Section 1H

(Page 1H-6).

I823H1020005-01

3) After finishing the spark plug inspection, reinstall the removed parts.

Tightening torque

Spark plug: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

Electrodes Condition

1) Remove the spark plugs. Refer to “Ignition Coil and

Spark Plug Removal and Installation” in Section 1H

(Page 1H-6).

2) Check the worn or burnt condition of the electrodes.

If it is extremely worn or burnt, replace the spark plug. And also replace the spark plug if it has a broken insulator, or damaged thread.

!

CAUTION

Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.

3) After finishing the spark plug inspection, reinstall the removed parts.

Tightening torque

Spark plug: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

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Fuel Line Inspection

B947H10206008

Inspect fuel line

Every 6 000 km (4 000 miles, 12 months)

Inspect the fuel line in the following procedures:

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Inspect the fuel feed hose (1) for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-10

Engine Oil Replacement

1) Place the motorcycle on the side-stand.

2) Place an oil pan below the engine, and drain engine oil by removing the oil drain plug (1) and filler cap

(2).

!

WARNING

When disconnecting the fuel feed hose from

E-33 model, drain fuel from the fuel tank first to prevent fuel leakage.

1

I947H1020009-01

1

I947H1020008-01

3) After finishing the fuel feed hose inspection, reinstall the removed parts.

Evaporative Emission Control System

Inspection (E-33 only)

B947H10206009

Inspect evaporative emission control system

Every 12 000 km (7 500 miles, 24 months)

Inspect the evaporative emission control system periodically (E-33 only). Refer to “Evaporative Emission

Control System Inspection (Only for E-33)” in Section 1B

(Page 1B-14).

Engine Oil and Filter Replacement

B947H10206010

Replace engine oil

Initially at 1 000 km (600 miles, 2 months) and every

6 000 km (4 000 miles, 12 months) thereafter

Replace oil filter

Initially at 1 000 km (600 miles, 2 months) and every

18 000 km (11 000 miles, 36 months) thereafter

Oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.

2

I947H1020010-01

3) Tighten the oil drain plug (1) to the specified torque.

!

CAUTION

Replace the gasket washer with a new one.

Tightening torque

Oil drain plug (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

1

(a)

I947H1020011-01

4) Pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 2.8 L (3.0/2.5 US/lmp qt) of oil.

Use of SF/SG or SH/SJ in API with MA in JASO.

5) Start up the engine and allow it to run for several minutes at idling speed.

6) Turn off the engine and wait about three minutes.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-11 Maintenance and Lubrication:

7) Hold the motorcycle vertically and check the oil level through the inspection window (3). The oil level should be between the low level “L” and full level “F”.

F

L

F

L

3

Oil Level Inspection

1) Place the motorcycle on the side-stand.

2) Start up the engine and allow it to run for several minutes at idle speed.

3) Turn off the engine and wait about three minutes.

4) Hold the motorcycle vertically and check the oil level through the inspection window (1). The oil level should be between the low level “L” and full level “F”.

1

I815H1020023-01

I815H1020024-01

4) Apply engine oil lightly to the O-ring of new oil filter, before installation.

!

CAUTION

ONLY USE A GENUINE SUZUKI

MOTORCYCLE OIL FILTER.

Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle.

5) Install new oil filter. Turn it by hand until you feel that the oil filter O-ring contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) using the special tool.

NOTE

To properly tighten the oil filter, use the special tool. Never tighten the oil filter by hand only.

Special tool

(A): 09915–40610 (Oil filter wrench)

Tightening torque

Oil filter (a): 20 N·m (2.0 kgf-m, 14.5 lbf-ft)

Oil Filter Replacement

1) Remove the right side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Drain engine oil as described in the engine oil replacement procedure.

3) Remove the oil filter (1) using the special tool.

Special tool

(A): 09915–40610 (Oil filter wrench)

(a)

(A)

I823H1020041-01

6) Add new engine oil and check the oil level is as described in the engine oil replacement procedure.

Necessary amount of engine oil

Oil change: 2 800 ml (3.0/2.5 US/lmp qt)

Oil and filter change: 3 300 ml (3.5/3.0 US/lmp qt)

Engine overhaul: 3 600 ml (2.8/3.2 US/lmp qt)

1

(A)

I947H1020012-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-12

Throttle Cable Play Inspection and Adjustment

B947H10206011

Inspect throttle cable play

Initially at 1 000 km (600 miles, 2 months) and every

6 000 km (4 000 miles, 12 months) thereafter

Inspect and adjust the throttle cable play “a” as follows:

Throttle cable play “a”

2.0 – 4.0 mm (0.08 – 0.16 in)

Throttle Valve Synchronization

B947H10206013

Inspect throttle valve synchronization

Initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 months)

Inspect the throttle valve synchronization periodically.

Refer to “Throttle Valve Synchronization” in Section 1D

(Page 1D-16).

“ a ”

I947H1020038-01

1) Remove the boot (1).

2) Loosen the lock-nut (2) of the throttle pulling cable.

3) Turn the adjuster (3) in or out until the throttle cable play “a” (at the throttle grip) is within 2 – 4 mm (0.08

– 0.16 in).

4) Tighten the lock-nut (2) while holding the adjuster

(3).

5) Fit the boot (1) positively onto the adjuster.

Cooling System Inspection

B947H10206014

Inspect cooling system

Every 6 000 km (4 000 miles, 6 months)

Replace engine coolant

Every 2 years

Engine Coolant Level Inspection

1) Hold the motorcycle vertically.

2) Check the engine coolant level by observing the “F” and “L” lines on the engine coolant reservoir tank. If the level is below the “L” line, add engine coolant to the “F” line from the engine coolant reservoir tank filler (1) behind the right side cowling. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

1

3

2

I947H1020013-02

!

WARNING

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.

PAIR System Inspection

Inspect PAIR system

Every 12 000 km (7 500 miles, 24 months)

B947H10206012

Inspect the PAIR (air supply) system periodically. Refer to “PAIR System Inspection” in Section 1B (Page 1B-9).

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1

I947H1020035-01

I947H1020054-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-13 Maintenance and Lubrication:

Engine Coolant Change

Refer to “Engine Coolant Description” in Section 1F

(Page 1F-1).

!

WARNING

Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes. If engine coolant gets into the eyes or in contact with the skin, flush thoroughly with plenty of water. If swallowed, induce vomiting and call physician immediately.

1) Remove the right side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Remove the radiator cap (1).

Air Bleeding From the Cooling Circuit

1) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Add engine coolant up to the radiator inlet.

3) Support the motorcycle upright.

4) Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit.

5) Add engine coolant up to the radiator inlet.

6) Start up the engine and bleed air from the radiator inlet completely.

7) Repeat the procedures 5) to 6) until no air bleeds from the radiator inlet.

Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

9) Loosen the air bleeder bolt (1) and (2), then check the engine coolant flows out.

1

2

1

3) Drain engine coolant by disconnecting the radiator outlet hose (2) and cylinder inlet hose (3).

I947H1020014-03

2

3

I947H1020015-01

4) Flush the radiator with fresh water if necessary.

5) Reconnect the hoses.

6) Pour the specified engine coolant up to the radiator inlet.

Engine coolant capacity (excluding reservoir)

2 500 ml (2.6/2.2 US/lmp qt)

7) Bleed air from the cooling circuit.

After changing engine coolant, reinstall the removed parts.

I947H1020016-02

10) Tighten the air bleeder bolt.

Tightening torque

Water pump air bleeder bolt: 13 N·m (1.3 kgf-m,

4.5 lbf-ft)

11) Close the radiator cap securely.

12) After warming up and cooling down the engine several times, add the engine coolant up to the full level of the reservoir.

!

CAUTION

Make sure that the radiator is filled with engine coolant up to the reservoir full level.

13) Reinstall the removed parts.

Radiator Hose Inspection

Check the radiator hoses for crack, damage or engine coolant leakage. Refer to “Water Hose Inspection” in

Section 1F (Page 1F-7).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-14

Clutch Cable Play Inspection and Adjustment

Inspect clutch cable play

Every 6 000 km (4 000 miles, 12 months)

B947H10206015

Inspect and adjust the clutch cable play “a” as follows.

Clutch cable play “a”

10 – 15 mm (0.4 – 0.6 in)

7) From this position, turn out the clutch release adjusting screw (6) 1 rotation, and tighten the locknut (5) while holding the screw (6).

Tightening torque

Clutch release adjusting screw lock-nut: 6 N·m (

0.6 kgf-m, 4.5 lbf-ft)

4

“ a ”

5

6

I947H1020055-01

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Turn in the adjuster (1) all the way into the clutch lever assembly.

Turn the cable adjuster (3) to obtain 10 – 15 mm (0.4

– 0.6 in) of free play “a” at the clutch lever end.

9) Tighten the lock-nut (2).

I947H1020019-01

1

I947H1020017-02

3) Loosen the lock-nut (2) and turn the clutch cable adjuster (3) to obtain proper cable play.

3

2

I947H1020018-02

4) Remove the clutch release adjuster cap (4).

5) Loosen the lock-nut (5) and turn out the clutch release adjusting screw (6) two or three rotations.

6) From that position, slowly turn in the clutch release adjusting screw (6) until resistance is felt.

3

2

10) Install the clutch release adjuster cap (4).

I947H1020018-02

Tightening torque

Clutch release adjuster cap: 11 N·m (1.1 kgf-m,

8.0 lbf-ft)

11) Reinstall the fuel tank.

Drive Chain Inspection and Adjustment

B947H10206016

Inspect drive chain

Initially at 1 000 km (600 miles, 2 months) and every

6 000 km (4 000 miles, 12 months) thereafter

Drive Chain Visual Check

1) With the transmission in neutral, support the motorcycle using a jack and turn the rear wheel slowly by hand.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-15 Maintenance and Lubrication:

2) Visually check the drive chain for the possible defects listed as follows. If any defects are found, the drive chain must be replaced. Refer to “Drive Chain

Replacement” in Section 3A (Page 3A-7).

• Loose pins

• Damaged rollers

• Dry or rusted links

• Kinked or binding links

• Excessive wear

• Improper chain adjustment

• Missing O-ring seals

NOTE

When replacing the drive chain, replace the drive chain and sprockets as a set.

1 2 3 19 20 21

I649G1020034-02

5) After finishing the drive chain length inspection, adjust the drive chain slack.

1

1. O-ring seal

2

2. Grease

I649G1020032-02

Drive Chain Slack Adjustment

1) Support the motorcycle with a jack.

2) Loosen the axle nut (1).

3) Loosen the left and right chain adjuster lock-nuts (2).

4) Loosen or tighten both chain adjuster bolts (3) until there is 20 – 30 mm (0.8 – 1.2 in) of slack “a” at the middle of the chain between the engine and rear sprockets as shown in the figure.

!

CAUTION

The reference marks “A” on both sides of the swingarm and the edge of each chain adjuster must be aligned to ensure that the front and rear wheels are correctly aligned.

Drive chain slack “a”

Standard: 20 – 30 mm (0.8 – 1.2 in)

Drive Chain Length Inspection

1) Loosen the axle nut (1).

2) Loosen the left and right chain adjuster lock-nuts (2).

3) Give tension to the drive chain fully by turning both chain adjuster bolts (3).

2

1

2

1

3

“A”

I947H1020021-01

3

I947H1020020-01

4) Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.

Drive chain 20-pitch length

Service limit: 319.4 mm (12.57 in)

“a”

I649G1020036-02

5) After adjusting the drive chain, tighten the axle nut

(1) to the specified torque.

Tightening torque

Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lbf-ft)

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6) Tighten both chain adjuster lock-nuts (2) securely.

7) Recheck the drive chain slack after tightening the axle nut.

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-16

Drive Chain Cleaning and Lubricating

B947H10206017

Clean and lubricate drive chain

Every 1 000 km (600 miles)

Clean and lubricate the drive chain in the following procedures:

1) Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.

!

CAUTION

Do not use trichloroethylene, gasoline or any similar solvent.

These fluids have too great dissolving power for this chain and they can damage the Orings. Use only kerosine to clean the drive chain.

2) After cleaning and drying the chain, oil it with a heavyweight motor oil.

!

CAUTION

• Do not use any oil sold commercially as

“drive chain oil”. Such oil can damage the

O-rings.

• The standard drive chain is a DID 50VAZ.

SUZUKI recommends to use this standard drive chain as a replacement.

!

WARNING

• The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluids. 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 a long period of time.

• Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.

Brake Fluid Level Check

1) Keep the motorcycle upright and place the handlebars straight.

2) Check the brake fluid level by observing the lower limit line “A” on the front and rear brake fluid reservoirs. When the brake fluid level is below the lower limit line “A”, replenish with brake fluid that meets the following specification.

BF: Brake fluid (DOT 4)

“A”

I947H1020023-01

I947H1020022-01

Brake System Inspection

B947H10206018

Inspect brake system

Initially at 1 000 km (600 miles, 2 months) and every

6 000 km (4 000 miles, 12 months) thereafter

Inspect brake hose and brake fluid

Every 6 000 km (4 000 miles, 12 months)

“A”

I947H1020024-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-17 Maintenance and Lubrication:

Brake Pads Check

The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Front Brake Pad

Replacement” in Section 4B (Page 4B-2) and “Rear

Brake Pad Replacement” in Section 4C (Page 4C-2).

!

CAUTION

Replace the brake pads as a set, otherwise braking performance will be adversely affected.

“A”

I947H1020025-02

I947H1020028-03

Brake Pedal Height Inspection and Adjustment

1) Inspect the brake pedal height “a” between the pedal top face and footrest.

Adjust the brake pedal height if necessary.

Brake pedal height “a”

Standard: 65 – 75 mm (2.6 – 3.0 in)

2) Loosen the lock-nut (1).

3) Turn the push rod (2) until the brake pedal becomes

65 – 75 mm (2.6 – 3.0 in) “a” below the top of the footrest.

4) Tighten the lock-nut (1) securely.

Tightening torque

Rear master cylinder rod lock-nut (a): 17 N·m (

1.7 kgf-m, 12.5 lbf-ft)

“A”

2

1

(a)

I947H1020026-03

Front and Rear Brake Hose Inspection

Inspect the brake hoses and hose joints for crack, damage or brake oil leakage. If any defects are found, replace the brake hose with a new one. Refer to “Front

Brake Hose Removal and Installation” in Section 4A

(Page 4A-8) and “Rear Brake Hose Removal and

Installation” in Section 4A (Page 4A-8).

“ a ”

I947H1020029-01

Brake Hose Replacement

Replace brake hose

Every 4 years

Refer to “Front Brake Hose Removal and Installation” in

Section 4A (Page 4A-8) and “Rear Brake Hose Removal and Installation” in Section 4A (Page 4A-8).

Brake Fluid Replacement

Replace brake fluid

Every 2 years

Refer to “Brake Fluid Replacement” in Section 4A

(Page 4A-6).

I947H1020027-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-18

Air Bleeding from Brake Fluid Circuit

Refer to “Air Bleeding from Brake Fluid Circuit” in

Section 4A (Page 4A-4).

Rear Brake Light Switch Adjustment

Refer to “Rear Brake Light Switch Inspection and

Adjustment” in Section 4A (Page 4A-4).

Tire Inspection

B947H10206019

Inspect tire

Every 6 000 km (4 000 miles, 12 months)

Tire Tread Condition

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.

Special tool

: 09900–20805 (Tire depth gauge)

Tire tread depth (Service limit)

Front: 1.6 mm (0.06 in)

Rear: 2.0 mm (0.08 in)

!

CAUTION

The standard tire fitted on this motorcycle is

120/70 ZR17 M/C (58W) for front and 190/50

ZR17 M/C (73W) for rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.

Tire type

BRIDGESTONE

• Front: BT016F N

• Rear: BT016R N

Steering System Inspection

B947H10206020

Inspect steering system

Initially at 1 000 km (600 miles, 2 months) and every

12 000 km (7 500 miles, 24 months) thereafter

Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability.

1) Check that there is no play in the front fork.

2) Support the motorcycle so that the front wheel is off the ground, with the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward.

If play is found, readjust the steering. Refer to

“Steering Tension Adjustment” in Section 6B

(Page 6B-11).

I310G1020068-02

Tire Pressure

If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability, or shorter tire life will result. Cold inflation tire pressure is as follows.

Cold inflation tire pressure

Solo riding kPa kgf/cm

2

Front 250

Rear 290

2.50

2.90

Dual riding psi kPa kgf/cm

2

36 250

42 290

2.50

2.90

psi

36

42

I947H1020030-02

I310G1020069-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-19 Maintenance and Lubrication:

Front Fork Inspection

Inspect front fork

Every 12 000 km (7 500 miles, 24 months)

B947H10206021

Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes.

Replace any defective parts, if necessary. Refer to

“Front Fork Disassembly and Assembly” in Section 2B

(Page 2B-4).

Chassis Bolt and Nut Inspection

B947H10206023

Tighten chassis bolt and nut

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.

2

(b)

3

(c)

1

(a)

4

(c)

I947H1020031-01

Rear Suspension Inspection

Inspect rear suspension

Every 12 000 km (7 500 miles, 24 months)

B947H10206022

Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm.

Replace any defective parts, if necessary. Refer to “Rear

Shock Absorber Removal and Installation” in Section 2C

(Page 2C-3), “Cushion Lever Removal and Installation” in Section 2C (Page 2C-7) and “Swingarm Removal and

Installation” in Section 2C (Page 2C-9).

1

2

3

4

I947H1020040-01

Steering stem lock-nut 80 N

⋅ m (8.0 kgf-m, 58.0 lbf-ft)

Steering stem head nut 90 N

⋅ m (9.0 kgf-m, 65.0 lbf-ft)

Front fork upper clamp bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Handlebar clamp bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

7

(e)

5

(d)

7

(e)

5

6

7

6

(c)

I947H1020041-02

Front brake master cylinder mounting bolt 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

Brake hose union bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Front master cylinder air bleeder valve 6 N

⋅ m (0.6 kgf-m, 4.5 lbfft)

9

(c)

I947H1020032-01

8

(c)

I947H1020039-01 email: [email protected] / www.motomatrix.co.uk

8

9

I947H1020042-01

Front fork lower clamp bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Steering damper bolt/nut 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

6

(c)

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-20

14

(i)

11

(c)

6

10

11

12

13

14

13

(h)

10

(f)

12

(g)

I947H1020043-02

Brake hose union bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Front axle bolt 100 N

⋅ m (10.0 kgf-m, 72.5 lbf-ft)

Front axle pinch bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Front brake disc bolt 18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft)

Front brake caliper mounting bolt 39 N

⋅ m (3.9 kgf-m, 28.0 lbf-ft)

Brake caliper air bleeder valve 7.5 N

⋅ m (0.75 kgf-m, 5.5 lbf-ft)

20

20

(j)

I947H1020046-02

Rear shock absorber bracket nut 115 N

⋅ m (11.5 kgf-m, 83.0 lbf-ft)

21

(k)

21

(k)

23

(l)

15

16

15

(f)

16

(c)

16

(c)

I947H1020044-03

Swingarm pivot nut 100 N

⋅ m (10.0 kgf-m, 72.5 lbf-ft)

Front footrest bracket bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

21

22

23

22

(l)

I947H1020047-02

Rear shock absorber mounting bolt/nut (Upper and Lower) 50

N

⋅ m (5.0 kgf-m, 36.0 lbf-ft)

Cushion rod bolt/nut (Front and Rear) 98 N

⋅ m (9.8 kgf-m, 71.0 lbfft)

Cushion lever mounting bolt/nut 98 N

⋅ m (9.8 kgf-m, 71.0 lbf-ft)

6

16

17

18

19

6

(c)

18

(d)

17

(b)

19

(g)

16

(c)

16

(c)

I947H1020045-03

Brake hose union bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Front footrest bracket bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Swingarm pivot lock-nut 90 N

⋅ m (9.0 kgf-m, 65.0 lbf-ft)

Rear brake master cylinder mounting bolt 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

Rear brake master cylinder rod lock-nut 18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft)

24

25

25

(m)

24

(f)

Rear axle nut 100 N

⋅ m (10.0 kgf-m, 72.5 lbf-ft)

Rear sprocket nut 60 N

⋅ m (6.0 kgf-m, 43.5 lbf-ft)

I947H1020048-02 email: [email protected] / www.motomatrix.co.uk

6

14

26

27

28

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0B-21 Maintenance and Lubrication:

14

(e)

6

(c)

Compression Pressure Check

B947H10206024

Refer to “Compression Pressure Check” in Section 1D

(Page 1D-3).

28

(p)

27

(o)

Oil Pressure Check

B947H10206025

Refer to “Oil Pressure Check” in Section 1E (Page 1E-

5).

26

(n)

SDS Check

B947H10206026

Refer to “SDS Check” in Section 1A (Page 1A-16).

I947H1020049-04

Brake hose union bolt 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

Brake caliper air bleeder valve 6 N

⋅ m (0.6 kgf-m, 4.5 lbf-ft)

Rear brake disc bolt 35 N

⋅ m (3.5 kgf-m, 25.5 lbf-ft)

Rear brake caliper sliding pin (Front) 27 N

⋅ m (2.7 kgf-m, 19.5 lbfft)

Rear brake caliper sliding pin (Rear) 12 N

⋅ m (1.2 kgf-m, 8.5 lbf-ft)

Specifications

Tightening Torque Specifications

Fastening part

Exhaust pipe bolt

Muffler chamber connecting bolt

Muffler chamber bracket bolt

Muffler chamber mounting bolt

Muffler connecting bolt

Muffler mounting bolt

Spark plug

N

⋅

m

23

30

25

23

23

25

Tightening torque kgf-m

2.3

3.0

2.5

2.3

2.3

2.5

lbf-ft

16.5

21.5

18.0

16.5

16.5

18.0

B947H10207001

Note

)

(Page 0B-4)

)

(Page 0B-4)

)

(Page 0B-4)

)

(Page 0B-4)

)

(Page 0B-4)

)

(Page 0B-4)

)

(Page 0B-9) /

11

Oil drain plug

Oil filter

Water pump air bleeder bolt

Clutch release adjusting screw lock-nut

Clutch release adjuster cap

Rear axle nut

Rear master cylinder rod lock-nut

23

20

13

6

11

100

17

2.3

2.0

1.3

0.6

1.1

10.0

1.7

16.5

14.5

4.5

4.5

8.0

72.5

12.5

)

(Page 0B-9)

)

(Page 0B-10)

)

(Page 0B-11)

)

(Page 0B-13)

)

(Page 0B-14)

)

(Page 0B-14)

)

(Page 0B-15)

)

(Page 0B-17)

NOTE

The specified tightening torque is described in the following.

“Chassis Bolt and Nut Inspection” (Page 0B-19)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Maintenance and Lubrication: 0B-22

Recommended Service Material

Special Tools and Equipment

Material

Brake fluid

SUZUKI recommended product or Specification

DOT 4 —

NOTE

Required service material is also described in the following.

“Lubrication Points” (Page 0B-3)

Special Tool

09900–20803

Thickness gauge

)

(Page 0B-6)

09900–20805

Tire depth gauge

)

(Page 0B-18)

Note

)

(Page 0B-16)

B947H10208001

B947H10208002

09915–40610

Oil filter wrench

)

(Page 0B-11) /

)

(Page 0B-11) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0C-1 Service Data:

General Information

Service Data

Specifications

Service Data

Valve + Guide

Unit: mm (in)

Item

Valve diam.

Valve clearance (when cold)

Valve guide to valve stem clearance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve seat width

Valve head radial runout

Valve spring free length

Valve spring tension

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

Inner

Outer

Inner

Outer

Standard

31.0 (1.22)

25.0 (0.98)

0.08 – 0.18 (0.003 – 0.007)

0.18 – 0.28 (0.007 – 0.011)

0.010 – 0.037 (0.0004 – 0.0015)

0.030 – 0.057 (0.0012 – 0.0022)

4.500 – 4.512 (0.1772 – 0.1776)

4.475 – 4.490 (0.1762 – 0.1768)

4.455 – 4.470 (0.1754 – 0.1760)

—

—

0.9 – 1.1 (0.035 – 0.043)

—

—

—

31.3 – 38.3 N (3.2 – 3.9 kgf, 7.0 – 8.6 lbs) at length 27.55 mm (1.085 in)

91.3 – 105.1 N (9.3 – 10.7 kgf, 20.5 – 23.6 lbs) at length 33.05 mm (1.301 in)

Camshaft + Cylinder Head

Unit: mm (in)

Item

Cam height

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

Camshaft runout

Cam chain pin (at arrow “3”)

Cylinder head distortion

IN.

EX.

IN. & EX.

IN. & EX.

IN. & EX.

Standard

37.68 – 37.73 (1.483 – 1.485)

36.88 – 36.93 (1.452 – 1.454)

0.032 – 0.066 (0.0013 – 0.0026)

24.012 – 24.025 (0.9454 – 0.9459)

23.959 – 23.980 (0.9433 – 0.9441)

—

14th pin

—

B947H10307001

Limit

—

—

—

—

—

—

—

—

—

0.25 (0.010)

0.05 (0.002)

—

0.03 (0.001)

30.1 (1.19)

35.3 (1.39)

—

—

Limit

37.38 (1.472)

36.58 (1.440)

0.150 (0.0059)

—

—

0.10 (0.004)

—

0.02 (0.0008) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Service Data: 0C-2

Cylinder + Piston + Piston Ring

Unit: mm (in)

Item

Compression pressure

Compression pressure difference

Piston-to-cylinder clearance

Cylinder bore

Piston diam.

Cylinder distortion

Piston ring free end gap

Piston ring end gap

Piston ring-to-groove clearance

Piston ring groove width

Piston ring thickness

Piston pin bore

Piston pin O.D.

Conrod + Crankshaft

Unit: mm (in)

Item

Conrod small end I.D.

Conrod big end side clearance

Conrod big end width

Crank pin width

Conrod big end oil clearance

Crank pin O.D.

Crankshaft journal oil clearance

Crankshaft journal O.D.

Crankshaft thrust bearing thickness

Crankshaft thrust clearance

Crankshaft runout

Standard

1 400 – 1 800 kPa (14 – 18 kgf/cm

2

, 199 – 256 psi)

—

1st

2nd

1st

2nd

1st

2nd

1st

0.030 – 0.040 (0.0012 – 0.0016)

74.500 – 74.515 (2.9331 – 2.9337)

74.465 – 74.480 (2.9317 – 2.9323)

Measure 10 mm (0.4 in) from the skirt end.

T

—

Approx. 7.0 (0.28)

Approx. 8.0 (0.32)

0.06 – 0.18 (0.002 – 0.007)

0.06 – 0.18 (0.002 – 0.007)

—

—

0.83 – 0.85 (0.0327 – 0.0335)

2nd

Oil

1st

1.30 – 1.32 (0.0512 – 0.0520)

0.81 – 0.83 (0.0319 – 0.0327)

1.51 – 1.53 (0.0594 – 0.0602)

0.76 – 0.81 (0.0299 – 0.0319)

2nd

1.08 – 1.10 (0.0425 – 0.0433)

0.77 – 0.79 (0.0303 – 0.0311)

15.002 – 15.008 (0.5906 – 0.5909)

14.995 – 15.000 (0.5903 – 0.5512)

Standard

15.010 – 15.018 (0.5909 – 0.5913)

0.10 – 0.20 (0.004 – 0.008)

19.95 – 20.00 (0.7854 – 0.7874)

20.10 – 20.15 (0.7913 – 0.7933)

0.040 – 0.064 (0.0016 – 0.0025)

34.976 – 35.000 (1.3770 – 1.3780)

0.016 – 0.034 (0.0006 – 0.0013)

Right side

34.982 – 35.000 (1.3772 – 1.3780)

2.420 – 2.440 (0.0953 – 0.0961)

Left side 2.360 – 2.500 (0.0929 – 0.0984)

0.060 – 0.110 (0.0024 – 0.0043)

—

Limit

1 000 kPa

(10 kgf/cm

2

,

142 psi)

200 kPa

(2 kgf/cm

2

, 28 psi)

0.120 (0.0047)

Nicks or scratches

74.380 (2.9283)

0.02 (0.0008)

5.6 (0.22)

6.4 (0.25)

0.50 (0.020)

0.50 (0.020)

0.180 (0.0071)

0.150 (0.0059)

—

—

—

—

—

15.030 (0.5917)

14.980 (0.5898)

Limit

15.040 (0.5921)

0.30 (0.012)

—

—

0.080 (0.0031)

—

0.080 (0.0031)

—

—

—

—

0.05 (0.002) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0C-3 Service Data:

Balancer

Unit: mm (in)

Item

Balancer shaft journal oil clearance

Balancer shaft journal O.D.

Standard

0.028 – 0.052 (0.0011 – 0.0020)

19.992 – 20.000 (0.7871 – 0.7874)

Oil Pump

Item

Oil pressure (at 60

°

C, 140

°

F)

Standard

100 – 400 kPa (1.0 – 4.0 kgf/cm

2

, 14 – 57 psi) at 3 000 r/min

Clutch

Unit: mm (in)

Item

Clutch drive plate thickness

Clutch drive plate claw width

Clutch driven plate distortion

Clutch spring free length

Clutch lifter pin height

Wave spring washer height

Clutch lever play

Clutch release screw

No. 1 & 2

No. 1 & 2

Standard

3.22 – 3.38 (0.127 – 0.133)

13.7 – 13.8 (0.539 – 0.543)

—

58.18 (2.29)

0.2 – 0.4 (0.008 – 0.016)

—

10 – 15 (0.4 – 0.6)

1 turn back

Drive Train

Unit: mm (in) Except ratio

Item

Primary reduction ratio

Final reduction ratio

Gear ratios

Low

2nd

3rd

4th

Gearshift fork to groove clearance

Gearshift fork groove width

Gearshift fork thickness

5th

Top

Drive chain

Drive chain slack (on side-stand)

Gearshift lever height

Type

Links

20-pitch length

Standard

1.617 (76/47)

2.470 (42/17)

2.562 (41/16)

2.052 (39/19)

1.714 (36/21)

1.500 (36/24)

1.360 (34/25)

1.269 (33/26)

0.1 – 0.3 (0.004 – 0.012)

5.0 – 5.1 (0.197 – 0.201)

4.8 – 4.9 (0.189 – 0.193)

DID50VAZ

114 links

—

20 – 30 (0.8 – 1.2)

65 – 75 (2.6 – 3.0)

Limit

0.080 (0.0031)

—

Limit

—

Limit

2.92 (0.115)

12.9 (0.508)

0.10 (0.004)

55.3 (2.18)

—

4.30 (0.169)

—

—

Limit

—

—

—

—

—

—

—

—

0.5 (0.02)

—

—

—

—

319.4 (12.57)

—

— email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Service Data: 0C-4

Thermostat + Radiator + Cooling Fan + Coolant

Item

Thermostat valve opening temperature

Thermostat valve lift

ECT sensor resistance

Standard/Specification

Approx. 82

°

C (180

°

F)

Over 8 mm (0.31 in) and at 95

°

C (203

°

F)

20

°

C

Approx. 2.45 k

Ω

(68

°

F)

50

°

C

(122

°

F)

80

°

C

Approx. 0.811 k

Approx. 0.318 k

Ω

Ω

(176

°

F)

110

°

C

(230

°

F)

Approx. 0.142 k

Ω

Radiator cap valve opening pressure

93 – 123 kPa (0.9 – 1.2 kgf/cm

2

, 13.2 – 17.5 psi)

Cooling fan operating temperature

Engine coolant type

Engine coolant

OFF

→

ON

ON

→

OFF

Approx. 105

°

C (221

°

F)

Approx. 100

°

C (212

°

F)

Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

Reservoir tank side

Engine side

Approx. 250 ml (0.3/0.2 US/lmp qt)

Approx. 2 500 ml (2.6/2.2 US/lmp qt)

Note

—

—

—

—

—

—

—

—

—

—

—

—

Injector + Fuel Pump + Fuel Pressure Regulator

Item

Injector resistance

Fuel pump discharge amount

Fuel pressure regulator operating set pressure

Specification

11 – 13

Ω

at 20

°

C (68

°

F)

222 ml (7.5/7.8 US/lmp oz) and more/10 sec.

Approx. 300 kPa (3.0 kgf/cm

2

, 43 psi)

Note

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0C-5 Service Data:

FI Sensors

Item

CKP sensor resistance

CKP sensor peak voltage

IAP sensor input voltage

IAP sensor output voltage

TP sensor input voltage

TP sensor output voltage

ECT sensor input voltage

ECT sensor output voltage

ECT sensor resistance

IAT sensor input voltage

IAT sensor output voltage

IAT sensor resistance

AP sensor input voltage

AP sensor output voltage

TO sensor resistance

TO sensor voltage

GP switch voltage

Injector voltage

Ignition coil primary peak voltage

HO2 sensor output voltage

HO2 sensor heater resistance

PAIR control solenoid valve resistance

STP sensor input voltage

STP sensor output voltage

STVA resistance

EXCVA position sensor input voltage

EXCVA position sensor output voltage

EXCVA position sensor resistance

EVAP system purge control solenoid valve resistance

ISC valve resistance

Steering damper solenoid valve resistance

Steering damper solenoid valve voltage

Closed

Opened

Standard/Specification

142 – 194

Ω

0.5 V and more

4.5 – 5.5 V

Approx. 2.7 V at idle speed

4.5 – 5.5 V

Approx. 1.1 V

Approx. 4.4 V

4.5 – 5.5 V

0.15 – 4.85 V

Approx. 2.45 k

Ω

at 20

°

C (68

°

F)

4.5 – 5.5 V

0.15 – 4.85 V

Approx. 2.58 k

Ω

at 20

°

C (68

°

F)

4.5 – 5.5 V

Normal

Leaning

Approx. 3.6 V at 100 kPa (760 mmHg)

16.5 – 22.3 k

Ω

0.4 – 1.4 V

3.7 – 4.4 V

0.6 V and more

Battery voltage

80 V and more

0.3 V and less at idle speed

0.6 V and more at 5 000 r/min

6.7 – 9.5

Ω

at 23

°

C (73

°

F)

20 – 24

Ω

at 20 – 30

°

C (68 – 86

°

F)

Closed

Opened

Closed

Opened

4.5 – 5.5 V

Approx. 0.7 V

Approx. 4.1 V

Approx. 6.5

Ω

4.5 – 5.5 V

0.45 – 1.4 V

3.6 – 4.55 V

Approx. 3.1 k

Ω

Approx. 32

Ω

at 20

°

C (68

°

F)

Approx. 80

Ω

at 20

°

C (68

°

F)

Approx. 12.5

Ω

at 20

°

C (68

°

F)

Approx. 10 V

Note

When cranking

When leaning 65

°

From 1st to Top

When cranking

At adjustment position

E-33 only

When battery fully charged email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Service Data: 0C-6

Throttle Body

Item

Bore size

I.D. No.

Idle r/min

Throttle cable play

Electrical

Unit: mm

Item

Firing order

Spark plug

Spark performance

CKP sensor resistance

CKP sensor peak voltage

Ignition coil resistance

Ignition coil primary peak voltage

Generator coil resistance

Generator maximum output

Generator no-load voltage (When engine is cold)

Regulated voltage

Starter motor brush length

Starter relay resistance

Battery

Type designation

Capacity

Headlight

HI

LO

Fuse size

Ignition

Signal

Fuel

Fan

Main

Specification

44 mm (1.73 in)

47H1 (For E-33), 47H0 (For others)

1 150

±

100 r/min

2.0 – 4.0 mm (0.08 – 0.16 in)

Type

Gap

Primary

Specification

1

⋅

2

⋅

4

⋅

3

NGK: CR9EIA-9

DENSO: IU27D

0.8 – 0.9 (0.031 – 0.035)

Over 8 (0.3) at 1 atm.

142 – 194

Ω

0.5 V and more

1.1 – 1.9

Ω

Secondary 6.4 – 9.6 k

Ω

80 V and more

0.12 – 0.6

Ω

Approx. 375 W at 5 000 r/min

85 V (AC) and more at 5 000 r/min

Standard

Limit

14.0 – 15.5 V at 5 000 r/min

7.0 (0.28)

3 – 6

Ω

3.5 (0.14)

FT12A-BS

12 V 36.0 kC (10 Ah)/10 HR

10 A

10 A

15 A

10 A

10 A

15 A

30 A

Note

When cranking

Terminal –

Terminal

Plug cap –

Terminal

When cranking email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0C-7 Service Data:

Wattage

Unit: W

Item

Headlight

HI

LO

Position light

Brake light/Taillight

Turn signal light

License plate light

Combination meter light

Turn signal indicator light

High beam indicator light

Neutral position indicator light

Oil pressure/Engine coolant temp. indicator light

FI/Steering damper indicator light

Fuel level indicator light

Engine RPM indicator light

Immobilizer indicator light

E-02, 19, 24, 51

65

55

5 x 2

LED

21 x 4

5

LED

LED

LED

LED

LED

LED

LED

LED

LED

Specification

E-03, 14, 28, 33

←

←

←

←

←

←

←

←

←

←

←

←

←

←

—

Brake + Wheel

Unit: mm (in)

Item

Rear brake pedal height

Brake disc thickness

Brake disc runout

Master cylinder bore

Front

Rear

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type

Wheel rim runout

Wheel rim size

Wheel axle runout

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Axial

Radial

Front

Rear

Front

Rear

Standard

65 – 75 (2.6 – 3.0)

5.3 – 5.7 (0.21 – 0.22)

4.8 – 5.2 (0.19 – 0.20)

—

17.460 – 17.503 (0.6874 – 0.6891)

14.000 – 14.043 (0.5512 – 0.5529)

17.417 – 17.444 (0.6857 – 0.6868)

13.957 – 13.984 (0.5495 – 0.5506)

Leading 30.280 – 30.330 (1.1921 – 1.1941)

Trailing 32.080 – 32.130 (1.2630 – 1.2650)

30.230 – 30.280 (1.1902 – 1.1921)

Leading 30.167 – 30.200 (1.1877 – 1.1890)

Trailing 31.967 – 32.000 (1.2585 – 1.2588)

30.148 – 3.0198 (1.1869 – 1.1889)

DOT 4

—

17 M/C x MT 3.50

17 M/C x MT 6.00

—

Limit

—

5.0 (0.20)

4.5 (0.18)

0.30 (0.012)

—

—

—

—

—

—

—

—

—

—

—

2.0 (0.08)

—

—

0.25 (0.010)

Tire

Item

Cold inflation tire pressure

(Solo riding)

Cold inflation tire pressure

(Dual riding)

Tire size

Tire type

Tire tread depth

(Recommended depth)

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Standard

250 kPa (2.50 kgf/cm

2 , 36 psi)

290 kPa (2.90 kgf/cm 2 , 42 psi)

250 kPa (2.50 kgf/cm 2 , 36 psi)

290 kPa (2.90 kgf/cm 2 , 42 psi)

120/70 ZR17M/C (58 W)

190/50 ZR17M/C (73 W)

BRIDGESTONE BT016F N

BRIDGESTONE BT016R N

—

—

Limit

—

—

—

—

—

—

—

—

1.6 mm (0.06 in)

2.0 mm (0.08 in) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Service Data: 0C-8

Suspension

Unit: mm (in)

Item

Front fork stroke

Front fork spring free length

Front fork oil level (Without spring, outer tube fully compressed)

Front fork oil type

Front fork oil capacity (Each leg)

Front fork inner tube O.D.

Front fork spring adjuster

Front fork damping force adjuster

Rear wheel travel

Swingarm pivot shaft runout

Standard

125 (4.9)

241 (9.49)

75 (2.95)

70 (2.76) 10 min. after adjustment

SUZUKI FORK OIL SS-05 or an equivalent fork oil

476 ml (16.1/16.8 US/lmp oz)

43 (1.7)

Rebound

Compression

4 turns in from softest position

4 turns out from stiffest position

5 turns from stiffest position

Rear shock absorber spring pre-set length

Rear shock absorber damping force adjuster

Rebound

Compression

184.3 (7.26)

2-3/4 turns from stiffed position

Lo: 2-1/4 turns from stiffest position

Hi: 3 turns from stiffest position

130 (5.12)

—

Fuel + Oil

Fuel type

Fuel tank capacity

Engine oil type

Item

Engine oil capacity

Specification

Use only unleaded gasoline of at least 90 pump octane (R/2

+ M/2).

Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Gasoline used should be graded 95 octane (Research

Method) or higher. Unleaded gasoline is recommended.

Including reserve

Fuel level indicator light

16.5 L (4.4/3.6 US/lmp gal)

17.5 L (4.6/3.8 US/lmp gal)

Approx. 3.5 L (0.9/0.8 US/lmp gal) lighting

SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Change

Filter change

Overhaul

2 800 ml (3.0/2.5 US/lmp qt)

3 300 ml (3.5/2.9 US/lmp qt)

3 600 ml (3.8/3.2 US/lmp qt)

Note

E-03, 14, 28, 33

E-02, 19, 24, 51

E-33

Others

Limit

—

236 (9.29)

—

—

—

—

—

—

—

—

—

—

—

0.3 (0.01) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

0C-9 Service Data:

Tightening Torque List

Engine

Item

Exhaust pipe bolt

Muffler chamber connecting bolt

Muffler chamber bracket bolt

Muffler chamber mounting bolt

Muffler connecting bolt

Muffler mounting bolt

Speed sensor rotor bolt

Speed sensor mounting bolt

Engine sprocket nut

Engine mounting bolt (Cylinder)

Engine mounting nut (Crankcase)

Engine mounting thrust adjuster

Engine mounting thrust adjuster lock-nut

Engine mounting pinch bolt

Cylinder head cover bolt

PAIR reed valve cover bolt

Spark plug

Cam chain guide No. 2 bolt

Cam chain guide No. 1 bolt

Camshaft journal holder bolt

Cam chain tension adjuster service cap

Cam chain tension adjuster mounting bolt

Cam chain tensioner bolt

Initial

Final

Cylinder head bolt

[M10]

[M6]

Water jacket plug

Clutch cover bolt

Clutch sleeve hub nut

Clutch spring set bolt

Clutch release adjuster cap

Clutch release adjusting screw lock-nut

Clutch lifter pin lock-nut

Valve timing inspection cap

Starter clutch bolt

Generator cover bolt

Generator rotor bolt

Generator stator set bolt

Generator lead wire set bolt

Oil pressure switch

Oil pressure switch lead wire screw

Oil filter

Crankshaft journal bolt

Crankcase bolt

Oil gallery plug

[M8]

[M9]

[M6]

Initial

Final

Cylinder head

[M6]

[M10]

[M12]

[M26]

Oil drain plug

Piston cooling oil jet bolt

Oil pump mounting bolt

Oil pump driven sprocket bolt email: [email protected] / www.motomatrix.co.uk

B947H10307002

6.5

145

55

75

23

45

23

10

N

⋅

m

23

30

25

23

23

25

28

0.65

14.5

5.5

7.5

2.3

4.5

2.3

1.0

kgf-m

2.3

3.0

2.5

2.3

2.3

2.5

2.8

14

10

11

10

1.4

1.0

1.1

1.0

10.0

7.0

8.0

7.0

23

10

23

10

2.3

1.0

2.3

1.0

16.5

7.0

16.5

7.0

23 2.3

16.5

31 N

⋅ m (3.1 kgf-m, 22.5 lbf-ft) then turn in 1/6

(60

°

) turn

10

11

6

23

10

9.5

10

95

1.0

0.95

1.0

9.5

1.0

1.1

0.6

2.3

7.0

6.9

7.0

68.5

7.0

8.0

4.5

16.5

4.5

105.0

39.8

54.0

16.5

32.5

16.5

7.0

lbf-ft

16.5

21.5

18.0

16.5

16.5

18.0

20.0

11

54

10

145

1.1

5.4

1.0

14.5

8.0

39.0

7.0

105.0

11

5.5

14

1.5

1.1

0.55

1.4

0.15

8.0

4.0

10.0

1.0

20 2.0

14.5

18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft) then turn in 50

°

10

18

15

11

12

15

26

10

23

10

10

10

1.2

1.5

2.6

1.0

1.0

1.8

1.5

1.1

2.3

1.0

1.0

1.0

8.5

11.0

19.0

7.0

7.0

13.0

11.0

8.0

16.5

7.0

7.0

7.0

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Service Data: 0C-10

Item

Conrod cap bolt

Breather cover bolt

Oil pan bolt

Oil cooler mounting bolt

Driveshaft bearing case bolt (LH and RH)

Driveshaft oil seal retainer screw

Gearshift arm stopper

Gearshift cam stopper bolt

Gearshift cam plate bolt

Gearshift cam bearing retainer screw

Gearshift shaft end screw

GP switch mounting bolt

Starter motor mounting bolt

Starter motor lead wire mounting bolt

Starter motor housing bolt

Regulator/rectifier mounting bolt

Intake pipe bolt

Bypass hose union

FI System + Intake Air System

Item

CMP sensor bolt

TP sensor mounting screw

STP sensor mounting screw

ISC valve mounting screw

CKP sensor mounting bolt

HO2 sensor

Fuel delivery pipe mounting screw

Fuel pump mounting bolt

EXCVA pulley mounting bolt

IAT sensor mounting screw

EVAP system purge control solenoid valve mounting nut (E-33 only)

EVAP system purge control solenoid valve bracket bolt (E-33 only)

N

⋅

m kgf-m lbf-ft

37 N

⋅ m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/6

(60

°

) turn

10

10

1.0

1.0

7.0

7.0

10

12

12

19

1.0

1.2

1.2

1.9

7.0

8.7

8.7

13.5

10

13

10

8.5

6.5

10

3

5

10

8.5

12

1.0

1.3

1.0

0.85

0.65

1.0

0.3

0.5

1.0

0.85

1.2

7.0

9.5

7.0

6.0

4.5

7.0

2.0

3.5

7.0

6.5

8.5

N

⋅

m

10

3.5

3.5

2

6.5

25

3.5

10

5

1.3

6.5

10

kgf-m

1.0

0.35

0.35

0.2

0.65

2.5

0.35

1.0

0.5

0.13

0.65

1.0

lbf-ft

7.0

2.5

2.5

1.5

4.5

18.0

2.5

7.0

3.5

1.0

4.5

7.0

Cooling System

Impeller securing bolt

Water pump case screw

Water pump mounting bolt

ECT sensor

Thermostat cover bolt

Water inlet connector bolt

Water pump air bleeder bolt

Item N

⋅

m

8

6

10

18

10

10

13

kgf-m

0.8

0.6

1.0

1.8

1.0

1.0

1.3

lbf-ft

6.0

4.5

7.0

13.0

7.0

7.0

9.5

email: [email protected] / www.motomatrix.co.uk

0C-11 Service Data:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Chassis

Item

Steering stem head nut

Steering stem lock-nut

Steering damper bolt

Steering damper nut

Front fork clamp bolt (Upper and Lower)

Front fork cap

Front fork piston rod nut

Rod guide case

Front axle bolt

Front axle pinch bolt

Handlebar clamp bolt

Front brake master cylinder holder bolt (Upper and Lower)

Front brake caliper mounting bolt

Front brake pad mounting pin

Brake hose union bolt

Air bleeder valve (Front caliper)

Air bleeder valve (Rear caliper)

Air bleeder valve (Front master cylinder)

Brake disc bolt (Front)

Brake disc bolt (Rear)

Rear brake pad mounting pin

Rear brake pad mounting pin plug

Rear brake master cylinder mounting bolt

Rear brake master cylinder rod lock-nut

Rear brake caliper sliding pin A

Rear brake caliper sliding pin B

Brake lever pivot bolt

Brake lever pivot bolt lock-nut

Swingarm pivot shaft

Swingarm pivot nut

Swingarm pivot lock-nut

Swingarm pivot boss nut

Cushion lever mounting nut

Cushion rod mounting nut (Front and Rear)

Rear shock absorber bracket nut

Rear shock absorber mounting nut (Upper and Lower)

Rear axle nut

Rear sprocket nut

Rear combination light mounting bolt

License plate light mounting nut

Side-stand nut

Side-stand bolt

Side-stand bracket mounting bolt

Bank sensor bolt

Footrest bracket bolt

Footrest guard screw

Footrest holder bolt

Seat rail mounting bolt

Cowling brace mounting bolt

Rear view mirror mounting nut

115

50

100

60

2.8

5

40

50

1

6

15

100

90

65

98

98

35

50

23

10

50

18

23

4.5

7.5

6

6

18

35

17

2.5

10

17

27

12

90

100

23

23

10

39

15

23

N

⋅

m

90

80

23

23

23

35

28

11.5

5.0

10.0

6.0

0.28

0.5

4.0

5.0

0.1

0.6

1.5

10.0

9.0

6.5

9.8

9.8

5.0

1.8

2.3

0.45

3.5

5.0

2.3

1.0

0.75

0.6

0.6

1.8

3.5

1.7

0.25

1.0

1.7

2.7

1.2

9.0

10.0

2.3

2.3

1.0

3.9

1.5

2.3

kgf-m

9.0

8.0

2.3

2.3

2.3

3.5

2.8

83.0

36.0

72.5

43.0

2.0

3.5

29.0

36.0

0.7

4.5

11.0

72.5

65.0

47.0

71.0

71.0

36.0

13.0

16.5

3.0

25.5

36.0

16.5

7.0

5.5

4.5

4.5

13.0

25.5

12.5

2.0

7.0

12.5

19.5

8.5

65.0

72.5

16.5

16.5

7.0

28.0

11.0

16.5

lbf-ft

65.0

58.0

16.5

16.5

16.5

25.5

20.0

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Service Data: 0C-12

Tightening Torque Chart

For other bolts and nuts not listed in the preceding page, refer to this chart:

Bolt Diameter

“a” (mm)

4

5

6

8

10

12

14

16

18

Conventional or “4” marked bolt

N

⋅

m kgf-m lbf-ft

1.5

3

5.5

13

29

45

65

105

160

0.15

0.3

0.55

1.3

2.9

4.5

6.5

10.5

16.0

1.0

2.0

4.0

9.5

21.0

32.5

47.0

76.0

115.5

N

⋅

m

2.3

4.5

10

23

50

85

135

210

240

“7” marked bolt kgf-m

0.23

0.45

1.0

2.3

5.0

8.5

13.5

21.0

24.0

lbf-ft

1.5

3.0

7.0

16.5

36.0

61.5

97.5

152.0

173.5

1 2 3

“ a ”

“ a ” “ a ”

I649G1030001-04

1. Conventional bolt 2. “4” marked bolt 3. “7” marked bolt email: [email protected] / www.motomatrix.co.uk

0C-13 Service Data:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 1- i

Section 1

Engine

CONTENTS

1

Precautions ………………………………………….1-1

Precautions……………………………………………………. 1-1

Precautions for Engine…………………………………… 1-1

Engine General Information and

Diagnosis …………………………………………. 1A-1

General Description ………………………………………1A-1

Injection Timing Description ………………………….. 1A-1

Self-Diagnosis Function ……………………………….. 1A-3

Schematic and Routing Diagram……………………1A-4

FI System Wiring Diagram ……………………………. 1A-4

Terminal Alignment of ECM Coupler………………. 1A-6

Component Location …………………………………….1A-7

FI System Parts Location ……………………………… 1A-7

Diagnostic Information and Procedures…………1A-8

Engine Symptom Diagnosis ………………………….. 1A-8

Self-Diagnostic Procedures ………………………… 1A-12

Use of SDS Diagnosis Reset Procedures……… 1A-14

Show Data When Trouble (Displaying Data at the Time of DTC) …………………………………….. 1A-15

SDS Check ………………………………………………. 1A-16

DTC Table………………………………………………… 1A-20

Fail-Safe Function Table …………………………….. 1A-22

FI System Troubleshooting …………………………. 1A-23

Malfunction Code and Defective Condition

Table ……………………………………………………… 1A-25

DTC “C11” (P0340): CMP Sensor Circuit

Malfunction……………………………………………… 1A-29

DTC “C12” (P0335): CKP Sensor Circuit

Malfunction……………………………………………… 1A-32

DTC “C13” (P0105-H/L): IAP Sensor Circuit

Malfunction……………………………………………… 1A-35

DTC “C14” (P0120-H/L): TP Sensor Circuit

Malfunction……………………………………………… 1A-43

DTC “C15” (P0115-H/L): ECT Sensor Circuit

Malfunction……………………………………………… 1A-50

DTC “C21” (P0110-H/L): IAT Sensor Circuit

Malfunction……………………………………………… 1A-55

DTC “C22” (P1450-H/L): AP Sensor Circuit

Malfunction……………………………………………… 1A-60

DTC “C23” (P1651-H/L): TO Sensor Circuit

Malfunction……………………………………………… 1A-68

DTC “C24” (P0351), “C25” (P0352), “C26”

(P0353) or “C27” (P0354): Ignition System

Malfunction………………………………………………1A-75

DTC “C28” (P1655): Secondary Throttle

Valve Actuator (STVA) Malfunction……………..1A-75

DTC “C29” (P1654-H/L): Secondary Throttle

Position Sensor (STPS) Circuit Malfunction….1A-79

DTC “C31” (P0705): GP Switch Circuit

Malfunction………………………………………………1A-86

DTC “C32” (P0201), “C33” (P0202), “C34”

(P0203) or “C35” (P0204): Primary Fuel

Injector Circuit Malfunction…………………………1A-88

DTC “C36” (P1764), “C37” (P1765), “C38”

(P1766) or “C39” (P1767): Secondary Fuel

Injector Circuit Malfunction…………………………1A-91

DTC “C40” (P0505 / P0506 / P0507): ISC

Valve Circuit Malfunction……………………………1A-94

DTC “C41” (P0230-H/L): FP Relay Circuit

Malfunction………………………………………………1A-98

DTC “C41” (P2505): ECM Power Input Signal

Malfunction…………………………………………….1A-101

DTC “C42” (P1650): IG Switch Circuit

Malfunction…………………………………………….1A-103

DTC “C44” (P0130/P0135): HO2 Sensor

(HO2S) Circuit Malfunction ………………………1A-103

DTC “C46” (P1657-H/L or P1658): EXCV

Actuator Circuit Malfunction ……………………..1A-109

DTC “C49” (P1656): PAIR Control Solenoid

Valve Circuit Malfunction………………………….1A-121

DTC “C60” (P0480): Cooling Fan Relay

Circuit Malfunction…………………………………..1A-124

DTC “C62” (P0443): EVAP System Purge

Control Solenoid Valve Circuit Malfunction

(E-33 only)……………………………………………..1A-127

DTC “C91” (P0500): Vehicle Speed Sensor

Circuit Malfunction…………………………………..1A-131

DTC “C93” (P1769): Steering Damper

Solenoid Valve Circuit Malfunction…………….1A-134

Specifications ……………………………………………1A-138

Service Data…………………………………………….1A-138

Special Tools and Equipment …………………….1A-139

Special Tool …………………………………………….1A-139 email: [email protected] / www.motomatrix.co.uk

1-ii Table of Contents

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices …………………. 1B-1

Precautions…………………………………………………..1B-1

Precautions for Emission Control Devices ………. 1B-1

General Description ………………………………………1B-1

Fuel Injection System Description………………….. 1B-1

Crankcase Emission Control System

Description ……………………………………………….. 1B-2

Exhaust Emission Control System

Description ……………………………………………….. 1B-3

PAIR System Diagram …………………………………. 1B-4

Noise Emission Control System Description……. 1B-4

Evaporative Emission Control System

Diagram (Only for E-33) ……………………………… 1B-5

Schematic and Routing Diagram ……………………1B-6

PAIR System Hose Routing Diagram …………….. 1B-6

EVAP Canister Hose Routing Diagram (Only for E-33) …………………………………………………… 1B-7

Repair Instructions ……………………………………….1B-8

Heated Oxygen Sensor (HO2S) Removal and

Installation ………………………………………………… 1B-8

Heated Oxygen Sensor (HO2S) Inspection …….. 1B-8

PAIR Reed Valve Removal and Installation…….. 1B-8

PAIR Control Solenoid Valve Removal and

Installation ………………………………………………… 1B-9

PAIR System Inspection ………………………………. 1B-9

Crankcase Breather (PCV) Hose Inspection….. 1B-11

Crankcase Breather (PCV) Hose / Reed

Valve / Cover Removal and Installation ………. 1B-11

Crankcase Breather (PCV) Cover Inspection … 1B-12

Evaporative Emission Control System

Removal and Installation (Only for E-33) …….. 1B-12

Evaporative Emission Control System

Inspection (Only for E-33) …………………………. 1B-14

Specifications……………………………………………..1B-16

Service Data……………………………………………… 1B-16

Tightening Torque Specifications…………………. 1B-16

Special Tools and Equipment ………………………1B-16

Recommended Service Material ………………….. 1B-16

Special Tool ……………………………………………… 1B-16

Engine Electrical Devices ………………….. 1C-1

Precautions…………………………………………………..1C-1

Precautions for Engine Electrical Device …………1C-1

Component Location …………………………………….1C-1

Engine Electrical Components Location ………….1C-1

Diagnostic Information and Procedures …………1C-1

Engine Symptom Diagnosis …………………………..1C-1

Repair Instructions ……………………………………….1C-1

ECM Removal and Installation……………………….1C-1

CMP Sensor Inspection ………………………………..1C-2

CMP Sensor Removal and Installation ……………1C-2

CKP Sensor Inspection …………………………………1C-2

CKP Sensor Removal and Installation …………….1C-2

IAP Sensor Inspection…………………………………..1C-2

IAP Sensor Removal and Installation………………1C-2

TP Sensor Inspection……………………………………1C-2

TP Sensor Removal and Installation……………….1C-3

TP Sensor Adjustment ………………………………….1C-3

ECT Sensor Inspection …………………………………1C-4

IAT Sensor Removal and Installation ………………1C-5

IAT Sensor Inspection …………………………………..1C-5

AP Sensor Inspection……………………………………1C-5

AP Sensor Removal and Installation……………….1C-5

TO Sensor Inspection …………………………………..1C-5

TO Sensor Removal and Installation ………………1C-6

STP Sensor Inspection …………………………………1C-6

STP Sensor Adjustment ………………………………..1C-6

STP Sensor Removal and Installation …………….1C-7

STV Actuator Inspection ……………………………….1C-7

STV Actuator Removal and Installation …………..1C-7

ISC Valve Inspection …………………………………….1C-7

ISC Valve Removal and Installation ………………..1C-7

ISC Valve Preset and Opening Initialization …….1C-8

HO2 Sensor Inspection …………………………………1C-8

HO2 Sensor Removal and Installation …………….1C-8

GP Switch Inspection ……………………………………1C-8

GP Switch Removal and Installation ……………….1C-8

Engine Mechanical ……………………………. 1D-1

ECT Sensor Removal and Installation …………….1C-4 email: [email protected] / www.motomatrix.co.uk

Specifications ……………………………………………….1C-9

Service Data………………………………………………..1C-9

Tightening Torque Specifications ……………………1C-9

Special Tools and Equipment ………………………1C-10

Special Tool ………………………………………………1C-10

Schematic and Routing Diagram ……………………1D-1

Camshaft and Sprocket Assembly Diagram …….1D-1

Throttle Cable Routing Diagram……………………..1D-2

Diagnostic Information and Procedures …………1D-3

Engine Mechanical Symptom Diagnosis ………….1D-3

Compression Pressure Check ……………………….1D-3

Repair Instructions ……………………………………….1D-4

Engine Components Removable with the

Engine in Place ………………………………………….1D-4

Air Cleaner Element Removal and Installation ….1D-6

Air Cleaner Box Removal and Installation………..1D-7

Air Cleaner Element Inspection and Cleaning ….1D-7

Throttle Cable Removal and Installation ………….1D-7

Throttle Cable Inspection ………………………………1D-7

Throttle Cable Play Inspection and

Adjustment ………………………………………………..1D-7

Throttle Body Components ……………………………1D-8

Throttle Body Construction…………………………….1D-9

Throttle Body Removal and Installation …………1D-10

Throttle Body Disassembly and Assembly ……..1D-11

Throttle Body Inspection and Cleaning ………….1D-16

ISC Valve Visual Inspection …………………………1D-16

Throttle Valve Synchronization …………………….1D-16

ISC Valve Reset …………………………………………1D-18

TP Reset …………………………………………………..1D-19

Engine Assembly Removal ………………………….1D-20

Engine Assembly Installation ……………………….1D-24

Engine Top Side Disassembly ……………………..1D-26

Engine Top Side Assembly ………………………….1D-28

Cylinder Head Cover Disassembly and

Assembly…………………………………………………1D-35

Cylinder Head Cover Related Parts

Inspection………………………………………………..1D-36

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 1-iii

Camshaft Inspection …………………………………..1D-36

Camshaft Sprocket …………………………………….1D-38

Cam Chain Tension Adjuster Inspection………..1D-38

Cam Chain Guide / Cam Chain Tensioner

Removal and Installation……………………………1D-39

Cam Chain Guide Inspection ……………………….1D-40

Cam Chain Tensioner Inspection………………….1D-40

Cylinder Head Disassembly and Assembly ……1D-40

Cylinder Head Related Parts Inspection ………..1D-44

Valve Guide Replacement …………………………..1D-47

Valve Seat Repair ………………………………………1D-49

Engine Bottom Side Disassembly …………………1D-49

Engine Bottom Side Assembly……………………..1D-56

Cylinder Inspection …………………………………….1D-69

Piston Ring Removal and Installation ……………1D-69

Piston and Piston Ring Inspection ………………..1D-71

Balancer Shaft Disassembly and Assembly……1D-73

Balancer Shaft Inspection ……………………………1D-73

Balancer Shaft Journal Bearing Removal and

Installation ……………………………………………….1D-74

Balancer Shaft Journal Bearing Inspection and Selection …………………………………………..1D-75

Conrod Crank Pin Bearing Removal and

Installation ……………………………………………….1D-76

Conrod and Crankshaft Inspection ……………….1D-77

Conrod Crank Pin Bearing Inspection and

Selection …………………………………………………1D-78

Crankshaft Journal Bearing Inspection and

Selection …………………………………………………1D-79

Crankshaft Thrust Clearance Inspection and

Selection …………………………………………………1D-82

Specifications……………………………………………..1D-84

Service Data ……………………………………………..1D-84

Tightening Torque Specifications………………….1D-86

Special Tools and Equipment ………………………1D-87

Recommended Service Material …………………..1D-87

Special Tool ………………………………………………1D-88

Engine Lubrication System ……………….. 1E-1

Precautions………………………………………………….. 1E-1

Precautions for Engine Oil ……………………………. 1E-1

Schematic and Routing Diagram…………………… 1E-2

Engine Lubrication System Chart Diagram ……… 1E-2

Engine Lubrication Circuit Diagram………………… 1E-3

Diagnostic Information and Procedures………… 1E-5

Engine Lubrication Symptom Diagnosis …………. 1E-5

Oil Pressure Check ……………………………………… 1E-5

Repair Instructions ………………………………………. 1E-6

Engine Oil and Filter Replacement ………………… 1E-6

Engine Oil Level Inspection ………………………….. 1E-6

Oil Pan / Oil Pressure Regulator / Oil Strainer

Removal and Installation…………………………….. 1E-6

Oil Pressure Regulator / Oil Strainer

Inspection…………………………………………………. 1E-7

Oil Cooler / Oil Cooler Hose Inspection and

Cleaning …………………………………………………… 1E-7

Oil Cooler / Oil Cooler Hose Removal and

Installation ………………………………………………… 1E-8

Oil Pressure Switch Removal and Installation …. 1E-9 email: [email protected] / www.motomatrix.co.uk

Oil Pressure Switch Inspection …………………….1E-10

Oil Jet Removal and Installation……………………1E-10

Oil Jet Inspection………………………………………..1E-12

Oil Pump Removal and Installation ……………….1E-12

Oil Pump Inspection ……………………………………1E-14

Oil Pump Drive Sprocket Removal and

Installation ……………………………………………….1E-14

Specifications ……………………………………………..1E-14

Service Data………………………………………………1E-14

Tightening Torque Specifications………………….1E-14

Special Tools and Equipment ………………………1E-15

Recommended Service Material …………………..1E-15

Special Tool ………………………………………………1E-15

Engine Cooling System ………………………1F-1

Precautions………………………………………………….. 1F-1

Precautions for Engine Cooling System………….. 1F-1

Precautions for Engine Coolant …………………….. 1F-1

General Description ……………………………………… 1F-1

Engine Coolant Description…………………………… 1F-1

Schematic and Routing Diagram …………………… 1F-2

Cooling Circuit Diagram ……………………………….. 1F-2

Water Hose Routing Diagram ……………………….. 1F-3

Diagnostic Information and Procedures ………… 1F-4

Engine Cooling Symptom Diagnosis………………. 1F-4

Repair Instructions ………………………………………. 1F-4

Cooling Circuit Inspection …………………………….. 1F-4

Radiator Cap Inspection……………………………….. 1F-5

Radiator Inspection and Cleaning ………………….. 1F-5

Radiator / Cooling Fan Motor Removal and

Installation ………………………………………………… 1F-6

Water Hose Inspection…………………………………. 1F-7

Water Hose Removal and Installation…………….. 1F-8

Radiator Reservoir Tank Inspection……………….. 1F-8

Radiator Reservoir Tank Removal and

Installation ………………………………………………… 1F-8

Cooling Fan Inspection ………………………………… 1F-9

Cooling Fan Relay Inspection ……………………….. 1F-9

ECT Sensor Removal and Installation ………….. 1F-10

ECT Sensor Inspection ………………………………. 1F-10

Thermostat Removal and Installation……………. 1F-10

Thermostat Inspection………………………………… 1F-11

Water Pump Components…………………………… 1F-12

Water Pump Construction …………………………… 1F-13

Water Pump Removal and Installation………….. 1F-13

Water Pump Disassembly and Assembly ……… 1F-14

Water Pump Related Parts Inspection ………….. 1F-17

Specifications …………………………………………….. 1F-18

Service Data……………………………………………… 1F-18

Tightening Torque Specifications…………………. 1F-19

Special Tools and Equipment ……………………… 1F-19

Recommended Service Material ………………….. 1F-19

Special Tool ……………………………………………… 1F-19

Fuel System ……………………………………… 1G-1

Precautions…………………………………………………. 1G-1

Precautions for Fuel System ………………………… 1G-1

General Description …………………………………….. 1G-2

Fuel Injection System Description…………………. 1G-2

1-iv Table of Contents

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Schematic and Routing Diagram ………………….. 1G-3

Fuel Tank Drain Hose and Breather Hose

Routing Diagram ………………………………………. 1G-3

Diagnostic Information and Procedures ……….. 1G-4

Fuel System Diagnosis ……………………………….. 1G-4

Repair Instructions ……………………………………… 1G-5

Fuel Pressure Inspection …………………………….. 1G-5

Fuel Pump Inspection …………………………………. 1G-6

Fuel Discharge Amount Inspection ……………….. 1G-6

Fuel Pump Relay Inspection ………………………… 1G-7

Fuel Hose Inspection ………………………………….. 1G-7

Fuel Level Gauge Inspection ……………………….. 1G-7

Fuel Tank Construction ……………………………….. 1G-8

Fuel Tank Removal and Installation………………. 1G-9

Fuel Pump Components ……………………………. 1G-10

Fuel Pump Disassembly and Assembly……….. 1G-11

Fuel Mesh Filter Inspection and Cleaning…….. 1G-13

Fuel Injector / Fuel Delivery Pipe / T-joint

Removal and Installation………………………….. 1G-13

Fuel Injector Inspection and Cleaning………….. 1G-13

Specifications……………………………………………. 1G-14

Service Data…………………………………………….. 1G-14

Tightening Torque Specifications………………… 1G-14

Special Tools and Equipment …………………….. 1G-15

Recommended Service Material …………………. 1G-15

Special Tool …………………………………………….. 1G-15

Ignition System…………………………………. 1H-1

General Description ………………………………………1H-1

Immobilizer Description (For E-02, 19, 24, 51) ….1H-1

Drive Mode Selector Description…………………….1H-2

Schematic and Routing Diagram ……………………1H-3

Ignition System Diagram ……………………………….1H-3

Ignition System Components Location…………….1H-3

Diagnostic Information and Procedures …………1H-4

Ignition System Symptom Diagnosis……………….1H-4

No Spark or Poor Spark ………………………………..1H-5

Repair Instructions ……………………………………….1H-6

Ignition Coil and Spark Plug Removal and

Installation …………………………………………………1H-6

Spark Plug Inspection and Cleaning ……………….1H-7

Ignition Coil Inspection ………………………………….1H-7

CKP Sensor Inspection …………………………………1H-9

CKP Sensor Removal and Installation …………..1H-10

Engine Stop Switch Inspection……………………..1H-10

Ignition Switch Inspection…………………………….1H-10

Ignition Switch Removal and Installation………..1H-11

Drive Mode Selector Inspection ……………………1H-12

Specifications……………………………………………..1H-13

Service Data………………………………………………1H-13

Tightening Torque Specifications………………….1H-13

Special Tools and Equipment ………………………1H-14

Recommended Service Material …………………..1H-14

Special Tool ………………………………………………1H-14

Starting System ………………………………….. 1I-1

Schematic and Routing Diagram ……………………. 1I-1

Starting System Diagram ………………………………. 1I-1

Component Location …………………………………….. 1I-1

Starting System Components Location ……………. 1I-1

Diagnostic Information and Procedures …………. 1I-1

Starting System Symptom Diagnosis ………………. 1I-1

Starter Motor Will Not Run …………………………….. 1I-2

Starter Motor Runs But Does Not Crank The

Engine ………………………………………………………. 1I-2

Repair Instructions ……………………………………….. 1I-3

Starter Motor Components …………………………….. 1I-3

Starter Motor Removal and Installation ……………. 1I-4

Starter Motor Disassembly and Assembly ……….. 1I-4

Starter Motor Inspection ………………………………… 1I-5

Starter Relay Removal and Installation ……………. 1I-6

Starter Relay Inspection ………………………………… 1I-6

Turn Signal / Side-stand Relay Removal and

Installation …………………………………………………. 1I-7

Side-stand / Ignition Interlock System Parts

Inspection………………………………………………….. 1I-7

Starter Torque Limiter Removal and

Installation …………………………………………………. 1I-9

Starter Torque Limiter Inspection ………………….. 1I-10

Starter Clutch Removal and Installation …………. 1I-10

Starter Clutch Inspection ……………………………… 1I-11

Starter Button Inspection……………………………… 1I-12

Specifications ……………………………………………… 1I-12

Service Data………………………………………………. 1I-12

Tightening Torque Specifications ………………….. 1I-12

Special Tools and Equipment ………………………. 1I-13

Recommended Service Material …………………… 1I-13

Special Tool ………………………………………………. 1I-13

Charging System ……………………………….. 1J-1

Schematic and Routing Diagram …………………… 1J-1

Charging System Diagram ……………………………. 1J-1

Component Location ……………………………………. 1J-1

Charging System Components Location…………. 1J-1

Diagnostic Information and Procedures ………… 1J-1

Charging System Symptom Diagnosis……………. 1J-1

Battery Runs Down Quickly ………………………….. 1J-2

Repair Instructions ………………………………………. 1J-3

Battery Current Leakage Inspection……………….. 1J-3

Regulated Voltage Inspection ……………………….. 1J-3

Generator Inspection……………………………………. 1J-3

Generator Removal and Installation……………….. 1J-4

Regulator / Rectifier Construction ………………….. 1J-7

Regulator / Rectifier Removal and Installation …. 1J-7

Regulator / Rectifier Inspection ……………………… 1J-8

Battery Components ……………………………………. 1J-9

Battery Charging …………………………………………. 1J-9

Battery Removal and Installation …………………. 1J-11

Battery Visual Inspection…………………………….. 1J-12

Specifications …………………………………………….. 1J-12

Service Data……………………………………………… 1J-12

Tightening Torque Specifications …………………. 1J-12

Special Tools and Equipment ……………………… 1J-13

Recommended Service Material ………………….. 1J-13

Special Tool ……………………………………………… 1J-13 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 1-v

Exhaust System………………………………… 1K-1

Precautions…………………………………………………..1K-1

Precautions for Exhaust System ……………………. 1K-1

General Description ………………………………………1K-1

Exhaust Control System Description………………. 1K-1

Exhaust Control System Operation………………… 1K-2

Repair Instructions ……………………………………….1K-4

Exhaust Control System Construction ……………. 1K-4

Exhaust System Components……………………….. 1K-5

EXCV Cable Removal and Installation……………. 1K-6

EXCVA Removal and Installation ………………….. 1K-7

EXCVA Inspection ………………………………………. 1K-9

EXCVA Pulley Inspection………………………………1K-9

EXCVA Adjustment ………………………………………1K-9

Muffler / Muffler Chamber / Exhaust Pipe

Removal and Installation……………………………1K-11

Exhaust System Inspection………………………….1K-13

Specifications ……………………………………………..1K-14

Service Data………………………………………………1K-14

Tightening Torque Specifications………………….1K-14

Special Tools and Equipment ………………………1K-15

Recommended Service Material …………………..1K-15

Special Tool ………………………………………………1K-15 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1-1 Precautions:

Engine

Precautions

Precautions

Precautions for Engine

B947H11000001

Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00

(Page 00-2).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-1

Engine

Engine General Information and Diagnosis

General Description

Injection Timing Description

B947H11101001

Injection Time (Injection Volume)

The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the 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.

I947H1110126-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-2 Engine General Information and Diagnosis:

Compensation of Injection Time (Volume)

The following different signals are output from the respective sensors for compensation of the fuel injection time

(volume).

Signal

ATMOSPHERIC PRESSURE SENSOR SIGNAL

ENGINE COOLANT TEMPERATURE SENSOR

SIGNAL

INTAKE AIR TEMPERATURE SENSOR SIGNAL

HEATED OXYGEN SENSOR SIGNAL

BATTERY VOLTAGE SIGNAL

ENGINE RPM SIGNAL

STARTING SIGNAL

ACCELERATION SIGNAL/DECELERATION

SIGNAL

Descriptions

When atmospheric pressure is low, the sensor sends the signal to the ECM and reduce the injection time (volume).

When engine coolant temperature is low, injection time (volume) is increased.

When intake air temperature is low, injection time (volume) is increased.

Air/fuel ratio is compensated to the theoretical ratio from density of oxygen in exhaust gas. The compensation occurs in such a way that more fuel is supplied if detected air/fuel ratio is lean and less fuel is supplied if it is rich.

ECM operates on the battery voltage and at the same time, it monitors the voltage signal for compensation of the fuel injection time (volume). A longer injection time is needed to adjust injection volume in the case of low voltage.

At high speed, the injection time (volume) is increased. This is the compensation of the SRAD.

When starting engine, additional fuel is injected during cranking engine.

During acceleration, the fuel injection time (volume) is increased, in accordance with the throttle opening speed and engine rpm.

During deceleration, the fuel injection time (volume) is decreased.

Injection Stop Control

Signal

TIP-OVER SENSOR SIGNAL (FUEL SHUT-OFF)

OVER-REV. LIMITER SIGNAL

Descriptions

When the motorcycle tips over, the tip-over sensor sends a signal to the ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors and ignition coils.

The fuel injectors stop operation when engine rpm reaches rev. limit rpm.

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 injectors. But under no load, the clutch lever is pulled or the gear position is in neutral, this circuit cuts off fuel when engine speed reaches 13 100 r/min.

!

CAUTION

Under no load, the engine can run over 13 100 r/min through the fuel cut-off circuit is effective, which may possibly cause engine damage. Do not run the engine without load over 13 100 r/min at anytime.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-3

Self-Diagnosis Function

B947H11101002

The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”.

The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided. In this check, the special tool is necessary to read the code of the malfunction items.

User Mode

Malfunction

“YES”

“NO”

Engine can start

Engine can not start

LCD (DISPLAY)

INDICATION “A”

Odd / Trip / Clock / Panel light brightness / Lap time counter

Odd / Trip / Clock / Panel light brightness / Lap time counter and “FI” letters

*1

“FI” letters

*2

FI INDICATOR LIGHT

INDICATION “B”

—

FI indicator light turns ON.

INDICATION MODE

—

Each 2 sec. Odd / Trip / Clock /

Panel light brightness / Lap time counter and “FI” is indicated.

FI indicator light turns ON and blinks.

“FI” is indicated continuously.

*1

When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case,

“FI” and Odd / Trip / Clock / Panel light brightness / Lap time counter are indicated in the LCD panel and motorcycle can run.

*2

The injection signal is stopped, when the camshaft position sensor signal, crankshaft position sensor signal, tip-over sensor signal, #1, #2, #3 and #4 ignition signals, #1, #2, #3 and #4 injector signals, fuel pump relay signal or ignition switch signal is not sent to ECM. In this case, “FI” is indicated in the LCD panel. Motorcycle does not run.

“CHEC”:

The LCD panel indicates “CHEC” when no communication signal from the ECM is received for 5 seconds.

For Example:

The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from ECM, and the panel indicates “CHEC”. If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the wiring harness between ECM and speedometer couplers.The possible cause of this indication is as follows:

Engine stop switch is in OFF position. Side-stand/ignition inter-lock system is not working. Ignition fuse is burnt.

“Sd”:

The LCD panel indicates “Sd” when the steering damper solenoid malfunction, battery abnormal voltage and speed sensor malfunction occurred.

“B”

“A”

I947H1110001-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-4 Engine General Information and Diagnosis:

Dealer Mode

The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

!

CAUTION

Before checking the malfunction code, do not disconnect the ECM coupler.

If the coupler from the ECM is disconnected, the malfunction code memory is erased and the malfunction code can not be checked.

Special tool

(A): 09930–82720 (Mode selection switch)

(A)

(A)

Malfunction

“NO”

“YES”

LCD (DISPLAY) INDICATION

C00

C** code is indicated from small numeral to large one.

I947H1110002-01 I947H1110003-01

FI LIGHT INDICATION INDICATION MODE

—

FI indicator light turns OFF.

For each 2 sec., code is indicated.

FI System Wiring Diagram

Schematic and Routing Diagram

B947H11102001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-5

Combination meter

*1 Immobilizer

*2 Ignition switch

Speed sensor

Br/Y

Y/Bl

G/R

O/Y

R/Y

O/Bl

B/Y

R/Bl

P

64*1

2

B/G

23 11 42 10

59

58

64*2

53*1

57

65*1

8

56

46

45

44

Lg

Lg/W

Lg/B

Lg/Bl

Gr/W

Gr/B

Gr/Y

Gr/R

43

CMPS

#1

Cooling fan motor

M

#2 #3

Cooling fan relay

#4

Fuel pump

15 A

CKPS

TPS

STPS

IAPS

APS

IATS

ECTS

TOS

HO2S

EXCVA/EXCVA position sensor

Drive mode selector

G/W

G/Bl

9

21

R

P/B

7

6

Y/W

18

G/B

19

G/Y

20

*3

ECM

#1

Primary fuel injector

#2

24

40

12

Y/R

Y/B

*1 O/G

48

W/Bl

*2 O/W

47

B

#1

#2

Ignition coil

Y

60

#3

72

61

55

G

Dbr

W/G

#4

Dg

33

PAIR control solenoid valve

67

22

Bl

P

B/Bl

32

B

31

W/G

W/B

B/Br

34

41

35

54

69

68

71

36

39

38

37

49

Bl

Y

G

Br

Y/G

B/Y

B/W

B/W

B/W

GP switch

ISC valve

B/R

R/B

Y

1

13

14

STVA

O/Bl

63

O/R

50

4

28

3

27

25

26

P/W

B/Lg

W/B

G

Br

W

#3

FP relay

Engine stop switch

#4

Neutral indicator light

Side-stand switch

Starter button

Starter relay

M

10 A

15 A

Side-stand relay

10 A

Starter motor

Ignition switch

30 A

Battery

Clutch lever position switch

Steering damper solenoid valve

*1: For E-02, 19, 24, 51

*2: For E-03, 14, 28, 33

*3: For E-33

I947H1110004-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-6 Engine General Information and Diagnosis:

Terminal Alignment of ECM Coupler

B947H11102002

TERMINAL NO.

1

2

3

6

7

4

5

12

13

14

15

16

8

9

10

11

CIRCUIT

EXCVA power (MO+)

Speed sensor signal

STVA signal (STVA, 2A)

STVA signal (STVA, 1A)

—

TP sensor signal (TPS)

Power source for sensors (VCC)

CMP sensor (CMPS+)

CKP sensor (CKPS+)

Power source for back-up (BATT)

Tachometer

Power source (+B)

EXCVA power (MO–)

EXCVA position sensor (MPS)

—

—

17

18

19

20

21

22

23

24

25

26

27

28

Blank

STP sensor (STPS)

IAP sensor signal (IAPS)

AP sensor signal (APS)

CKP sensor signal (CKPS–)

Gear position switch signal (GP)

Serial data for speedometer

Power source for fuel injectors (VM)

Steering damper solenoid (SSO–)

Steering damper solenoid (SSO+)

STVA signal (STVA, 2B)

STVA signal (STVA, 1B)

29

30

31

32

33

34

35

36

Blank

Blank

TO sensor signal (TOS)

ECT sensor signal (ECTS)

IAT sensor signal (IATS)

HO2 sensor (HO2S)

Sensor ground (E2)

ECM ground (E1)

TERMINAL NO.

37

38

39

40

41

42

43

48

49

50

51

52

44

45

46

47

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

I837H1110004-01

CIRCUIT

ISC valve signal (ISC, 2A)

ISC valve signal (ISC, 1B)

ISC valve signal (ISC, 1A)

Fuel pump relay (FP relay)

HO2 sensor heater (HO2SH)

Cooling fan relay (FAR)

Primary injector #4 (#41)

Primary injector #3 (#31)

Primary injector #2 (#21)

Primary injector #1 (#11)

Ignition coil #2

Ignition coil #1

ISC valve signal (ISC, 2B)

Drive mode selector 2 (DMS 2)

—

—

Immobilizer communication (For E-02, 19,

24, 51)

Starter switch

PAIR control solenoid (PAIR)

Secondary injector #4 (#42)

Secondary injector #3 (#32)

Secondary injector #2 (#22)

Secondary injector #1 (#12)

Ignition coil #3

EVAP system purge control solenoid valve

(For E-33)

Serial data for self-diagnosis

Drive mode selector 1 (DMS 1)

Immobilizer indicator (For E-02, 19, 24, 51)/

Ignition switch signal (For E-03, 14, 28, 33)

Immobilizer communication (For E-02, 19,

24, 51)

—

Neutral signal

General ground (E01)

Clutch lever switch

Mode select switch

Ignition system ground (E03)

Ignition coil #4 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-7

Component Location

FI System Parts Location

B947H11103001

“I”

“A”

“K”

“J”

“F”

“E”

“C”

“D”

“B”

“G”

“H”

“A”: ECM

“B”: Throttle position sensor (TPS)

“C”: Secondary throttle position sensor (STPS)

“D”: Secondary throttle valve actuator (STVA)

“E”: Intake air pressure sensor (IAPS)

“F”: EVAP system purge control solenoid valve (E-33 only)

“G”: Heated oxygen sensor (HO2S)

“H”: Crankshaft position sensor (CKPS)

I947H1110005-01

“I”: Fuel pump relay (FP relay)

“J”: Fuel pump (FP)

“K”: Tip-over sensor (TOS) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-8 Engine General Information and Diagnosis:

“Z”

“Y”

“O”

“P”

“Q”

“R”

“N”

“L”

“S”

“T”

“U”

“V”

“X”

“W”

“A”

“M”

“A”: ECM

“L”: Exhaust control valve actuator (EXCVA)

“M”: Cooling fan relay

“N”: Cooling fan

“O”: Intake air temperature sensor (IATS)

“P”: PAIR control solenoid valve

“Q”: Camshaft position sensor (CMPS)

“R”: Ignition coil (IG coil)

“S”: Secondary fuel injector

“T”: Primary fuel injector

“U”: Engine coolant temperature sensor (ECTS)

“V”: Speed sensor

I947H1110006-01

“W”: Atmospheric pressure sensor (APS)

“X”: Gear position switch (GP switch)

“Y”: Drive mode selector

“Z”: Combination meter

Diagnostic Information and Procedures

Engine Symptom Diagnosis

Condition

Engine will not start or is hard to start

(Compression too low)

Possible cause

Valve clearance out of adjustment.

Worn valve guide or poor seating of valve.

Mistimed valve.

Excessively worn piston ring.

Worn-down cylinder bore.

Too slow Starter motor cranking.

Engine will not start or is hard to start (Plug not sparking)

Engine will not start or is hard to start (No fuel reaching the intake manifold)

Poor seating of spark plug.

Fouled spark plug.

Wet spark plug.

Defective ignition coil.

Defective CKP sensor.

Defective ECM.

Open-circuited wiring connection.

Clogged fuel filter or fuel hose.

Defective fuel pump.

Defective fuel pressure regulator.

Defective fuel injector.

Defective fuel pump relay.

Defective ECM.

Open-circuited wiring connection.

email: [email protected] / www.motomatrix.co.uk

B947H11104001

Correction / Reference Item

Adjust.

Repair or replace.

Adjust.

Replace.

Replace.

Refer to “Starting System Diagram” in Section

1I (Page 1I-1).

Retighten.

Clean.

Clean and dry.

Replace.

Replace.

Replace.

Repair or replace.

Clean or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Check and repair.

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-9

Condition

Engine will not start or is hard to start (Incorrect fuel/air mixture)

Engine idles poorly

Engine stalls often

(Incorrect fuel/air mixture)

Engine stalls often (Fuel injector improperly operating)

Engine stalls often

(Control circuit or sensor improperly operating)

Engine stalls often

(Engine internal parts improperly operating)

Noisy engine (Excessive valve chatter)

Possible cause

TP sensor out of adjustment.

Defective fuel pump.

Defective fuel pressure regulator.

Defective TP sensor.

Defective CKP sensor.

Defective IAP sensor.

Defective ECM.

Defective ECT sensor.

Defective IAT sensor.

Defective AP sensor.

Clogged ISC valve air passage way.

Valve clearance out of adjustment.

Poor seating of valve.

Defective valve guide.

Worn down camshaft.

Too wide spark plug gap.

Defective ignition coil/plug cap.

Defective CKP sensor.

Defective ECM.

Defective TP sensor.

Defective fuel pump.

Imbalanced throttle valve.

Damaged or cranked vacuum hose.

Damaged or clogged ISC valve.

ISC incorrect learning.

Defective IAP sensor or circuit.

Clogged fuel filter.

Defective fuel pump.

Defective fuel pressure regulator.

Defective ECT sensor.

Defective thermostat.

Defective IAT sensors.

Damaged or cracked vacuum hose.

Damaged or cogged ISC valve.

Defective fuel injector.

No injection signal from ECM.

Open or short circuited wiring connection.

Replace.

Replace.

Replace.

Replace or repair.

Replace.

Repair or replace.

Repair or replace.

Defective battery or low battery voltage.

Replace or recharge.

Defective ECM.

Replace.

Defective fuel pressure regulator.

Defective TP sensor.

Replace.

Replace.

Defective IAT sensors.

Defective CMP sensors.

Defective CKP sensor.

Defective ECT sensor.

Replace.

Replace.

Replace.

Replace.

Defective fuel pump relay.

Defective ISC valve.

ISC incorrect learning.

Fouled spark plug.

Defective CKP sensor or ECM.

Clogged fuel hose.

Out of valve clearance adjustment.

Too large valve clearance.

Weakened or broken valve spring.

Worn tappet or cam surface.

Worn or burnt camshaft journal.

Replace.

Replace.

Reset learned value.

Clean.

Replace.

Clean.

Adjust.

Adjust.

Replace.

Replace.

Replace.

Adjust.

Replace.

Correction / Reference Item

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Repair or replace.

Adjust.

Replace or repair.

Replace.

Replace.

Adjust or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Adjust.

Replace.

Repair or replace.

Reset learned value.

Repair or replace.

Clean or replace.

Replace.

Replace.

Replace.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-10 Engine General Information and Diagnosis:

piston)

Noisy engine (Noise seems to come from cam chain)

Noisy engine (Noise seems to come from clutch)

Condition

Noisy engine (Noise seems to come from

Noisy engine (Noise seems to come from crankshaft)

Possible cause

Worn down piston or cylinder.

Combustion chamber fouled with

Replace.

Clean.

Correction / Reference Item

carbon.

Worn piston pin or piston pin bore.

Worn piston ring or ring groove.

Stretched cam chain.

Worn sprocket.

Replace.

Replace.

Replace.

Replace.

Cam chain tension adjuster not working.

Repair or replace.

Worn splines of countershaft or hub.

Worn teeth of clutch plate.

Replace.

Replace.

Distorted clutch plate.

Worn clutch release bearing.

Weakened clutch damper.

Worn clutch lifter related parts.

Rattling bearing due to wear.

Worn or burnt big-end bearing.

Worn or burnt journal bearing.

Too large thrust clearance.

Worn and burnt journal bearings.

Replace.

Replace.

Replace the primary driven gear.

Replace related parts as a set.

Replace.

Replace.

Replace.

Replace thrust bearing.

Replace.

Noisy engine (Noise seems to come from balancer)

Noisy engine (Noise seems to come from transmission)

Noisy engine (Noise seems to come from water pump)

Engine runs poorly in high speed range

(Defective engine internal/ electrical parts)

Engine runs poorly in high speed range

(Defective air flow system)

Worn or rubbing gear.

Worn spline.

Worn or rubbing primary gear.

Worn bearing.

Replace.

Replace.

Replace.

Replace.

Too much play on pump shaft bearing.

Replace.

Worn or damaged impeller shaft.

Replace.

Worn or damaged mechanical seal.

Contact between pump case and

Replace.

Replace.

impeller.

Weakened valve spring.

Worn camshaft.

Valve timing out of adjustment.

Too narrow spark plug gap.

Ignition not advanced sufficiently due to poorly. working timing advance circuit.

Defective ignition coil.

Replace.

Replace.

Adjust.

Adjust.

Replace ECM.

Defective CKP sensor.

Defective ECM.

Clogged air cleaner element.

Clogged fuel hose, resulting in inadequate fuel. supply to injector.

Defective fuel pump.

Defective TP sensor.

Defective STP sensor or STVA.

Clogged air cleaner element.

Defective throttle valve.

Defective secondary throttle valve.

Sucking air from throttle body joint.

Defective ECM.

Imbalancing throttle valve synchronization.

Defective STP sensor or STVA.

Replace.

Replace.

Replace.

Clean.

Clean and prime.

Replace.

Replace.

Replace.

Clean or replace.

Adjust or replace.

Adjust or replace.

Repair or replace.

Replace.

Adjust.

Replace.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-11

Condition

Engine runs poorly in high speed range

(Defective control circuit or sensor)

Possible cause

Low fuel pressure.

Defective TP sensor.

Defective IAT sensors.

Defective CMP sensor.

Defective CKP sensor.

Defective GP sensor.

Engine lacks power

(Defective engine internal/ electrical parts)

Defective IAP sensor.

Defective ECM.

TP sensor out of adjustment.

Defective STP sensor and/or STVA.

Defective EXCVA.

Loss of valve clearance.

Weakened valve spring.

Valve timing out of adjustment.

Engine lacks power

(Defective control circuit or sensor)

Correction / Reference Item

Repair or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Adjust.

Replace.

Replace.

Adjust.

Replace.

Adjust.

Worn piston ring or cylinder.

Poor seating of valve.

Fouled spark plug.

Incorrect spark plug.

Clogged fuel injector.

Defective secondary fuel injector.

TP sensor out of adjustment.

Clogged air cleaner element.

Replace.

Repair.

Clean or replace.

Adjust or replace.

Replace.

Replace.

Adjust.

Replace.

Adjust.

Imbalancing throttle valve synchronization.

Sucking air from throttle valve or vacuum hose.

Retighten or replace.

Too much engine oil.

Defective fuel pump or ECM.

Drain out excess oil.

Replace.

Defective CKP sensor and ignition coil.

Replace.

Defective STP sensor or STVA.

Replace.

Low fuel pressure.

Defective TP sensor.

Defective IAT sensor.

Defective CKP sensor.

Defective GP switch.

Defective IAP sensor.

Defective AP sensor.

TP sensor out of adjustment.

Repair or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Adjust.

Engine overheats

(Defective engine internal parts)

Defective STP sensor and/or STVA.

Defective EXCVA.

Replace.

Replace.

Heavy carbon deposit on piston crown.

Clean.

Not enough oil in the engine.

Add oil.

Defective oil pump or clogged oil circuit.

Replace or clean.

Sucking air from intake pipe.

Retighten or replace.

Use of incorrect engine oil.

Defective cooling system.

Change.

See radiator section.

Engine overheats (Lean fuel/air mixture)

Engine overheats (Other factors)

Short-circuited IAP sensor/lead wire.

Short-circuited IAT sensor/lead wire.

Sucking air from intake pipe joint.

Defective fuel injector.

Defective ECT sensor.

Ignition timing is too advanced due to defective timing advance system (ECT sensor, GP switch, CKP sensor or

Repair or replace.

Repair or replace.

Repair or replace.

Replace.

Replace.

Replace.

ECM).

Too tight drive chain.

ISC incorrect learning.

Adjust.

Reset learned value.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-12 Engine General Information and Diagnosis:

Condition

Dirty or heavy exhaust smoke

Possible cause

Too much engine oil.

Worn piston ring or cylinder.

Worn valve guide.

Scored or scuffed cylinder wall.

Worn valve stem.

Defective stem seal.

Worn oil ring side rail.

Correction / Reference Item

Check with inspection window, drain out excess oil.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Self-Diagnostic Procedures

Use of Mode Select Switch

B947H11104002

5) Check the DTC to determine the malfunction part.

Refer to “DTC Table” (Page 1A-20).

Special tool

(A): 09930–82720 (Mode selection switch)

NOTE

• Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection may erase memorized information in ECM memory.

• DTC stored in ECM memory can be checked by the special tool.

• Before checking DTC, read self-diagnosis function “User mode and dealer mode”

(Refer to “Self-Diagnosis Function”

(Page 1A-3).) carefully to have good understanding as to what functions are available and how to use it.

• Be sure to read “Precautions for Electrical

Circuit Service” (Refer to “Precautions for

Electrical Circuit Service” in Section 00

(Page 00-2).) before inspection and observe what is written there.

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Connect the special tool to the mode select switch coupler.

Special tool

(A): 09930–82720 (Mode selection switch)

(A)

I718H1110006-04

(A)

I947H1110007-01

3) Start the engine or crank the engine for more than 4 seconds.

4) Turn the special tool’s switch ON.

email: [email protected] / www.motomatrix.co.uk

I947H1110008-01

6) After repairing the trouble, turn OFF the ignition switch and turn ON again. If DTC is indicated (C00), the malfunction is cleared.

NOTE

• Even though DTC (C00) is indicated, the previous malfunction history DTC still remains stored in the ECM. Therefore, erase the history DTC memorized in the

ECM using SDS.

• DTC is memorized in the ECM also when the lead wire coupler of any sensor is disconnected. Therefore, when a lead wire coupler has been disconnected at the time of diagnosis, erase the stored history DTC using SDS. Refer to “Use of SDS Diagnosis

Reset Procedures” (Page 1A-14).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-13

7) Turn the ignition switch OFF and disconnect the special tool from the mode select switch coupler.

Reinstall the front seat.

Use of SDS

NOTE

• Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection may erase the memorized information in

ECM memory.

• DTC stored in ECM memory can be checked by SDS.

• Be sure to read “Precautions for Electrical

Circuit Service” in Section 00 (Page 00-2) before inspection and observe what is written there.

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Set up the SDS tools. (Refer to the SDS operation manual for further details.)

Special tool

(A): 09904–41010 (SUZUKI Diagnostic system set)

(B): 99565–01010–020 (CD-ROM Ver.20)

3) Click the DTC inspection button (1).

(A)

(B)

I705H1110116-03

1

I947H1110009-01

I705H1110003-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-14 Engine General Information and Diagnosis:

4) Start the engine or crank the engine for more than 4 seconds.

5) Check the DTC to determine the malfunction part.

Refer to “DTC Table” (Page 1A-20).

NOTE

• Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaying data at the time of DTC) according to instructions displayed on SDS.

• SDS is not used only for detecting

Diagnostic Trouble Codes but also for reproducing and checking on screen the failure condition as described by customers using the trigger. (Refer to

“Show Data When Trouble (Displaying

Data at the Time of DTC)” (Page 1A-15).)

• How to use trigger. (Refer to the SDS operation manual for further details.)

6) After repairing the trouble, clear to delete history code (Past DTC). Refer to “Use of SDS Diagnosis

Reset Procedures” (Page 1A-14).

7) Close the SDS tool and turn the ignition switch OFF.

Disconnect the SDS tool and install the front seat.

3) Check the DTC.

4) The previous malfunction history code (Past DTC) still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS tool.

5) Click “Clear” (2) to delete history code (Past DTC).

6) Follow the displayed instructions.

2

I705H1110005-01

Use of SDS Diagnosis Reset Procedures

B947H11104003

NOTE

The malfunction code is memorized in the

ECM also when the lead wire coupler of any sensor is disconnected. Therefore, when a lead wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.

1) After repairing the trouble, turn OFF the ignition switch and turn ON again.

2) Click the DTC inspection button (1).

I947H1110144-01

I947H1110145-01

7) Check that both “Current DTC” (3) and “Past DTC”

(4) are deleted (NIL).

1

3

4

I705H1110003-01 email: [email protected] / www.motomatrix.co.uk

I705H1110008-01

Close the SDS tool and turn the ignition switch OFF.

9) Disconnect the SDS tool and install the front seat.

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-15

Show Data When Trouble (Displaying Data at the Time of DTC)

B947H11104004

Use of SDS

ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is 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. This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM.

Also, ECM has a function to store each show data when trouble for two different malfunctions in the order of occurrence as the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been detected. Its use is helpful when rechecking or diagnosing a trouble.

1) Click “Show data when trouble” (1) to display the data.

1

I718H1110269-02

I837H1110167-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-16 Engine General Information and Diagnosis:

2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected.

2

I718H1110270-01

SDS Check

B947H11104005

Using SDS, sample the data at the time of new and periodic vehicle inspections.

After saving the sampled data in the computer, file them by 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.

For example, when a vehicle is brought in for service but the troubleshooting of a failure is not easy, comparing the current data value to past filed data value at time of normal condition can allow the specific engine failure to be determined.

Also, in the case of a customer vehicle which is not periodically brought in for service with no past data value having been saved, if the data value of a good vehicle condition have been already saved as a master (STD), comparison between the same models helps to facilitate the troubleshooting.

1) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

2) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

Special tool

: 09904–41010 (SUZUKI Diagnostic system set)

: 99565–01010–020 (CD-ROM Ver.20)

NOTE

• Before taking the sample of data, check and clear the Past DTC.

• A number of different data under a fixed condition as shown should be saved or filed as sample.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-17

Sample

Data sampled from cold starting through warm-up

Check the engine r/min.

XXX r/min

Check the engine coolant temperature.

XX ˚C

Check the manifold absolute pressure.

XXX kPa

I947H1110146-01

Data at 3 000 r/min under no load

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Approx. 3 000 r/min

Check the engine coolant temperature.

XX ˚C

Check the manifold absolute pressure.

XXX kPa

I947H1110147-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-18 Engine General Information and Diagnosis:

Data at the time of racing

Throttle: Quick wide open

Throttle: Slowly open

Secondary throttle valve opens closes in according with the throttle valve opening

Data of intake negative pressure during idling (100

°

C)

PAIR control solenoid valve

ON OFF in according with the throttle valve opens closes

I947H1110148-01

Check the manifold absolute pressure.

XXX kPa

Check the engine coolant temperature.

XX ˚C

I947H1110149-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-19

Data of manifold absolute pressure operation at the time of starting

Check the manifold absolute pressure.

XXX kPa

I947H1110150-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-20 Engine General Information and Diagnosis:

Example of Trouble

Three data; value 3 (current data 3), value 1 (past data 1) and value 2 (past data 2); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.

NOTE

With DTC not output, if the engine idling speed and ISC valve stepping position are found to be abnormal than the data saved previously, the possible cause may probably lie in the hardware side such as ISC valve air inlet hose crumple, bend, etc.

Unstable idling speed

Abnormal value of ISC valve position

No DTC output

I947H1110151-02

DTC Table

Code

C00

C11 (P0340)

)

(Page 1A-29)

C12 (P0335)

)

(Page 1A-32)

C13 (P0105-H/L)

)

(Page 1A-35)

C14 (P0120-H/L)

)

(Page 1A-43)

C15 (P0115-H/L)

)

(Page 1A-50)

C21 (P0110-H/L)

)

(Page 1A-55)

C22 (P1450-H/L)

)

(Page 1A-60)

C23 (P1651-H/L)

)

(Page 1A-68)

C24 (P0351)

)

(Page 1A-75)

None

Malfunction Part

Camshaft position sensor (CMPS)

Crankshaft position sensor (CKPS)

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) email: [email protected] / www.motomatrix.co.uk

No defective part

Remarks

Pick-up coil signal, signal generator

*1

For #1 cylinder

B947H11104006

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-21

P0507)

)

(Page 1A-94)

C41 (P0230-H/L,

P2505)

)

(Page 1A-98) /

)

(Page 1A-101)

C42 (P1650)

)

(Page 1A-103)

C44 (P0130,

P0135)

)

(Page 1A-103)

C46 (P1657-H/L,

P1658)

)

(Page 1A-109)

C49 (P1656)

)

(Page 1A-121)

C60 (P0480)

)

(Page 1A-124)

C62 (P0443)

)

(Page 1A-127)

C91 (P0500)

)

(Page 1A-131)

C93 (P1769)

)

(Page 1A-134)

Code

C25 (P0352)

)

(Page 1A-75)

C26 (P0353)

)

(Page 1A-75)

C27 (P0354)

)

(Page 1A-75)

C28 (P1655)

)

(Page 1A-75)

C29 (P1654-H/L)

)

(Page 1A-79)

C31 (P0705)

)

(Page 1A-86)

C32 (P0201)

)

(Page 1A-88)

C33 (P0202)

)

(Page 1A-88)

C34 (P0203)

)

(Page 1A-88)

C35 (P0204)

)

(Page 1A-88)

C36 (P1764)

)

(Page 1A-91)

C37 (P1765)

)

(Page 1A-91)

C38 (P1766)

)

(Page 1A-91)

C39 (P1767)

)

(Page 1A-91)

C40 (P0505/P0506/

Malfunction Part

Ignition signal #2 (IG coil #2)

Ignition signal #3 (IG coil #3)

Ignition signal #4 (IG coil #4)

Secondary throttle valve actuator (STVA)

Secondary throttle position sensor (STPS)

Gear position signal (GP switch)

Primary Injector signal #1

Primary Injector signal #2

Primary Injector signal #3

Primary Injector signal #4

Secondary Injector signal #1

Secondary Injector signal #2

Secondary Injector signal #3

Secondary Injector signal #4

Idle speed control valve (ISC valve)

Fuel pump control system (FP control system),

ECM/PCM power input signal

Ignition switch signal (Anti-theft)

Heated oxygen sensor (HO2S)

Exhaust control valve actuator (EXCVA)

PAIR control solenoid valve

Cooling fan control system

EVAP system purge control solenoid valve

Vehicle speed sensor

Steering damper solenoid valve

For #2 cylinder

For #3 cylinder

For #4 cylinder

For #1 cylinder

For #2 cylinder

For #3 cylinder

For #4 cylinder

For #1 cylinder

For #2 cylinder

For #3 cylinder

For #4 cylinder

Ignition switch for E-03, 14, 28, 33/immobilizer for E-02, 19, 24, 51

Remarks

Fuel pump, fuel pump relay

Cooling fan relay

E-33 only

In the LCD (DISPLAY) panel, the malfunction code is indicated from small code to large code.

*1 To get the proper signal from the throttle position sensor, the sensor basic position is indicated in the LCD

(DISPLAY) panel. The malfunction code is indicated in three digits. In front of the three digits, a line appears in any of the three positions, upper, middle or lower line. If the indication is upper or lower line when engine rpm is 1 200 r/min, slightly turn the throttle position sensor and bring the line to the middle.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-22 Engine General Information and Diagnosis:

Fail-Safe Function Table

B947H11104007

FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.

CMP sensor

IAP sensor

TP sensor

ECT sensor

IAT sensor

AP sensor

STV actuator

STP sensor

HO2 sensor

ISC valve

Item

Ignition signal

Primary injection signal

Secondary injection signal

Gear position signal

PAIR control solenoid valve

EXCV actuator

Fail-Safe Mode

When camshaft position signal has failed during running, the ECM determines the cylinder positions as # to be the same as before occurrence of such a failure.

Intake air pressure value is fixed to 101 KPa

(760 mmHg).

The throttle opening is fixed to full open position.

Ignition timing is also fixed.

Engine coolant temperature value is fixed to

80

°

C (176

°

F).

Cooling fan is fixed on position.

Intake air temperature value is fixed to 40

°

C

(104

°

F).

Atmospheric pressure is fixed to 101 kPa

(760 mmHg).

#1 fuel-cut

(primary side and secondary side)

#2 fuel-cut

(primary side and secondary side)

#3 fuel-cut

(primary side and secondary side)

#4 fuel-cut

(primary side and secondary side)

—

—

—

—

Starting Ability

“NO”

Motorcycle can run, but once engine stops, engine can not start.

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

Running Ability

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

#2, #3 & #4 cylinders can run.

“YES”

#1, #3 & #4 cylinders can run.

“YES”

#1, #2 & #4 cylinders can run.

“YES”

#1, #2 & #3 cylinders can run.

“YES” “YES”

#2, #3 & #4 cylinders can run.

“YES” “YES”

#1, #3 & #4 cylinders can run.

“YES” “YES”

#1, #2 & #4 cylinders can run.

“YES” “YES”

#1, #2 & #3 cylinders can run.

—

—

—

—

— “YES”

#2, #3 & #4 cylinders can run.

— “YES”

#1, #3 & #4 cylinders can run.

— “YES”

#1, #2 & #4 cylinders can run.

— “YES”

#1, #2 & #3 cylinders can run.

Secondary throttle valve is fixed to full close position. When motor disconnection or lock occurs, power from ECM is shut off.

Secondary throttle valve is fixed to full open position.

Gear position signal is fixed to 6th gear.

Feedback compensation is inhibited. (Air/ fuel ratio is fixed to normal.)

ECM stops controlling PAIR control solenoid valve.

EXCV actuator is fixed to full open position.

When motor disconnection or lock occurs, power from ECM is shut off.

When motor disconnection or lock occurs, power from ECM is shut off.

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES”

“YES” email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-23

EVAP system purge control solenoid valve (E-33 only)

Vehicle speed sensor

Steering damper solenoid valve

Item Fail-Safe Mode

ECM stops controlling EVAP system purge control solenoid valve.

ECM stops controlling steering damper solenoid valve.

ECM stops controlling steering damper solenoid valve.

Starting Ability

“YES”

“YES”

“YES”

Running Ability

“YES”

“YES”

“YES”

The engine can start and can run even if the signal in the table is not received from each sensor. But, the engine running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.

When two ignition signals or two injector signals are not received by ECM, the fail-safe circuit can not work and ignition or injection is stopped.

FI System Troubleshooting

B947H11104008

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 following will facilitate collecting information to the point required for proper analysis and diagnosis.

NOTE

This form is a standard sample. The form should be modified according to conditions and characteristic of each market.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name:

Date of issue:

Model:

Date Reg.:

VIN:

Date of problem: Mileage:

Malfunction indicator light condition (LED)

Malfunction display/code

(LCD)

†

Always ON /

†

Sometimes ON /

†

Always OFF /

†

Good condition

User mode:

†

No display /

†

Malfunction display ( )

Dealer mode:

†

No code /

†

Malfunction code ( )

†

†

†

†

†

†

Difficult Starting

No cranking

No initial combustion

No combustion

Poor starting at

(

†

cold /

Other

†

warm /

†

always)

PROBLEM SYMPTOMS

†

Poor Driveability

†

Hesitation on acceleration

†

Back fire /

†

After fire

†

Lack of power

†

Surging

†

Abnormal knocking

†

Engine rpm jumps briefly

†

Other

†

Poor Idling

†

Poor fast Idle

†

Abnormal idling speed

(

†

High /

†

Low) ( r/min)

†

Unstable

†

Hunting ( r/min to r/min)

†

Other

†

OTHERS:

†

Engine Stall when

†

Immediately after start

†

Throttle valve is opened

†

Throttle valve is closed

†

Load is applied

†

Other

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-24 Engine General Information and Diagnosis:

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Weather

Temperature

Frequency

Road

Environmental condition

†

Fair /

†

Cloudy /

†

Rain /

†

Snow /

†

Always /

†

Other

†

Hot /

†

Warm /

†

Cool /

†

Cold (

°

C /

°

F) /

†

Always

†

Always /

†

Sometimes ( times / day, month) /

†

Only once

†

Under certain condition

†

Urban /

†

Suburb /

†

Highway /

†

Mountainous (

†

Uphill /

†

Downhill)

†

Tarmacadam /

†

Gravel /

†

Other

Motorcycle condition

Engine condition

†

Cold /

†

Warming up phase /

†

Warmed up /

†

Always /

†

Other at starting

†

Immediately after start /

†

Racing without load /

†

Engine speed ( r/min)

Motorcycle condition During driving:

†

Constant speed /

†

Accelerating /

†

Decelerating

†

Right hand corner /

†

Left hand corner

†

At stop /

†

Motorcycle speed when problem occurs ( km/h, mile/h)

†

Other:

Visual Inspection

Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.

• Engine oil level and leakage. Refer to “Engine Oil and Filter Replacement” in Section 0B (Page 0B-10).

• Engine coolant level and leakage. Refer to “Cooling Circuit Inspection” in Section 1F (Page 1F-4).

• Fuel level and leakage. Refer to “Fuel Line Inspection” in Section 0B (Page 0B-10).

• Clogged air cleaner element. Refer to “Air Cleaner Element Inspection” in Section 0B (Page 0B-3).

• Battery condition.

• Throttle cable play. Refer to “Throttle Cable Play Inspection and Adjustment” in Section 0B (Page 0B-12).

• Vacuum hose looseness, bend and disconnection.

• Broken fuse.

• FI indicator light operation. Refer to “Combination Meter Inspection” in Section 9C (Page 9C-3).

• Each warning indicator light operation. Refer to “Combination Meter Inspection” in Section 9C (Page 9C-3).

• Speedometer operation. Refer to “Speedometer Inspection” in Section 9C (Page 9C-5).

• Exhaust gas leakage and noise. Refer to “Exhaust System Inspection” in Section 1K (Page 1K-13).

• Each coupler disconnection.

• Clogged radiator fins. Refer to “Radiator Inspection and Cleaning” in Section 1F (Page 1F-5).

email: [email protected]otomatrix.co.uk / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-25

Malfunction Code and Defective Condition Table

Malfunction

Code

C00

C11

Detected Item

NO FAULT

P0340

CMP sensor

C12

P0335

C13

P0105

C14

P0120

C15

P0115

C21

P0110

C22

P1450

H

IAP sensor

L

H

TP sensor

L

H

ECT sensor

L

H

IAT sensor

L

H

AP sensor

L

CKP sensor

B947H11104009

Detected Failure Condition Check For

—

The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

—

CMP sensor wiring and mechanical parts

CMP sensor, intake cam pin, wiring/coupler connection

CKP sensor wiring and mechanical parts

CKP sensor, lead wire/coupler connection

The sensor should produce following voltage.

0.5 V

≤

Sensor voltage < 4.85 V

In other than the above range, C13 (P0105) is indicated.

IAP sensor, lead wire/coupler connection

IAP sensor circuit shorted to

VCC or ground circuit open

IAP sensor circuit open or shorted to ground or VCC circuit open

The sensor should produce following voltage.

0.2 V

≤

Sensor voltage < 4.8 V TP sensor, lead wire/coupler

In other than the above range, C14 (P0120) is indicated.

connection

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

TP sensor circuit shorted to

VCC or ground circuit open

TP sensor circuit open or shorted to ground or VCC circuit open

The sensor voltage should be the following.

0.15 V

≤

Sensor voltage < 4.85 V

In other than the above range, C15 (P0115) is indicated.

ECT sensor, lead wire/coupler connection

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

ECT sensor circuit open or ground circuit open

ECT sensor circuit shorted to ground

The sensor voltage should be the following.

0.15 V

≤

Sensor voltage < 4.85 V

In other than the above range, C21 (P0110) is indicated.

IAT sensor, lead wire/coupler connection

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

IAT sensor circuit open or ground circuit open

IAT sensor circuit shorted to ground

The sensor voltage should be the following.

0.5 V

≤

Sensor voltage < 4.85 V

In other than the above range, C22 (P1450) is indicated.

AP sensor, lead wire/coupler connection

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

AP sensor circuit shorted to

VCC or ground circuit open

AP sensor circuit open or shorted to ground or VCC circuit open email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-26 Engine General Information and Diagnosis:

Malfunction

Code

Detected Item Detected Failure Condition Check For

C23

P1651

C24/C25

C26/C27

P0351/P0352

P0353/P0354

C28

P1655

C29

P1654

C31

P0705

C32/C33

C34/C35

H

L

H

L

P0201/P0202

P0203/P0204

Ignition signal

Primary fuel injector

C36/C37

C38/C39

P1764/P1765

P1766/P1767

Secondary fuel injector

C40/P0505

C40/P0506

C40/P0507

TO sensor

STV actuator

STP sensor

Gear position signal

ISC valve

The sensor voltage should be the following for

2 sec. and more, after ignition switch is turned

ON.

0.2 V

≤

Sensor voltage < 4.8 V

In other than the above value, C23 (P1651) is indicated.

TO sensor, lead wire/coupler connection

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

TO sensor circuit shorted to

VCC or ground circuit open

TO sensor circuit open or shorted to ground or VCC circuit open

CKP sensor (pick-up coil) signal is produced, but signal from ignition coil is interrupted 8 times or more continuously. In this case, the code C24 (P0351), C25 (P0352), C26 (P0353) or C27 (P0354) is indicated.

When no actuator control signal is supplied from the ECM, communication signal does not reach ECM or operation voltage does not reach STVA motor, C28 (P1655) is indicated.

STVA can not operate properly or its motor locked.

The sensor should produce following voltage.

0.15 V

≤

Sensor voltage < 4.85 V

In other than the above range, C29 (P1654) is indicated.

Ignition coil, wiring/coupler connection, power supply from the battery

STVA motor, STVA lead wire/ coupler connection

STP sensor, lead wire/coupler connection

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

STP sensor circuit shorted to

VCC or ground circuit open

STP sensor circuit open or shorted to ground or VCC circuit open

Gear position signal voltage should be higher than the following for 3 seconds and more.

Gear position sensor voltage

≥

0.6 V

If lower than the above value, C31 (P0705) is indicated.

CKP sensor (pickup coil) signal is produced, but fuel injector signal is interrupted 4 times or more continuously. In this case, the code C32

(P0201), C33 (P0202), C34 (P0203) or C35

(P0204) is indicated.

Some failure exists in the fuel injector signal in a high load, high revolution condition. In this case, the code C36 (P1764), C37 (P1765),

C38 (P1766) or C39 (P1767) is indicated.

GP switch, wiring/coupler connection, gearshift cam, etc.

Primary fuel injector, wiring/ coupler connection, power supply to the injector

Secondary fuel injector, wiring/ coupler connection, power supply to the injector

The circuit voltage of motor drive is unusual.

Idle speed is lower than the desired idle speed.

Idle speed is higher than the desired idle speed.

ISC valve circuit open or shorted to ground

Power source circuit open

Air passage clogged

ISC valve is fixed

ISC valve preset position is incorrect

ISC valve hose connection

ISC valve is fixed

ISC valve preset position is incorrect email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-27

Malfunction

Code

C41

P0230

C42

P1650

C46

P1657

P1658

C49

P1656

C60

P0480

C62

P0443

H

L

C41/P2505

C44/P0130

C44/P0135

H

L

Detected Item Detected Failure Condition Check For

FP relay

ECM/PCM power input signal

Ignition switch

HO2 sensor

EXCV actuator

PAIR control solenoid valve

Cooling fan relay

EVAP system purge control solenoid valve

(E-33 only)

No voltage is applied to the fuel pump, although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF.

Voltage is applied to fuel pump although fuel pump relay is turned OFF.

Fuel pump relay, lead wire/ coupler connection, power source to fuel pump relay and fuel injectors

Fuel pump relay switch circuit shorted to power source

Fuel pump relay (switch side)

Fuel pump relay circuit open or

No voltage is applied to the fuel pump, although fuel pump relay is turned ON.

No voltage is applied to the ECM.

short

Fuel pump relay (coil side)

Lead wire/coupler connection of ECM terminal to fuel fuse

Ignition switch signal is not input to the ECM.

* When the I.D. agreement is not verified.

* ECM does not receive communication signal from the immobilizer antenna.

Ignition switch, lead wire/ coupler, etc.

* Immobilizer/anti-theft system

HO2 sensor output voltage is not input to ECM during engine operation and running condition.

(Sensor voltage > 1.0 V)

C44 (P0130) is indicated.

HO2 sensor is circuit open or shorted to the power source

The Heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit, C44 (P0135) is indicated.

Heated circuit open or shorted to ground

Battery voltage supply to the

HO2 sensor

EXCVA position sensor produces following voltage.

0.14 V

≤

sensor voltage < 4.9 V

In other than the above range, C46 (P1675) is indicated.

When no actuator control signal is supplied from the ECM, communication signal does not

EXCVA, EXCVA lead wire/ coupler reach ECM or operation voltage does not reach EXCVA motor, C46 (P1658) is indicated. EXCVA can not operate.

EXCVA position sensor voltage is higher than specified value.

EXCVA position sensor voltage is lower than specified value.

EXCVA position sensor circuit shorted to VCC or ground circuit open

EXCVA position sensor circuit open or shorted to ground or

VCC circuit open

When no operation voltage reaches EXCVA motor, C46 (P1658) is indicated. EXCVA

EXCVA, EXCVA motor lead wire/coupler motor can not be operated.

PAIR control solenoid valve voltage is not input to ECM.

Cooling fan relay signal is not input to ECM.

EVAP system purge control solenoid valve voltage is not input to ECM.

PAIR control solenoid valve, lead wire/coupler connection

Cooling fan relay, lead wire/ coupler connection

EVAP system purge control solenoid valve, lead wire/ coupler connection email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-28 Engine General Information and Diagnosis:

Malfunction

Code

C91

P0500

C93

P1769

H

L

Detected Item

Vehicle speed sensor

Steering damper solenoid valve

Detected Failure Condition Check For

Speedometer does not receive signal from the vehicle speed sensor for more than 6 sec. when the motorcycle is running.

ECM does not receive signal from the vehicle speed sensor for more than 6 sec. when the motorcycle is running.

Failure in communication between ECM and speedometer with reference to vehicle speed.

Steering damper control current does not flow to the solenoid valve.

With IG turned ON, ECM detects a failure of internal circuit element. Solenoid current does not converge to the target value. Battery voltage is 10 V or below with the engine running.

Steering damper control current is higher than specified value.

An abnormal current is detected during the vehicle standstill. Solenoid current is 0.7 A or above.

Steering damper control current is lower than specified value.

With IG turned ON, ECM detects a discontinuity. An abnormal current is detected during the vehicle standstill.

Speed sensor and speedometer wiring/coupler connection between ECM and speedometer

Steering damper solenoid valve circuit interrupter element shorted, feedback current convergence failure, low battery voltage

Steering damper solenoid valve circuit shorted to VCC

Steering damper solenoid valve circuit open or shorted

* : Immobilizer system equipped model only. (E-02, 19, 24, 51) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-29

DTC “C11” (P0340): CMP Sensor Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

Possible Cause

• CMP sensor circuit open or short.

• CMP sensor malfunction.

• ECM malfunction.

B947H11104010

Wiring Diagram

ECM

CMP sensor

Bl/Y

W

B/Bl

R

B/Y

B/Br

7

8

VCC

CMPS

35

E2

I837H1110006-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a

needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-30 Engine General Information and Diagnosis:

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Remove the air cleaner box. Refer to “Air Cleaner Box

Removal and Installation” in Section 1D (Page 1D-7).

4) Check the CMP sensor coupler (1) for loose or poor contacts.

If OK, remove the CMP sensor. Refer to “CMP Sensor

Removal and Installation” in Section 1C (Page 1C-2).

1

• B/Y, R or B/Br wire open or shorted to ground.

Yes No

• Inspect that metal particles or foreign material stuck on the

CMP sensor and camshaft tip.

• Loose or poor contacts on the CMP sensor coupler or

ECM coupler

(Terminal “7”, “8” or

“35”).

• If wires and connection are OK, intermittent trouble or faulty ECM.

• If there are no metal particles and foreign material, then replace the CMP sensor with a new one.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

I947H1110010-01

5) Connect 3 new 1.5 V batteries in series, 1 k

Ω

resistor and the multi-circuit tester as shown in the figure.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

(–) (+)

W

1 k

Ω

Bl/Y

B/Bl

I823H1110005-04 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-31

Step Action

1 6) Under this condition, if a suitable screwdriver touching the pick-up surface of the CMP sensor is moved, the tester reading voltage changes (0.8 V and less

↔

4.3 V and more).

• B/Y, R or B/Br wire open or shorted to ground.

Yes No

• Inspect that metal particles or foreign material stuck on the

CMP sensor and camshaft tip.

• Loose or poor contacts on the CMP sensor coupler or

ECM coupler

(Terminal “7”, “8” or

“35”).

• If wires and connection are OK, intermittent trouble or faulty ECM.

• If there are no metal particles and foreign material, then replace the CMP sensor with a new one.

Is the voltage OK?

I823H1110007-01

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-32 Engine General Information and Diagnosis:

DTC “C12” (P0335): CKP Sensor Circuit Malfunction

B947H11104011

Detected Condition and Possible Cause

Detected Condition

The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

Possible Cause

• Metal particles or foreign material being stuck on the

CKP sensor and rotor tip.

• CKP sensor circuit open or short.

• CKP sensor malfunction.

• ECM malfunction.

Wiring Diagram

ECM

CKP sensor

B

Bl/Y

G/W

G/BI

9 CKP

21

CKP

I947H1110011-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-33

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the CKP sensor coupler (1) for loose or poor contacts.

If OK, then measure the CKP sensor resistance.

Yes

Go to Step 2.

No

Replace the CKP sensor with a new one.

1

I947H1110012-01

4) Disconnect the CKP sensor coupler and measure the

CKP sensor resistance.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

CKP sensor resistance

142 – 194

Ω

(B – Bl/Y)

(A)

I947H1110013-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-34 Engine General Information and Diagnosis:

Step Action

1 5) If OK, then check the continuity between each terminal and ground.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

CKP sensor continuity

∞ Ω

(Infinity) (B – Ground, Bl/Y– Ground)

No

Replace the CKP sensor with a new one.

(A)

I947H1110014-01

Are the resistance and continuity OK?

2 1) Crank the engine several seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

CKP sensor peak voltage

0.5 V and more

((+) terminal: B – (–) terminal: Bl/Y)

(A)

Peakvolt adaptor

V

• B or Bl/Y wire of the harness side open or shorted to ground.

• Loose or poor contacts on the CKP sensor coupler or

ECM coupler

(Terminal “9” or “21”).

• If the wires and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Inspect that metal particles or foreign material stuck on the

CKP sensor and rotor tip.

• If there are no metal particles and foreign material, then replace the CKP sensor with a new one. Refer to

“CKP Sensor

Removal and

Installation” in

Section 1C

(Page 1C-2).

I947H1110015-01

2) Repeat the 1) test procedures several times and measure the highest peak voltage.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

Is the voltage OK?

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-35

DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

IAP sensor voltage is not within the following range.

0.5 V

≤

Sensor voltage < 4.85 V

C13

NOTE

Note that atmospheric pressure varies depending on weather conditions as well as altitude.

Take that into consideration when inspecting voltage.

B947H11104012

Possible Cause

• Clogged vacuum passage between throttle body and

IAP sensor.

• Air being drawn from vacuum passage between throttle body and IAP sensor.

• IAP sensor circuit open or shorted to ground.

• IAP sensor malfunction.

• ECM malfunction.

P0105

H

L

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

Wiring Diagram

• IAP sensor circuit is open or shorted to VCC or ground circuit open.

• IAP sensor circuit is shorted to ground or VCC circuit open.

ECM

IAP sensor

G/B

B/Br

R

19

35

7

IAPS

E2

VCC

I837H1110010-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-36 Engine General Information and Diagnosis:

C13 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the IAP sensor coupler (1) for loose or poor contacts.

If OK, then measure the IAP sensor input voltage.

Yes

Go to Step 3.

No

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the R or B/Br wire.

1

I947H1110016-01

4) Disconnect the IAP sensor coupler.

5) Turn the ignition switch ON.

6) Measure the input voltage between the R wire and ground.

If OK, then measure the voltage between the R wire and

B/Br wire.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

IAP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

(A)

V

I823H1110016-05

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-37

P0105-H for IAP sensor (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the IAP sensor coupler (1) for loose or poor contacts.

If OK, then check the IAP sensor lead wire continuity.

Yes

Go to Step 3.

No

G/B wire shorted to

VCC, or B/Br wire open.

1

I947H1110017-01

4) Disconnect the IAP sensor coupler.

5) Check the continuity between the R wire and G/B wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

(A)

I823H1110017-05

6) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

7) Insert the needle pointed probes to the lead wire coupler.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-38 Engine General Information and Diagnosis:

Step Action

1 Check the continuity between the G/B wire and terminal

“19”.

If OK, then check the continuity between the B/Br wire and terminal “35”.

Yes

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

No

G/B wire shorted to

VCC, or B/Br wire open.

(A)

?

(B)

“19”

(Black)

Is the continuity OK?

“35”

(Gray)

I837H1110017-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-39

P0105-L for IAP sensor (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the IAP sensor coupler (1) for loose or poor contacts.

If OK, then check the IAP sensor lead wire continuity.

Yes

Go to Step 2.

No

R and G/B wire open, G/

B wire shorted to ground.

1

I947H1110018-01

4) Disconnect the IAP sensor coupler.

5) Check the continuity between the G/B wire and ground.

Also, check the continuity between the G/B wire and B/

Br wire. If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

(A)

I823H1110019-02

6) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

7) Insert the needle pointed probes to the lead wire coupler.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-40 Engine General Information and Diagnosis:

Step Action

1 Check the continuity between the R wire and terminal

“7”. Also, check the continuity between the G/B wire and terminal “19”.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity ( )

ECM couplers (Harness side)

No

R and G/B wire open, G/

B wire shorted to ground.

?

(A)

(B)

“19”

“7”

(Black) (Gray)

I837H1110019-02

Is the continuity OK?

2 1) Connect the ECM couplers.

2) Turn the ignition switch ON.

3) Measure the input voltage between the R wire and ground.

If OK, then measure the voltage between the R wire and

B/Br wire.

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

IAP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the R or B/Br wire.

(A)

V

I823H1110016-05

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-41

Step Action

3 1) Turn the ignition switch OFF.

2) Connect the ECM couplers and IAP sensor coupler.

3) Insert the needle pointed probes to the lead wire coupler.

4) Run the engine at idle speed and measure the IAP sensor output voltage between the G/B wire and B/Br wire.

Yes

Go to Step 4.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

IAP sensor output voltage

Approx. 2.7 V at idle speed

((+) terminal: G/B – (–) terminal: B/Br)

• Check the vacuum hose for crack or damage.

No

• Open or short circuit in the G/B wire.

• If vacuum hose and wire are OK, replace the IAP sensor with a new one. Refer to

“IAP Sensor Removal and Installation” in

Section 1C

(Page 1C-2).

(A)

V

(B)

I947H1110020-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-42 Engine General Information and Diagnosis:

Step Action

4 1) Turn the ignition switch OFF.

2) Remove the IAP sensor. Refer to “IAP Sensor Removal and Installation” in Section 1C (Page 1C-2).

3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor.

Yes

• G/B, R or B/Br wire open or shorted to ground, or poor “19”,

“7” or “35” connection.

4) Arrange 3 new 1.5 V batteries (1) in series (check that total voltage is 4.5 – 5.0 V) and connect (–) terminal to the ground terminal “B” and (+) terminal to the VCC terminal “A”.

• If wire and connection are OK, intermittent trouble or faulty ECM.

5) Check the voltage between Vout terminal “C” and ground. Also, check if voltage reduces when vacuum is applied by using vacuum pump gauge.

Special tool

(A): 09917–47011 (Vacuum pump gauge set)

(B): 09900–25008 (Multi circuit tester set)

• Recheck each terminal and wire harness for open circuit and poor connection.

Tester knob indication

Voltage ( )

“C”

“B”

(A)

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

No

If check result is not satisfactory, replace the

IAP sensor with a new one. Refer to “IAP

Sensor Removal and

Installation” in Section

1C (Page 1C-2).

“A”

(B)

1

I718H1110030-02

ALTITUDE (Reference) m

0 – 610

611 – 1 524

1 525 – 2 438

2 439 – 3 048 ft

0 – 2 000

2 001 – 5 000

5 001 – 8 000

8 001 – 10 000

ATOMOSPHERIC

PRESSURE kPa mmHg

100 – 94

94 – 85

85 – 76

76 – 70

760 – 707

707 – 634

634 – 567

567 – 526

OUTPUT

VOLTAGE

V

3.1 – 3.6

2.8 – 3.4

2.6 – 3.1

2.4 – 2.9

I823H1110023-02

Is the voltage OK?

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DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction

B947H11104013

Detected Condition and Possible Cause

C14

P0120

H

L

Detected Condition

Output voltage is not within the following range.

Difference between actual throttle opening

Possible Cause

• TP sensor maladjusted.

• TP sensor circuit open or short.

• TP sensor malfunction.

and opening calculated by ECM is larger than specified value.

0.2 V

≤

Sensor voltage < 4.8 V

• ECM malfunction.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

• TP sensor circuit is shorted to VCC or ground circuit is open.

• TP sensor circuit is open or shorted to ground or VCC circuit is open.

Wiring Diagram

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-43

ECM

TP sensor

R

P/B

B/Br

P/B

6

TPS

R

B/Br

7

35

VCC

E2

I947H1110117-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-44 Engine General Information and Diagnosis:

C14 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the TP sensor couplers (1) and (2) for loose or poor contacts.

If OK, then measure the TP sensor input voltage.

Yes

Go to Step 3.

No

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the R wire or B/Br wire.

2

1

I947H1110021-02

4) Disconnect the TP sensor coupler (1).

5) Turn the ignition switch ON.

6) Measure the input voltage between the R wire and ground. Also, measure the voltage between the R wire and B/Br wire.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

TP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

(A)

V

I947H1110045-01

Is the voltage OK?

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-45

P0120-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the TP sensor couplers (1) and (2) for loose or poor contacts.

If OK, then check the TP sensor lead wire continuity.

Yes

Go to Step 3.

No

P/B wire shorted to

VCC, or B/Br wire open.

2

1

I947H1110022-02

4) Disconnect the TP sensor couplers (1) and (2).

5) Check the continuity between the P/B wire and R wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

(A)

I947H1110118-01

6) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-46 Engine General Information and Diagnosis:

Step Action

1 7) Check the continuity between the P/B wire and terminal

“6”. Also, check the continuity between the B/Br wire and terminal “35”.

Yes

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

No

P/B wire shorted to

VCC, or B/Br wire open.

?

(A)

(B)

“6”

“35”

Is the continuity OK?

(Black) (Gray)

I947H1110119-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-47

P0120-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the TP sensor couplers (1) and (2) for loose or poor contacts.

If OK, then check the TP sensor lead wire continuity.

Yes

Go to Step 2.

No

R or P/B wire open, or

Y/W wire shorted to ground.

2

1

I947H1110023-02

4) Disconnect the TP sensor couplers (1) and (2).

5) Check the continuity between the P/B wire and ground.

Also, check the continuity between the P/B wire and B/Br wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

(A)

I947H1110120-01

6) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-48 Engine General Information and Diagnosis:

Step Action

1 7) Check the continuity between the P/B wire and terminal

“6”. Also, check the continuity between the R wire and terminal “7”.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

No

R or P/B wire open, or

Y/W wire shorted to ground.

?

(A)

(B)

“6”

“7”

(Black) (Gray)

I947H1110121-02

Is the continuity OK?

2 1) Connect the ECM couplers.

2) Turn the ignition switch ON.

3) Measure the input voltage between the R wire and ground. Also, measure the input voltage between the R wire and B/Br wire.

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

TP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

(A)

V

Open or short circuit in the R or B/Br wire.

I947H1110122-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-49

Step Action

3 1) Turn the ignition switch OFF.

2) Connect the ECM couplers and TP sensor couplers.

3) Insert the needle point probes to the lead wire coupler.

4) Turn the ignition switch ON.

5) Measure the TP sensor output voltage between the P/B wire (+) and B/Br wire (–) with turning the throttle grip open and close.

Yes

• P/B, R or B/Br wire open or shorted to ground, or poor “6”,

“7” or “35” connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

No

If check result is not satisfactory, replace TP sensor with a new one.

Refer to “Throttle Body

Disassembly and

Assembly” in Section

1D (Page 1D-11).

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

• Recheck each terminal and wire harness for open circuit and poor connection.

TP sensor output voltage

Throttle valve is closed: Approx. 1.1 V

Throttle valve is opened: Approx. 4.4 V

((+) terminal: P/B – (–) terminal: B/Br)

V

(A)

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

(B)

I947H1110123-01

Is the voltage OK?

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-50 Engine General Information and Diagnosis:

DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction

B947H11104014

Detected Condition and Possible Cause

C15

Detected Condition

Output voltage is not with in the following range.

0.15 V

≤

Sensor voltage < 4.85 V

P0115

H

L

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

Possible Cause

• ECT sensor circuit open or short.

• ECT sensor malfunction.

• ECM malfunction.

• ECT sensor circuit is open or ground circuit open.

• ECT sensor circuit shorted to ground.

Wiring Diagram

ECT sensor

ECM

B/BI

B/Br

32 ECTS

35

E2

I837H1110027-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-51

C15 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the ECT sensor coupler (1) for loose or poor contacts.

If OK, then measure the ECT sensor input voltage.

Yes

Go to Step 2.

No

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the B/Bl or B/Br wire.

1

I947H1110114-01

4) Disconnect the ECT coupler and turn the ignition switch

ON.

5) Measure the input voltage between the B/Bl wire and ground.

If OK, then measure the input voltage between the B/Bl wire and B/Br wire.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

ECT sensor input voltage

4.5 – 5.5 V

((+) terminal: B/Bl – (–) terminal: Ground, (+) terminal: B/Bl – (–) terminal: B/Br)

(A)

I718H1110048-03

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-52 Engine General Information and Diagnosis:

P0115-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the ECT sensor coupler (1) for loose or poor contacts.

If OK, then check the ECT sensor lead wire continuity.

Yes

Go to Step 2.

No

B/Bl or B/Br wire open.

1

I947H1110115-01

4) Disconnect the ECT sensor coupler.

5) Disconnect the ECM coupler. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

6) Insert the needle pointed probes to the lead wire coupler.

7) Check the continuity between the B/Bl wire and terminal

“32”. Also, check the continuity between the B/Br wire and terminal “35”.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

(A)

?

(B)

“32”

(Black)

Is the continuity OK?

“35”

(Gray)

I837H1110030-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-53

P0115-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the ECT sensor coupler (1) for loose or poor contacts.

If OK, then check the ECT sensor lead wire continuity.

Yes

Go to Step 2.

No

• B/Bl wire shorted to ground.

• If wire is OK, go to

Step 2.

1

I947H1110116-01

4) Disconnect the ECT sensor coupler.

5) Check the continuity between the B/Bl wire and ground.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

(A)

I718H1110054-03

6) Connect the ECT sensor coupler.

7) Insert the needle pointed probes to the lead wire coupler.

Turn the ignition switch ON.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-54 Engine General Information and Diagnosis:

Step Action

1 9) Measure the output voltage between the B/Bl wire and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

ECT sensor output voltage

0.15 – 4.85 V

((+) terminal: B/Bl – (–) terminal: Ground)

Yes

Go to Step 2.

No

• B/Bl wire shorted to ground.

• If wire is OK, go to

Step 2.

V

(A)

(B)

I947H1110024-01

Are the continuity and voltage OK?

2 1) Turn the ignition switch OFF.

2) Disconnect the ECT sensor coupler.

3) Measure the ECT sensor resistance.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

ECT sensor resistance

Approx. 2.45 k

Ω

at 20

°

C (68

°

F)

(Terminal – Terminal)

(A)

• B/Bl or B/Br wire open or shorted to ground, or poor “32” or “35” connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

Replace the ECT sensor with a new one.

Refer to “ECT Sensor

Removal and

Installation” in Section

1C (Page 1C-4).

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

I947H1110025-01

NOTE

Refer to “ECT Sensor Inspection” in Section 1C

(Page 1C-4) for details.

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-55

DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction

B947H11104015

Detected Condition and Possible Cause

C21

Detected Condition

Output voltage is not with in the following range.

0.15 V

≤

Sensor voltage < 4.85 V

P0110

H

L

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

Possible Cause

• IAT sensor circuit open or short.

• IAT sensor malfunction.

• ECM malfunction.

• IAT sensor circuit open or ground circuit open.

• IAT sensor circuit shorted to ground.

Wiring Diagram

IAT sensor

ECM

Dg

B/Br

Dg

B/Br

33 IATS

35

E2

I947H1110124-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-56 Engine General Information and Diagnosis:

C21 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Move the air cleaner box upward. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D (Page 1D-

7).

4) Check the IAT sensor coupler (1) for loose or poor contacts.

If OK, then measure the IAT sensor input voltage.

Yes

Go to Step 2.

No

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the Dg or B/Br wire.

1

I947H1110026-01

5) Disconnect the IAT sensor coupler and turn the ignition switch ON.

6) Measure the input voltage between the Dg wire terminal and ground.

If OK, then measure the input voltage between the Dg wire terminal and B/Br wire terminal.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

IAT sensor input voltage

4.5 – 5.5 V

((+) terminal: Dg – (–) terminal: Ground, (+) terminal:

Dg – (–) terminal: B/Br)

V

(A)

I823H1110040-03

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-57

P0110-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Move the air cleaner box upward. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D (Page 1D-

7).

4) Check the IAT sensor coupler (1) for loose or poor contacts.

If OK, then check the IAT sensor lead wire continuity.

Yes

Connect the ECM coupler and go to Step

2.

No

Dg or B/Br wire open.

1

I947H1110027-01

5) Disconnect the IAT sensor coupler.

6) Disconnect the ECM coupler. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

7) Insert the needle pointed probes to the lead wire coupler.

Check the continuity between the Dg wire and terminal

“33”. Also, check the continuity between the B/Br wire and terminal “35”.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

(A)

?

(B)

“33”

“35”

(Black)

Is the continuity OK?

(Gray)

I837H1110037-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-58 Engine General Information and Diagnosis:

P0110-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Move the air cleaner box upward. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D (Page 1D-

7).

4) Check the IAT sensor coupler (1) for loose or poor contacts.

If OK, then check the IAT sensor lead wire continuity.

Yes

Go to Step 2.

No

• Dg wire shorted to ground.

• If wire is OK, go to

Step 2.

1

I947H1110028-01

5) Disconnect the IAT sensor coupler.

6) Check the continuity between the Dg wire and ground. If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

(A)

I823H1110042-03

7) Connect the IAT sensor coupler.

Turn the ignition switch ON.

9) Insert the needle pointed probes to the lead wire coupler.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-59

Step Action

1 10) Measure the output voltage between the Dg wire and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

IAT sensor output voltage

0.15 – 4.85 V

((+) terminal: Dg – (–) terminal: Ground)

Yes

Go to Step 2.

No

• Dg wire shorted to ground.

• If wire is OK, go to

Step 2.

(A)

V

(B)

(A)

I947H1110029-01

Are the continuity and voltage OK?

2 1) Turn the ignition switch OFF.

2) Remove the air cleaner box. Refer to “Air Cleaner Box

Removal and Installation” in Section 1D (Page 1D-7).

3) Measure the IAT sensor resistance.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

IAT sensor resistance

Approx. 2.58 k

Ω

at 20

°

C (68

°

F)

(Terminal – Terminal)

• Dg or B/Br wire open or shorted to ground, or poor “33” or “35” connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

Replace the IAT sensor with a new one. Refer to

“IAT Sensor Removal and Installation” in

Section 1C (Page 1C-

5).

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

I815H1110031-01

NOTE

IAT sensor resistance measurement method is the same way as that of the ECT sensor. Refer to

“ECT Sensor Inspection” in Section 1C

(Page 1C-4).

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-60 Engine General Information and Diagnosis:

DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

AP sensor voltage is not within the following range.

0.5 V

≤

Sensor voltage < 4.85 V

Possible Cause

• Clogged vacuum passage with dust.

• AP sensor circuit open or shorted to ground.

• AP sensor malfunction.

• ECM malfunction.

C22

NOTE

Note that atmospheric pressure varies depending on weather conditions as well as altitude.

Take that into consideration when inspecting voltage.

B947H11104016

P1450

H

L

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

Wiring Diagram

• AP sensor circuit is open or shorted to VCC or ground circuit open.

• AP sensor circuit is shorted to ground or VCC circuit open.

ECM

AP sensor

G/Y

B/Br

R

20

35

7

APS

E2

VCC

I837H1110040-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-61

C22 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

Yes

Go to Step 3.

3) Remove the starter relay from the bracket.

4) Check the AP sensor coupler (1) for loose or poor contacts.

If OK, then measure the AP sensor input voltage.

No

• Loose or poor contacts on the ECM couplers.

• Open or short circuit in the R or B/Br wire.

1

I947H1110030-01

5) Disconnect the AP sensor coupler.

6) Turn the ignition switch ON.

7) Measure the input voltage between the R wire and ground.

If OK, then measure the voltage between the R wire and

B/Br wire.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

AP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

(A)

V

I823H1110016-05

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-62 Engine General Information and Diagnosis:

P1450-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

Yes

Go to Step 3.

3) Remove the starter relay from the bracket.

4) Check the AP sensor coupler (1) for loose or poor contacts.

If OK, then check the AP sensor lead wire continuity.

No

G/Y wire shorted to

VCC, or B/Br wire open.

1

I947H1110031-01

5) Disconnect the AP sensor coupler.

6) Check the continuity between the R wire and G/Y wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

(A)

I823H1110017-05

7) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

Insert the needle pointed probes to the lead wire coupler.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-63

Step Action

1 9) Check the continuity between the G/Y wire and terminal

“20”.

If OK, then check the continuity between the B/Br wire and terminal “35”.

Yes

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM coupler (Harness side)

No

G/Y wire shorted to

VCC, or B/Br wire open.

(A)

?

(B)

“20”

“35”

(Black)

Is the continuity OK?

(Gray)

I837H1110043-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-64 Engine General Information and Diagnosis:

P1450-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

Yes

Go to Step 2.

3) Remove the starter relay from the bracket.

4) Check the AP sensor coupler (1) for loose or poor contacts.

If OK, then check the AP sensor lead wire continuity.

No

R and G/Y wire open, G/

Y wire shorted to ground.

1

I947H1110032-01

5) Disconnect the AP sensor coupler.

6) Check the continuity between the G/Y wire and ground.

Also, check the continuity between the G/Y wire and B/

Br wire. If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

(A)

I823H1110019-02

7) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

Insert the needle pointed probes to the lead wire coupler.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-65

Step Action

1 9) Check the continuity between the R wire and terminal

“7”. Also, check the continuity between the G/Y wire and terminal “20”.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity ( )

ECM coupler (Harness side)

No

R and G/Y wire open, G/

Y wire shorted to ground.

(A)

?

(B)

“20”

“7”

(Black) (Gray)

I837H1110045-02

Is the continuity OK?

2 1) Connect the ECM couplers.

2) Turn the ignition switch ON.

3) Measure the input voltage between the R wire and ground.

If OK, then measure the voltage between the R wire and

B/Br wire.

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

AP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

• Loose or poor contacts on the ECM couplers.

• Open or short circuit in the R or B/Br wire.

(A)

V

I823H1110016-05

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-66 Engine General Information and Diagnosis:

Step Action

3 1) Turn the ignition switch OFF.

2) Connect the ECM couplers and AP sensor coupler.

3) Insert the needle pointed probes to the lead wire coupler.

4) Run the engine at idle speed and measure the AP sensor output voltage between the G/Y wire and B/Br wire.

Yes

Go to Step 4.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

AP sensor output voltage

Approx. 3.6 V at 100 kPa (760 mmHg)

((+) terminal: G/Y – (–) terminal: B/Br)

No

• Check the vacuum port for crack or damage.

• Open or short circuit in the G/Y wire.

• If vacuum hose and lead wire are OK, replace the AP sensor with a new one. Refer to “AP

Sensor Removal and

Installation” in

Section 1C

(Page 1C-5).

V

(A)

Is the voltage OK?

(B)

I947H1110033-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-67

Step Action

4 1) Turn the ignition switch OFF.

2) Remove the AP sensor. Refer to “AP Sensor Removal and Installation” in Section 1C (Page 1C-5).

3) Connect the vacuum pump gauge to the vacuum port of the AP sensor.

Yes

• G/Y, R or B/Br wire open or shorted to ground, or poor “7”,

“20” or “35” connection.

4) Arrange 3 new 1.5 V batteries in series (1) (check that total voltage is 4.5 – 5.0 V) and connect (–) terminal to the ground terminal “B” and (+) terminal to the VCC terminal “A”.

• If wire and connection are OK, intermittent trouble or faulty ECM.

5) Check the voltage between Vout terminal “C” and ground. Also, check if voltage reduces when vacuum is applied up to 53 kPa (400 mmHg) by using vacuum pump gauge.

• Recheck each terminal and wire harness for open circuit and poor connection.

Special tool

(A): 09917–47011 (Vacuum pump gauge set)

(B): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

“C”

“B”

(A)

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

No

If check result is not satisfactory, replace the

AP sensor with a new one. Refer to “AP

Sensor Removal and

Installation” in Section

1C (Page 1C-5).

“A”

(B)

1

I718H1110030-02

ALTITUDE (Reference) m

0 – 610

611 – 1 524

1 525 – 2 438

2 439 – 3 048 ft

0 – 2 000

2 001 – 5 000

5 001 – 8 000

8 001 – 10 000

ATOMOSPHERIC

PRESSURE kPa mmHg

100 – 94

94 – 85

85 – 76

76 – 70

760 – 707

707 – 634

634 – 567

567 – 526

OUTPUT

VOLTAGE

V

3.1 – 3.6

2.8 – 3.4

2.6 – 3.1

2.4 – 2.9

I823H1110023-02

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-68 Engine General Information and Diagnosis:

DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction

B947H11104017

Detected Condition and Possible Cause

C23

P1651

H

L

Detected Condition

The sensor voltage should be the

Sensor voltage is higher than specified value.

Possible Cause

• TO sensor circuit open or short.

following for 2 sec. and more, after ignition

• TO sensor malfunction.

switch is turned ON.

0.2 V

≤

Sensor voltage < 4.8 V

• ECM malfunction.

• TO sensor circuit is open or ground circuit open.

Sensor voltage is lower than specified value.

• TO sensor circuit is open or shorted to ground or VCC circuit open.

Wiring Diagram

ECM

TO sensor

R 7 VCC

B

B/Br

31 TOS

35 E2

I837H1110047-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-69

C23 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

Yes

Go to Step 2.

3) Remove the AP sensor from the bracket.

4) Check the TO sensor coupler (1) for loose or poor contacts.

If OK, then measure the TO sensor resistance.

No

Replace the TO sensor with a new one. Refer to

“TO Sensor Removal and Installation” in

Section 1C (Page 1C-

6).

1

I947H1110034-01

5) Remove the TO sensor.

6) Measure the resistance between terminal “A” and terminal “C”.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

TO sensor resistance

16.5 – 22.3 k

Ω

(Terminal “A” – Terminal “C”)

(A)

Is the resistance OK?

“C” “A”

I837H1110049-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-70 Engine General Information and Diagnosis:

P1651-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

Yes

Go to Step 2.

3) Check the TO sensor coupler (1) for loose or poor contacts.

If OK, then check the TO sensor lead wire continuity.

No

B wire shorted to VCC, or B/Br wire open.

1

I947H1110035-01

4) Disconnect the TO sensor coupler.

5) Check the continuity between the R wire and B wire. If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

(A)

I823H1110051-01

6) Disconnect the ECM coupler. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

7) Insert the needle pointed probes to the lead wire coupler.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-71

Step Action

1 Check the continuity between the B wire and terminal

“31”. Also, check the continuity between B/Br wire and terminal “35”.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM coupler (Harness side)

Yes

Go to Step 2.

No

B wire shorted to VCC, or B/Br wire open.

(A)

?

(B)

“31”

(Black)

“35”

Is the continuity OK?

(Gray)

I837H1110051-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-72 Engine General Information and Diagnosis:

P1651-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

Yes

Go to Step 2.

3) Check the TO sensor coupler (1) for loose or poor contacts.

If OK, then check the TO sensor lead wire continuity.

No

R or B wire open, or B wire shorted to ground.

1

I947H1110036-01

4) Disconnect the TO sensor coupler.

5) Check the continuity between the B wire and ground.

Also, check the continuity between the B wire and B/Br wire. If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

(A)

I823H1110053-02

6) Disconnect the ECM coupler. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

7) Insert the needle pointed probes to the lead wire coupler.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-73

Step Action

1 Check the continuity between the R wire and terminal

“7”. Also, then check the continuity between B wire and terminal “31”.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM coupler (Harness side)

No

R or B wire open, or B wire shorted to ground.

(A)

?

(B)

“7”

(Black)

Is the continuity OK?

“31”

(Gray)

I837H1110053-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-74 Engine General Information and Diagnosis:

Step Action

2 1) Connect the ECM coupler and TO sensor coupler.

2) Insert the needle pointed probes to the lead wire coupler.

3) Turn the ignition switch ON.

Yes

• R, B or B/Br wire open or shorted to ground, or poor “7”,

“31” or “35”

4) Measure the voltage at the wire side coupler between B wire and B/Br wire.

connection.

• If wire and connection are OK,

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

intermittent trouble or faulty ECM.

Tester knob indication

Voltage ( )

TO sensor voltage (Normal)

0.4 – 1.4 V

((+) terminal: B – (–) terminal: B/Br)

• Recheck each terminal and wire harness for open circuit and poor connection.

coupler.

No

• Loosen or poor contacts on the ECM

• Open or short circuit.

• Replace the TO sensor with a new one. Refer to “TO

Sensor Removal and

Installation” in

Section 1C

(Page 1C-6).

(A)

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

(B)

I947H1110037-02

5) Dismount the TO sensor from its bracket and measure the voltage when it is leaned 65

°

and more, left and right, from the horizontal level.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

TO sensor voltage (Leaning)

3.7 – 4.4 V

((+) terminal: B – (–) terminal: B/Br)

(A)

(B)

I947H1110038-01

Is the voltage OK?

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DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction

B947H11104018

NOTE

Refer to “No Spark or Poor Spark” in Section 1H (Page 1H-5) for details.

DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction

Detected Condition and Possible Cause

Detected Condition

The operation voltage does not reach the STVA.

ECM does not receive communication signal from the

STVA. STVA can not operate properly or its motor locked.

Possible Cause

• STVA malfunction.

• STVA circuit open or short.

• STVA motor malfunction.

B947H11104019

Wiring Diagram

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-75

STVA

B

P

G

W/B

B/Lg

P/W

G

W/B

ECM

28

4

27

3

STVA. 1B

STVA. 1A

STVA. 2B

STVA. 2A

I947H1110039-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-76 Engine General Information and Diagnosis:

Step Action

1 1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

2) Remove the air cleaner box cover. Refer to “Air Cleaner

Element Removal and Installation” in Section 1D

(Page 1D-6).

Yes

Go to Step 2.

3) Check the STVA lead wire coupler (1) for loose or poor contacts.

No

• Loose or poor contacts on the STVA coupler.

• Open or short circuit in the B/Lg, P/W, G or

W/B wire.

• If wire and connection are OK, go to Step 2.

1

I947H1110040-01

4) Check whether the STVs open by turning the ignition switch ON.

I947H1110127-01

Is the operation OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-77

Step Action

2 1) Turn the ignition switch OFF.

2) Disconnect the STVA lead wire coupler.

3) Check the continuity between each terminal and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Yes

• B/Lg, P/W, G and W/

B wire open or shorted to ground, or poor “3”, “4”, “27” and

“28” connection.

• Loose or poor contacts on the ECM coupler.

No

Tester knob indication

Resistance (

∞ Ω

(Infinity)

Ω

)

STVA continuity

(Terminal – Ground)

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the throttle body assembly with a new one. Refer to

“Throttle Body

Disassembly and

Assembly” in Section

1D (Page 1D-11).

(A)

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

I947H1110041-02

4) If OK, then measure the STVA resistance (between the

P wire “A” and B wire “B”) and (between the W/B wire

“C” and G wire “D”).

Special tool

(A): 09900–25008 (Multi circuit tester set)

STVA resistance

Approx. 6.5

Ω

(Terminal “A” – Terminal “B”, Terminal “C” –

Terminal “D”)

“B”

“A”

“D”

“C”

(A)

I947H1110042-02

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-78 Engine General Information and Diagnosis:

Active Control Inspection

1) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

2) Turn the ignition switch ON.

3) Click “Secondary throttle operating control” (1).

1

I947H1110128-01

4) Click each button (2).

At this time, if an operation sound is heard from the STVA, the function is normal.

2

2

I947H1110129-01 email: [email protected] / www.motomatrix.co.uk

DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction

B947H11104020

Detected Condition and Possible Cause

C29

P1654

H

L

Detected Condition

Output voltage is not within the following range.

Difference between actual throttle opening

Possible Cause

• STP sensor maladjusted.

• STP sensor circuit open or short.

• STP sensor malfunction.

and opening calculated by ECM is larger than specified value.

0.15 V

≤

Sensor voltage < 4.85 V

• ECM malfunction.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

• STP sensor circuit shorted to VCC or ground circuit open.

• STP sensor circuit open or shorted to ground or VCC circuit open.

Wiring Diagram

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-79

ECM

STP sensor

R

Y/W

B/Br

Y/W

R

B/Br

ECM coupler (Harness side)

18 STPS

7

35

VCC

E2

I947H1110043-01

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-80 Engine General Information and Diagnosis:

C29 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the STP sensor couplers (1) and (2) for loose or poor contacts.

If OK, then measure the STP sensor input voltage.

Yes

Go to Step 3.

No

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the R wire or B/Br wire.

2

1

I947H1110044-01

4) Disconnect the STP sensor coupler (1).

5) Turn the ignition switch ON.

6) Measure the input voltage between the R wire and ground. Also, measure the voltage between the R wire and B/Br wire.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

STP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

(A)

V

I947H1110045-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-81

P1654-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the STP sensor couplers (1) and (2) for loose or poor contacts.

If OK, then check the STP sensor lead wire continuity.

Yes

Go to Step 3.

No

Y/W wire shorted to

VCC, or B/Br wire open.

2

1

I947H1110046-01

4) Disconnect the STP sensor couplers (1) and (2).

5) Check the continuity between the Y/W wire and R wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

(A)

I947H1110047-02

6) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-82 Engine General Information and Diagnosis:

Step Action

1 7) Check the continuity between the Y/W wire and terminal

“18”. Also, check the continuity between the B/Br wire and terminal “35”.

Yes

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

No

Y/W wire shorted to

VCC, or B/Br wire open.

?

(A)

(B)

“18”

“35”

Is the continuity OK?

(Black) (Gray)

I947H1110048-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-83

P1654-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the STP sensor couplers (1) and (2) for loose or poor contacts.

If OK, then check the STP sensor lead wire continuity.

Yes

Go to Step 2.

No

R or Y/W wire open, or

Y/W wire shorted to ground.

2

1

I947H1110054-01

4) Disconnect the STP sensor couplers (1) and (2).

5) Check the continuity between the Y/W wire and ground.

Also, check the continuity between the Y/W wire and B/

Br wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

(A)

I947H1110049-01

6) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-84 Engine General Information and Diagnosis:

Step Action

1 7) Check the continuity between the Y/W wire and terminal

“18”. Also, check the continuity between the R wire and terminal “7”.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

No

R or Y/W wire open, or

Y/W wire shorted to ground.

(B)

?

(A)

“7”

“18”

(Black) (Gray)

I947H1110050-01

Is the continuity OK?

2 1) Connect the ECM couplers.

2) Turn the ignition switch ON.

3) Measure the input voltage between the R wire and ground. Also, measure the input voltage between the R wire and B/Br wire.

Go to Step 3.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

STP sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground, (+) terminal: R

– (–) terminal: B/Br)

(A)

V

Open or short circuit in the R or B/Br wire.

I947H1110051-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-85

Step Action

3 1) Turn the ignition switch OFF.

2) Connect the ECM couplers and STP sensor couplers.

3) Remove the air cleaner box cover. Refer to “Air Cleaner

Element Removal and Installation” in Section 1D

(Page 1D-6).

Yes

• R, Y/W or B/Br wire open or shorted to ground, or poor “7”,

“18” or “35” connection.

4) Disconnect the STVA lead wire coupler (1).

• If wire and connection are OK, intermittent trouble or faulty ECM.

No

If check result is not satisfactory, replace the

STP sensor with a new one. Refer to “STP

Sensor Removal and

Installation” in Section

1C (Page 1C-7).

• Recheck each terminal and wire harness for open circuit and poor connection.

1

I947H1110052-01

5) Insert the needle point probes to the lead wire coupler.

6) Turn the ignition switch ON.

7) Measure the STP sensor output voltage at the coupler

(between the Y/W wire (+) and B/Br wire (–)) by turning the secondary throttle valve (close and open) with your finger.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

STP sensor output voltage

Secondary throttle valve is closed: Approx. 0.7 V

Secondary throttle valve is opened: Approx. 4.1 V

((+) terminal: Y/W – (–) terminal: B/Br)

(A)

V

(B)

I947H1110053-01

I705H1110071-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-86 Engine General Information and Diagnosis:

DTC “C31” (P0705): GP Switch Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

No Gear Position switch voltage

GP switch voltage is not within the following range.

GP switch voltage > 0.6 V

Possible Cause

• GP switch circuit open or short.

• GP switch malfunction.

• ECM malfunction.

Wiring Diagram

ECM

22

36

GP

E1

P

B/W

To the engine stop switch

Side-stand relay

Bl

P

6

GP switch

N

1

B/W

5

4

3

2

Neutral indicator light

Side-stand switch

Ignition switch

ECM coupler (Harness side)

B947H11104021

I837H1110067-01

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-87

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the GP switch coupler (1) for loose or poor contacts.

If OK, then measure the GP switch voltage.

Yes

• P wire open or shorted to ground.

• If wire and connection are OK, intermittent trouble or faulty ECM.

No

• P or B/W wire open, or P wire shorted to ground.

• Loose or poor contacts on the ECM coupler.

1

I947H1110055-01

4) Support the motorcycle with a jack.

5) Fold the side-stand to up position.

6) Make sure the engine stop switch is in the “RUN” position.

7) Insert the needle pointed probe to the lead wire coupler.

Turn the ignition switch ON.

9) Measure the voltage between the P and B/W wire, when shifting the gearshift lever from 1st to Top.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

• If wire and connection are OK, replace the GP switch with a new one. Refer to “Gear

Position (GP) Switch

Removal and

Installation” in

Section 5B (Page 5B-

14).

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

GP switch voltage

0.6 V and more

((+) terminal: P – (–) terminal: B/W)

Is the voltage OK?

(B)

V

(A)

I947H1110056-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-88 Engine General Information and Diagnosis:

DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit

Malfunction

B947H11104022

Detected Condition and Possible Cause

Detected Condition

CKP signal is produced but fuel injector signal is interrupted by 4 times or more continuity.

Possible Cause

• Injector circuit open or short.

• Injector malfunction.

• ECM malfunction.

Wiring Diagram

ECM

Y/R

Fuel pump relay

To engine stop switch

46

45

44

43

#11

#21

#31

#41

Gr/W

Gr/B

Gr/Y

Gr/R

#4 #3 #2

Primary fuel injector

#1

ECM coupler (Harness side)

I837H1110070-02

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-89

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the primary fuel injector coupler (1) for loose or poor contacts.

If OK, then measure the injector resistance.

Yes

Go to Step 2.

No

Replace the injector with a new one. Refer to

“Throttle Body

Disassembly and

Assembly” in Section

1D (Page 1D-11).

1

I947H1110057-01

4) Disconnect the injector coupler and measure the resistance between terminals.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

Injector resistance

11 – 13

Ω

at 20

°

C (68

°

F)

(Terminal – Terminal)

(A)

I947H1110058-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-90 Engine General Information and Diagnosis:

Step Action

1 5) If OK, then check the continuity between each terminal and ground.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Injector continuity

∞ Ω

(Infinity)

No

Replace the injector with a new one. Refer to

“Throttle Body

Disassembly and

Assembly” in Section

1D (Page 1D-11).

(A)

I947H1110059-01

Are the resistance and continuity OK?

2 1) Turn the ignition switch ON.

2) Measure the injector voltage between the Y/R wire and ground.

• Gr/W wire open or shorted to ground, or poor “46” connection

(#1 cylinder side).

Open circuit in the Y/R wire.

NOTE

Injector voltage can be detected only for 3 seconds after ignition switch is turned ON.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

• Gr/B wire open or shorted to ground, or poor “45” connection

(#2 cylinder side).

• Gr/Y wire open or shorted to ground, or poor “44” connection

(#3 cylinder side).

Injector voltage

Battery voltage

((+) terminal: Y/R – (–) terminal: Ground)

Is the voltage OK?

(A)

I947H1110060-01

• Gr/R wire open or shorted to ground, or poor “43” connection

(#4 cylinder side).

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

email: [email protected] / www.motomatrix.co.uk

DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit

Malfunction

B947H11104023

Detected Condition and Possible Cause

Detected Condition

Some failure exists in the fuel injector signal in a high load, high revolution condition.

Possible Cause

• Injector circuit open or short.

• Injector malfunction.

• ECM malfunction.

Wiring Diagram

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-91

ECM

Y/R

Fuel pump relay

To engine stop switch

59

58

57

56

#12

#22

#32

#42

Lg

Lg/W

Lg/B

Lg/Bl

#4 #3 #2

Secondary fuel injector

#1

ECM coupler (Harness side)

I947H1110125-01

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-92 Engine General Information and Diagnosis:

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the secondary fuel injector coupler (1) for loose or poor contacts.

If OK, then measure the injector resistance.

Yes

Go to Step 2.

No

Replace the injector with a new one. Refer to

“Throttle Body

Disassembly and

Assembly” in Section

1D (Page 1D-11).

1

I947H1110061-01

4) Disconnect the injector coupler and measure the resistance between terminals.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

Injector resistance

11 – 13

Ω

at 20

°

C (68

°

F)

(Terminal – Terminal)

(A)

I947H1110062-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-93

Step Action

1 5) If OK, then check the continuity between each terminal and ground.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Injector continuity

∞ Ω

(Infinity)

No

Replace the injector with a new one. Refer to

“Throttle Body

Disassembly and

Assembly” in Section

1D (Page 1D-11).

(A)

I947H1110063-01

Are the resistance and continuity OK?

2 1) Turn the ignition switch ON.

2) Measure the injector voltage between the Y/R wire and ground.

• Lg wire open or shorted to ground, or poor “59” connection

(#1 cylinder side).

Open circuit in the Y/R wire.

NOTE

Injector voltage can be detected only for 3 seconds after ignition switch is turned ON.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

• Lg/W wire open or shorted to ground, or poor “58” connection

(#2 cylinder side).

• Lg/B wire open or shorted to ground, or poor “57” connection

(#3 cylinder side).

Injector voltage

Battery voltage

((+) terminal: Y/R – (–) terminal: Ground)

Is the voltage OK?

(A)

I947H1110064-01

• Lg/Bl wire open or shorted to ground, or poor “56” connection

(#4 cylinder side).

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-94 Engine General Information and Diagnosis:

DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction

Detected Condition and Possible Cause

C40/P0505

C40/P0506

C40/P0507

Detected Condition

The circuit voltage of motor drive is unusual.

Idle speed is lower than the desired idle speed.

Idle speed is higher than the desired idle speed.

Possible Cause

• ISC valve circuit open or shorted to ground.

• Air passage clogged.

• ISC valve is fixed.

• ISC valve preset position is incorrect.

• Disconnected ISC valve hose.

• ISC valve is fixed.

• ISC valve preset position is incorrect.

B947H11104024

Wiring Diagram

ISC valve

Bl

Y

G

Br

Bl

Y

G

Br

39

ECM

ISC. 1A

38 ISC. 1B

37 ISC. 2A

49 ISC. 2B

I947H1110065-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

• Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned to OFF.

If the ECM coupler is disconnected within 5 seconds after ignition switch is turned to OFF, there is a possibility of an unusual value being written in the ECM and causing an error of ISC valve operation.

• When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-95

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the air cleaner box. Refer to “Air Cleaner Box

Removal and Installation” in Section 1D (Page 1D-7).

3) Check the ISC valve coupler (1) for loose or poor contacts.

If OK, then check the ISC valve lead wire continuity.

Yes

Go to Step 2.

No

Bl, Y, G or Br wire open.

1

I947H1110066-01

4) Disconnect the ISC valve coupler and ECM coupler.

Refer to “ECM Removal and Installation” in Section 1C

(Page 1C-1).

5) Check the continuity between terminal “A” and terminal

“39”, terminal “B” and terminal “38”, terminal “C” and terminal “37”, terminal “D” and terminal “49”.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity test ( )

ECM couplers (Harness side)

“A”

“C”

“D”

“B”

(A)

(B)

Is the continuity OK?

“37”

“49”

“38”

“39”

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-96 Engine General Information and Diagnosis:

Step Action

2 1) Check the continuity between each ISC valve terminal and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

ISC valve continuity

∞ Ω

(Infinity)

(Terminal – Ground)

Yes

If wire is OK, intermittent trouble or faulty ECM.

No

Replace the ISC valve with a new one. Refer to

“Throttle Body Removal and Installation” in

Section 1D (Page 1D-

10).

(A)

I947H1110068-01

2) If OK, then measure the resistance (between the Bl wire terminal “A” and Y wire terminal “B”) and (between the G wire terminal “C” and Br wire terminal “D”).

ISC valve resistance

Approx. 80

Ω

at 20

°

C (68

°

F)

(Terminal: “A” – Terminal: “B”, Terminal: “C” –

Terminal: “D”)

“B”

“D”

“C”

“A”

(A)

I947H1110069-01

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-97

ACTIVE CONTROL INSPECTION (ISC RPM

CONTROL)

Check 1

1) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

2) Check that the engine is running.

3) Click the “Active control”.

4) Click the “ISC rpm control” (1).

Check 2

1) Click the button (4) and decrease the “Spec” (2) to 1

050 rpm slowly.

2) Check that the “Desired idle speed” (3) is nearly equal to the “Spec” (2). At the same time, check that the number of steps (5) in the ISC valve position decreases.

3) Click the button (6) and increase the “Spec” (2) slowly.

4) Check that the “Desired idle speed” (3) is nearly equal to the “Spec” (2). Also, check that the number of steps (5) in the ISC valve position increases.

6

2

4

I947H1110154-01

1

I947H1110130-02

5) Check that the “Spec” (2) is idle speed 1 150

±

100 rpm.

6) Check that the “Desired idle speed” (3) is within the specified idle rpm.

3

5

I947H1110155-01

Check 3

1) Click the button (6) and increase the “Spec” (2) to 1

500 rpm slowly.

2) Check that the “Desired idle speed” (3) is nearly equal to the “Spec” (2). Also, check that the number of steps (5) in the ISC valve position increases.

6

2

I947H1110156-01

3

2

I947H1110152-01

5

I947H1110157-01

3

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-98 Engine General Information and Diagnosis:

Check 4

1) Click the button (6) and increase the “Spec” (2) to 1

900 rpm.

2) Check that the “Desired idle speed” (3) is approx. 1

900 rpm.

3) Check that the “Engine speed” (7) is close to 1 900 rpm.

NOTE

Be careful not to increase the “Spec” to 2 000 rpm, or the “Engine speed” may reach the upper limit.

2

6

I947H1110158-01

7

3

I947H1110159-01

If the ISC valve does not function properly, inspect the

ISC valve or replace the ISC valve. Refer to “DTC “C40”

(P0505 / P0506 / P0507): ISC Valve Circuit Malfunction”

(Page 1A-94) or “Throttle Body Disassembly and

Assembly” in Section 1D (Page 1D-11).

DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

No voltage is applied to fuel pump.

C41

P0230

H

Voltage is applied to fuel pump although fuel pump relay is turned OFF.

L

No voltage is applied to fuel pump although fuel pump relay is turned ON.

B947H11104025

Possible Cause

• Fuel pump relay circuit open or short.

• Fuel pump relay malfunction.

• Fuel pump relay switch circuit is shorted to power source.

• Faulty pump relay (switch side).

• Fuel pump relay coil circuit open or short.

• Faulty pump relay (coil side).

Wiring Diagram

ECM

24

40

VM

FP relay

Y/R

Y/B

M

Fuel pump

Fuel pump relay

R/BI

O/W

Engine stop switch

To side-stand switch

Side-stand relay

Ignition switch

I837H1110088-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

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Engine General Information and Diagnosis: 1A-99

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

C41 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the frame covers. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the FP relay coupler (1) for loose or poor contacts.

If OK, then check the FP relay. Refer to “Fuel Pump

Relay Inspection” in Section 1G (Page 1G-7).

Is the FP relay OK?

1

I947H1110070-01

Yes

• ECM power input signal malfunction.

Refer to “DTC “C41”

(P2505): ECM Power

Input Signal

Malfunction”

(Page 1A-101).

• Y/B or O/W wire open or short or poor “40” connection.

• Y/R or R/Bl wire open, shorted or poor

“24” connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

No

Replace the FP relay with a new one.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-100 Engine General Information and Diagnosis:

P0230-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the frame covers. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the FP relay coupler (1) for loose or poor contacts.

If OK, then check the FP relay. Refer to “Fuel Pump

Relay Inspection” in Section 1G (Page 1G-7).

Is the FP relay OK?

1

I947H1110071-01

Yes

• Y/B wire shorted to power source.

• Y/B wire shorted to ground.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

No

Replace the FP relay with a new one.

P0230-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the frame covers. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the FP relay coupler (1) for loose or poor contacts.

If OK, then check the FP relay. Refer to “Fuel Pump

Relay Inspection” in Section 1G (Page 1G-7).

Is the FP relay OK?

1

I947H1110072-01

Yes

• Y/B wire open or poor

“40” connection.

No

Replace the FP relay with a new one.

• O/W wire open or shorted to ground.

• R/Bl or Y/R wire open or shorted to ground, or poor “24” connection.

• If wire and connection are OK, intermittent trouble of faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-101

DTC “C41” (P2505): ECM Power Input Signal Malfunction

Detected Condition and Possible Cause

Detected Condition

No voltage is applied to the ECM.

C41/P2505

B947H11104026

Possible Cause

• Lead wire/coupler connection of ECM terminal to fuel fuse.

• Fuel fuse.

Wiring Diagram

To speedometer

ECM

10 BATT

R/Bl

Fuel pump

M

24

40

VM

FP relay

Y/R

Y/B

Fuel pump relay

R/BI

O/W

Engine stop switch

To side-stand switch

Side-stand relay

Ignition switch

I837H1110092-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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1A-102 Engine General Information and Diagnosis:

Step

1

Action

1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

Yes

• Fuel pump relay circuit malfunction.

3) Check the ECM coupler for loose or poor contacts. If OK, then measure the ECM input voltage.

Refer to “DTC “C41”

(P0230-H/L): FP

Relay Circuit

Malfunction”

(Page 1A-98).

No

Open or short circuit in the R/Bl wire.

I947H1110073-01

4) Disconnect the ECM coupler. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

5) Insert the needle pointed probe to ECM coupler.

6) Measure the voltage between terminal “10” and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

ECM input voltage

Battery voltage

((+) terminal: “10” – (–) terminal: Ground)

• R/Bl wire open or short or poor “10” connection.

• Power source of speedometer shorted to the grand or open.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

ECM couplers (Harness side)

(A)

(B)

“10”

I837H1110093-01

Is the voltage OK?

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Engine General Information and Diagnosis: 1A-103

DTC “C42” (P1650): IG Switch Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

Ignition switch signal is not input to the ECM.

When the ID agreement is not verified.

ECM does not receive communication signal from the immobilizer antenna.

(For E-02, 19, 24, 51)

Possible Cause

• Ignition system circuit open or short.

• ECM malfunction.

• Immobilizer system malfunction.

(For E-02, 19, 24, 51)

B947H11104027

Troubleshooting

NOTE

• Refer to “Ignition Switch Inspection” in Section 9C (Page 9C-7) for details.

• After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction

B947H11104028

Detected Condition and Possible Cause

C44/P0130

C44/P0135

Detected Condition

HO2 sensor output voltage is not input to

ECM during engine operation and running condition.

Possible Cause

• HO2 sensor circuit is open or shorted to the power source.

Sensor voltage > 1.0 V

The heater can not operate so that heater • Heated circuit is open or shorted to ground.

operation voltage is not supplied to the oxygen heater circuit.

• Battery voltage is not supply to the HO2 sensor.

Wiring Diagram

ECM

35 E2

34 HO2S

41 HO2SH

B/Br

W/G

W/B

Engine stop Side-stand switch relay

O/W

To Side-stand switch

Ignition switch

HO2 sensor

ECM coupler (Harness side)

I837H1110094-01

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-104 Engine General Information and Diagnosis:

Troubleshooting (When Indicating C44/P0130:)

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the HO2 sensor coupler (1) for loose or poor contacts.

If OK, then check the HO2 sensor lead wire continuity.

Yes

Go to Step 2.

No

W/G wire shorted to the power source, or W/G or B/Br wire open.

1

I947H1110074-01

4) Disconnect the HO2 sensor coupler.

5) Check the continuity between the W/G wire and O/W wire. If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

(A)

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-105

Step Action

1 6) Disconnect the ECM coupler. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-1).

7) Check the continuity between the W/G wire and terminal

“34”. Also, check the continuity between the B/Br wire and terminal “35”.

Yes

Go to Step 2.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity ( )

ECM couplers (Harness side)

(A)

?

No

W/G wire shorted to the power source, or W/G or B/Br wire open.

(B)

Is the continuity OK?

“34”

“35”

(Black) (Gray)

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-106 Engine General Information and Diagnosis:

Step Action

2 1) Connect the ECM coupler and HO2 sensor coupler.

2) Warm up the engine enough.

3) Insert the needle pointed probes to the lead wire coupler.

4) Measure the HO2 sensor output voltage between the W/

G (B) wire and B/Br (Gr) wire, in idling condition.

Yes

• W/G or B/Br wire open or shorted to the power source, or poor “34” or “35” connection.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

• If wire and connection are OK, intermittent trouble or faulty ECM.

No

Replace the HO2 sensor with a new one.

Refer to “HO2 Sensor

Removal and

Installation” in Section

1C (Page 1C-8).

Tester knob indication

Voltage ( )

HO2 sensor output voltage at idle speed

0.3 V and less

((+) terminal: W/G (B) – (–) terminal: B/Br (Gr))

(B)

(A)

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspection it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

I947H1110076-01

5) If OK, then remove the air cleaner box and pinch the

PAIR hose (1) with a proper hose clamp.

1

I947H1110077-01

6) Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r/min.

HO2 sensor output voltage at 5 000 r/min

0.6 V and more

((+) terminal: W/G – (–) terminal: B/Br)

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-107

Troubleshooting (When Indicating C44/P0135:)

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the HO2 sensor coupler (1) for loose or poor contacts.

If OK, then measure the HO2 sensor resistance.

Yes

Go to Step 2.

No

Replace the HO2 sensor with a new one.

Refer to “HO2 Sensor

Removal and

Installation” in Section

1C (Page 1C-8).

1

I947H1110078-01

4) Disconnect the HO2 sensor coupler and measure the resistance between terminals.

!

CAUTION

• Temperature of the sensor affects resistance value largely.

• Make sure that the sensor heater is in atmospheric temperature.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

HO2 sensor heater resistance

6.7 – 9.5

Ω

at 23

°

C (73

°

F)

(W – W)

(A)

I947H1110079-01

Is the resistance OK?

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1A-108 Engine General Information and Diagnosis:

Step Action

2 1) Connect the HO2 sensor coupler.

2) Insert the needle pointed probes to the lead wire coupler.

3) Turn the ignition switch ON and measure the heater voltage between the W/B wire and ground.

If the tester voltage indicates the battery voltage, it is good condition.

Yes

• O/W or W/B wire open or shorted to ground, or poor “41” connection.

• Recheck each terminal and wire

NOTE

harness for open circuit and poor

Battery voltage can be detected only before starting the engine.

connection.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

• If wire and connection are OK, intermittent trouble or faulty ECM.

Tester knob indication

Voltage ( )

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Heater voltage

Battery voltage

((+) terminal: W/B – (–) terminal: Ground)

Removal and

Installation” in

Section 1C

(Page 1C-1).

• Open or short circuit in the W/B wire or O/

W wire.

No

• Loose or poor contacts on the ECM coupler or HO2 sensor coupler.

(A)

(B)

I947H1110080-01

Is the voltage OK?

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DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction

B947H11104029

C46

P1657

P1658

H

L

Detected Condition

The operation signal does not reach the

EXCV actuator.

EXCVA position sensor voltage low or high

0.14 V

≤

Sensor voltage < 4.9 V

(without the above range)

EXCVA can not operate properly.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

The operation signal does not reach the

EXCVA motor.

EXCVA can not operate properly.

Possible Cause

• EXCVA maladjusted.

• EXCVA circuit open or short.

• EXCVA motor malfunction.

• EXCVA position sensor malfunction.

• EXCVA position sensor circuit shorted to VCC or ground circuit open.

• EXCVA position sensor circuit open or shorted to ground or VCC circuit open.

• EXCVA motor circuit open or short.

• EXCVA motor malfunction.

Wiring Diagram

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-109

ECM

EXCVA

Gr

P

B

Y

W

B/R

R/B

R

Y

B/Br

1

13

7

14

35

EXCVA

EXCVA

VCC

EXCVAS

E2

I947H1110081-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-110 Engine General Information and Diagnosis:

C46 (Use of mode select switch)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the EXCVA coupler (1) for loose or poor contacts.

Yes

Go to Step 2.

No

Go to Step 6.

1

I947H1110082-01

4) Turn the ignition switch ON.

5) Check the operation of the EXCVA.

(EXCVA operation order: Full close

→

Full open

→

Approx. 80% open)

Is the operation OK?

I947H1110083-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-111

P1657-H (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the EXCVA coupler (1) for loose or poor contacts.

If OK, then check the EXCVA position sensor lead wire continuity.

Yes

Go to Step 4.

No

Y wire shorted to VCC, or B/Br wire open.

1

I947H1110084-01

4) Disconnect the EXCVA coupler.

5) Check the continuity between R wire and Y wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

(A)

?

I947H1110085-01

6) Disconnect the ECM couplers.

7) Check the continuity between Y wire and terminal “14”.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-112 Engine General Information and Diagnosis:

Step Action

1 Also, check the continuity between B/Br wire and terminal “35”.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity ( )

EXCVA lead wire continuity

Continuity ( )

ECM couplers (Harness side)

Yes

Go to Step 4.

No

Y wire shorted to VCC, or B/Br wire open.

?

(A)

(B)

“14”

“35”

(Black) (Gray)

I947H1110086-01

Is the continuity OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-113

P1657-L (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the EXCVA coupler (1) for loose or poor contacts.

If OK, then check the EXCVA position sensor lead wire continuity.

Yes

Go to Step 2 and go to

Step 4.

No

R or Y wire open, or Y wire shorted to ground.

1

I947H1110087-01

4) Disconnect the EXCVA coupler.

5) Check the continuity between Y wire and ground.

6) Also, check the continuity between Y wire and B/Br wire.

If the sound is not heard from the tester, the circuit condition is OK.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

(A)

?

I947H1110088-01

7) Disconnect the ECM coupler.

Check the continuity between Y wire and terminal “14”.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-114 Engine General Information and Diagnosis:

Step Action

1 9) Also, check the continuity between R wire and terminal

“7”.

Yes

Go to Step 2 and go to

Step 4.

No

R or Y wire open, or Y wire shorted to ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Continuity ( )

EXCVA lead wire continuity

Continuity ( )

ECM couplers (Harness side)

(A)

?

(B)

“14”

“7”

(Black) (Gray)

I947H1110089-01

Is the continuity OK?

P1658 (Use of SDS)

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the EXCVA coupler (1) for loose or poor contacts.

Yes

Go to Step 6.

No

Loose or poor contacts on the EXCVA coupler.

Is the connection OK?

1

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-115

Step Action

2 1) Turn the ignition switch OFF.

2) Check the installation of EXCV cables. If it is necessary, adjust the EXCV cables. Refer to “EXCV Cable Removal and Installation” in Section 1K (Page 1K-6).

Yes

Go to Step 3.

No

• Loose or poor contacts on the ECM coupler (terminal “7” or “35”).

• Open or short circuit in the R or B/Br wire.

3) Disconnect the EXCVA coupler (1).

I947H1110091-01

1

I947H1110092-01

4) Turn the ignition switch ON.

5) Measure the voltage between the R wire and ground.

6) If OK, then measure the voltage between the R wire and

B/Br wire.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

EXCVA position sensor input voltage

4.5 – 5.5 V

((+) terminal: R – (–) terminal: Ground)

((+) terminal: R – (–) terminal: B/Br)

(A)

V

I947H1110093-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-116 Engine General Information and Diagnosis:

Step Action

3 1) Turn the ignition switch OFF.

2) Check the continuity between Y wire and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

EXCVA position sensor continuity

∞ Ω

(Infinity)

Yes

Go to Step 4.

No

Replace the EXCVA with a new one.

(A)

I947H1110094-01

3) If OK, then measure the EXCVA position sensor resistance.

4) Connect the EXCVA coupler and set the EXCVA to adjustment position. Refer to “EXCV Cable Removal and

Installation” in Section 1K (Page 1K-6).

5) Disconnect the EXCVA coupler and measure the resistance between Y and W wires.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

EXCVA position sensor resistance at adjustment position

Approx. 3.1 k

Ω

((+) Y – (–) W)

(A)

I947H1110095-02

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-117

Step Action

4 1) Turn the ignition switch OFF.

2) Connect the EXCVA coupler.

3) Set up the SDS tools. Refer to “Self-Diagnostic

Procedures” (Page 1A-12).

4) Turn the ignition switch ON.

5) Click “Exhaust valve operating control” (1).

Yes

Replace the ECM with a known good one, and inspect it again.

No

Go to Step 5.

1

I947H1110131-01

6) Click “Full closed” (2).

2

I947H1110132-01

7) Insert the needle pointed probes into the back side of the

EXCVA coupler (3). ((+) Y – (–) W)

Measure the EXCVA position sensor output voltage at

EXCV fully closed position.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

EXCVA position sensor output voltage

EXCV is fully closed: 0.45 – 1.4 V

((+) Y – (–) W)

(B)

3

(A)

I947H1110097-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-118 Engine General Information and Diagnosis:

Step

4 9) Click “Full opened” (4).

Action Yes

Replace the ECM with a known good one, and inspect it again.

No

Go to Step 5.

4

I947H1110098-02

10) Measure the EXCVA position sensor output voltage at

EXCV fully opened position.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

EXCVA position sensor output voltage

EXCV is fully opened: 3.6 – 4.55 V

((+) Y – (–) W)

(B)

(A)

I947H1110099-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-119

Step Action

5 1) If the EXCVA position sensor output voltage is 0.45 V and less at EXCV fully closed position, adjust the output voltage to the specified value by turning the No. 1 cable adjuster (1). Refer to “EXCV Cable Removal and

Installation” in Section 1K (Page 1K-6).

Yes

Replace the ECM with a known good one, and inspect it again.

No

Replace the EXCVA with a new one.

2) Repeat the procedure in Step 4 until the output voltage is set within the specified value. (If C46/P1657 code is indicated after adjusting the voltage, increase the voltage to 0.9 V).

!

CAUTION

• Adjusting the cable with the EXCV fully opened or fully closed can damage the

EXCVA. Be sure to adjust the cable with the

EXCV set in the adjustment position. Refer to

“EXCV Cable Removal and Installation” in

Section 1K (Page 1K-6).

• Do not turn the EXCVA pulley using a wrench.

3) If the EXCVA position sensor output voltage is 4.55 V and more at EXCV fully opened position, adjust the output voltage to the specified value by turning the No. 2 cable adjuster (2). Refer to “EXCV Cable Removal and

Installation” in Section 1K (Page 1K-6). Repeat the procedure in Step 4 until the output voltage is set within the specified value.

EXCVA position sensor output voltage

EXCV is fully closed: 0.45

≤

Output voltage

≤

1.4

EXCV is fully opened: 3.6

≤

Output voltage

≤

4.55

2

1

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-120 Engine General Information and Diagnosis:

Step Action

6 1) Turn the ignition switch OFF.

2) Disconnect the EXCVA coupler (1).

1

I947H1110101-01

3) Apply 12 V to the terminals and check the operation of

EXCVA.

Yes

• Loose or poor contacts on the

EXCVA or ECM coupler (terminal “13” or “1”).

No

• Replace the EXCVA with a new one.

• Inspect that the

EXCV and two cables move smoothly.

• Open or short circuit in the B/R wire or R/B wire.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

I947H1110102-01

4) Then, switch the wires supplied 12 V and check the operation of EXCVA. (Check the operation of EXCVA in both way.)

Is the operation OK?

I947H1110103-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-121

DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction

B947H11104030

Detected Condition and Possible Cause

Detected Condition Possible Cause

PAIR control solenoid valve voltage is not input to ECM.

• PAIR control solenoid valve circuit open or short.

• PAIR control solenoid valve malfunction.

• ECM malfunction.

Wiring Diagram

ECM

55

PAIR

W/G

Engine stop switch

O/W

To side-stand switch

Side-stand relay

Ignition switch

PAIR control solenoid valve

I837H1110103-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-122 Engine General Information and Diagnosis:

Step Action

1 1) Turn the ignition switch OFF.

2) Remove the air cleaner box. Refer to “Air Cleaner Box

Removal and Installation” in Section 1D (Page 1D-7).

3) Check the PAIR control solenoid valve coupler (1) for loose or poor contacts.

If OK, then measure the PAIR control solenoid valve resistance.

Yes

Go to Step 2.

No

Replace the PAIR control solenoid valve with a new one. Refer to

“PAIR Control Solenoid

Valve Removal and

Installation” in Section

1B (Page 1B-9).

1

I947H1110143-01

4) Remove the PAIR control solenoid valve. Refer to “PAIR

Control Solenoid Valve Removal and Installation” in

Section 1B (Page 1B-9).

5) Measure the resistance between terminals.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

PAIR control solenoid valve resistance

20 – 24

Ω

at 20 – 30

°

C (68 – 86

°

F)

(Terminal – Terminal)

(A)

I947H1110105-01

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-123

Step Action

2 1) Turn the ignition switch ON.

2) Measure the voltage between the O/W wire and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Yes

• W/G wire open or shorted to ground, or poor “55” connection failure.

No

Open or short circuit in the O/W wire.

Tester knob indication

Voltage ( )

• If wire and connection are OK, intermittent trouble or faulty ECM.

PAIR control solenoid valve voltage

Battery voltage

((+) terminal: O/W – (–) terminal: Ground)

• Recheck each terminal and wire harness for open circuit and poor connection.

V

(A)

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

I947H1110106-02

Is the voltage OK?

Active Control Inspection

1) Set up the SDS tool. (Refer to SDS operation manual for further details.)

2) Turn the ignition switch ON.

3) Click “PAIR Sol operating control” (1).

1

I947H1110133-01

4) Click each button (2). At this time, if an operating sound is heard from the PAIR control solenoid valve, the function is normal.

2

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-124 Engine General Information and Diagnosis:

DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

Cooling fan relay signal is not input to ECM.

Possible Cause

• Cooling fan relay circuit open or short.

• ECM malfunction.

Wiring Diagram

ECM

42

FAR

G/R

Cooling fan relay

Engine stop switch

Side-stand relay

O/W

To Side-stand switch

Cooling fan motor

Ignition switch

B947H11104031

I837H1110109-02

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-125

Step

1

Action

1) Turn the ignition switch OFF.

2) Remove the frame covers. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-6).

3) Check the cooling fan relay (1) coupler for loose or poor contacts.

If OK, then inspection the cooling fan relay. Refer to

“Cooling Fan Inspection” in Section 1F (Page 1F-9).

Yes

• O/W and G/R wire open or shorted to ground, or poor “42” connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

No

Replace the cooling fan relay with a new one.

Is the cooling fan relay OK?

1

I947H1110107-01

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

Active Control Inspection

1) Set up the SDS tool. (Refer to SDS operation manual for further details.)

2) Start the engine and run it in idling condition.

3) Click “Cooling fan relay control” (1).

1

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-126 Engine General Information and Diagnosis:

4) Click the “Operate” (2).

At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal.

NOTE

The cooling fan relay and cooling fan motor inspection is operational at any engine coolant temperature until reaching 100

°

C (212

°

F). In a hot engine condition with the intake air temperature exceeding 40

°

C (104

°

F), however, the engine coolant temperature at which the inspection is operational will be restricted to 95

°

C (203

°

F).

2

I947H1110136-03

5) Click the “Stop” (3) to check the operation properly.

3

I947H1110137-03

6) Click the “Off” (4) 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 reaches each temp. of 50

°

C (122

°

F), 70

°

C (158

°

F), 90

°

C (194

°

F) and 110

°

C (230

°

F)/above 4 000 r/ min. It is cooling fan motor malfunction or its circuit failure when the motor would not run even if the relay turns ON.

• There is a tolerance of operating temperature of cooling fan relay.

4

I947H1110138-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-127

DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only)

B947H11104032

Detected Condition and Possible Cause

Detected Condition

EVAP system purge control valve voltage is not input to

ECM.

Possible Cause

• EVAP system purge control valve circuit open or short.

• EVAP system purge control valve malfunction.

• ECM malfunction.

Wiring Diagram

ECM

61 EVAP

Dbr

Engine stop switch

O/W

To side-stand switch

Side-stand relay

Ignition switch

EVAP purge control valve

I837H1110113-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-128 Engine General Information and Diagnosis:

Step Action

1 1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the EVAP system purge control valve coupler (1) for loose or poor contacts.

If OK, then measure the EVAP system purge control valve resistance.

Yes

Go to Step 2.

No

Replace the EVAP system purge control with a new one. Refer to

“Evaporative Emission

Control System

Removal and

Installation (Only for E-

33)” in Section 1B

(Page 1B-12).

1

I947H1110108-01

4) Disconnect the EVAP system purge control valve coupler.

5) Measure the resistance between terminals.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

EVAP system purge control valve resistance

Approx. 32

Ω

at 20

°

C (68

°

F)

(Terminal – Terminal)

(A)

I947H1110109-01

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-129

Step Action

2 1) Turn the ignition switch ON.

2) Measure the voltage between the O/W wire and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Yes

• Dbr wire open or shorted to ground, or poor “61” connection failure.

No

Open or short circuit in the O/W wire.

Tester knob indication

Voltage ( )

• If wire and connection are OK, intermittent trouble or faulty ECM.

EVAP system purge control valve voltage

Battery voltage

((+) terminal: O/W – (–) terminal: Ground)

(A)

• Recheck each terminal and wire harness for open circuit and poor connection.

V

• Replace the ECM with a known good one, and inspect it again. Refer to “ECM

Removal and

Installation” in

Section 1C

(Page 1C-1).

I718H2110003-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-130 Engine General Information and Diagnosis:

Active Control Inspection

1) Set up the SDS tool. (Refer to SDS operation manual for further details.)

2) Turn the ignition switch ON.

3) Click “EVAP purge valve operating control” (1).

1

I947H1110139-01

4) Click each button (2). At this time, if an operating sound is heard from the EVAP system purge control valve, the function is normal.

2

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-131

DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction

Detected Condition and Possible Cause

Detected Condition

Speedometer does not receive signal from the vehicle speed sensor for more than 6 sec. when the motorcycle is running. ECM does not receive signal from the vehicle speed sensor for more than 6 sec. when the motorcycle is running. Failure in communication between ECM and speedometer with reference to vehicle speed.

Possible Cause

• Speed sensor circuit open or short.

• Speed sensor malfunction.

• Speedometer malfunction.

• ECM malfunction.

Wiring Diagram

B947H11104033

To Speedometer

ECM

Speed sensor

B/R

B

B/W

B/R

P

B/W

2 Speed sensor

I837H1110116-01

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-132 Engine General Information and Diagnosis:

Step

1

Action

1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-9).

3) Check the speed sensor coupler (1) for loose or poor contacts.

If OK, remove the speed sensor. Refer to “Speed Sensor

Removal and Installation” in Section 9C (Page 9C-5).

Yes

• P wire open or shorted to ground.

• Loose or poor contacts on the speed sensor coupler or ECM coupler

(terminal “2”).

• If wires and connection are OK, intermittent trouble or faulty ECM.

rotor tip.

No

• Inspect that metal particles or foreign material stuck on the speed sensor and

• If there are no metal particles and foreign material, then replace the speed sensor with a new one.

1

• Recheck each terminal and wire harness for open circuit and poor connection.

I947H1110110-01

4) Connect 12 V battery, 10 k

Ω

resistor and the multi-circuit tester as shown in the figure.

• Replace the ECM with a known good one, and inspect it again.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

B

12 V

B/W

B/R

Speed sensor

I837H1110118-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-133

Step Action

1 5) Under this condition, if a suitable screwdriver touching the pick-up surface of the speed sensor is moved, the tester reading voltage changes (0 V

→

12 V or 12 V

→

0

NOTE

Yes

• P wire open or shorted to ground.

V). If the tester reading voltage does not change, replace the speedometer sensor with a new one.

• Loose or poor contacts on the speed sensor coupler or ECM coupler

(terminal “2”).

While testing, the highest voltage reading should be the same as the battery voltage (12 V).

• If wires and connection are OK, intermittent trouble or faulty ECM.

rotor tip.

No

• Inspect that metal particles or foreign material stuck on the speed sensor and

• If there are no metal particles and foreign material, then replace the speed sensor with a new one.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

I837H1110119-01

Is the voltage OK?

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-134 Engine General Information and Diagnosis:

DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction

B947H11104034

Detected Condition and Possible Cause

C93

P1769

H

L

Detected Condition

Steering damper control current does not flow to the solenoid valve. With IG turned ON, ECM detects a failure of internal circuit element.

Possible Cause

• Steering damper solenoid valve circuit interrupter element shorted.

Solenoid current does not converge to the target value. Battery voltage is 10 V or below with the engine running.

Steering damper control current is higher than

• Feedback current convergence failure.

• Low battery voltage.

• ECM malfunction.

specified value. An abnormal current is detected during the vehicle standstill. Solenoid current is 0.7

• Steering damper solenoid valve circuit shorted to VCC.

A or above.

Steering damper control current is lower than specified value. With IG turned ON, ECM detects a discontinuity. An abnormal current is detected during the vehicle standstill.

• Steering damper solenoid valve circuit open.

• Steering damper solenoid valve circuit shorted.

Wiring Diagram

ECM

Steering damper solenoid valve

B/Bl

B/O

W

Br

26

Steering damper

25 Steering damper

I947H1110111-02

ECM coupler (Harness side)

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60

61 62 63 64 65 66 67 68 69 70 71 72

I837H1110007-02

Troubleshooting

!

CAUTION

When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage.

NOTE

After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset

Procedures” (Page 1A-14).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-135

Step Action

1 1) Turn the ignition switch OFF.

2) Check the steering damper solenoid valve coupler (1) for loose or poor contacts.

If OK, then measure the steering damper solenoid valve resistance.

Yes

Go to Step 2.

No

Replace the steering damper with a new one.

1

I947H1110112-01

3) Disconnect the steering damper solenoid valve coupler.

4) Measure the steering damper solenoid valve resistance.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

Steering damper solenoid valve resistance

Approx. 12.5

Ω

at 20

°

C (68

°

F)

(A)

I837H1110121-01

Is the resistance OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-136 Engine General Information and Diagnosis:

Step Action

2 1) Turn the ignition switch ON.

2) Measure the voltage between B/Bl wire and ground.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

Steering damper solenoid valve voltage

Approx. 10 V when battery is fully charged condition

((+) terminal: B/Bl – (–) terminal: Ground)

Yes

• B/Bl (W) wire shorted to VCC, or poor “26” connection failure.

No

• Low battery voltage or fuse is blown.

• B/O (Br) wire open or shorted to ground, or poor “25” connection failure.

• B/Bl (W) wire open or shorted to ground, or poor “26” connection failure.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• If wire and connection are OK, intermittent trouble or faulty ECM.

(A)

• Recheck each terminal and wire harness for open circuit and poor connection.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

• Replace the ECM with a known good one, and inspect it again.

I947H1110113-01

Is the voltage OK?

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-137

Active Control Inspection

1) Set up the SDS tool. (Refer to SDS operation manual for further details.)

2) Raise the front wheel off the ground.

3) Turn the ignition switch ON.

4) Click “Steering damper solenoid operating control” (1).

1

5) Click each button (2) ON/OFF while turning the handlebars left and right.

I947H1110141-01

1

2

I947H1110142-01

NOTE

At this time, if the steering damping resistance changes from light to heavy by switching ON/OFF, the function is normal.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-138 Engine General Information and Diagnosis:

Specifications

Service Data

Injector + Fuel Pump + Fuel Pressure Regulator

Item

Injector resistance

Specification

11 – 13

Ω

at 20

°

C (68

°

F)

FI Sensors

Item

CKP sensor resistance

CKP sensor peak voltage

IAP sensor input voltage

IAP sensor output voltage

TP sensor input voltage

TP sensor output voltage

ECT sensor input voltage

ECT sensor output voltage

ECT sensor resistance

IAT sensor input voltage

IAT sensor output voltage

IAT sensor resistance

AP sensor input voltage

AP sensor output voltage

TO sensor resistance

TO sensor voltage

GP switch voltage

Injector voltage

Ignition coil primary peak voltage

HO2 sensor output voltage

HO2 sensor heater resistance

PAIR control solenoid valve resistance

STP sensor input voltage

STP sensor output voltage

STVA resistance

EXCVA position sensor input voltage

EXCVA position sensor output voltage

EXCVA position sensor resistance

EVAP system purge control solenoid valve resistance

ISC valve resistance

Steering damper solenoid valve resistance

Steering damper solenoid valve voltage

Closed

Opened

Standard/Specification

142 – 194

Ω

0.5 V and more

4.5 – 5.5 V

Approx. 2.7 V at idle speed

4.5 – 5.5 V

Approx. 1.1 V

Approx. 4.4 V

4.5 – 5.5 V

0.15 – 4.85 V

Approx. 2.45 k

Ω

at 20

°

C (68

°

F)

4.5 – 5.5 V

0.15 – 4.85 V

Approx. 2.58 k

Ω

at 20

°

C (68

°

F)

4.5 – 5.5 V

Normal

Approx. 3.6 V at 100 kPa (760 mmHg)

16.5 – 22.3 k

Ω

0.4 – 1.4 V

Leaning 3.7 – 4.4 V

0.6 V and more

Battery voltage

80 V and more

0.3 V and less at idle speed

0.6 V and more at 5 000 r/min

6.7 – 9.5

Ω

at 23

°

C (73

°

F)

20 – 24

Ω

at 20 – 30

°

C (68 – 86

°

F)

Closed

Opened

Closed

Opened

4.5 – 5.5 V

Approx. 0.7 V

Approx. 4.1 V

Approx. 6.5

Ω

4.5 – 5.5 V

0.45 – 1.4 V

3.6 – 4.55 V

Approx. 3.1 k

Ω

Approx. 32

Ω

at 20

°

C (68

°

F)

Approx. 80

Ω

at 20

°

C (68

°

F)

Approx. 12.5

Ω

at 20

°

C (68

°

F)

Approx. 10 V

B947H11107001

Note

Note

When cranking

When leaning 65

°

From 1st to Top

When cranking

At adjustment position

E-33 only

Battery fully charged email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine General Information and Diagnosis: 1A-139

Special Tools and Equipment

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1A-30) /

)

(Page 1A-33) /

)

(Page 1A-34) /

)

(Page 1A-107) /

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(Page 1A-36) /

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(Page 1A-135) /

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(Page 1A-54) /

)

(Page 1A-56) /

)

(Page 1A-57) /

)

(Page 1A-58)

09904–41010

SUZUKI Diagnostic system set

)

(Page 1A-13) /

)

(Page 1A-16)

)

(Page 1A-59) /

)

(Page 1A-59) /

)

(Page 1A-61) /

)

(Page 1A-62) /

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(Page 1A-63) /

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(Page 1A-90) /

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(Page 1A-92) /

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(Page 1A-96) /

)

(Page 1A-102) /

)

(Page 1A-104) /

)

(Page 1A-105) /

)

(Page 1A-106)

09917–47011

Vacuum pump gauge set

)

(Page 1A-42) /

)

(Page 1A-67)

09900–25009

Needle-point probe set

)

(Page 1A-106) /

)

(Page 1A-108) /

)

(Page 1A-112) /

)

(Page 1A-114) /

)

(Page 1A-117) /

)

(Page 1A-118) /

)

(Page 1A-38) /

)

(Page 1A-40) /

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(Page 1A-41) /

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(Page 1A-46) /

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)

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)

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)

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)

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)

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)

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)

(Page 1A-84) /

)

(Page 1A-85) /

)

(Page 1A-87) /

)

(Page 1A-95) /

)

(Page 1A-102) /

)

(Page 1A-105)

B947H11108001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1A-140 Engine General Information and Diagnosis:

09930–82720

Mode selection switch

)

(Page 1A-4) /

)

(Page 1A-

12) /

)

(Page 1A-12)

99565–01010–020

CD-ROM Ver.20

)

(Page 1A-13) /

)

(Page 1A-16) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices: 1B-1

Engine

Emission Control Devices

Precautions

Precautions for Emission Control Devices

Refer to “General Precautions” in Section 00 (Page 00-1).

B947H11200001

General Description

Fuel Injection System Description

B947H11201001

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. Adjusting, interfering with, improper replacement, or resetting of any of the fuel injection components may adversely affect injection performance and cause the motorcycle to exceed the exhaust emission level limits.

1

7

5

8

2

6

1. Fuel tank

2. Fuel pump

3. Fuel mesh filter

4. Fuel feed hose

5. Fuel delivery pipe

6. Primary fuel injector email: [email protected] / www.motomatrix.co.uk

3

4

“A”

“B”

“C”

7. Secondary fuel injector

8. Fuel pressure regulator

“A”: Pre-pressurized fuel

I947H1120001-03

“B”: Pressurized fuel

“C”: Relieved fuel

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1B-2 Emission Control Devices:

Crankcase Emission Control System Description

B947H11201002

The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the

PCV (breather) hose, air cleaner and throttle body.

1

2

“A”

“B”

“C”

“D”

“E”

1. PAIR control solenoid valve

2. PCV hose

“A”: Fresh air

“B”: Fuel/Air mixture

“C”: Exhaust gas

“D”: Blow-by gas

“E”: Return oil

I947H1120002-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices: 1B-3

Exhaust Emission Control System Description

B947H11201003

The exhaust emission control system is composed of the PAIR system, exhaust control system, HO2 sensor, threeway catalyst system and ISC system. The fresh air is drawn into the exhaust ports through the PAIR control solenoid valve and PAIR reed valves. The PAIR control solenoid valve is operated by the ECM, which is controlled according to the signals from TPS, ECTS, IAPS and CKPS. The exhaust gas flow is performed by the exhaust control valve actuator which is controlled by the ECM by changing the exhaust control valve angle. ISC valve adjusts the bypass air volume of the throttle body to control engine idling speed with various sensor signals by varying engine running conditions.

3

6

5

4

1

2

7

9

“A”

“B”

10

1. PAIR control solenoid valve

2. PAIR reed valve

3. Air cleaner box

4. Primary fuel injector

5. Secondary fuel injector

6. ECM

8

7. Exhaust control valve actuator

8. Exhaust control valve

9. Three-way catalyst

10. HO2 sensor

“A”: Fresh air

“B”: Exhaust gas

I947H1120003-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1B-4 Emission Control Devices:

PAIR System Diagram

B947H11201006

2

1

2

1

“A”

“B”

I947H1120004-01

1. PAIR control solenoid valve 2. PAIR reed valve “A”: Fresh air “B”: Exhaust gas

Noise Emission Control System Description

B947H11201004

TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof:

• The removal or rendering inoperative by any 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

• The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices: 1B-5

Among Those Acts Presumed to Constitute Tampering are the Acts Listed Below:

• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases.

• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air.

• Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label.

Evaporative Emission Control System Diagram (Only for E-33)

B947H11201005

2

1

3

10

4

6

8

5

7

1. Fuel tank

2. Fuel-vapor separator

3. Fuel pump

4. Fuel feed hose

5. Fuel shut-off valve

9

“A”

“B”

“C”

“D”

6. IAP sensor

7. Surge hose

8. EVAP canister

9. Purge hose

10. EVAP system purge control solenoid valve

“A”: Fuel

“B”: HC vapor

“C”: Fresh air

“D”: Vacuum

I947H1120005-02 email: [email protected] / www.motomatrix.co.uk

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1B-6 Emission Control Devices:

Schematic and Routing Diagram

PAIR System Hose Routing Diagram

“F”

“ b ”

B947H11202001

2

“ a ”

“ b ”

“C”

“D”

“B”

“E”

“A”

“ c ”

1

“ b ”

1. PAIR control solenoid valve

2. PAIR reed valve

“A”: White marking (hidden side)

“B”: Yellow marking

“B”

“C”: Blue marking

“D”: Red marking

“E”: Face the clamp end to the top.

“F”: Make sure the clamp is not contacted to the frame or air cleaner box.

“a”: 90

°

“b”: 45

°

“c”: 15

°

I947H1120006-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices: 1B-7

EVAP Canister Hose Routing Diagram (Only for E-33)

B947H11202002

6

5

2

“D”

“B”

4

2

“A”

“C”

“E”

1

“F”

“G”

3

“H”

“J”

3

3

3

2

7

2

1

“L”

3

“I”

“A”

6

3

2

2

6

1

“K”

1. EVAP system purge control solenoid valve

2. Surge hose

3. Purge hose

4. Fuel shut-off valve

5. Rear fender

6. EVAP canister

7. Seat hook

“A”: White marking

“B”: Yellow marking

“C”: UP

“D”: Face the clamp end downward.

“E”: Face the clamp end to the left.

“F”: Pass the hoses above the harness.

“G”: Pass the hoses between the seat rail and battery holder.

I947H1120007-03

“H”: Stick the clamp firmly in this area.

“I”: Pass the hoses inside the parts holder.

“J”: Face the clamp end forward.

“K”: Face the clamp end backward.

“L”: Face the clamp end to the outside.

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1B-8 Emission Control Devices:

Repair Instructions

Heated Oxygen Sensor (HO2S) Removal and

Installation

B947H11206001

Removal

!

WARNING

Do not remove the HO2 sensor while it is hot.

!

CAUTION

• Be careful not to expose the HO2 sensor to excessive shock.

• Do not use an impact wrench when removing or installing the HO2 sensor.

• Be careful not to twist or damage the HO2 sensor lead wires.

1) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

2) Disconnect the HO2 sensor coupler (1).

Installation

Install the HO2 sensor in the reverse order of removal.

Pay attention to the following points:

!

CAUTION

Do not apply oil or other materials to the sensor air hole.

• Tighten the HO2 sensor to the specified torque.

Tightening torque

HO2 sensor (a): 25 N·m (2.5 kgf-m, 18.0 lbf-ft)

(a)

1

3) Remove the HO2 sensor (2).

2

I947H1120008-01

I947H1120010-01

Heated Oxygen Sensor (HO2S) Inspection

B947H11206002

Refer to “DTC “C44” (P0130/P0135): HO2 Sensor

(HO2S) Circuit Malfunction” in Section 1A (Page 1A-

103).

PAIR Reed Valve Removal and Installation

B947H11206003

Removal

1) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

3) Remove the PAIR control solenoid valve (1) along with the PAIR reed valve covers (2). Refer to “PAIR

Control Solenoid Valve Removal and Installation”

(Page 1B-9).

1

I947H1120009-01

2

I947H1120011-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices: 1B-9

4) Remove the PAIR reed valves (3).

3) Remove the PAIR control solenoid valve (1) along with the PAIR reed valve covers (2).

1

3

I947H1120013-01

Installation

Install the PAIR reed valve in the reverse order of removal. Pay attention to the following points:

• Apply thread lock to the PAIR reed valve cover bolts and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

PAIR reed valve cover bolt (a): 10 N·m (1.0 kgf-m,

7.0 lbf-ft)

2

I947H1120015-02

4) Disconnect the PAIR control solenoid valve coupler

(3).

3

I947H1120016-02

5) Disconnect the PAIR hoses (4).

(a)

(a)

I947H1120014-02

PAIR Control Solenoid Valve Removal and

Installation

B947H11206004

Removal

1) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

4

I947H1120042-01

Installation

Install the PAIR control solenoid valve in the reverse order of removal. Pay attention to the following point:

• Connect the PAIR hoses properly. Refer to “PAIR

System Hose Routing Diagram” (Page 1B-6).

PAIR System Inspection

B947H11206005

PAIR Hose

1) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

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1B-10 Emission Control Devices:

3) Inspect the PAIR hoses for wear or damage. If it is worn or damaged, replace the PAIR hose with a new one. Refer to “PAIR System Hose Routing Diagram”

(Page 1B-6).

2) Check that air flows through the air inlet port to the air outlet ports. If air does not flow out, replace the

PAIR control solenoid valve with a new one.

I947H1120017-01

4) Reinstall the removed parts.

PAIR Reed Valve

1) Remove the PAIR reed valves. Refer to “PAIR Reed

Valve Removal and Installation” (Page 1B-8).

2) Inspect the reed valves for carbon deposit.

If carbon deposit is found on the reed valve, replace the PAIR reed valve with a new one.

I947H1120019-01

3) 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 condition.

I947H1120018-01

3) Reinstall the PAIR reed valves. Refer to “PAIR Reed

Valve Removal and Installation” (Page 1B-8).

PAIR Control Solenoid Valve

NOTE

PAIR control solenoid valve can be checked without removing it from the motorcycle.

Refer to “DTC “C49” (P1656): PAIR Control

Solenoid Valve Circuit Malfunction” in

Section 1A (Page 1A-121).

1) Remove the PAIR control solenoid valve. Refer to

“PAIR Control Solenoid Valve Removal and

Installation” (Page 1B-9).

12V

I947H1120020-01

4) Check the resistance between the terminals of the

PAIR control solenoid valve.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

PAIR control solenoid valve resistance

20 – 24

Ω

at 20 – 30

°

C (68 – 86

°

F)

(A)

I947H1120021-01

5) Reinstall the PAIR control solenoid valve. Refer to

“PAIR Control Solenoid Valve Removal and

Installation” (Page 1B-9).

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Emission Control Devices: 1B-11

4) Remove the crankcase breather (PCV) cover (2).

Crankcase Breather (PCV) Hose Inspection

B947H11206006

Inspect the crankcase breather (PCV) hose in the following procedures:

1) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

2) Inspect the crankcase breather (PCV) hose (1) for wear and damage.

If it is worn or damaged, replace the crankcase breather (PCV) hose with a new one.

3) Check that the crankcase breather (PCV) hose (1) is securely connected.

2

I947H1120024-02

Installation

Installation is in the reverse order of removal.

Pay attention to the following points:

• Apply bond to the hatching part of crankcase breather

(PCV) cover.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

1

I947H1120022-01

4) Install the removed parts.

Crankcase Breather (PCV) Hose / Reed Valve /

Cover Removal and Installation

B947H11206007

Removal

1) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

3) Disconnect the crankcase breather (PCV) hose (1).

• Fit the clamp to the bolt “A”.

I947H1140293-01

1

I947H1120023-01

“A”

I947H1120025-03

• Connect the crankcase breather (PCV) hose securely.

Refer to “Throttle Body Construction” in Section 1D

(Page 1D-9).

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1B-12 Emission Control Devices:

3) Remove the EVAP canister (3) from the bracket.

Crankcase Breather (PCV) Cover Inspection

B947H11206008

Inspect the crankcase breather (PCV) cover in the following procedures:

1) Remove the crankcase breather (PCV) cover. Refer to “Crankcase Breather (PCV) Hose / Reed Valve /

Cover Removal and Installation” (Page 1B-11).

2) Inspect the crankcase breather (PCV) cover for carbon deposit. If carbon deposit is found in the crankcase breather (PCV) cover, remove the carbon.

3

2

1

I947H1120026-01

3) Reinstall the crankcase breather (PCV) cover. Refer to “Crankcase Breather (PCV) Hose / Reed Valve /

Cover Removal and Installation” (Page 1B-11).

I947H1120027-01

Installation

1) Install the EVAP canister as shown in the EVAP canister hose routing diagram. Refer to “EVAP

Canister Hose Routing Diagram (Only for E-33)”

(Page 1B-7).

2) Reinstall the removed parts.

EVAP System Purge Control Solenoid Valve

Removal

1) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

2) Disconnect the coupler (1) and purge hoses (2).

3) Remove the EVAP system purge control solenoid valve (3) with the bracket.

Evaporative Emission Control System Removal and Installation (Only for E-33)

B947H11206010

Hose

Removal

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Remove the frame cover assembly. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

3) Remove the EVAP hoses as shown in the EVAP canister hose routing diagram. Refer to “PAIR

System Hose Routing Diagram” (Page 1B-6).

Installation

1) Install the EVAP hoses as shown in the EVAP canister hose routing diagram. Refer to “EVAP

Canister Hose Routing Diagram (Only for E-33)”

(Page 1B-7).

2) Reinstall the removed parts.

EVAP Canister

Removal

1) Remove the frame cover assembly. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

2) Disconnect the surge hose (1) and purge hose (2).

3

2

1

I947H1120028-01

4) Remove the EVAP system purge control solenoid valve from the bracket.

I947H1120029-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices: 1B-13

6) Disconnect the license plate light coupler (2).

Installation

Install the EVAP system purge control solenoid valve in the reverse order of removal. Pay attention to the following point:

• Tighten the EVAP system purge control solenoid valve mounting nut to the specified torque.

Tightening torque

EVAP system purge control solenoid valve mounting nut (a): 6.5 N·m (0.65 kgf-m, 4.5 lbf-ft)

2

1

I947H1120031-01

7) Remove the rear fender (rear) (3).

(a)

I947H1120030-01

• Tighten the EVAP system purge control solenoid valve bracket bolt.

Tightening torque

EVAP system purge control solenoid valve bracket bolt (b): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

Remove the battery mat (4).

3

(b)

I947H1120032-01

4

I947H1120041-01

Fuel Shut-off Valve

Removal

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Remove the battery. Refer to “Battery Removal and

Installation” in Section 1J (Page 1J-11).

3) Remove the ECM. Refer to “ECM Removal and

Installation” in Section 1C (Page 1C-1).

4) Remove the frame cover assembly. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

5) Disconnect the cooling fan relay (1) from the rear fender (front).

I947H1120033-01

9) Disconnect the fuse box (5), AP sensor (6) and TO sensor (7) from the rear fender (front).

10) Remove the rear fender (front) mounting bolt (8).

5

6

7

8

I947H1120034-01 email: [email protected] / www.motomatrix.co.uk

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1B-14 Emission Control Devices:

11) Disconnect the surge hose (9).

9

EVAP Canister

Inspect the EVAP canister for damage to the body. If any defect is found, replace the EVAP canister with a new one.

I947H1120035-01

12) Move the rear fender (front) backward.

13) Disconnect the surge hose (10).

14) Remove the bracket (11) and fuel shaft-off valve

(12).

12

11

10

I947H1120036-01

Installation

Install the fuel shut-off valve in the reverse order of removal. Pay attention to the following point:

• Install the fuel shut-off valve as shown in the EVAP canister hose routing diagram. Refer to “EVAP

Canister Hose Routing Diagram (Only for E-33)”

(Page 1B-7).

Evaporative Emission Control System

Inspection (Only for E-33)

B947H11206011

Refer to “Evaporative Emission Control System Removal and Installation (Only for E-33)” (Page 1B-12).

Hose

Inspect the hoses for wear or damage. If it is worn or damage, replace the hose with a new one.

NOTE

Make sure that the hoses are securely connected.

I947H1120037-01

EVAP System Purge Control Solenoid Valve

NOTE

EVAP system purge control solenoid valve can be checked without removing it from the motorcycle. Refer to “DTC “C62” (P0443):

EVAP System Purge Control Solenoid Valve

Circuit Malfunction (E-33 only)” in Section 1A

(Page 1A-127).

1) Check that no air flows through both of the air inlet and outlet ports. If air flows out, replace the EVAP system purge control solenoid valve with a new one.

I947H1120038-01

2) Connect the 12 V battery to the terminals of the

EVAP system purge control solenoid valve and check the air flow. If air flows out, the solenoid valve is in normal condition.

I947H1120039-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Emission Control Devices: 1B-15

3) Check the resistance between the terminals of the

EVAP system purge control solenoid valve. If the resistance is not within the standard range, replace the EVAP system purge control solenoid valve with a new one.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

EVAP system purge control solenoid valve resistance

Approx. 32

Ω

at 20

°

C (68

°

F)

Fuel Shut-off Valve

!

WARNING

Gasoline and gasoline vapor is toxic. A small amount of fuel remains in the fuel shut-off valve when checking it. Do not swallow the fuel when blowing the fuel shut-off valve.

1) When air is blown into the fuel shut-off valve with its side “A” positioned upward, the air can pass through to the canister side.

“A”

(A)

I947H1120040-01

I823H1120037-01

2) When air is blown into the fuel shut-off valve with its side “A” positioned sideways, the air cannot pass through to the canister side. If the fuel shut-off valve operates otherwise, it must be replaced.

“A”

I823H1120038-02 email: [email protected] / www.motomatrix.co.uk

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1B-16 Emission Control Devices:

Specifications

Service Data

FI sensors

Item

HO2 sensor output voltage

HO2 sensor heater resistance

PAIR control solenoid valve resistance

EVAP system purge control solenoid valve resistance

Specification

0.3 V and less at idle speed

0.6 V and more at 5 000 r/min

6.7 – 9.5

Ω

at 23

°

C (73

°

F)

20 – 24

Ω

at 20 – 30

°

C (68 – 86

°

F)

Approx. 32

Ω

at 20

°

C (68

°

F)

B947H11207001

Note

E-33 only

Tightening Torque Specifications

Fastening part

HO2 sensor

PAIR reed valve cover bolt

EVAP system purge control solenoid valve mounting nut

EVAP system purge control solenoid valve bracket bolt

N

⋅

m

25

10

6.5

10

Tightening torque kgf-m

2.5

1.0

lbf-ft

18.0

7.0

B947H11207002

Note

)

(Page 1B-8)

)

(Page 1B-9)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

Sealant

Material

Thread lock cement

SUZUKI recommended product or Specification

SUZUKI BOND No.1207B or

Note

P/No.: 99000–31140

)

(Page 1B-11) equivalent

THREAD LOCK CEMENT SUPER P/No.: 99000–32110

)

(Page 1B-9)

“1322” or equivalent

B947H11208001

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1B-10) /

)

(Page 1B-15)

B947H11208002 email: [email protected] / www.motomatrix.co.uk

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Engine Electrical Devices: 1C-1

8Engine

Engine Electrical Devices

Precautions

Precautions for Engine Electrical Device

B947H11300001

Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00

(Page 00-2).

Component Location

Engine Electrical Components Location

Refer to “Electrical Components Location” in Section 0A (Page 0A-7).

Diagnostic Information and Procedures

Engine Symptom Diagnosis

Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-8).

B947H11303001

B947H11304001

Repair Instructions

ECM Removal and Installation

B947H11306001

Removal

1) Remove the frame covers. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Disconnect the battery (–) lead wire.

3) Remove the tool set (1) and prop stay (2).

5) Remove the electric parts holder bracket (5).

3

5

4

1

I947H1130002-01

6) Disconnect the couplers and remove the ECM (6).

2

6

I947H1130001-01

4) Disconnect the hose clamp (3) (E-33 only) and starter relay (4).

I947H1130003-01

Installation

Install the ECM in the reverse order of removal.

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1C-2 Engine Electrical Devices:

CMP Sensor Inspection

B947H11306002

Refer to “DTC “C11” (P0340): CMP Sensor Circuit

Malfunction” in Section 1A (Page 1A-29).

CKP Sensor Removal and Installation

Removal

B947H11306005

1) Remove the clutch cover. Refer to “Clutch Removal” in Section 5C (Page 5C-5).

2) Remove the CKP sensor (1).

CMP Sensor Removal and Installation

B947H11306003

Removal

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Remove the PAIR control solenoid valve. Refer to

“PAIR Control Solenoid Valve Removal and

Installation” in Section 1B (Page 1B-9).

3) Disconnect the coupler (1) and remove the CMP sensor (2).

1

1

2

I947H1130004-02

Installation

Install the CMP sensor in the reverse order of removal.

Pay attention to the following points:

!

CAUTION

When installing the CMP sensor, make sure to clean the sensor surface.

• Tighten the CMP sensor bolt (1) to the specified torque.

Tightening torque

CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

I947H1130006-01

Installation

Install the CKP sensor in the reverse order of removal.

Refer to “Clutch Installation” in Section 5C (Page 5C-7).

IAP Sensor Inspection

B947H11306006

Refer to “DTC “C13” (P0105-H/L): IAP Sensor Circuit

Malfunction” in Section 1A (Page 1A-35).

IAP Sensor Removal and Installation

B947H11306007

Removal

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Disconnect the coupler (1) and vacuum hose (2).

3) Remove the IAP sensor (3) from the air cleaner box.

3

1

1

(a)

2

I947H1130007-01

Installation

Install the IAP sensor in the reverse order of removal.

I947H1130005-02

CKP Sensor Inspection

B947H11306004

Refer to “CKP Sensor Inspection” in Section 1H

(Page 1H-9).

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TP Sensor Inspection

B947H11306008

Refer to “DTC “C14” (P0120-H/L): TP Sensor Circuit

Malfunction” in Section 1A (Page 1A-43).

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Engine Electrical Devices: 1C-3

TP Sensor Removal and Installation

B947H11306009

Refer to “Throttle Body Disassembly and Assembly” in

Section 1D (Page 1D-11).

4) Check the position of the bar in the left of C code displayed on the LCD panel.

Removal

1) Remove the throttle body. Refer to “Throttle Body

Removal and Installation” in Section 1D (Page 1D-

10).

2) Remove the TP sensor (1) with the special tool.

Special tool

: 09930–11950 (Torx wrench (5 mm))

NOTE

Prior to disassembly, mark the TP sensor’s original position with a paint or scribe for accurate reinstallation.

“A”: Incorrect position

“A”

“B”

“A”

“B”: Correct position

I823H1130022-01

5) If the TP sensor adjustment is necessary, turn off the engine and lift up the throttle body from the intake pipes. Refer to “Throttle Body Removal and

Installation” in Section 1D (Page 1D-10).

6) Loosen the TP sensor mounting screw using the special tool and turn the TP sensor to bring the bar to the correct position.

Special tool

: 09930–11950 (Torx wrench (5 mm))

1

I947H1130008-01

Installation

Install the TP sensor in the reverse order of removal.

Refer to “Throttle Body Disassembly and Assembly” in

Section 1D (Page 1D-11).

TP Sensor Adjustment

B947H11306010

Inspect the TP sensor setting position and adjust it if necessary in the following procedures:

1) Connect the special tool (Mode select switch) to the dealer mode coupler. Refer to “Self-Diagnostic

Procedures” in Section 1A (Page 1A-12).

Special tool

: 09930–82720 (Mode selection switch)

2) Warn up the engine and keep it running in idling speed.

3) Turn the mode select switch ON.

I947H1130009-01

7) Tighten the TP sensor mounting screw to the specified torque.

Tightening torque

TP sensor mounting screw: 3.5 N·m (0.35 kgfm, 2.5 lbf-ft)

Reinstall the throttle body.

9) Turn on the engine and make sure that the TP sensor bar is at the correct position.

10) Turn off the engine and reinstall the removed parts.

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1C-4 Engine Electrical Devices:

ECT Sensor Removal and Installation

B947H11306011

Removal

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Drain engine coolant. Refer to “Cooling System

Inspection” in Section 0B (Page 0B-12).

3) Disconnect the coupler and remove the ECT sensor

(1).

!

CAUTION

Take special care when handling the ECT sensor. It may cause damage if it gets an excessive impact.

1

I947H1130010-01

Installation

Install the ECT sensor in the reverse order of removal.

Pay attention to the following points:

• Tighten the ECT sensor (1) to the specified torque.

!

CAUTION

Use new gasket washer to prevent engine coolant leakage.

Tightening torque

ECT sensor (a): 18 N·m (1.8 kgf-m, 13.0 lbf-ft)

ECT Sensor Inspection

B947H11306012

Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit

Malfunction” in Section 1A (Page 1A-50).

Inspect the ECT sensor in the following procedures:

1) Remove the ECT sensor. Refer to “ECT Sensor

Removal and Installation” (Page 1C-4).

2) Connect the ECT sensor (1) to the circuit tester and place it in the oil (2) contained in a pan, which is placed on a stove.

3) Heat the oil to raise its temperature slowly and read the column thermometer (3) and ohmmeter.

If the ECT sensor ohmic value does not change in the proportion indicated, replace it with a new one.

!

CAUTION

• Take special care when handling the ECT sensor. It may cause damage if it gets an excessive sharp impact.

• Do not contact the ECT sensor and column thermometer with a pan.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

ECT sensor specification

Temperature

20

°

C (68

°

F)

50

°

C (122

°

F)

80

°

C (176

°

F)

110

°

C (230

°

F)

Standard resistance

Approx. 2.45 k

Ω

Approx. 0.811 k

Ω

Approx. 0.318 k

Ω

Approx. 0.142 k

Ω

3

1

(A)

1

(a)

I947H1130011-01

• Pour engine coolant. Refer to “Cooling System

Inspection” in Section 0B (Page 0B-12).

2

I718H1130014-01

4) Install the ECT sensor. Refer to “ECT Sensor

Removal and Installation” (Page 1C-4).

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Engine Electrical Devices: 1C-5

IAT Sensor Removal and Installation

B947H11306013

Removal

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Remove the IAT sensor (1) from the air cleaner box.

!

CAUTION

• The IAT sensor operative temperature range is –30 – 120

°

C (–22 – 248

°

F).

• Do not heat the oil up to 120

°

C (248

°

F) or more for this inspection.

IAT sensor specification

Temperature

20

40

°

°

100

°

C (68

°

C (104

C (212

°

F)

°

F)

F)

Standard resistance

Approx. 2.58 k

Approx. 1.14 k

Approx. 0.16 k

Ω

Ω

Ω

AP Sensor Inspection

B947H11306015

Refer to “DTC “C22” (P1450-H/L): AP Sensor Circuit

Malfunction” in Section 1A (Page 1A-60).

1

I947H1130012-01

Installation

Install the IAT sensor in the reverse order of removal.

Pay attention to the following point:

• Tighten the IAT sensor screw (1) to the specified torque.

Tightening torque

IAT sensor mounting screw (a): 1.3 N·m (0.13 kgfm, 1.0 lbf-ft)

AP Sensor Removal and Installation

B947H11306016

Removal

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Disconnect the starter relay (1) from the holder.

1

I947H1130014-01

3) Disconnect the coupler (2) and remove the AP sensor (3).

1

(a)

I947H1130013-01

IAT Sensor Inspection

B947H11306014

Refer to “DTC “C21” (P0110-H/L): IAT Sensor Circuit

Malfunction” in Section 1A (Page 1A-55).

Inspect the IAT sensor.

NOTE

IAT sensor resistance measurement method is the same way as that of the ECT sensor.

Refer to “ECT Sensor Inspection” (Page 1C-

4).

3

2 email: [email protected] / www.motomatrix.co.uk

I947H1130015-01

Installation

Install the AP sensor in the reverse order of removal.

TO Sensor Inspection

B947H11306017

Refer to “DTC “C23” (P1651-H/L): TO Sensor Circuit

Malfunction” in Section 1A (Page 1A-68).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1C-6 Engine Electrical Devices:

2) Disconnect the STVA lead wire coupler (1).

TO Sensor Removal and Installation

B947H11306018

Removal

1) Remove the AP sensor. Refer to “AP Sensor

Removal and Installation” (Page 1C-5).

2) Disconnect the coupler (1) and remove the TO sensor (2).

1

2

1

I947H1130016-01

Installation

Install the TO sensor in the reverse order of removal.

Pay attention to the following point:

• When installing the TO sensor, bring the “UP” letters

“A” upward.

3) Insert the needle pointed probes to the STP sensor coupler (between Y/W and B/Br wires).

4) Turn the ignition switch ON.

I947H1130018-01

5) Close the secondary throttle valve by finger and measure the STP sensor output voltage.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

STP sensor output voltage

ST valve is fully closed: Approx. 0.7 V ((+): Y/W –

(–): B/Br)

“A”

I718H1130017-01

I947H1130017-01

STP Sensor Inspection

B947H11306019

Refer to “DTC “C29” (P1654-H/L): Secondary Throttle

Position Sensor (STPS) Circuit Malfunction” in Section

1A (Page 1A-79).

STP Sensor Adjustment

B947H11306020

Adjust the STP sensor in the following procedures:

1) Remove the air cleaner box cover. Refer to “Air

Cleaner Element Removal and Installation” in

Section 1D (Page 1D-6).

V

(A)

(B)

I947H1130019-01

6) Move the throttle body upward by loosing the throttle body mounting screws.

7) Loosen the STP sensor mounting screw using the special tool and adjust the STP sensor until the output voltage comes within the specified value.

Special tool

: 09930–11950 (Torx wrench (5 mm))

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Electrical Devices: 1C-7

Tighten the STP sensor mounting screw to the specified torque.

Tightening torque

STP sensor mounting screw: 3.5 N·m (0.35 kgfm, 2.5 lbf-ft)

STV Actuator Inspection

B947H11306022

Refer to “DTC “C28” (P1655): Secondary Throttle Valve

Actuator (STVA) Malfunction” in Section 1A (Page 1A-

75).

9) Reinstall the removed parts.

I947H1130020-01

STV Actuator Removal and Installation

B947H11306023

Refer to “Throttle Body Disassembly and Assembly” in

Section 1D (Page 1D-11).

!

CAUTION

Never remove the STVA from the throttle body.

ISC Valve Inspection

B947H11306024

Refer to “DTC “C40” (P0505 / P0506 / P0507): ISC Valve

Circuit Malfunction” in Section 1A (Page 1A-94).

STP Sensor Removal and Installation

B947H11306021

Removal

1) Remove the throttle body. Refer to “Throttle Body

Removal and Installation” in Section 1D (Page 1D-

10).

2) Remove the STP sensor (1) with the special tool.

Special tool

: 09930–11950 (Torx wrench (5 mm))

NOTE

Prior to disassembly, mark the STP sensor’s original position with a paint or scribe for accurate reinstallation.

1

ISC Valve Removal and Installation

B947H11306025

Refer to “Throttle Body Disassembly and Assembly” in

Section 1D (Page 1D-11).

!

CAUTION

• Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned to OFF. If the ECM coupler or ISC valve coupler is disconnected within 5 seconds after ignition switch is turned to OFF, there is a possibility of an unusual valve position being written in

ECM and causing an error of ISC valve operation.

• When the throttle body assembly is replaced with a new one, the ISC valve must be set present position. Refer to “ISC

Valve Preset and Opening Initialization”

(Page 1C-8).

I947H1130021-01

Installation

Install the STP sensor in the reverse order of removal.

Refer to “Throttle Body Disassembly and Assembly” in

Section 1D (Page 1D-11).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1C-8 Engine Electrical Devices:

ISC Valve Preset and Opening Initialization

B947H11306026

When removing or replacing the ISC valve, set the ISC valve to the following procedures:

1) Turn the ignition switch ON.

2) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

3) Click the “Active control”.

4) Click the “ISC learned value reset” (1).

NOTE

The leaned value of the ISC valve is set at

Preset position.

2

1

I947H1130022-01

5) Click the “Reset” button (2) to clear the ISC leaned value.

I947H1130024-01

6) Close the SDS tool and turn the ignition switch OFF.

NOTE

The ISC valve opening initialization is automatically started after the ignition switch is turned OFF position.

HO2 Sensor Inspection

B947H11306027

Refer to “DTC “C44” (P0130/P0135): HO2 Sensor

(HO2S) Circuit Malfunction” in Section 1A (Page 1A-

103).

HO2 Sensor Removal and Installation

B947H11306028

Refer to “Heated Oxygen Sensor (HO2S) Removal and

Installation” in Section 1B (Page 1B-8).

GP Switch Inspection

B947H11306029

Refer to “Side-stand / Ignition Interlock System Parts

Inspection” in Section 1I (Page 1I-7).

GP Switch Removal and Installation

B947H11306030

Refer to “Gear Position (GP) Switch Removal and

Installation” in Section 5B (Page 5B-14).

I947H1130023-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Electrical Devices: 1C-9

Specifications

Service Data

FI Sensors

Item

CKP sensor resistance

CKP sensor peak voltage

IAP sensor input voltage

IAP sensor output voltage

TP sensor input voltage

TP sensor output voltage

ECT sensor input voltage

ECT sensor output voltage

ECT sensor resistance

IAT sensor input voltage

IAT sensor output voltage

IAT sensor resistance

AP sensor input voltage

AP sensor output voltage

TO sensor resistance

TO sensor voltage

GP switch voltage

Injector voltage

Ignition coil primary peak voltage

HO2 sensor output voltage

HO2 sensor heater resistance

PAIR control solenoid valve resistance

STP sensor input voltage

STP sensor output voltage

STVA resistance

EVAP system purge control solenoid valve resistance

ISC valve resistance

Closed

Opened

Standard/Specification

142 – 194

Ω

0.5 V and more

4.5 – 5.5 V

Approx. 2.7 V at idle speed

4.5 – 5.5 V

Approx. 1.1 V

Approx. 4.4 V

4.5 – 5.5 V

0.15 – 4.85 V

Approx. 2.45 k

Ω

at 20

°

C (68

°

F)

4.5 – 5.5 V

0.15 – 4.85 V

Approx. 2.58 k

Ω

at 20

°

C (68

°

F)

4.5 – 5.5 V

Normal

Leaning

Approx. 3.6 V at 100 kPa (760 mmHg)

16.5 – 22.3 k

Ω

0.4 – 1.4 V

3.7 – 4.4 V

0.6 V and more

Battery voltage

80 V and more

0.3 V and less at idle speed

0.6 V and more at 5 000 r/min

6.7 – 9.5

Ω

at 23

°

C (73

°

F)

20 – 24

Ω

at 20 – 30

°

C (68 – 86

°

F)

Closed

Opened

4.5 – 5.5 V

Approx. 0.7 V

Approx. 4.1 V

Approx. 6.5

Ω

Approx. 32

Ω

at 20

°

C (68

°

F)

Approx. 80

Ω

at 20

°

C (68

°

F)

B947H11307001

Note

When cranking

When leaning 65

°

From 1st to Top

When cranking

E-33 only

Tightening Torque Specifications

Fastening part

CMP sensor bolt

TP sensor mounting screw

ECT sensor

IAT sensor mounting screw

STP sensor mounting screw

N

⋅

m

10

3.5

18

1.3

3.5

Tightening torque kgf-m

1.0

0.35

1.8

0.13

0.35

lbf-ft

7.0

2.5

13.0

1.0

2.5

B947H11307002

Note

)

(Page 1C-2)

)

(Page 1C-3)

)

(Page 1C-4)

)

(Page 1C-5)

)

(Page 1C-7)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1C-10 Engine Electrical Devices:

Special Tools and Equipment

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1C-4) /

)

(Page 1C-

6)

09900–25009

Needle-point probe set

)

(Page 1C-6)

B947H11308001

09930–11950

Torx wrench (5 mm)

)

(Page 1C-3) /

)

(Page 1C-

3) /

)

(Page 1C-6) /

)

(Page 1C-7)

09930–82720

Mode selection switch

)

(Page 1C-3) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-1

Engine

Engine Mechanical

Schematic and Routing Diagram

Camshaft and Sprocket Assembly Diagram

B947H11402001 email: [email protected] / www.motomatrix.co.uk

I947H1140249-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-2 Engine Mechanical:

Throttle Cable Routing Diagram

“A”

B947H11402002

1

2

3

2

3

1

4

2

(a)

“ a ”

1

“ a ”

(a)

3

“ a ”

“B”

2

3

“C”

3

“D”

1

1. Throttle cable No. 1

2. Throttle cable No. 2

3. Clutch cable

4. Front brake hose

“A”: Pass the throttle cables in front of the front brake hose.

I947H1140250-02

“B”: Pass the clutch cable above the right air intake pipe.

“C”: Clamp the clutch cable at the white taping point and make sure it does not slip out of the clamped position when steering.

Cut off the excess tip of the clamp.

“D”: Pass the clutch cable outside of the regulator/rectifier harness and water bypass hose.

: 4.5 Nm (0.45 kgf-m, 3.0 lbf-ft)

“a”: 0 – 1 mm (0 – 0.04 in) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-3

Diagnostic Information and Procedures

Engine Mechanical Symptom Diagnosis

B947H11404001

Refer to “Engine Symptom Diagnosis” in Section 1A

(Page 1A-8).

6) Keep the throttle grip in the fully-opened position.

Compression Pressure Check

B947H11404002

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 maintenance records kept at your dealership should include compression readings for each maintenance service.

NOTE

• Before checking the engine for compression pressure, make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted.

• Make sure that the battery is in fullycharged condition.

1) Warm up the engine.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

3) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” (Page 1D-7).

4) Remove all the spark plugs. Refer to “Ignition Coil and Spark Plug Removal and Installation” in Section

1H (Page 1H-6).

5) Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.

Special tool

(A): 09915–64512 (Compression gauge)

(B): 09915–63311 (Compression gauge attachment)

(A)

I947H1140251-01

7) Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder compression.

Repeat this procedure with the other cylinders.

Compression pressure specification

Standard

1 400 – 1 800 kPa

(14 – 18 kgf/cm

2

,

199 – 256 psi)

Limit

1 000 kPa

(10 kgf/cm

2

,

142 psi)

Difference

200 kPa

(2 kgf/cm

2

,

28 psi)

Low compression pressure can indicate any of the following conditions:

• Excessively worn cylinder walls

• Worn piston or piston rings

• Piston rings stuck in grooves

• Poor valve seating

• Ruptured or otherwise defective cylinder head gasket

Overhaul the engine in the following cases:

• Compression pressure in one of the cylinders is 1

000 kPa (10 kgf/cm

2

, 142 psi) and less.

• The difference in compression pressure between any two cylinders is 200 kPa (2 kgf/cm

2

, 28 psi) and more.

• All compression pressure readings are below 1

400 kPa (14 kgf/cm

2

, 199 psi) even when they measure 1 000 kPa (10 kgf/cm

2

, 142 psi) and more.

9) After checking the compression pressure, reinstall the removed parts.

(B)

I947H1140294-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-4 Engine Mechanical:

Repair Instructions

Engine Components Removable with the Engine in Place

B947H11406001

Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component.

Center of Engine

Item

Air cleaner element

PAIR control solenoid valve

Cylinder head cover

Camshafts

Throttle body

Thermostat

Crankcase breather cover

Starter motor

Oil filter

Oil cooler

Exhaust pipe/Muffler

Removal

Refer to “Air Cleaner

Element Removal and

Installation” (Page 1D-6).

Refer to “PAIR Control

Solenoid Valve Removal and

Installation” in Section 1B

(Page 1B-9).

Refer to “Engine Top Side

Disassembly” (Page 1D-26).

Inspection

Refer to “Air Cleaner

Element Inspection” in

Section 0B (Page 0B-3).

Refer to “PAIR System

Inspection” in Section 1B

(Page 1B-9).

—

Refer to “Engine Top Side

Disassembly” (Page 1D-26).

Refer to “Throttle Body

Removal and Installation”

(Page 1D-10).

Refer to “Thermostat

Removal and Installation” in

Section 1F (Page 1F-10).

Refer to “Crankcase

Breather (PCV) Hose / Reed

Valve / Cover Removal and

Installation” in Section 1B

(Page 1B-11).

Refer to “Starter Motor

Removal and Installation” in

Section 1I (Page 1I-4).

Refer to “Engine Oil and

Filter Replacement” in

Section 0B (Page 0B-10).

Refer to “Oil Cooler / Oil

Cooler Hose Removal and

Installation” in Section 1E

(Page 1E-8).

Refer to “Muffler / Muffler

Chamber / Exhaust Pipe

Removal and Installation” in

Section 1K (Page 1K-11).

Refer to “Camshaft

Inspection” (Page 1D-36).

Refer to “Throttle Body

Inspection and Cleaning”

(Page 1D-16).

Refer to “Thermostat

Inspection” in Section 1F

(Page 1F-11).

Refer to “Crankcase

Breather (PCV) Cover

Inspection” in Section 1B

(Page 1B-12).

Refer to “Starter Motor

Inspection” in Section 1I

(Page 1I-5).

—

—

Refer to “Exhaust System

Inspection” in Section 1K

(Page 1K-13).

Installation

Refer to “Air Cleaner

Element Removal and

Installation” (Page 1D-6).

Refer to “PAIR Control

Solenoid Valve Removal and

Installation” in Section 1B

(Page 1B-9).

Refer to “Engine Top Side

Assembly” (Page 1D-28).

Refer to “Engine Top Side

Assembly” (Page 1D-28).

Refer to “Throttle Body

Removal and Installation”

(Page 1D-10).

Refer to “Thermostat

Removal and Installation” in

Section 1F (Page 1F-10).

Refer to “Crankcase

Breather (PCV) Hose / Reed

Valve / Cover Removal and

Installation” in Section 1B

(Page 1B-11).

Refer to “Starter Motor

Removal and Installation” in

Section 1I (Page 1I-4).

Refer to “Engine Oil and

Filter Replacement” in

Section 0B (Page 0B-10).

Refer to “Oil Cooler / Oil

Cooler Hose Removal and

Installation” in Section 1E

(Page 1E-8).

Refer to “Muffler / Muffler

Chamber / Exhaust Pipe

Removal and Installation” in

Section 1K (Page 1K-11).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-5

Engine Right Side

Item

Cam chain tension adjuster

Clutch cover

Clutch plates

Clutch sleeve hub

Primary driven gear

Oil pump drive sprocket

Gearshift shaft

CKP sensor rotor/Cam chain drive sprocket

Cam chain tensioner

CKP sensor

Starter idle gear

Starter clutch

Starter torque limiter

Removal

Refer to “Engine Top Side

Disassembly” (Page 1D-26).

Refer to “Clutch Removal” in

Section 5C (Page 5C-5).

Refer to “Clutch Removal” in

Section 5C (Page 5C-5).

Refer to “Clutch Removal” in

Section 5C (Page 5C-5).

Refer to “Clutch Removal” in

Section 5C (Page 5C-5).

Refer to “Engine Bottom

Side Disassembly”

(Page 1D-49).

Refer to “Gearshift Shaft /

Gearshift Cam Plate

Removal and Installation” in

Section 5B (Page 5B-17).

Refer to “Engine Bottom

Side Disassembly”

(Page 1D-49).

Refer to “Engine Bottom

Side Disassembly”

(Page 1D-49).

Refer to “CKP Sensor

Removal and Installation” in

Section 1C (Page 1C-2).

Refer to “Starter Clutch

Removal and Installation” in

Section 1I (Page 1I-10).

Refer to “Starter Clutch

Removal and Installation” in

Section 1I (Page 1I-10).

Refer to “Starter Torque

Limiter Removal and

Installation” in Section 1I

(Page 1I-9).

Inspection

Refer to “Cam Chain Tension

Adjuster Inspection”

(Page 1D-38).

Installation

Refer to “Engine Top Side

Assembly” (Page 1D-28).

—

Refer to “Clutch Installation” in Section 5C (Page 5C-7).

Refer to “Clutch Parts

Inspection” in Section 5C

(Page 5C-11).

Refer to “Clutch Installation” in Section 5C (Page 5C-7).

—

Refer to “Clutch Installation” in Section 5C (Page 5C-7).

Refer to “Clutch Parts

Inspection” in Section 5C

(Page 5C-11).

Refer to “Clutch Installation” in Section 5C (Page 5C-7).

Refer to “Gearshift Linkage

Inspection” in Section 5B

(Page 5B-20).

—

—

Refer to “Cam Chain

Tensioner Inspection”

(Page 1D-40).

Refer to “CKP Sensor

Inspection” in Section 1C

(Page 1C-2).

Refer to “Engine Bottom

Side Assembly” (Page 1D-

56).

Refer to “Gearshift Shaft /

Gearshift Cam Plate

Removal and Installation” in

Section 5B (Page 5B-17).

Refer to “Engine Bottom

Side Assembly” (Page 1D-

56).

Refer to “Engine Bottom

Side Assembly” (Page 1D-

56).

Refer to “CKP Sensor

Removal and Installation” in

Section 1C (Page 1C-2).

—

Refer to “Starter Clutch

Removal and Installation” in

Section 1I (Page 1I-10).

Refer to “Starter Clutch Refer to “Starter Clutch

Inspection” in Section 1I

(Page 1I-11).

Refer to “Starter Torque

Limiter Inspection” in Section

1I (Page 1I-10).

Removal and Installation” in

Section 1I (Page 1I-10).

Refer to “Starter Torque

Limiter Removal and

Installation” in Section 1I

(Page 1I-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-6 Engine Mechanical:

Engine Left Side

Item

Speed sensor

Engine sprocket

Drive chain

Gear position switch

Generator cover

Generator rotor

Water pump

Oil pressure switch

Removal

Refer to “Speed Sensor

Removal and Installation” in

Section 9C (Page 9C-5).

Refer to “Engine Sprocket

Removal and Installation” in

Section 3A (Page 3A-2).

Refer to “Drive Chain

Replacement” in Section 3A

(Page 3A-7).

Refer to “Gear Position (GP)

Switch Removal and

Installation” in Section 5B

(Page 5B-14).

Refer to “Generator Removal and Installation” in Section

1J (Page 1J-4).

Refer to “Generator Removal and Installation” in Section

1J (Page 1J-4).

Refer to “Water Pump

Removal and Installation” in

Section 1F (Page 1F-13).

Refer to “Oil Pressure Switch

Removal and Installation” in

Section 1E (Page 1E-9).

Inspection

Refer to “Speed Sensor

Inspection” in Section 9C

(Page 9C-6).

Refer to “Drive Chain

Related Parts Inspection” in

Section 3A (Page 3A-5).

Refer to “Drive Chain

Inspection and Adjustment” in Section 0B (Page 0B-14).

Refer to “Gear Position (GP)

Switch Inspection” in Section

5B (Page 5B-13).

—

—

Refer to “Water Pump

Related Parts Inspection” in

Section 1F (Page 1F-17).

Refer to “Oil Pressure

Indicator Inspection” in

Section 9C (Page 9C-6).

Installation

Refer to “Speed Sensor

Removal and Installation” in

Section 9C (Page 9C-5).

Refer to “Engine Sprocket

Removal and Installation” in

Section 3A (Page 3A-2).

Refer to “Drive Chain

Replacement” in Section 3A

(Page 3A-7).

Refer to “Gear Position (GP)

Switch Removal and

Installation” in Section 5B

(Page 5B-14).

Refer to “Generator Removal and Installation” in Section

1J (Page 1J-4).

Refer to “Generator Removal and Installation” in Section

1J (Page 1J-4).

Refer to “Water Pump

Removal and Installation” in

Section 1F (Page 1F-13).

Refer to “Oil Pressure Switch

Removal and Installation” in

Section 1E (Page 1E-9).

3) Remove the air cleaner element (2).

Air Cleaner Element Removal and Installation

B947H11406002

Removal

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Remove the air cleaner box cover (1).

2

1

I947H1140001-02

Installation

Installation is in the reverse order of removal.

I947H1140002-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-7

7) Remove the air cleaner box.

Air Cleaner Box Removal and Installation

B947H11406003

Removal

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Remove the air cleaner box cover. Refer to “Air

Cleaner Element Removal and Installation”

(Page 1D-6).

3) Remove the air cleaner mounting bolt.

4

5

4) Remove the air cleaner box bolt.

I947H1140004-01

5) Disconnect the IAT sensor coupler (1), PCV hose (2) and PAIR hose (3).

1

2

3

I947H1140003-01

I947H1140005-01

6) Disconnect ISC hose (4) and IAP sensor (5).

email: [email protected] / www.motomatrix.co.uk

I947H1140006-01

Installation

Install the air cleaner box in the reverse order of removal. Pay attention to the following point:

• Route the hoses properly. Refer to “Throttle Body

Construction” (Page 1D-9).

• Tighten air cleaner box bolts in the ascending order.

Refer to “Throttle Body Construction” (Page 1D-9).

Air Cleaner Element Inspection and Cleaning

B947H11406004

Refer to “Air Cleaner Element Inspection” in Section 0B

(Page 0B-3).

Throttle Cable Removal and Installation

B947H11406005

Removal

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” (Page 1D-7).

2) Remove the right handlebar switch box. Refer to

“Handlebar Removal and Installation” in Section 6B

(Page 6B-2).

3) Remove the throttle cables as shown in the cable routing diagram. Refer to “Throttle Cable Routing

Diagram” (Page 1D-2).

Installation

Install the throttle cables in the reverse order of removal.

Pay attention to the following points:

• Install the throttle cables as shown in the cable routing diagram. Refer to “Throttle Cable Routing Diagram”

(Page 1D-2).

• Check the throttle cable play and proper operation.

Refer to “Throttle Cable Play Inspection and

Adjustment” in Section 0B (Page 0B-12).

Throttle Cable Inspection

B947H11406006

Check that the throttle grip moves smoothly from full open to full close. If it does not move smoothly, lubricate the throttle cables.

Throttle Cable Play Inspection and Adjustment

B947H11406007

Refer to “Throttle Cable Play Inspection and Adjustment” in Section 0B (Page 0B-12).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-8 Engine Mechanical:

Throttle Body Components

1

(a)

2

8

6

5 3 1

(a)

(a)

3

3

8

7

3

4 10

3

11

B947H11406008

(a)

3

9

(b)

3

(d)

(c)

12

[A]

1. Fuel delivery pipe

2. Fuel delivery pipe T-joint

3. O-ring

4. TP sensor

5. STP sensor

6. Secondary fuel injector

7. Primary fuel injector

8. Cushion seal

9. ISC valve

10. Air screw

11. Vacuum hose

12. EVAP system purge control solenoid valve

[A]: For E-33 only

: 3.5 Nm (0.35 kgf-m, 2.5 lbf-ft)

: 2 Nm (0.2 kgf-m, 1.5 lbf-ft)

I947H1140252-03

: 6.5 Nm (0.65 kgf-m, 4.5 lbf-ft)

: 10 Nm (1.0 kgf-m, 7.0 lbf-ft)

: Apply engine oil.

: Do not reuse.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-9

Throttle Body Construction

B947H11406009

1

(a)

(b)

(c)

(d)

3

FWD

“D”

2

“A”

“K”

“G”

“B”

“C”

(d)

4

(e)

5

“5”

“2”

“3”

“H”

(d)

“J”

“1” “6”

“I”

“F”

“4”

“5”

“4”

“7”

“1”

“2”

“6”

“3”

“H”

(f)

“G”

1. Intake pipe

2. EVAP system purge control solenoid valve

(E-33 only)

3. EVAP canister (E-33 only)

4. IAT sensor

5. ISC valve hose

6. HO2 sensor

“A”: Face the clamp end left side.

“B”: Yellow marking should face upward.

“E”

6

(g)

“C”: Face the end of clamps upward and keep clearance from the seat rail and fuel tank.

“D”: Arrange the hose and wiring harnesses in parallel to the frame bridge.

“E”: Yellow paint should face downward.

“F”: Face the clamp end backward.

“G”: Face the clamp end downward.

“H”: Tighten the bolts in the ascending of numbers.

“I”: Route the fuel pump lead wire above the fuel nipple.

“J”: Pass the HO2 sensor lead wire between the frame and engine.

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I947H1140253-03

“K”: Face the clamp end right side.

: 8.5 N

⋅ m (0.85 kgf-m, 6.5 lbf-ft)

: 1.5 N

⋅ m (0.15 kgf-m, 1.0 lbf-ft)

: 7 N

⋅ m (0.7 kgf-m, 5.0 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: 1.3 N

⋅ m (0.13 kgf-m, 1.0 lbf-ft)

: 4.3 N

⋅ m (0.43 kgf-m, 3.0 lbf-ft)

: 25 N

⋅ m (2.5 kgf-m, 18.0 lbf-ft)

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-10 Engine Mechanical:

Throttle Body Removal and Installation

B947H11406010

Removal

1) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” (Page 1D-7).

3) Remove the clamps (1).

4) Disconnect the IAP sensor (2) from the vacuum hose.

5) Disconnect the STVA lead wire coupler (3).

6) Disconnect secondary fuel injector couplers (4) and primary fuel injector couplers (5).

7) Disconnect the purge hose (6) from the EVAP system purge control solenoid valve. (E-33 only)

10) Place a rag under the fuel feed hose (9) and disconnect the fuel feed hose from the fuel pump.

!

WARNING

For E-33 models, drain fuel from the fuel tank before disconnecting the fuel feed hose to prevent fuel leakage.

9

4

2 4

1 1

I947H1140007-02

11) Loosen the throttle body clamp screws, left and right.

3

5

6

Remove the clamp (7).

9) Disconnect the ISC valve coupler (8).

I947H1140254-01

8

I947H1140256-01

12) Lift up the throttle body from the intake pipes.

13) Disconnect the STP sensor coupler (10) and TP sensor coupler (11).

10

7

I947H1140255-01

11

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-11

14) Disconnect the throttle cables.

!

CAUTION

After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body.

15) Remove the throttle body.

• Connect the throttle cable No. 1 (3) and throttle cable

No. 2 (4) to the throttle cable drum.

3

“ a ”

4

“ a ”

I947H1140258-01

Installation

Installation is in the reverse order of removal. Pay attention to the following points:

• Connect the primary injector couplers (1) and secondary injector couplers (2) to the respective 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.

2

#1

#2

#3

#4

1

I947H1140259-01

Primary injector Secondary injector

Y/R and Gr/W Y/R and Lg

Y/R and Gr/B

Y/R and Gr/Y

Y/R and Gr/R

Y/R and Lg/W

Y/R and Lg/B

Y/R and Lg/Bl

I837H1140016-01

“a”: 0 – 1 mm (0 – 0.04 in)

• Loosen each throttle cable lock-nut.

• Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance “a” is 0 – 1 mm

(0 – 0.04 in).

• Tighten each lock-nut.

Tightening torque

Throttle cable lock-nut: 4.5 N·m (0.45 kgf-m, 3.0 lbf-ft)

• Adjust the throttle cable play. Refer to “Throttle Cable

Play Inspection and Adjustment” in Section 0B

(Page 0B-12).

• Reset the ISC valve and TP sensor learned values.

Refer to “ISC Valve Reset” (Page 1D-18) and “TP

Reset” (Page 1D-19).

Throttle Body Disassembly and Assembly

B947H11406011

Refer to “Throttle Body Removal and Installation”

(Page 1D-10).

Disassembly

!

CAUTION

Identify the position of each removed part.

Organize the parts in their respective groups so that they can be reinstalled in their original positions.

1) Disconnect the fuel feed hose (1), ISC valve hose (2) and vacuum hoses (3).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-12 Engine Mechanical:

2) Disconnect the purge hose (4). (E-33 only) 5) Remove the fuel pipe (9) from the primary fuel injectors (7).

2

9

7

1

3

4

I947H1140299-01

3) Remove the fuel delivery pipe assembly (5).

!

CAUTION

Be careful not to twist the fuel delivery pipes and T-joint (6) when removing them, or joint part “A” of the fuel delivery pipe get damage.

I947H1140010-01

6) Remove the T-joint (6) from the fuel delivery pipes.

5

“A”

6

I947H1140008-01

4) Remove the primary fuel injectors (7) and secondary fuel injectors (8) from the fuel delivery pipes.

8

6

I947H1140011-01

7) Remove the ISC valve hoses (10) and ISC valve

(11).

10

11

I947H1140012-01

7

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-13

Remove the TP sensor (12) and STP sensor (13) with the special tool.

Special tool

: 09930–11950 (Torx wrench (5 mm))

NOTE

Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation.

!

CAUTION

• These adjusting screws (17), (18) and (19) are factory-adjusted at the time of delivery and do not turn or remove them.

• Do not separate the throttle body.

13

12

I947H1140013-01

!

CAUTION

Never remove the STVA (14) from the throttle body.

14

I947H1140014-01

!

CAUTION

Never remove the throttle valves (15) and secondary throttle valves (16).

17

19

18

I947H1140016-01

Assembly

Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:

• With the secondary throttle valves fully opened, install the STP sensor (Black) and tighten the STP sensor mounting screw to the specified torque.

NOTE

• Apply thin coat of engine oil to the O-ring.

• Align the secondary throttle valve shaft end “A” with the groove “B” of the STP sensor.

• Apply grease to the secondary throttle valve shaft end “A” if necessary.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

Special tool

: 09930–11950 (Torx wrench (5 mm))

Tightening torque

STP sensor mounting screw: 3.5 N·m (0.35 kgfm, 2.5 lbf-ft)

“A”

“B”

I947H1140017-01

15

16

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-14 Engine Mechanical:

NOTE

• Make sure the secondary throttle valves smoothly open and close.

• If necessary, adjust the STP sensor. Refer to “STP Sensor Adjustment” in Section 1C

(Page 1C-6).

NOTE

• Make sure the throttle valves smoothly open and close.

• If necessary, adjust the TP sensor. Refer to

“TP Sensor Adjustment” in Section 1C

(Page 1C-3).

I947H1140018-01

• With the throttle valves fully closed, install the TP sensor (Gray) and tighten the TP sensor mounting screw to the specified torque.

!

CAUTION

• Apply thin coat of engine oil to the O-ring.

• Align the throttle valve shaft end “C” with the groove “D” of the TP sensor.

• Apply grease to the throttle valve shaft end

“C” if necessary.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

Special tool

: 09930–11950 (Torx wrench (5 mm))

Tightening torque

TP sensor mounting screw: 3.5 N·m (0.35 kgf-m,

2.5 lbf-ft)

I947H1140020-01

• Apply a thin coat of engine oil to the O-ring, install the

ISC valve to the throttle body and tighten the ISC valve mounting screw to the specified torque.

Special tool

: 09930–11960 (Torx wrench (4 mm))

Tightening torque

ISC valve mounting screw (a): 2 N·m (0.2 kgf-m,

1.5 lbf-ft)

(a)

I947H1140021-01

“C”

“D”

I947H1140019-01 email: [email protected] / www.motomatrix.co.uk

1

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-15

• Apply thin coat of engine oil to the new O-rings (1) and cushion seals (2).

!

CAUTION

Replace the O-rings and cushion seals with new ones.

1

• Install each fuel injector by pushing it straight to the delivery pipe.

!

CAUTION

Never turn the injector while pushing it.

NOTE

Align the coupler “F” of injector with boss

“G” of the delivery pipe.

“F”

“G”

2

2

“G”

I947H1140022-01

1

“F”

I947H1140025-01

• Install the fuel delivery pipe assembly to the throttle body.

• Tighten the fuel delivery pipe mounting screws to the specified torque.

Tightening torque

Fuel delivery pipe mounting screw (b): 3.5 N·m (

0.35 kgf-m, 2.5 lbf-ft)

I947H1140023-01

• Assemble the fuel delivery pipes so the T-joint is set in proper angle as shown in the figure.

!

CAUTION

Be careful not to twist the fuel delivery pipes and T-joint when installing them, or joint part

“E” of the fuel delivery pipe may get damage.

(b) (b)

I947H1140026-01

• Connect the hoses properly. Refer to “Throttle Body

Construction” (Page 1D-9).

“E”

I947H1140024-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-16 Engine Mechanical:

Throttle Body Inspection and Cleaning

B947H11406012

Refer to “Throttle Body Disassembly and Assembly”

(Page 1D-11).

ISC Valve Visual Inspection

B947H11406013

Visually inspect the ISC valve if necessary.

• Inspect the ISC valve for any carbon deposition defects. Clean or replace the ISC valve if necessary.

Cleaning

!

WARNING

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 with a spray-type carburetor cleaner and blow dry with compressed air.

!

CAUTION

Never clean the throttle body main bore. Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the throttle body components. Do not apply carburetor cleaning chemicals to the rubber and plastic materials.

Inspection

Check following items for any defects or clogging.

Replace the damaged part if necessary.

• O-rings

• Throttle valves

• Secondary throttle valves

• Vacuum hoses

• ISC valve hoses

• Fuel delivery pipes

• Cushion seals

• Fuel injectors

Throttle Valve Synchronization

B947H11406014

Check and adjust the throttle valve synchronization among four cylinders.

1) Start the engine and run it in idling condition for warming up.

2) Stop the warmed-up engine.

3) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

4) Remove the clamps (1).

1

I947H1140027-01

I947H1140308-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-17

5) Disconnect the respective vacuum hoses (2) from vacuum nipples on the throttle body.

6) Disconnect the IAP sensor coupler (3).

9) Start the engine.

10) Click “Data monitor”.

11) Warm up the engine (Engine coolant temp. more than 80

°

C (176

°

F)).

3

I947H1140311-01

12) Click “Active control”.

13) Click “ISC air volume control” (5).

2

I947H1140309-01

7) Connect the respective vacuum tester hoses (4) to the vacuum nipples.

5

4

I947H1140310-01

Set up the SDS tool. (Refer to the SDS operation manual for further details.)

14) Click “ON” button (6) to fix the ISC air volume of four cylinders.

I947H1140300-02

NOTE

When making this synchronization, be sure that the engine coolant temperature is within 80 – 100

°

C

(176 – 212

°

F).

“A”

“B”

6

I947H1140312-01

“A”: Engine speed: Approx 1 150 rpm “B”: ISC valve position: Approx 48 step email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-18 Engine Mechanical:

15) Check for the synchronization of vacuum from #1 to

#4 cylinders.

ISC Valve Reset

B947H11406015

When removing or replacing the throttle body assembly, reset the ISC valve learned value in the following procedures:

1) Turn the ignition switch ON position.

2) Set up the SDS tools. (Refer to the SDS operation manual for further details.)

3) Click “Active control”.

4) Click “ISC learned value reset” (1).

I947H1140313-01

16) Equalize the vacuum of the cylinders by turning each air screw (7) and keep it running at idling speed.

NOTE

Always set the engine rpm at idle rpm.

1

7

I947H1140314-01

17) If the adjustment is not yet correct, remove each air screw and clean them with a spray-type carburetor cleaner and blow dry with a compressed air. Also, clean the air screw passageways.

NOTE

• Slowly turn the air screw clockwise and count the number of turns until the screw is lightly seated.

• Make a note of how many turns were made so the screw can be reset correctly after cleaning.

18) Repeat the procedures from 9) to 16).

19) Close the SDS tool and turn the ignition switch OFF.

20) Disconnect the vacuum tester and reinstall the removed parts.

21) After completing the throttle valve synchronization, clear the DTC and reset the ISC learned value using

SDS tool. Refer to “ISC Valve Preset and Opening

Initialization” in Section 1C (Page 1C-8).

I947H1140301-01

5) Click “Reset” button (2) to clear the ISC learned value.

2

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-19

NOTE

The learned value of the ISC valve is set at

RESET position.

5) Click the “Reset” button (2) to clear the TP learned value.

2

I947H1140303-01

6) Close the SDS tool.

7) Turn the ignition switch OFF position.

NOTE

The ISC valve opening initialization is automatically started after the ignition switch is turned OFF.

TP Reset

B947H11406016

When replacing the throttle body assembly or TP sensor with a new one or reinstalling the TP sensor, reset the

TP learned value in the following procedures:

NOTE

Keep the throttle valves fully closed while resetting the TP learned value.

1) Turn the ignition switch ON.

2) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

3) Click the “Active control”.

4) Click the “TP learned value reset” (1).

I947H1140305-01

NOTE

The leaned value of the TP sensor is set at

Preset position.

I947H1140306-01

6) Close the SDS tool and turn the ignition switch OFF.

1

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-20 Engine Mechanical:

Engine Assembly Removal

B947H11406017

Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps:

1) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

3) Disconnect the battery (–) lead wire (1).

11) Remove the radiator assembly. Refer to “Radiator /

Cooling Fan Motor Removal and Installation” in

Section 1F (Page 1F-6).

12) Disconnect the water/air bleed hose (2) and radiator inlet hose (3).

2

3

I947H1140261-01

13) Remove the horn (4) and radiator heat guard (5).

1

I947H1140260-02

4) Jack up the motorcycle and fix it for safety.

5) Drain engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

6) Drain engine coolant. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

7) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” (Page 1D-7).

9) Remove the throttle body assembly. Refer to

“Throttle Body Removal and Installation” (Page 1D-

10).

10) Remove the oil cooler and hoses. Refer to “Oil

Cooler / Oil Cooler Hose Removal and Installation” in

Section 1E (Page 1E-8).

5

4

I947H1140262-01

14) Remove the radiator/oil cooler mounting bracket (6).

6

I947H1140263-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-21

21) Remove the crankcase breather (PCV) hose (15).

15) Remove the exhaust system components. Refer to

“Muffler / Muffler Chamber / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K-11).

16) Remove the clamp (7).

17) Disconnect the oil pressure switch lead wire coupler

(8), generator lead wire coupler (9) and ECT sensor coupler (10).

15

14

10

9

8

I947H1140267-03

22) Disconnect the PAIR solenoid valve coupler (16).

7

I947H1140264-01

18) Disconnect the GP switch lead wire coupler (11).

16

11

I947H1140265-01

19) Disconnect the starter motor lead wire (12) and engine ground lead wire (13).

I947H1140268-01

23) Disconnect the CMP sensor lead wire coupler (17) and ignition coil couplers (18).

24) Remove the ignition coils.

!

CAUTION

• Do not remove the ignition coil before disconnecting its coupler.

• Do not pry up the ignition coil/plug cap with a screwdriver or a bar to avoid its damage.

• Be careful not to drop the ignition coil/plug cap to prevent its short or open circuit.

12

13

17

I947H1140266-02

20) Disconnect the CKP sensor lead wire coupler (14).

18

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-22 Engine Mechanical:

28) Support the engine using an engine jack.

25) Remove the engine sprocket cover (19). Refer to

“Engine Sprocket Removal and Installation” in

Section 3A (Page 3A-2).

19

I947H1140271-02

26) Remove the dowel pins and clutch push rod (20).

I947H1140274-01

29) Loosen the engine mounting pinch bolts (22) (RH).

30) Remove the engine mounting bolts (23) (RH).

31) Remove the engine mounting bolts (24) (LH).

23

24

20

I947H1140272-03

27) Remove the engine sprocket (21). Refer to “Engine

Sprocket Removal and Installation” in Section 3A

(Page 3A-2).

22

I947H1140275-02

32) Remove the engine mounting nut (25).

33) Remove the engine mounting thrust adjuster locknut (26) with the special tool.

21

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-23

34) Loosen the engine mounting thrust adjuster (27) fully.

Special tool

(A): 09940–14990 (Engine mounting adjust wrench)

NOTE

Do not remove the engine mounting bolt at this stage.

37) Loosen the engine mounting thrust adjuster (30) fully.

Special tool

(A): 09940–14990 (Engine mounting adjust wrench)

NOTE

Do not remove the engine mounting bolt at this stage.

25

28

(A)

27

I947H1140276-03

(A)

30

I947H1140279-03

26

25

I947H1140277-03

29

28

I947H1140280-03

27

I947H1140278-02

35) Remove the engine mounting nut (28).

36) Loosen the engine mounting thrust adjuster lock-nut

(29) with the special tool.

30

I947H1140281-02

38) Remove the engine mounting bolts and gradually lower the front side of the engine. Then, take off the drive chain from the driveshaft.

39) Remove the engine assembly.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-24 Engine Mechanical:

Engine Assembly Installation

B947H11406018

Install the engine in the reverse order of engine removal.

Pay attention to the following points:

• Before installing the engine, install the collars (1).

2

(a)

I947H1140285-02

1

I947H1140282-01

• Before installing the engine, install the engine mounting thrust adjusters (2).

2

(a)

2

I947H1140283-01

• Gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft.

!

CAUTION

Be careful not to catch the wiring harness between the frame and the engine.

I947H1140286-02

• Tighten the engine mounting thrust adjuster lock-nuts

(3) to the specified torque with the special tool.

Tightening torque

Engine mounting thrust adjuster lock-nut (b): 45

N·m (4.5 kgf-m, 32.5 lbf-ft)

Special tool

(A): 09940–14990 (Engine mounting adjust wrench)

3

(b)

(A)

I947H1140287-02

I947H1140284-01

• Install all engine mounting bolts and tighten them temporarily.

• Tighten the engine mounting thrust adjusters (2) to the specified torque.

Tightening torque

Engine mounting thrust adjuster (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

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3

(b)

(A)

I947H1140288-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-25

• Tighten all engine mounting bolts and nuts to the specified torque, as shown in the following illustration.

NOTE

The engine mounting nuts are self-locking.

Once the nuts have been removed, they are no longer of any use.

• Tighten the engine mounting pinch bolt to the specified torque, as shown in the following illustration.

LH RH

A

5

(d)

C

5

(d)

1

6

(d)

B

D

1

6

(d)

E

G

4

4

F

2

(a)

3

(b)

7

(c)

7

(c)

H

3

(b)

2

(a)

F, H

2

3

E, F

G, H

C, D

A, B

8

(a)

1. Collar

2. Engine mounting thrust adjuster

3. Engine mounting thrust adjuster lock-nut

4. Engine mounting bolt (220 mm)

5. Engine mounting bolt (45 mm)

6. Engine mounting bolt (55 mm)

7. Engine mounting nut

8. Engine mounting pinch bolt email: [email protected] / www.motomatrix.co.uk

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 45 N

⋅ m (4.5 kgf-m, 32.5 lbf-ft)

: 75 N

⋅ m (7.5 kgf-m, 54.0 lbf-ft)

: 55 N

⋅ m (5.5 kgf-m, 40.0 lbf-ft)

I947H1140289-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-26 Engine Mechanical:

• Install the engine sprocket. Refer to “Engine Sprocket

Removal and Installation” in Section 3A (Page 3A-2).

• Install the exhaust pipe assembly and muffler. Refer to

“Muffler / Muffler Chamber / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K-11).

• Install the radiator. Refer to “Radiator / Cooling Fan

Motor Removal and Installation” in Section 1F

(Page 1F-6).

• Install the throttle body. Refer to “Throttle Body

Removal and Installation” (Page 1D-10).

• Install the air cleaner box. Refer to “Air Cleaner Box

Removal and Installation” (Page 1D-7).

• After remounting the engine, route the wiring harness, cable and hoses properly. Refer to “Wiring Harness

Routing Diagram” in Section 9A (Page 9A-7), “Throttle

Cable Routing Diagram” (Page 1D-2) and “Water

Hose Routing Diagram” in Section 1F (Page 1F-3).

• Pour engine coolant and engine oil. Refer to “Cooling

System Inspection” in Section 0B (Page 0B-12) and

“Engine Oil and Filter Replacement” in Section 0B

(Page 0B-10).

• After finishing the engine installation, check the following items.

– Throttle cable play

Refer to “Throttle Cable Play Inspection and

Adjustment” in Section 0B (Page 0B-12).

– Throttle valve synchronization

Refer to “Throttle Valve Synchronization” (Page 1D-

16).

– Clutch cable play

Refer to “Clutch Cable Play Inspection and

Adjustment” in Section 0B (Page 0B-14).

– Drive chain slack

Refer to “Drive Chain Inspection and Adjustment” in

Section 0B (Page 0B-14).

– Engine oil and coolant leakage

Refer to “Cooling Circuit Inspection” in Section 1F

(Page 1F-4).

Engine Top Side Disassembly

B947H11406019

It is unnecessary to remove the engine assembly from the frame when servicing the cylinder head cover and camshafts.

NOTE

Before servicing the engine top side components (until camshafts removal) with the engine in place, remove the following parts:

• Air cleaner box

• Throttle body

Other parts except for these “Engine Top

Side Components” can not be serviced with the engine installed in the frame. Refer to

“Engine Assembly Removal” (Page 1D-20) and “Engine Assembly Installation”

(Page 1D-24).

!

CAUTION

Identify the position of each removed part.

Organize the parts in their respective groups

(e.g., intake, exhaust) so that they can be reinstalled in their original positions.

Cylinder Head Cover

1) Remove the spark plugs. Refer to “Ignition Coil and

Spark Plug Removal and Installation” in Section 1H

(Page 1H-6).

2) Remove the cylinder head cover (1) and its gasket.

1

3) Remove the dowel pins and O-rings.

I947H1140028-03

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-27

Camshafts

1) Remove the valve timing inspection cap (1).

3) Remove the cam chain tension adjuster (2).

1

2

I947H1140034-02

I947H1140030-01

2) Turn the crankshaft to bring the line “A” on the CKP sensor rotor to the slit “B” of cap hole thread and also to bring the camshafts to the position as shown.

4) Remove the gasket (3).

“A”

“B”

I947H1140031-01

3

5) Remove the cam chain guide No. 2 (4).

6) Remove the camshaft journal holders (5).

I947H1140035-01

!

CAUTION

Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.

4

I947H1140295-01

7) Remove the dowel pins.

5

I947H1140036-01

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-28 Engine Mechanical:

Remove the intake camshaft (6) and exhaust camshaft (7).

4) Remove the cylinder head.

6

7

I947H1140037-01

Cylinder Head

NOTE

The cylinder head can not be serviced with the engine installed in the frame.

1) Disconnect the water bypass hose (1).

1

I947H1140040-01

5) Remove the dowel pins and cylinder head gasket

(3).

3

2) Remove the cylinder head bolts (M6) (2).

I947H1140038-01

2

I947H1140041-01

Engine Top Side Assembly

B947H11406020

Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points:

Cylinder Head

• Install the dowel pins and a new cylinder head gasket

(1) to the cylinder.

!

CAUTION

Use a new gasket to prevent gas leakage.

I947H1140039-01

3) Remove the cylinder head bolts (M10) and washers.

NOTE

When loosening the cylinder head bolts, loosen each bolt little by little diagonally.

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1

I947H1140042-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-29

• Place the cylinder head on the gasket.

NOTE

• When installing the cylinder head, keep the cam chain taut.

• Apply engine oil to the washer and thread portion of the cylinder head bolts (M10) before tightening them.

• After firmly tightening the cylinder head bolts (M10), tighten the cylinder head bolts (M6) (2).

Tightening torque

Cylinder head bolt (M6) (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

2

(a)

I823H1140063-01

• Tighten the cylinder head bolts (M10) to the specified torque with a torque wrench sequentially and diagonally.

• Additionally tighten the cylinder head bolts with the specified angles diagonally using an angular torque gauge.

Tightening torque

Cylinder head bolt (M10): 31 N

⋅

m (3.1 kgf-m, 22.5 lbf-ft) then turn in 1/6 (60

°

) turn

• Connect the water bypass hose (3).

3

I947H1140044-01

I947H1140043-01

I947H1140045-01

Camshaft

• The camshafts are identified by the embossed letters.

IN: Intake camshaft

EX: Exhaust camshaft

• Before placing the camshafts on the cylinder head, apply molybdenum oil to their journals, cam faces and holders.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-30 Engine Mechanical:

• Turn the crankshaft clockwise and align the line “A” on the CKP sensor rotor to the slit “B” of cap hole thread while keeping the cam chain pulled upward.

!

CAUTION

• Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.

• To adjust the camshaft timing correctly, be sure to align the line “A” with slit “B” and hold this position when installing the camshafts.

• Bind the cam chain and the sprocket with a proper clamp (1) to prevent the cam chain disengagement while installing the camshaft journal holders.

• The other arrow marked “2” “D” should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked “2” “D”, count out 14 roller pins (from the exhaust camshaft side going towards the intake camshaft side).

• Engage the 14th roller pin “E” on the cam chain with the arrow marked “3” on the intake camshaft sprocket.

• Bind the cam chain and the sprocket with a proper clamp (2) to prevent the cam chain disengagement while installing the camshaft journal holders.

NOTE

The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster are secured.

1

“D”

I947H1140047-01

2

“C”

“E”

I947H1140049-01

“A”

“B”

I947H1140296-01

• Pull the cam chain lightly.

• Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.

(The exhaust camshaft sprocket has an arrow marked

“1” “C”.)

• Engage the cam chain with the exhaust camshaft sprocket.

NOTE

Before installing the camshaft, check that the tappets are installed correctly.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-31

I947H1140051-01

• Install the dowel pins.

“F”

3

I947H1140052-01

• Install the camshaft journal holders and cam chain guide No. 2 (3).

• Have the camshaft journal holders seated evenly by tightening the camshaft journal holder bolts lightly, in the ascending order of numbers.

NOTE

• Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.

• Each camshaft journal holder is identified with a cast-on letter “F”.

• The ascending order of numbers are indicated on the camshaft journal holders.

I947H1140053-02

• Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque.

Tightening torque

Camshaft journal holder bolt: 10 N·m (1.0 kgf-m,

7.0 lbf-ft)

!

CAUTION

The camshaft journal holder bolts are made of a special material and much superior in strength, compared with other types of high strength bolts.

Take special care not to use other types of bolts.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-32 Engine Mechanical:

• Remove the clamps.

10

9

5

6

(1) 7

(2) 8

(2) 6

(1) 5

9

10

(3) 11

(4) 12

13

14

8

7

4

3

12

11

I947H1140054-03

“A”

“C”

“B”

I823H1140365-01

I947H1140055-01

Cam Chain Tension Adjuster

• Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body until the outer circlip “A” reaches the groove “B”.

!

CAUTION

Do not turn the adjuster body until the outer circlip “A” exceeds the groove “B”.

If the inner circlip “C” is caught in the groove

“B”, plunger may not go out automatically from the adjuster body even if pushing force is applied on the head.

In such case, it needs to be disassembled.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-33

• Hook the outer circlip “A” into the groove “B”, then turn the plunger head clockwise more than 90

°

to make a little play in the inner thread mechanism.

• Rotate the crankshaft (some turns) and recheck the valve timing.

!

CAUTION

Make sure that the adjuster works properly by checking no slack at point “D”.

“A”

“B”

“A”

I823H1140355-01

• Fit a new gasket (1).

!

CAUTION

Use a new gasket to prevent oil leakage.

5

I947H1140058-01

“A”

1

I947H1140056-01

• Install the cam chain tension adjuster (2).

Tightening torque

Cam chain tension adjuster mounting bolt (a): 10

N·m (1.0 kgf-m, 7.0 lbf-ft)

• Remove the cam chain tension adjuster service cap

(3) and gasket (4).

“D”

5

I837H1140308-02

2

3

(a)

4

I947H1140057-01

• Unhook the outer circlip “A” from its groove by pushing the stepped part (5) of the plunger head with a screwdriver.

I947H1140246-03

NOTE

The cam chain tension adjuster can be serviced with the engine installed in the frame.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-34 Engine Mechanical:

• Tighten the cam chain tension adjuster service cap (6) to the specified torque.

!

CAUTION

Use a new gasket to prevent oil leakage.

Tightening torque

Cam chain tension adjuster service cap (b): 23

N·m (2.3 kgf-m, 16.5 lbf-ft)

• Tighten the valve timing inspection cap (7) to the specified torque.

!

CAUTION

Use a new O-ring to prevent oil leakage.

Tightening torque

Valve timing inspection cap (c): 11 N·m (1.1 kgfm, 8.0 lbf-ft)

• Install new gaskets to the cylinder head cover.

• Apply bond to the cam end cap points of the gasket as shown.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

!

CAUTION

Use new gaskets to prevent oil leakage.

7

(c)

6

(b)

I947H1140061-01

• Place the cylinder head cover on the cylinder head.

• Fit a new gasket (1) to each head cover bolt.

!

CAUTION

Use new gaskets to prevent oil leakage.

• Apply engine oil to both sides of the gaskets.

I947H1140059-01

Cylinder Head Cover

• Check and adjust the valve clearance. Refer to “Valve

Clearance Inspection and Adjustment” in Section 0B

(Page 0B-5).

• Pour engine oil in each oil pocket on the cylinder head.

• Install the dowel pins and O-rings.

!

CAUTION

Replace the O-rings with new ones.

1

I947H1140062-03

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-35

• Tighten the cylinder head cover bolts to the specified torque in two steps.

Tightening torque

Cylinder head cover bolt (Initial): 10 N·m (1.0 kgfm, 7.0 lbf-ft)

Cylinder head cover bolt (Final): 14 N·m (1.4 kgfm, 10.0 lbf-ft)

4) Remove the PAIR reed valves (5) and CMP sensor

(6).

6

I947H1140063-02

• Install the spark plugs. Refer to “Ignition Coil and

Spark Plug Removal and Installation” in Section 1H

(Page 1H-6).

Cylinder Head Cover Disassembly and

Assembly

B947H11406045

Disassembly

1) Remove the cylinder head cover. Refer to “Engine

Top Side Disassembly” (Page 1D-26).

2) Remove the gaskets (1) and (2).

5

I947H1140103-02

Assembly

Assembly is in the reverse order of disassembly. Pay attention to the following points:

• Install the CMP sensor.

NOTE

When installing the CMP sensor, clean the sensor surface.

• Tighten the CMP sensor bolt (1) to the specified torque.

Tightening torque

CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

2

1

I947H1140100-01

3) Remove the PAIR control solenoid valve (3) along with the PAIR reed valve covers (4).

• Install the PAIR reed valves.

3

1

(a)

I947H1140105-02

4

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-36 Engine Mechanical:

• Apply thread lock to the PAIR reed valve cover bolts

(2) and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

PAIR reed valve cover bolt (b): 10 N·m (1.0 kgf-m,

7.0 lbf-ft)

PAIR Reed Valve

Inspect the PAIR reed valves for carbon deposit. If the carbon deposit is found, replace the reed valve with a new one.

I947H1140106-01

2

(b)

2

(b)

I947H1140104-02

• Fit new gaskets and install the cylinder head cover to the cylinder head. Refer to “Engine Top Side

Assembly” (Page 1D-28).

Camshaft Inspection

B947H11406021

Refer to “Engine Top Side Disassembly” (Page 1D-26).

Refer to “Engine Top Side Assembly” (Page 1D-28).

Camshaft Identification

The exhaust camshaft has the embossed letters “EX” and the intake camshaft has the embossed letters “IN”.

Cylinder Head Cover Related Parts Inspection

B947H11406046

Refer to “Engine Top Side Disassembly” (Page 1D-26).

Refer to “Engine Top Side Assembly” (Page 1D-28).

Refer to “Cylinder Head Cover Disassembly and

Assembly” (Page 1D-35).

Cylinder Head Cover

Clean and check the gasket grooves “A” and PAIR reed valve mating surfaces “B” of the cylinder head cover.

If there is anything unusual, replace the cylinder head cover with a new one.

“B”

“A”

“B”

I947H1140290-02

CMP Sensor

NOTE

CMP sensor can be checked without removing it from the cylinder head cover.

Refer to “DTC “C11” (P0340): CMP Sensor

Circuit Malfunction” in Section 1A (Page 1A-

29).

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I947H1140064-01

Cam Wear

Check the camshaft for wear or damage.

Measure the cam height “a” with a micrometer.

Replace a camshaft if the cams are worn to the service limit.

Special tool

: 09900–20202 (Micrometer (25 – 50 mm))

Cam height “a”

Service limit (IN.): 37.38 mm (1.472 in)

Service limit (EX.): 36.58 mm (1.440 in)

“a”

I649G1140199-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-37

Camshaft Runout

Measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit.

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

(C): 09900–21304 (V blocks)

Camshaft runout (IN. & EX.)

Service limit: 0.10 mm (0.004 in)

(A)

3) Install each camshaft journal holder to its original position. Refer to “Engine Top Side Assembly”

(Page 1D-28).

4) Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque.

Refer to “Engine Top Side Assembly” (Page 1D-28).

NOTE

Do not rotate the camshafts with the plastigauge in place.

Tightening torque

Camshaft journal holder bolt: 10 N·m (1.0 kgfm, 7.0 lbf-ft)

(B)

(C)

I837H1140240-02

Camshaft Journal Wear

Inspect the camshaft journal wear in the following procedures:

1) Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.

2) Use the plastigauge to read the clearance at the widest portion, which is specified as follows.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076 mm))

(B): 09900–22302 (Plastigage (0.051 – 0.152 mm))

I947H1140066-01

5) Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale.

6) This measurement should be taken at the widest part of the compressed plastigauge.

Camshaft journal oil clearance (IN. & EX.)

Service limit: 0.150 mm (0.0059 in)

(A), (B)

I947H1140065-01

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-38 Engine Mechanical:

7) If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification.

Special tool

(C): 09900–20602 (Dial gauge)

(D): 09900–22403 (Small bore gauge (18 –

35 mm))

(E): 09900–20205 (Micrometer (0 – 25 mm))

Camshaft journal holder I.D. (IN. & EX.)

Standard: 24.012 – 24.025 mm (0.9454 – 0.9459 in)

Camshaft journal O.D. (IN. & EX.)

Standard: 23.959 – 23.980 mm (0.9433 – 0.9441 in)

Camshaft Sprocket

B947H11406022

Inspect the camshaft sprocket in the following procedures:

1) Remove the intake and exhaust camshafts. Refer to

“Engine Top Side Disassembly” (Page 1D-26).

2) Inspect the teeth of each camshaft sprocket for wear or damage.

If they are worn or damaged, replace the sprocket/ camshaft assembly and cam chain as a set.

(E)

(D)

(C)

I947H1140068-01

I947H1140069-01

3) Install the camshafts. Refer to “Engine Top Side

Assembly” (Page 1D-28).

Cam Chain Tension Adjuster Inspection

B947H11406023

The cam chain tension adjuster is maintained to proper tension automatically.

1) Remove the cam chain tension adjuster. Refer to

“Engine Top Side Disassembly” (Page 1D-26).

2) Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body until the outer circlip “A” reaches the groove “B”.

I649G1140204-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-39

3) Hook the outer circlip “A” into the groove “B”, then turn the plunger head clockwise more than 90

°

to make a little play in the inner thread mechanism.

4) Check that the plunger goes out automatically when its head “D” is tapped. If it does not work smoothly, replace the cam chain tension adjuster with a new one.

“B”

“A”

I823H1140355-01

NOTE

If it is difficult to compress the plunger because of internal engine oil, disassemble the adjuster by releasing the inner circlip “C” and spill out the oil.

!

CAUTION

Do not turn the adjuster body until the outer circlip “A” exceeds the groove “B”.

If the inner circlip “C” is caught in the groove

“B”, plunger may not go out automatically from the adjuster body even if pushing force is applied on the head.

In such case, it needs to be disassembled.

“D”

I823H1140367-01

5) Install the cam chain tension adjuster. Refer to

“Engine Top Side Assembly” (Page 1D-28).

Cam Chain Guide / Cam Chain Tensioner

Removal and Installation

B947H11406024

Removal

1) Remove the cylinder head cover. Refer to “Engine

Top Side Disassembly” (Page 1D-26).

2) Remove the cam chain guide No. 2 (1).

1

“C”

“A”

“B”

I823H1140365-01

I947H1140070-01

3) Remove the cylinder head. Refer to “Engine Top

Side Disassembly” (Page 1D-26) and “Engine

Bottom Side Disassembly” (Page 1D-49).

4) Remove the starter clutch. Refer to “Starter Clutch

Removal and Installation” in Section 1I (Page 1I-10).

5) Remove the cam chain guide No. 1 (2) and cam chain tensioner (3).

3

2

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I947H1140247-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-40 Engine Mechanical:

Installation

Install the cam chain guides/cam chain tensioner in the reverse order of removal.

Cam Chain Guide Inspection

B947H11406025

Inspect the cam chain guide in the following procedures:

1) Remove the cam chain guides. Refer to “Cam Chain

Guide / Cam Chain Tensioner Removal and

Installation” (Page 1D-39).

2) Check the contacting surface of the cam chain guides. If it is worn or damaged, replace it with a new one.

Cylinder Head Disassembly and Assembly

B947H11406027

Refer to “Engine Top Side Disassembly” (Page 1D-26).

Refer to “Engine Top Side Assembly” (Page 1D-28).

!

CAUTION

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.

Disassembly

1) Remove the tappet (1) and shim (2) by fingers or magnetic hand.

1

2

I947H1140291-01

3) Install the cam chain guides. Refer to “Cam Chain

Guide / Cam Chain Tensioner Removal and

Installation” (Page 1D-39).

Cam Chain Tensioner Inspection

B947H11406026

Inspect the cam chain tensioner in the following procedures:

1) Remove the cam chain tensioner. Refer to “Cam

Chain Guide / Cam Chain Tensioner Removal and

Installation” (Page 1D-39).

2) Check the contacting surface of the cam chain tensioner. If it is worn or damaged, replace it with a new one.

I947H1140071-01

2) Insert the special tool (A) between the valve springs and cylinder head.

3) Using the special tools, compress the valve springs and remove the two cotter halves (3) from the valve stem.

!

CAUTION

Be careful not to damage the tappet sliding surface with the special tool.

Special tool

(A): 09919–28620 (Sleeve protector)

(B): 09916–14522 (Valve lifter attachment)

(C): 09916–14510 (Valve lifter)

: 09916–84511 (Tweezer)

(B)

(A)

(C)

I947H1140292-01

3) Install the cam chain tensioner. Refer to “Cam Chain

Guide / Cam Chain Tensioner Removal and

Installation” (Page 1D-39).

3

I947H1140072-01

4) Remove the valve spring retainer (4) and valve springs (5).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-41

5) Pull out the valve (6) from the combustion chamber side.

11) Remove the bypass hose union (12).

5

4

12

6

I947H1140073-01

6) Remove the oil seal (7) and spring seat (8).

7) Remove the other valves in the same manner as described previously.

12) Remove the oil jet (13).

13

11

7

I947H1140076-01

I947H1140077-01

8

Remove the ECT sensor (9).

9) Remove the thermostat cover (10).

I947H1140074-01

13) Remove the intake pipes (14).

9

10) Remove the thermostat (11).

10

I947H1140075-01

14

I947H1140078-01

14) Remove the oil gallery plug (15).

15) Remove the cam chain tension adjuster service cap

(16).

16

15

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-42 Engine Mechanical:

Assembly

Assembly is in the reverse order of disassembly. Pay attention to the following points:

• Tighten the cam chain tension adjuster service cap (1) and oil gallery plug (2) to the specified torque.

!

CAUTION

Replace the gaskets with new ones.

Tightening torque

Cam chain tension adjuster service cap (a): 23

N·m (2.3 kgf-m, 16.5 lbf-ft)

Oil gallery plug (Cylinder head) (b): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

“A”

3

(c)

3

(c)

I947H1140082-01

• Apply engine oil to the O-ring and install the oil jet.

!

CAUTION

Use new O-ring to prevent oil pressure leakage.

1

(a)

2

(b)

• Apply grease to O-rings of the intake pipes.

I947H1140080-01

!

CAUTION

Replace the O-rings with new ones.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1140083-01

• Apply bond to the thread part of bypass hose union (4) and tighten it to the specified torque.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

Tightening torque

Bypass hose union (d): 12 N·m (1.2 kgf-m, 8.5 lbfft)

4

(d)

I947H1140081-01

• Install the intake pipes with the UP mark “A” facing top side.

• Tighten the intake pipe bolts (3) to the specified torque.

Tightening torque

Intake pipe bolt (c): 8.5 N·m (0.85 kgf-m, 6.5 lbf-ft)

I947H1140084-01

• Install the thermostat (5).

NOTE

The air bleeder hole “B” of the thermostat faces upside.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-43

• Tighten the thermostat cover bolts (6) to the specified torque.

Tightening torque

Thermostat cover bolt (e): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

9

“B”

8

5

6

(e)

I947H1140085-01

• Tighten the ECT sensor (7) to the specified torque.

Tightening torque

ECT sensor (f): 18 N·m (1.8 kgf-m, 13.0 lbf-ft)

!

CAUTION

• Take special care when handling the temperature sensor. It may cause damage if it gets a sharp impact.

• Replace a gasket with a new one.

I947H1140087-01

• Insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break.

!

CAUTION

When inserting the valve, take care not to damage the lip of the oil seal.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

7

(f)

I947H1140086-01

• Install the valve spring seat (8).

• Apply molybdenum oil to the oil seal (9), and press-fit it into the position.

!

CAUTION

Do not reuse the removed oil seal.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

I705H1140165-01

• Install each valve spring with the small-pitch portion

“C” facing cylinder head.

“F”

“E”

“D”

“C”

“C”: Small-pitch portion

“D”: Large-pitch portion

“E”: Upward

“F”: Paint

I947H1140088-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-44 Engine Mechanical:

• Put on the valve spring retainer (10), and using the special tools, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.

!

CAUTION

• Be sure to restore each spring and valve to their original positions.

• Be careful not to damage the valve and valve stem when handling them.

• Be careful not to damage the tappet sliding surface with the special tool.

Special tool

(A): 09916–14510 (Valve lifter)

(B): 09916–14522 (Valve lifter attachment)

(C): 09919–28620 (Sleeve protector)

: 09916–84511 (Tweezer)

• Install the tappet shims and the tappets to their original positions.

NOTE

• Apply engine oil to the stem end, shim and tappet before fitting them.

• When seating the tappet shim, be sure the figure printed surface faces the tappet.

I947H1140091-01

(C)

10

(B)

(A)

I947H1140089-01

• Be sure that the rounded lip “G” of the cotter fits snugly into the groove “H” in the stem end.

“H”

“G”

10

Cylinder Head Related Parts Inspection

B947H11406028

Refer to “Cylinder Head Disassembly and Assembly”

(Page 1D-40).

Cylinder Head Distortion

1) Decarbonize the combustion chambers.

2) Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge.

Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head.

Special tool

: 09900–20803 (Thickness gauge)

Cylinder head distortion

Service limit: 0.02 mm (0.0008 in)

11

10. Valve spring retainer 11. Cotter

I947H1140090-02

• Install the other valves and springs in the same manner as described previously.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-45

Valve Stem Runout

Support the valve using V-blocks, as shown in the figure, and check its runout using the dial gauge. If the runout exceeds the service limit, replace the valve.

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

(C): 09900–21304 (V blocks)

Valve stem runout (IN. & EX.)

Service limit: 0.05 mm (0.002 in)

Valve Stem and Valve Face Wear Condition

Visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one.

(A)

(B)

(C)

I649G1140231-03

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.

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

(C): 09900–21304 (V blocks)

Valve head radial runout (IN. & EX.)

Service limit: 0.03 mm (0.001 in)

(A)

I947H1140093-01

Valve Stem Deflection

Lift the valve about 10 mm (0.39 in) from the valve seat.

Measure the valve stem deflection in two directions, “X” and “Y”, perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine whether the valve or the guide should be replaced with a new one.

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

Valve stem deflection (IN. & EX.)

Service limit: 0.25 mm (0.010 in)

(A)

(B)

I837H1140061-03

(B)

(C)

I649G1140232-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-46 Engine Mechanical:

Valve Stem Wear

Measure the valve stem O.D. using the micrometer. If it is out of specification, replace the valve with a new one.

If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, recheck the deflection.

Special tool

(A): 09900–20205 (Micrometer (0 – 25 mm))

Valve stem O.D.

Standard (IN.): 4.475 – 4.490 mm (0.1762 – 0.1768 in)

Standard (EX.): 4.455 – 4.470 mm (0.1754 – 0.1760 in)

NOTE

If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide replacement. Refer to “Valve Guide

Replacement” (Page 1D-47).

“ a ”

“ b ”

(A)

I718H1140122-01

Valve Spring

The force of the coil springs keep the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism.

Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range, replace both the inner and outer springs as a set.

Special tool

(A): 09900–20102 (Vernier calipers (200 mm))

Valve spring free length (IN. & EX.)

Service limit: Inner: 30.1 mm (1.19 in)

Service limit: Outer: 35.3 mm (1.39 in)

Valve spring tension (IN. & EX.)

Standard: Inner: 31.3 – 38.3 N (3.2 – 3.9 kgf, 7.0 – 8.6 lbs)/27.55 mm (1.085 in)

Standard: Outer: 91.3 – 105.1 N (9.3 – 10.7 kgf, 20.5 –

23.6 lbs)/33.05 mm (1.301 in)

Inner

Outer

Tension “a”

31.3 – 38.3 N

(3.2 – 3.9 kgf, 7.0 – 8.6 lbs)

91.3 – 105.1 N

(9.3 – 10.7 kgf, 20.5 – 23.6 lbs)

I649G1140238-03

Length “b”

27.55 mm

(1.085 in)

33.05 mm

(1.301 in)

Valve Seat Width

1) Visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve.

2) Coat the valve seat with a red lead (Prussian Blue) and set the valve in place.

!

CAUTION

Do not use lapping compound.

3) Rotate the valve with light pressure.

Special tool

(A): 09916–10911 (Valve lapper set)

(A)

(A)

I649G1140237-03

I947H1140094-01 email: [email protected] / www.motomatrix.co.uk

4) Check that the transferred red lead (blue) on the valve face is uniform all around and in center of the valve face.

If the seat width “a” measured exceeds the standard value, or seat width is not uniform reface the seat using the seat cutter. Refer to “Valve Seat Repair”

(Page 1D-49).

Valve seat width “a” (IN. & EX.)

Standard: 0.9 – 1.1 mm (0.035 – 0.043 in)

“a”

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-47

I649G1140246-02

Valve Guide Replacement

B947H11406029

1) Remove the cylinder head. Refer to “Engine Top

Side Disassembly” (Page 1D-26).

2) Remove the valves. Refer to “Cylinder Head

Disassembly and Assembly” (Page 1D-40).

3) Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side.

Special tool

(A): 09916–43211 (Valve guide installer & remover)

NOTE

• Discard the removed valve guide subassemblies.

• Only oversized valve guides are available as replacement parts. (Part No. 11115-

29G70)

Valve Seat Sealing Condition

1) Clean and assemble the cylinder head and valve components.

2) Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Refer to “Valve Seat

Repair” (Page 1D-49).

!

WARNING

Always use extreme caution when handling gasoline.

(A)

I947H1140096-01

4) Refinish the valve guide holes in the cylinder head using the reamer and handle.

!

CAUTION

When refinishing or removing the reamer from the valve guide hole, always turn it clockwise.

Special tool

(B): 09916–33320 (Valve guide reamer (9.8 mm))

(C): 09916–34542 (Reamer handle)

I947H1140095-01

NOTE

After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. Refer to “Valve

Clearance Inspection and Adjustment” in

Section 0B (Page 0B-5).

(C)

(B)

I947H1140097-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-48 Engine Mechanical:

5) Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 –

150

°

C (212 – 302

°

F) with a hot plate.

!

CAUTION

Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.

6) Apply engine oil to each valve guide and valve guide hole.

7) Drive the guide into the guide hole using the valve guide installer.

!

CAUTION

Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head.

Special tool

(A): 09916–43211 (Valve guide installer & remover)

(D): 09916–53380 (Valve guide installer attachment)

After installing the valve guides, refinish their guiding bores using the reamer. Be sure to clean and oil the guides after reaming.

NOTE

• Be sure to cool down the cylinder head to ambient air temperature.

• Insert the reamer from the combustion chamber and always turn the reamer handle clockwise.

Special tool

(C): 09916–34542 (Reamer handle) mm))

(E): 09916–33210 (Valve guide reamer (4.5

(C)

(E)

(A)

(D)

“ a ”

1. Cylinder head

1

I838H1140077-01

“a”: 13.7 – 13.9 mm (0.54 – 0.55 in)

[IN and EX]

I947H1140099-01

9) Reassemble the cylinder head. Refer to “Cylinder

Head Disassembly and Assembly” (Page 1D-40).

10) Install the cylinder head assembly. Refer to “Engine

Top Side Assembly” (Page 1D-28).

(A)

(D)

I947H1140098-01 email: [email protected] / www.motomatrix.co.uk

45 q

60 q

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-49

Valve Seat Repair

B947H11406030

The valve seats (1) for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45

°

.

30 q

45 q

60 q

15 q

Engine Bottom Side Disassembly

B947H11406031

NOTE

The crankcase must be separated to service the crankshaft and conrod.

1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal” (Page 1D-20).

2) Remove the engine top side (1). Refer to “Engine

Top Side Disassembly” (Page 1D-26).

1 1

Crankcase Breather (PCV) Cover

Remove the crankcase breather (PCV) cover (1).

[A]

[A]: Intake valve

[B]

[B]: Exhaust valve

I837H1140069-01

1

Seat angle

Seat width

Valve diameter

Valve guide

I.D.

Intake

30

°

/45

°

/60

°

0.9 – 1.1 mm

(0.035 – 0.043 in)

31.0 mm

(1.22 in)

4.500 – 4.512 mm

(0.1772 – 0.1776 in)

Exhaust

15

°

/45

←

25.0 mm

(0.98 in)

←

°

/60

°

!

CAUTION

• The valve seat contact area must be inspected after each cut.

• Do not use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation.

• The titanium valves are coated with an oxidized membrane treatment to resist wear but the membrane tend to removed if lapped after valve seat servicing.

NOTE

After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. Refer to “Valve

Clearance Inspection and Adjustment” in

Section 0B (Page 0B-5).

Starter Motor

Remove the starter motor (1).

I947H1140108-03

Clutch

Remove the clutch component parts (1). Refer to “Clutch

Removal” in Section 5C (Page 5C-5).

1

1

I947H1140107-02

I947H1140109-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-50 Engine Mechanical:

Gearshift System

Remove the gearshift shaft (1) and gearshift cam plate

(2). Refer to “Gearshift Shaft / Gearshift Cam Plate

Removal and Installation” in Section 5B (Page 5B-17).

2) Remove the cam chain tensioner (2) and cam chain guide No. 1 (3).

3) Remove the cam chain drive sprocket (4) and cam chain (5).

5

1

4

2

I947H1140110-02

Starter Torque Limiter / Starter Clutch

Remove the starter torque limiter (1) and starter clutch

(2) component parts. Refer to “Starter Torque Limiter

Removal and Installation” in Section 1I (Page 1I-9) and

“Starter Clutch Removal and Installation” in Section 1I

(Page 1I-10).

2

3

I947H1140113-02

Generator

Remove the generator cover (1) and rotor. Refer to

“Generator Removal and Installation” in Section 1J

(Page 1J-4).

1

1

2

I947H1140111-02

Cam Chain / Cam Chain Tensioner / Cam Chain

Guide No. 1

1) Remove the washer (1).

Water Pump

1) Remove the water inlet connector (1).

I947H1140114-01

1

1

I947H1140115-01

I947H1140112-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-51

2) Remove the water pump (2).

(A)

1

2

Gear Position Switch

Remove the gear position switch (1).

I947H1140116-01

Oil Pan

1) Remove the plate (1).

2) Remove the oil pan (2) and gasket.

I947H1140119-01

2

1

1

I947H1140117-01

Oil Pressure Switch

Remove the oil pressure switch lead wire (1) and switch

(2).

Oil Pressure Regulator / Oil Strainer

1) Remove the oil pressure regulator (1).

2) Remove the oil strainer (2).

2

2

I947H1140297-01

1

Oil Filter

Remove the oil filter (1) with the special tool.

Special tool

(A): 09915–40610 (Oil filter wrench)

I947H1140118-01

3) Remove the O-ring (3).

3

1

I947H1140121-01

I947H1140122-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-52 Engine Mechanical:

Oil Pump

1) Remove the spacer (1) and bearing (2).

Crankcase

1) Remove the clutch push rod oil seal retainer (1).

1

2

1

2) Remove the oil pump drive sprocket (3) and chain

(4).

3) Remove the thrust washer (5).

I947H1140126-01

4

3

5

I947H1140123-01

2) Remove the cap (2).

3) Remove the crankcase bolts from upper side.

NOTE

Loosen the crankcase bolts diagonally and smaller size ones first.

4) Remove the oil pump assembly (6).

5) Remove the dowel pins and O-ring (7).

I947H1140127-01

2

I947H1140124-02

7

6

6) Remove the breather oil return pipe (8).

I947H1140128-02

I947H1140125-02

4) Remove the crankcase bolts from lower side.

8

I947H1140129-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-53

5) Remove the crankshaft journal bolts (M9).

Transmission

Remove the transmission component. Refer to

“Transmission Removal” in Section 5B (Page 5B-3).

6) Make sure that all of the bolts are removed. Then, tap the sides of the lower crankcase using a plastic hammer to separate the upper and lower crankcase halves and then lift the lower crankcase off the upper crankcase.

7) Remove the dowel pins and O-rings (3).

I947H1140130-01

3

I947H1140133-01

I947H1140131-04

Balancer Shaft

Remove the balancer shaft assembly (1) and plug (2).

I947H1140134-01

Crankshaft

1) Loosen the conrod cap bolts using a 10 mm, 12point socket wrench.

1

2

I947H1140132-01

I947H1140135-01

2) Remove the conrod caps by tapping the bolts lightly with a plastic hammer.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-54 Engine Mechanical:

3) Remove the crankshaft (1) and thrust bearings (2).

1

2

I947H1140137-01

Piston Cooling Oil Jet

Remove the piston cooling oil jet (1) from the upper crankcase.

2) Remove the piston pin circlip (1).

1

I947H1140140-01

I947H1140138-01

Piston / Conrod

1) Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase.

!

CAUTION

Be careful not to damage the cylinder wall by the conrod.

1

I947H1140141-01

3) Draw out the piston pin (2) and remove the piston from the conrod.

NOTE

Scribe the cylinder number on the piston head.

2

I947H1140142-01

I947H1140139-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-55

Crankshaft Journal Bearing

Remove the crankshaft journal bearings, upper and lower.

!

CAUTION

• When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.

• Do not touch the bearing surfaces with your hands. Grasp the bearings by their edges.

NOTE

• Do not remove the crankshaft journal bearings unless absolutely necessary.

• Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions.

Oil Jet

Remove the oil jet (1) (for transmission) from the lower crankcase.

1

I947H1140145-01

Oil Gallery Plug

1) Remove the oil gallery plug (1), (2) and (3) from the lower crankcase.

1

I947H1140146-01

I947H1140143-01

2

I947H1140147-01

I947H1140144-01

3

I947H1140148-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-56 Engine Mechanical:

2) Remove the oil gallery plug (4) from the upper crankcase.

Breather Oil Return Plate

Remove the breather oil return plate (1) from the upper crankcase.

4

1

I947H1140149-01

Water Jacket Plug

Remove the water jacket plugs (1) from the upper crankcase.

1

1

I947H1140150-01

Oil Seal / Bearing

Remove the oil seal and bearings if necessary. Refer to

“Transmission Removal” in Section 5B (Page 5B-3).

I947H1140153-01

Engine Bottom Side Assembly

B947H11406032

Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points:

NOTE

Apply engine oil to each running and sliding part before reassembling.

Breather Oil Return Plate

When installing the breather oil return plate (1), apply thread lock to the bolts.

: Thread lock cement 99000–32110 (THREAD

LOCK CEMENT SUPER “1322” or equivalent)

1

I947H1140151-01

I947H1140154-01

Oil Seal / Bearing

Install the oil seal and bearings. Refer to “Transmission

Installation” in Section 5B (Page 5B-5).

Water Jacket Plug

• Apply engine coolant to the O-rings of the water jacket plugs.

I947H1140152-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-57

• Tighten each plug to the specified torque.

!

CAUTION

Replace the O-rings with new ones.

Tightening torque

Water jacket plug (a): 9.5 N·m (0.95 kgf-m, 6.9 lbfft)

(b)

(a)

(a)

I947H1140155-01

Oil Gallery Plug

!

CAUTION

Replace the gaskets with new ones.

• Apply thread lock to the oil gallery plug (M10) and tighten it to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Oil gallery plug (M10) (a): 18 N·m (1.8 kgf-m, 13.0 lbf-ft)

I947H1140157-01

• Tighten the oil gallery plugs to the specified torque.

Tightening torque

Oil gallery plug (M26) (c): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

Oil gallery plug (M6) (d): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

(c)

I947H1140159-01

(d)

I947H1140158-01

(a)

I947H1140156-01

• Apply thread lock to the oil gallery plug (M12) and tighten it to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Oil gallery plug (M12) (b): 15 N·m (1.5 kgf-m, 11.0 lbf-ft)

Oil Jet

Install the oil jet (1) (for transmission).

1 email: [email protected] / www.motomatrix.co.uk

I947H1140160-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-58 Engine Mechanical:

Crankshaft Journal Bearing

When fitting the crankshaft journal bearings to the upper and lower crankcases, be sure to fix the stopper part “A” first and press the other end.

!

CAUTION

Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.

NOTE

Inspect and select the crankshaft journal bearing if necessary. Refer to “Crankshaft

Journal Bearing Inspection and Selection”

(Page 1D-79).

• Install the piston pin circlips (1).

!

CAUTION

Use new piston pin circlips (1) to prevent circlip failure which will occur when it is bent.

NOTE

End gap of the circlip “C” should not be aligned with the cutaway in the piston pin bore.

“C”

“A”

1

I947H1140161-01

Piston and Conrod

• Apply a small quantity of molybdenum oil solution onto each piston pin.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

• Assemble the piston and conrod.

NOTE

When installing the pistons, the indent “A” on the piston head must be brought to the other side of ID code “B” on the conrod big end.

I947H1140163-01

• Apply a small quantity of molybdenum oil solution to the sliding surface of the pistons and cylinder walls.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

NOTE

Be sure to install the pistons in the cylinders from which they were removed in disassembly, referring to the cylinder numbers, #1 through #4, scribed on the piston.

“B”

I947H1140164-01

“A”

I947H1140162-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-59

• Install the pistons with conrods into the cylinders from topside using the special tool.

NOTE

When installing the pistons, the indent “D” of each piston head must be brought to the exhaust side.

Special tool

(A): 09916–77310 (Piston ring compressor)

1

“D”

(A)

I947H1140165-01

• Check that I.D. code “E” on each conrod faces intake side.

!

CAUTION

Be sure to clean the conrod big end.

I947H1140167-01

• Install each piston cooling oil jet.

NOTE

Apply a small quantity of thread lock to the bolts and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Piston cooling oil jet bolt (a): 10 N·m (1.0 kgf-m,

7.0 lbf-ft)

(a)

“E”

I947H1140166-01

Piston Cooling Oil Jet

• Fit new O-ring (1) to each piston cooling oil jet and apply engine oil to it.

!

CAUTION

Use new O-ring to prevent oil pressure leakage.

I947H1140168-02

Crankshaft

1) Apply molybdenum oil to each crank pin bearing surface and crankshaft journal bearing surface.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

I947H1140169-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-60 Engine Mechanical:

6) Apply engine oil to the conrod cap bolts.

2) Position the No. 2 and No. 3 conrod big ends on the same side, and the No. 1 and No. 4 conrod big ends on the opposite side of No. 2 and No. 3.

“A”

I947H1140170-01

3) Set the crankshaft onto the conrods and upper crankcase.

I947H1140173-01

7) Tighten the conrod cap bolt by using a 10 mm, 12 point socket wrench in the following two steps.

Tightening torque

Conrod cap bolt: 37 N

⋅

m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/6 (60

°

) turn

I947H1140171-01

4) Apply molybdenum oil to each crank pin and bearing surface.

!

CAUTION

Be sure to clean the conrod big end.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

I947H1140174-01

“ a ”

I947H1140172-01

5) When fitting the conrod cap, make sure that I.D. code “A” on each conrod faces intake side.

I947H1140175-01

“a”: 60

°

Apply engine oil to the conrod big end side surfaces.

9) Apply molybdenum oil to each crankshaft journal and bearing lightly.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-61

10) Check the conrod movement for smooth turning.

I947H1140176-01

11) Insert the right and left thrust bearings with the oil grooves “B” facing towards the crankshaft web.

NOTE

• Right-thrust bearing has green painting.

• Inspect and select the crankshaft thrust clearance if necessary. Refer to

“Crankshaft Thrust Clearance Inspection and Selection” (Page 1D-82).

I947H1140179-01

Balancer Shaft

• Apply a molybdenum oil solution to each balancer shaft journal and bearing lightly.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

• Set the balancer shaft so that its punch mark “A” is aligned with the index “B” on the crankshaft.

“B”

“A”

I947H1140180-01

“B”

“B”

I947H1140177-02

Transmission

Install the transmission. Refer to “Transmission

Installation” in Section 5B (Page 5B-5).

• Install the plug (1).

1

I947H1140181-01

I947H1140178-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-62 Engine Mechanical:

Crankcase

• Install the dowel pins and O-rings (1).

!

CAUTION

Replace the O-rings with new ones.

1

• Apply bond to the mating surface of the lower crankcase as follows.

NOTE

• Make mating surfaces free from moisture, oil, dust and other foreign materials.

• Spread the sealant on surfaces thinly to form an even layer, and assemble the crankcases within a few minutes.

• Take extreme care not to apply sealant to any oil hole, oil groove and bearing.

• Apply sealant to distorted surfaces as it forms a comparatively thick film.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

I947H1140182-02

: Apply bond.

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I947H1140183-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-63

• Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in the following two steps.

!

CAUTION

Fit new gasket washers to the bolts “A” to prevent oil leakage.

Tightening torque

Crankshaft journal bolt (M9): 18 N

⋅

m (1.8 kgf-m,

13.0 lbf-ft) then turn in 50

°

I947H1140186-02

“A” “A”

“B”

“B”

2

“B”

• Tighten the crankcase bolts a little at a time to equalize the pressure.

• Install the cap (2).

I947H1140184-01

!

CAUTION

• Fit new gasket washers to the bolts “B” to prevent oil leakage.

• Fit new O-ring to the cap (2) and apply grease to it.

Tightening torque

Crankcase bolt (M8) (Initial): 15 N·m (1.5 kgf-m,

11.0 lbf-ft)

Crankcase bolt (M8) (Final): 26 N·m (2.6 kgf-m,

19.0 lbf-ft)

Crankcase bolt (M6): 12 N·m (1.2 kgf-m, 8.5 lbf-ft)

I947H1140187-03

• After the crankshaft journal bolts and crankcase bolts have been tightened, check that the crankshaft rotates smoothly.

• Also check that the driveshaft and countershaft rotate smoothly.

I947H1140188-01

I947H1140185-01

I947H1140189-01

• Install the clutch push rod oil seal retainer (3).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-64 Engine Mechanical:

• Apply thread lock to the bolts.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

• Install the oil pump (3) and tighten the oil pump bolts to the specified torque.

Tightening torque

Oil pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

3

Oil Pump

• Install the breather oil return pipe (1).

1

I947H1140190-02

3

I947H1140193-01

• Install the thrust washer (4) to the countershaft.

NOTE

The chamfer side “A” of thrust washer should face the crankcase side.

“A”

I947H1140191-01

• Apply grease to new O-ring (2).

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

!

CAUTION

Use a new O-ring to prevent oil leakage.

• Install the O-ring and dowel pins.

4

I947H1140194-01

• Install the oil pump drive sprocket (5) to the countershaft.

NOTE

Teeth “B” on the sprocket must face the clutch side.

• Pass the chain (6) between the oil pump drive and driven sprockets.

• Apply engine oil to the countershaft.

5

6

2

I947H1140192-01

“B”

I947H1140195-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-65

• Apply engine oil to the bearing (7) and spacer (8) and install them into the sprocket.

7

8

I947H1140196-01

Oil Pan

• Install new gasket.

!

CAUTION

Use new gasket to prevent oil leakage.

• Install the oil pan (1) and plate (2).

• Apply thread lock to the plate bolts “A”.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

• Tighten the oil pan bolts and plate bolts diagonally to the specified torque.

Tightening torque

Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

Oil Strainer / Oil Pressure Regulator

• Apply grease to new O-ring (1).

!

CAUTION

Use a new O-ring to prevent oil leakage.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Install the oil strainer (2).

2

1

2

1

“A”

I947H1140298-01

Oil Filter

Install the oil filter with the special tool. Refer to “Engine

Oil and Filter Replacement” in Section 0B (Page 0B-10).

Special tool

(A): 09915–40610 (Oil filter wrench)

I947H1140197-01

• Apply grease to new O-ring (3).

!

CAUTION

Use a new O-ring to prevent oil leakage.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Push in the oil pressure regulator (4) to the oil pump as shown.

(A)

I947H1140201-01

3

4

I947H1140198-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-66 Engine Mechanical:

Oil Pressure Switch

• Apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque.

NOTE

Be careful not to apply bond to the hole of thread end.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

Tightening torque

Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lbf-ft)

• Tighten the gear position switch mounting bolts to the specified torque.

Tightening torque

Gear position switch mounting bolt (a): 6.5 N·m (

0.65 kgf-m, 4.7 lbf-ft)

(a)

I718H1140233-01

• Route the oil pressure switch lead wire properly and tighten the screw to the specified torque. Refer to

“Wiring Harness Routing Diagram” in Section 9A

(Page 9A-7).

Gear Position Switch

• Apply grease to the O-ring.

!

CAUTION

Replace the O-ring with a new one.

NOTE

Insert the gear position switch pin “A” into the gearshift cam hole “B”.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1140203-01

Water Pump

• Apply grease to new O-ring (1).

!

CAUTION

Use the new O-ring to prevent oil leakage.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Install the water pump assembly with the slot of the pump shaft end “A” securely engaged with the flat “B” of the oil pump shaft.

1

“A”

“B”

I947H1140204-02

“B”

“A”

I947H1140202-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-67

• Tighten the water pump mounting bolts (2) to the specified torque.

Tightening torque

Water pump mounting bolt (a): 10 N·m (1.0 kgfm, 7.0 lbf-ft)

2

(a)

Cam Chain / Cam Chain Tensioner / Cam Chain

Guide No. 1

• Install the cam chain drive sprocket (1) to the crankshaft.

NOTE

When installing the cam chain drive sprocket, align the wide spline teeth of the sprocket and crankshaft.

• Install the cam chain (2).

1

I947H1140205-02

• Apply engine coolant to the O-ring.

!

CAUTION

Replace the O-ring with a new one.

• Tighten the water inlet connector mounting bolts.

2

I947H1140208-01

• Insert the cam chain tensioner and tighten the cam chain tensioner bolt (3) to the specified torque.

Tightening torque

Cam chain tensioner bolt (a): 23 N·m (2.3 kgf-m,

16.5 lbf-ft)

• Insert the cam chain guide No. 1 while pulling the chain upward.

• Tighten the cam chain guide No. 1 bolt (4) to the specified torque.

Tightening torque

Cam chain guide No. 1 bolt (b): 23 N·m (2.3 kgfm, 16.5 lbf-ft)

I947H1140206-01

Generator

Install the generator rotor and cover (1). Refer to

“Generator Removal and Installation” in Section 1J

(Page 1J-4).

1

3

(a)

4

(b)

I947H1140209-01

I947H1140207-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-68 Engine Mechanical:

• Install the washer (5).

Clutch

Install the clutch component parts (1). Refer to “Clutch

Installation” in Section 5C (Page 5C-7).

1

5

I947H1140210-01

Starter Clutch / Starter Torque Limiter

Install the starter clutch (1) and starter torque limiter (2) component parts. Refer to “Starter Clutch Removal and

Installation” in Section 1I (Page 1I-10) and “Starter

Torque Limiter Removal and Installation” in Section 1I

(Page 1I-9).

I947H1140213-01

Starter Motor

Install the starter motor (1). Refer to “Starter Motor

Removal and Installation” in Section 1I (Page 1I-4).

1

2

1

I947H1140211-02

Gearshift System

Install the gearshift cam plate (1) and gearshift shaft (2).

Refer to “Gearshift Shaft / Gearshift Cam Plate Removal and Installation” in Section 5B (Page 5B-17).

I947H1140214-02

Crankcase Breather (PCV) Cover

• Apply bond to the hatching part of crankcase breather

(PCV) cover.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

2

1

I947H1140212-01

I947H1140293-01

• Fit the clamp to the bolt “A”. Refer to “Wiring Harness

Routing Diagram” in Section 9A (Page 9A-7).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-69

• Tighten the crankcase breather (PCV) cover bolts.

(A)

“A”

I947H1140215-03

Engine Top Side

Assemble the engine top side. Refer to “Engine Top Side

Disassembly” (Page 1D-26).

Cylinder Inspection

B947H11406033

Refer to “Engine Top Side Disassembly” (Page 1D-26).

Refer to “Engine Top Side Assembly” (Page 1D-28).

Cylinder Distortion

Check the gasket surface of the cylinder for distortion.

Use a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the crankcase set.

Special tool

: 09900–20803 (Thickness gauge)

Cylinder distortion

Service limit: 0.02 mm (0.0008 in)

I947H1140217-02

I837H1140180-01

Piston-to-cylinder Clearance

Refer to “Piston and Piston Ring Inspection” (Page 1D-

71).

Piston Ring Removal and Installation

B947H11406034

Removal

1) Remove the piston. Refer to “Engine Bottom Side

Disassembly” (Page 1D-49).

2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove it.

NOTE

Do not expand the piston ring excessively since it is apt to be broken down.

I947H1140216-01

Cylinder Bore

Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston.

The remaining cylinders must also be rebored accordingly; otherwise, the imbalance might cause excessive vibration.

Special tool

(A): 09900–20530 (Cylinder gauge set)

Cylinder bore

Standard: 74.500 – 74.515 mm (2.9331 – 2.9337 in)

email: [email protected] / www.motomatrix.co.uk

I837H1140181-01

3) Remove the 2nd ring and oil ring in the same manner.

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-70 Engine Mechanical:

Installation

NOTE

• When installing the piston ring, be careful not to damage the piston.

• Do not expand the piston ring excessively since it is apt to be broken down.

1) Install the piston rings in the order of the oil ring, second ring and top ring.

a) The first member to go into the oil ring groove is the spacer (1).

After placing the spacer, fit the two side rails (2).

b) Install the 2nd ring (3) and 1st ring (4) to piston.

NOTE

1st ring (4) and 2nd ring (3) differ in shape.

4

3

2

1

2

I947H1140218-01

NOTE

Face the side with the stamped mark upward when assembling.

I718H1140143-02

!

CAUTION

When installing the spacer, be careful not to allow its two ends to overlap in the groove.

I947H1140219-01

2) Position the gaps of the three rings and side rails as shown. Before inserting piston into the cylinder, check that the gaps are so located.

“D”

[A] “C”

“E” [B]

“A”: INCORRECT “B”: CORRECT

I705H1140170-02

I837H1140282-02

“C”: 1st ring and upper side rail

“D”: Spacer

“E”: 2nd ring and lower side rail

[A]: IN

[B]: EX

3) Install each piston and piston pin. Refer to “Engine

Bottom Side Assembly” (Page 1D-56).

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Piston and Piston Ring Inspection

B947H11406035

Refer to “Piston Ring Removal and Installation”

(Page 1D-69).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-71

Piston Diameter

Measure the piston diameter using the micrometer at 15 mm (0.6 in) “a” from the skirt end. If the piston diameter is less than the service limit, replace the piston.

Special tool

(A): 09900–20203 (Micrometer (50 – 75 mm))

Piston diameter

Service limit: 74.380 mm (2.9283 in)

“ a ”

I837H1140184-01

Piston Ring-to-groove Clearance

Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any of the clearances exceed the limit, replace both the piston and piston rings.

Special tool

(A): 09900–20803 (Thickness gauge)

(B): 09900–20205 (Micrometer (0 – 25 mm))

Piston ring-to-groove clearance

Service limit (1st): 0.180 mm (0.0071 in)

Service limit (2nd): 0.150 mm (0.0059 in)

Piston ring groove width

Standard (1st): 0.83 – 0.85 mm (0.0327 – 0.0335 in)

Standard (1st): 1.30 – 1.32 mm (0.0512 – 0.0520 in)

Standard (2nd): 0.81 – 0.83 mm (0.0319 – 0.0327 in)

Standard (Oil): 1.51 – 1.53 mm (0.0594 – 0.0602 in)

Piston ring thickness

Standard (1st): 0.76 – 0.81 mm (0.0299 – 0.0319 in)

Standard (1st): 1.08 – 1.10 mm (0.0425 – 0.0433 in)

Standard (2nd): 0.77 – 0.79 mm (0.0303 – 0.0311 in)

“a”: 10 mm (0.4 in)

(A)

(A)

I649G1140262-03

Piston-to-cylinder Clearance

Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.

Piston-to-cylinder clearance

Service limit: 0.120 mm (0.0047 in)

(B)

I649G1140263-03

I649G1140264-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-72 Engine Mechanical:

Piston Ring Free End Gap and Piston Ring End Gap

Measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceed the service limit, replace the piston ring with a new one.

Special tool

(A): 09900–20102 (Vernier calipers (200 mm))

Piston ring free end gap

Service limit (1st): 5.6 mm (0.22 in)

Service limit (2nd): 6.4 mm (0.25 in)

Special tool

(B): 09900–20803 (Thickness gauge)

Piston ring end gap

Service limit (1st): 0.50 mm (0.020 in)

Service limit (2nd): 0.50 mm (0.020 in)

Piston Pin and Pin Bore

Measure the piston pin bore inside diameter using the small bore gauge. If either is out of specification or the difference between these measurements surpass limits, replace the piston.

Special tool

(A): 09900–20602 (Dial gauge) mm))

(B): 09900–22401 (Small bore gauge (10 – 18

Piston pin bore

Service limit: 15.030 mm (0.5917 in)

(B)

(A)

(A)

I649G1140265-03

I649G1140267-03

Measure the piston pin outside diameter at three positions using the micrometer. If any of the measurements are out of specification, replace the piston pin.

Special tool

(C): 09900–20205 (Micrometer (0 – 25 mm))

Piston pin O.D.

Service limit: 14.980 mm (0.5898 in)

(C)

I649G1140268-03

I947H1140307-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-73

Balancer Shaft Disassembly and Assembly

B947H11406036

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Disassembly

1) Remove the balancer shaft. Refer to “Engine Bottom

Side Disassembly” (Page 1D-49).

2) Remove the washers, balancer gear and dampers from the shaft.

• Set the dampers and install the balancer shaft to balancer gear.

NOTE

• Fit the stopper of the balancer shaft between the dampers.

• Align the line “A” on the balancer shaft with the punch “B” on the balancer gear.

I947H1140221-01

Assembly

Assembly is in the reverse order of disassembly. Pay attention to the following points:

• Apply molybdenum oil solution to each part.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

“B”

“A”

I838H1140055-01

Balancer Shaft Inspection

B947H11406037

Refer to “Balancer Shaft Disassembly and Assembly”

(Page 1D-73).

Balancer Shaft

Inspect the balancer shaft for wear or damage. Replace the balancer shaft if there is anything unusual.

Damper

Inspect the dampers for wear and damage, replace them if any defects are found.

I947H1140222-01

I947H1140223-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-74 Engine Mechanical:

Balancer Shaft Journal Bearing Removal and

Installation

B947H11406038

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Removal

Remove the balancer shaft journal bearings (1).

NOTE

• Do not remove the bearings (1) unless absolutely necessary.

• Make a note of where the bearings are removed from so that they can be reinstalled in their original positions.

!

CAUTION

When removing the bearings, be careful not to scratch the bearings.

Installation

When installing the bearings to the crankcases, be sure to install the tab “A” first, and then press in the other opposite side of the bearing.

NOTE

Inspect and select the balancer shaft journal bearing if necessary. Refer to “Balancer Shaft

Journal Bearing Inspection and Selection”

(Page 1D-75).

“A”

I947H1140226-01

1

I947H1140224-02

“A”

I947H1140227-02

1

I947H1140225-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-75

Balancer Shaft Journal Bearing Inspection and

Selection

B947H11406039

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Inspection

Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings.

(A)

I947H1140228-02

I947H1140230-01

2) Mate the lower crankcase with the upper crankcase, and tighten the crankcase bolts (M8) and crankshaft journal bolts (M9) to the specified torque.

Tightening torque

Crankshaft journal bolt (M9): 18 N

⋅

m (1.8 kgf-m,

13.0 lbf-ft) then turn in 50

°

Crankcase bolt (M8) (Initial): 15 N·m (1.5 kgf-m,

11.0 lbf-ft)

Crankcase bolt (M8) (Final): 26 N·m (2.6 kgf-m,

19.0 lbf-ft)

Crankcase bolt (M6): 12 N·m (1.2 kgf-m, 8.5 lbfft)

I947H1140229-01

Selection

1) Place the plastigauge axially along the balancer shaft journal as shown.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076 mm))

!

CAUTION

Never rotate the balancer shaft when a piece of plastigauge is installed.

I947H1140231-01

3) Remove the lower crankcase and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.

Balancer shaft journal oil clearance

Standard: 0.028 – 0.052 mm (0.0011 – 0.0020 in)

Service limit: 0.080 mm (0.0031 in)

I947H1140232-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-76 Engine Mechanical:

4) Check the corresponding crankcase journal I.D. code number “A”, [A], [B] or [C] which is stamped on the rear of upper crankcase.

Conrod Crank Pin Bearing Removal and

Installation

B947H11406040

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

“A”

Removal

Remove the conrod crank pin bearings (1).

NOTE

• Do not remove the bearings (1) unless absolutely necessary.

• Make a note of where the bearings are removed from so that they can be reinstalled in their original positions.

!

CAUTION

When removing the bearings, be careful not to scratch the conrods and the bearings.

I947H1140233-01

Bearing selection table

Crankcase I.D. “A”

A

B

C

Green

Black

Brown

Crankcase I.D. specification

Code

A

B

C

I.D. specification

23.000 – 23.008 mm

(0.9055 – 0.9058 in)

23.008 – 23.016 mm

(0.9058 – 0.9061 in)

23.016 – 23.024 mm

(0.9061 – 0.9065 in)

Balancer shaft journal O.D. specification

19.992 – 20.000 mm (0.7871 – 0.7874 in)

Bearing thickness specification

Color (Part No.)

Green

(12229-47H00-0A0)

Black

(12229-47H00-0B0)

Brown

(12229-47H00-0C0)

Thickness

1.482 – 1.486 mm

(0.0583 – 0.0585 in)

1.486 – 1.490 mm

(0.0585 – 0.0587 in)

1.490 – 1.494 mm

(0.0587 – 0.0588 in)

NOTE

The balancer shaft journal bearings on upper and lower crankcases are the same.

1

I718H1140269-01

Installation

When installing the bearings into the conrod cap and conrod, be sure to install the tab “A” first, and then press in the other opposite side of the bearing.

NOTE

Inspect and select the conrod crank pin bearing if necessary. Refer to “Conrod Crank

Pin Bearing Inspection and Selection”

(Page 1D-78).

“A”

I823H1140578-01

I947H1140234-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-77

Conrod and Crankshaft Inspection

B947H11406041

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Conrod Small End I.D.

Measure the conrod small end inside diameter using the small bore gauge.

If the conrod small end inside diameter exceeds the service limit, replace the conrod.

Special tool

(A): 09900–20602 (Dial gauge) mm))

(B): 09900–22401 (Small bore gauge (10 – 18

Conrod small end I.D.

Service limit: 15.040 mm (0.5921 in)

2) If the clearance exceeds the limit, remove the conrod and measure the conrod big end width and crank pin width. Refer to “Engine Bottom Side Assembly”

(Page 1D-56). If any of the measurements are out of specification, replace the conrod or crankshaft.

Special tool

(B): 09900–20205 (Micrometer (0 – 25 mm)) mm))

(C): 09900–20605 (Dial calipers (10 – 34

Conrod big end width

Standard: 19.95 – 20.00 mm (0.7854 – 0.7874 in)

Crank pin width

Standard: 20.10 – 20.15 mm (0.7913 – 0.7933 in)

(C)

(B)

(A)

I823H1140280-01

Conrod Big End Side Clearance

1) Check the conrod big end side clearance using the thickness gauge.

Special tool

(A): 09900–20803 (Thickness gauge)

Conrod big end side clearance

Service limit: 0.30 mm (0.012 in)

(A)

(B)

I823H1140282-01

Crankshaft Runout

Support the crankshaft using V-blocks as shown, with the two end journals resting on the blocks. Set up the dial gauge as shown, and rotate the crankshaft slowly to read the runout. Replace the crankshaft if the runout exceeds the service limit.

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

(C): 09900–21304 (V blocks)

Crankshaft runout

Service limit: 0.05 mm (0.002 in)

(A)

I823H1140281-01

(C)

(C)

(B)

I947H1140235-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-78 Engine Mechanical:

Conrod Crank Pin Bearing Inspection and

Selection

B947H11406042

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Inspection

1) Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings.

4) Remove the conrod cap bolts and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge.

If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076 mm))

Conrod big end oil clearance

Standard: 0.040 – 0.064 mm (0.0016 – 0.0025 in)

Conrod big end oil clearance

Service limit: 0.080 mm (0.0031 in)

I718H1140285-01

2) Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown in the figure.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076 mm))

(A)

(A)

I718H1140289-01

Selection

1) Check the corresponding conrod I.D. code numbers

([1] or [2]) “A”.

I718H1140286-01

3) Tighten the conrod cap bolts to the specified torque, in two stages.

NOTE

• When installing the conrod cap bolts to the crank pin, make sure that I.D code “A” on the conrod faces towards the intake side.

• Never rotate the crankshaft or conrod when a piece of plastigauge is installed.

Tightening torque

Conrod cap bolt: 37 N

⋅

m (3.7 kgf-m, 26.5 Ib-ft) then turn in 1/6 (60

°

) turn

“A”

I718H1140290-01

Conrod I.D. specification

Code “A”

1

2

I.D. specification

38.000 – 38.008 mm

(1.4961 – 1.4964 in)

38.008 – 38.016 mm

(1.4964 – 1.4967 in)

“A”

I823H1140284-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-79

2) Check the corresponding crank pin O.D. code numbers ([1], [2] or [3]) “B”.

Bearing thickness specification

Color “C” (Part No.)

Yellow

(12164-47H00-0D0)

Brown

(12164-47H00-0C0)

Black

(12164-47H00-0B0)

Green

(12164-47H00-0A0)

Thickness

1.488 – 1.492 mm

(0.0586 – 0.0587 in)

1.484 – 1.488 mm

(0.0584 – 0.0586 in)

1.480 – 1.484 mm

(0.0583 – 0.0584 in)

1.476 – 1.480 mm

(0.0581 – 0.0583 in)

“B”

“C”

I947H1140236-01

3) Measure the conrod crank pin O.D. with the special tool. If any of the measurements are out of specification, replace the crankshaft.

Crank pin O.D. specification

Code “B”

1

2

3

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)

Special tool

(A): 09900–20202 (Micrometer (25 – 50 mm))

(A)

I823H1140595-01

“C”: Color code

Crankshaft Journal Bearing Inspection and

Selection

B947H11406043

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Inspection

1) Inspect each upper and lower crankcase bearing for any damage.

I823H1140286-01

4) Select the specified bearings from the bearing selection table.

!

CAUTION

The bearings should be replaced as a set.

Bearing selection table

Conrod

I.D. “A”

Code

1

2

1

Green

Black

Crank pin O.D. “B ”

2

Black

Brown

3

Brown

Yellow

I718H1140293-01 email: [email protected] / www.motomatrix.co.uk

I947H1140237-01

I947H1140238-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-80 Engine Mechanical:

2) Set the crankshaft onto the upper crank case.

3) Install the plastigauge onto each crankshaft journal.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076 mm))

6) Remove the lower crankcase and measure the width of compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.

Crankshaft journal oil clearance

Standard: 0.016 – 0.034 mm (0.0006 – 0.0013 in)

Crankshaft journal oil clearance

Service limit: 0.080 mm (0.0031 in)

(A)

I947H1140239-01

4) Mate the lower crankcase with the upper crankcase.

5) Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in the following two steps.

NOTE

Do not rotate the crankshaft when a piece of plastigauge is installed.

Tightening torque

Crankshaft journal bolt (M9): 18 N

⋅

m (1.8 kgf-m,

13.0 lbf-ft) then turn in 50

°

I947H1140241-01

Selection

1) Check the corresponding crankcase journal I.D. codes “A” ([A], [B] or [C]), which are stamped on the rear of the upper crankcase.

I947H1140240-01

“A”

I947H1140242-01

Crankcase journal I.D. specification

Code “A”

A

B

C

I.D. specification

38.000 – 38.006 mm

(1.4961 – 1.4963 in)

38.006 – 38.012 mm

(1.4963 – 1.4965 in)

38.012 – 38.018 mm

(1.4965 – 1.4968 in)

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-81

2) Check the corresponding crankshaft journal O.D. codes “B” ([A], [B] or [C]), which are stamped on the crankshaft.

4) Select the specified bearings from the bearing selection table.

Bearing selection table

“B”

I947H1140243-01

3) Measure the crankshaft O.D. with the special tool. If any of the measurements are out of specification, replace the crankshaft.

Crankshaft journal O.D. specification

Code “B”

A

B

C

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)

Special tool

(A): 09900–20202 (Micrometer (25 – 50 mm))

Crankcase

I.D. “A”

Code

A

B

C

A

Green

Black

Crankshaft O.D. “B”

B

Black

Brown

C

Brown

Yellow

Brown Yellow Blue

I823H1140299-01

Bearing thickness specification

Color “C” (Part No.)

Blue

(12229-47H10-0E0)

Yellow

(12229-47H10-0D0)

Brown

(12229-47H10-0C0)

Black

(12229-47H10-0B0)

Green

(12229-47H10-0A0)

Thickness

1.501 – 1.504 mm

(0.0591 – 0.0592 in)

1.498 – 1.501 mm

(0.0590 – 0.0591 in)

1.495 – 1.498 mm

(0.0589 – 0.0590 in)

1.492 – 1.495 mm

(0.0587 – 0.0589 in)

1.489 – 1.492 mm

(0.0586 – 0.0587 in)

“C”

I947H1140245-01

“C”: Color code

(A)

I947H1140244-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-82 Engine Mechanical:

Crankshaft Thrust Clearance Inspection and

Selection

B947H11406044

Refer to “Engine Bottom Side Disassembly” (Page 1D-

49).

Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Inspection

1) With the crankshaft’s right-side and left-side thrust bearings inserted into the upper crankcase.

2) Measure the thrust clearance “a” between the leftside thrust bearing and crankshaft using the thickness gauge. If the thrust clearance exceeds the standard range, adjust the thrust clearance.

NOTE

Pull the crankshaft to the left (generator side) so that there is no clearance on the right-side thrust bearing.

Special tool

: 09900–20803 (Thickness gauge)

Crankshaft thrust clearance “a”

Standard: 0.060 – 0.110 mm (0.0024 – 0.0043 in)

“B”

2

1

Selection

1) Remove the right-side thrust bearing and measure its thickness using the micrometer. If the thickness of the right-side thrust bearing is below standard, replace it with a new bearing and measure the thrust clearance again, as described in Inspection 1) and

2).

Special tool

(A): 09900–20205 (Micrometer (0 – 25 mm))

Right-side thrust bearing thickness

Standard: 2.420 – 2.440 mm (0.0953 – 0.0961 in)

(A)

I649G1140343-02

2) If the right-side thrust bearing is within the standard range, reinsert the right-side thrust bearing and remove the left-side thrust bearing.

3) With the left-side thrust bearing removed, measure the clearance “a” using the thickness gauge as shown.

Special tool

(B): 09900–20803 (Thickness gauge)

“A”

“ a ”

1. Right-side thrust bearing

2. Left-side thrust bearing

“A”: Front side

“B”: Left side

I947H1140248-01

“ a ”

(B)

I837H1140198-02

(A)

I837H1140197-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-83

4) Select a left-side thrust bearing from the selection table.

NOTE

Right-side thrust bearing has the same specification as the GREEN (12228-48B00-0E0) of left-side thrust bearing.

Thrust bearing selection table

Clearance before inserting left-side thrust bearing

2.570 – 2.590 mm

(0.1012 – 0.1020 in)

2.550 – 2.570 mm

(0.1004 – 0.1012 in)

2.530 – 2.550 mm

(0.0996 – 0.1004 in)

2.510 – 2.530 mm

(0.0988 – 0.0996 in)

2.490 – 2.510 mm

(0.0980 – 0.0988 in)

2.470 – 2.490 mm

(0.0972 – 0.0980 in)

2.440 – 2.470 mm

(0.0961 – 0.0972 in)

Color “A” (Part No.)

Brown

(12228-48B00-0B0)

Red

(12228-48B00-0C0)

Yellow

(12228-48B00-0D0)

Green

(12228-48B00-0E0)

Blue

(12228-48B00-0F0)

Orange

(12228-48B00-0G0)

Black

(12228-48B00-0H0)

Thrust bearing thickness

2.480 – 2.500 mm

(0.0976 – 0.0984 in)

2.460 – 2.480 mm

(0.0969 – 0.0976 in)

2.440 – 2.460 mm

(0.0961 – 0.0969 in)

2.420 – 2.440 mm

(0.0953 – 0.0961 in)

2.400 – 2.420 mm

(0.0945 – 0.0953 in)

2.380 – 2.400 mm

(0.0937 – 0.0945 in)

2.360 – 2.380 mm

(0.0929 – 0.0937 in)

Thrust clearance

0.070 – 0.110 mm

(0.0028 – 0.0043 in)

0.060 – 0.110 mm

(0.0024 – 0.0043 in)

“A”

I649G1140345-02

“A”: Color code

5) After selecting a left-side thrust bearing, install it and then measure the thrust clearance again.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-84 Engine Mechanical:

Specifications

Service Data

Valve + Guide

Unit: mm (in)

Item

Valve diam.

Valve clearance (when cold)

Valve guide to valve stem clearance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve seat width

Valve head radial runout

Valve spring free length

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

Inner

Outer

Inner

Valve spring tension

Outer

Standard

31.0 (1.22)

25.0 (0.98)

0.08 – 0.18 (0.003 – 0.007)

0.18 – 0.28 (0.007 – 0.011)

0.010 – 0.037 (0.0004 – 0.0015)

0.030 – 0.057 (0.0012 – 0.0022)

4.500 – 4.512 (0.1772 – 0.1776)

4.475 – 4.490 (0.1762 – 0.1768)

4.455 – 4.470 (0.1754 – 0.1760)

—

—

0.9 – 1.1 (0.035 – 0.043)

—

—

—

31.3 – 38.3 N (3.2 – 3.9 kgf, 7.0 – 8.6 lbs) at length 27.55 mm (1.085 in)

91.3 – 105.1 N (9.3 – 10.7 kgf, 20.5 – 23.6 lbs) at length 33.05 mm (1.301 in)

Camshaft + Cylinder Head

Unit: mm (in)

Item

Cam height

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

Camshaft runout

Cam chain pin (at arrow “3”)

Cylinder head distortion

IN.

EX.

IN. & EX.

IN. & EX.

IN. & EX.

Standard

37.68 – 37.73 (1.483 – 1.485)

36.88 – 36.93 (1.452 – 1.454)

0.032 – 0.066 (0.0013 – 0.0026)

24.012 – 24.025 (0.9454 – 0.9459)

23.959 – 23.980 (0.9433 – 0.9441)

—

14th pin

—

B947H11407001

Limit

—

—

—

—

—

—

—

—

—

0.25 (0.010)

0.05 (0.002)

—

0.03 (0.001)

30.1 (1.19)

35.3 (1.39)

—

—

Limit

37.38 (1.472)

36.58 (1.440)

0.150 (0.0059)

—

—

0.10 (0.004)

—

0.02 (0.0008) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-85

Cylinder + Piston + Piston Ring

Unit: mm (in)

Item Standard

Compression pressure

Compression pressure difference

Piston-to-cylinder clearance

Cylinder bore

Piston diam.

Cylinder distortion

Piston ring free end gap

Piston ring end gap

Piston ring-to-groove clearance

Piston ring groove width

Piston ring thickness

Piston pin bore

Piston pin O.D.

1 400 – 1 800 kPa (14 – 18 kgf/cm

2

, 199 – 256 psi)

—

1st

2nd

1st

2nd

1st

2nd

1st

0.030 – 0.040 (0.0012 – 0.0016)

74.500 – 74.515 (2.9331 – 2.9337)

74.465 – 74.480 (2.9317 – 2.9323)

Measure 10 mm (0.4 in) from the skirt end.

T

—

Approx. 7.0 (0.28)

Approx. 8.0 (0.32)

0.06 – 0.18 (0.002 – 0.007)

0.06 – 0.18 (0.002 – 0.007)

—

—

0.83 – 0.85 (0.0327 – 0.0335)

2nd

Oil

1st

1.30 – 1.32 (0.0512 – 0.0520)

0.81 – 0.83 (0.0319 – 0.0327)

1.51 – 1.53 (0.0594 – 0.0602)

0.76 – 0.81 (0.0299 – 0.0319)

2nd

1.08 – 1.10 (0.0425 – 0.0433)

0.77 – 0.79 (0.0303 – 0.0311)

15.002 – 15.008 (0.5906 – 0.5909)

14.995 – 15.000 (0.5903 – 0.5512)

Limit

1 000 kPa

(10 kgf/cm

2

,

142 psi)

200 kPa

(2 kgf/cm

2

, 28 psi)

0.120 (0.0047)

Nicks or scratches

74.380 (2.9283)

0.02 (0.0008)

5.6 (0.22)

6.4 (0.25)

0.50 (0.020)

0.50 (0.020)

0.180 (0.0071)

0.150 (0.0059)

—

—

—

—

—

15.030 (0.5917)

14.980 (0.5898)

Conrod + Crankshaft

Unit: mm (in)

Item

Conrod small end I.D.

Conrod big end side clearance

Conrod big end width

Crank pin width

Conrod big end oil clearance

Crank pin O.D.

Crankshaft journal oil clearance

Crankshaft journal O.D.

Crankshaft thrust bearing thickness

Crankshaft thrust clearance

Crankshaft runout

Balancer

Unit: mm (in)

Item

Balancer shaft journal oil clearance

Balancer shaft journal O.D.

Throttle Body

Item

Bore size

I.D. No.

Idle r/min

Throttle cable play

Standard

15.010 – 15.018 (0.5909 – 0.5913)

0.10 – 0.20 (0.004 – 0.008)

19.95 – 20.00 (0.7854 – 0.7874)

20.10 – 20.15 (0.7913 – 0.7933)

0.040 – 0.064 (0.0016 – 0.0025)

34.976 – 35.000 (1.3770 – 1.3780)

0.016 – 0.034 (0.0006 – 0.0013)

Right side

34.982 – 35.000 (1.3772 – 1.3780)

2.420 – 2.440 (0.0953 – 0.0961)

Left side 2.360 – 2.500 (0.0929 – 0.0984)

0.060 – 0.110 (0.0024 – 0.0043)

—

Standard

0.028 – 0.052 (0.0011 – 0.0020)

19.992 – 20.000 (0.7871 – 0.7874)

Specification

44 mm (1.73 in)

47H1 (For E-33), 47H0 (For others)

1 150

±

100 r/min

2.0 – 4.0 mm (0.08 – 0.16 in)

Limit

15.040 (0.5921)

0.30 (0.012)

—

—

0.080 (0.0031)

—

0.080 (0.0031)

—

—

—

—

0.05 (0.002)

Limit

0.080 (0.0031)

— email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-86 Engine Mechanical:

Tightening Torque Specifications

Fastening part

Throttle cable lock-nut

STP sensor mounting screw

TP sensor mounting screw

ISC valve mounting screw

Fuel delivery pipe mounting screw

Engine mounting thrust adjuster

Engine mounting thrust adjuster lock-nut

Cylinder head bolt (M10)

Cylinder head bolt (M6)

Camshaft journal holder bolt

Cam chain tension adjuster mounting bolt

Cam chain tension adjuster service cap

Valve timing inspection cap

Cylinder head cover bolt (Initial)

Cylinder head cover bolt (Final)

CMP sensor bolt

PAIR reed valve cover bolt

Oil gallery plug (Cylinder head)

Intake pipe bolt

Bypass hose union

Thermostat cover bolt

ECT sensor

Water jacket plug

Oil gallery plug (M10)

Oil gallery plug (M12)

Oil gallery plug (M26)

Oil gallery plug (M6)

Piston cooling oil jet bolt

Conrod cap bolt

Crankshaft journal bolt (M9)

Crankcase bolt (M8) (Initial)

B947H11407002

N

⋅

m

4.5

3.5

3.5

2

3.5

23

Tightening torque kgf-m

0.45

0.35

0.35

0.2

0.35

2.3

lbf-ft

3.0

2.5

2.5

1.5

2.5

16.5

45 4.5 32.5

31 N

⋅ m (3.1 kgf-m, 22.5 lbf-ft) then turn in 1/

6 (60

°

) turn

10 1.0 7.0

Note

)

(Page 1D-11)

)

(Page 1D-13)

)

(Page 1D-14)

)

(Page 1D-14)

)

(Page 1D-15)

)

(Page 1D-24)

)

(Page 1D-24)

)

(Page 1D-29)

)

(Page 1D-29)

10

10 1.0 7.0

)

(Page 1D-33)

23

18

9.5

18

15

1.8

0.95

1.8

1.5

13.0

6.9

13.0

11.0

11

10

1.1

1.0

8.0

7.0

37 N

10 1.0 7.0

⋅ m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/

6 (60

°

) turn

18 N

50

°

⋅

10

10

8.5

12

10

11

10

14

10

1.1

1.0

1.4

1.0

1.0

1.0

0.85

1.2

1.0

8.0

7.0

10.0

7.0

7.0

7.0

6.5

8.5

7.0 m (1.8 kgf-m, 13.0 lbf-ft) then turn in

)

(Page 1D-34)

)

(Page 1D-35)

)

(Page 1D-35)

)

(Page 1D-35)

)

(Page 1D-36)

)

(Page 1D-42)

)

(Page 1D-42)

)

(Page 1D-42)

)

(Page 1D-43)

)

(Page 1D-43)

)

(Page 1D-57)

)

(Page 1D-57)

)

(Page 1D-57)

)

(Page 1D-57)

)

(Page 1D-57)

)

(Page 1D-59)

)

(Page 1D-60) /

)

(Page 1D-78)

)

(Page 1D-63) /

)

(Page 1D-75) /

)

(Page 1D-80)

15

Crankcase bolt (M8) (Final)

26

Crankcase bolt (M6)

Oil pump mounting bolt

Oil pan bolt

Oil pressure switch

Gear position switch mounting bolt

Water pump mounting bolt

Cam chain tensioner bolt

Cam chain guide No. 1 bolt

12

10

10

14

6.5

10

23

23

1.0

1.0

1.4

0.65

1.0

2.3

2.3

7.0

7.0

10.0

4.7

7.0

16.5

16.5

)

(Page 1D-64)

)

(Page 1D-65)

)

(Page 1D-66)

)

(Page 1D-66)

)

(Page 1D-67)

)

(Page 1D-67)

)

(Page 1D-67) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-87

NOTE

The specified tightening torque is described in the following.

“Throttle Cable Routing Diagram” (Page 1D-2)

“Throttle Body Components” (Page 1D-8)

“Throttle Body Construction” (Page 1D-9)

“Engine Assembly Installation” (Page 1D-24)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

Grease

Molybdenum oil

Sealant

Material

Thread lock cement

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or

Note

P/No.: 99000–25010

)

(Page 1D-13) / equivalent

)

(Page 1D-14) /

)

(Page 1D-42) /

)

(Page 1D-64) /

)

(Page 1D-65) /

)

(Page 1D-65) /

)

(Page 1D-66) /

MOLYBDENUM OIL SOLUTION —

)

(Page 1D-66)

)

(Page 1D-29) /

)

(Page 1D-43) /

SUZUKI BOND No.1207B or equivalent

THREAD LOCK CEMENT SUPER

“1322” or equivalent

)

(Page 1D-43) /

)

(Page 1D-58) /

)

(Page 1D-58) /

)

(Page 1D-59) /

)

(Page 1D-60) /

)

(Page 1D-60) /

)

(Page 1D-61) /

)

(Page 1D-73)

P/No.: 99000–31140

)

(Page 1D-34) /

)

(Page 1D-42) /

)

(Page 1D-62) /

)

(Page 1D-66) /

)

(Page 1D-68)

P/No.: 99000–32110

)

(Page 1D-36) /

)

(Page 1D-56) /

)

(Page 1D-57) /

)

(Page 1D-57) /

)

(Page 1D-59) /

)

(Page 1D-64) /

)

(Page 1D-65)

B947H11408001

NOTE

Required service material is also described in the following.

“Throttle Body Components” (Page 1D-8)

“Engine Bottom Side Assembly” (Page 1D-56)

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-88 Engine Mechanical:

Special Tool

09900–20102

Vernier calipers (200 mm)

)

(Page 1D-46) /

)

(Page 1D-72)

09900–20202

Micrometer (25 – 50 mm)

)

(Page 1D-36) /

)

(Page 1D-79) /

)

(Page 1D-81)

09900–20203

Micrometer (50 – 75 mm)

)

(Page 1D-71)

09900–20530

Cylinder gauge set

)

(Page 1D-69)

09900–20605

Dial calipers (10 – 34 mm)

)

(Page 1D-77)

09900–20701

Dial gauge chuck

)

(Page 1D-37) /

)

(Page 1D-45) /

)

(Page 1D-45) /

)

(Page 1D-45) /

)

(Page 1D-77)

09900–21304

V blocks

)

(Page 1D-37) /

)

(Page 1D-45) /

)

(Page 1D-45) /

)

(Page 1D-77)

09900–22302

Plastigage (0.051 – 0.152 mm)

)

(Page 1D-37)

09900–20205

Micrometer (0 – 25 mm)

)

(Page 1D-38) /

)

(Page 1D-46) /

)

(Page 1D-71) /

)

(Page 1D-72) /

)

(Page 1D-77) /

)

(Page 1D-82)

09900–20602

Dial gauge

)

(Page 1D-38) /

)

(Page 1D-72) /

)

(Page 1D-77)

09900–20607

Dial gauge

)

(Page 1D-37) /

)

(Page 1D-45) /

)

(Page 1D-45) /

)

(Page 1D-45) /

)

(Page 1D-77)

09900–20803

Thickness gauge

)

(Page 1D-44) /

)

(Page 1D-69) /

)

(Page 1D-71) /

)

(Page 1D-72) /

)

(Page 1D-77) /

)

(Page 1D-82) /

)

(Page 1D-82)

09900–22301

Plastigage (0.025 – 0.076 mm)

)

(Page 1D-37) /

)

(Page 1D-75) /

)

(Page 1D-78) /

)

(Page 1D-78) /

)

(Page 1D-80)

09900–22401

Small bore gauge (10 – 18 mm)

)

(Page 1D-72) /

)

(Page 1D-77)

B947H11408002 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Mechanical: 1D-89

09900–22403

Small bore gauge (18 – 35 mm)

)

(Page 1D-38)

09915–40610

Oil filter wrench

)

(Page 1D-51) /

)

(Page 1D-65)

09915–63311

Compression gauge attachment

)

(Page 1D-3)

09915–64512

Compression gauge

)

(Page 1D-3)

09916–10911

Valve lapper set

)

(Page 1D-46)

09916–14522

Valve lifter attachment

)

(Page 1D-40) /

)

(Page 1D-44)

09916–33320

Valve guide reamer (9.8 mm)

)

(Page 1D-47)

09916–43211

Valve guide installer & remover

)

(Page 1D-47) /

)

(Page 1D-48)

09916–77310

Piston ring compressor

)

(Page 1D-59)

09916–14510

Valve lifter

)

(Page 1D-40) /

)

(Page 1D-44)

09916–33210

Valve guide reamer (4.5 mm)

)

(Page 1D-48)

09916–34542

Reamer handle

)

(Page 1D-47) /

)

(Page 1D-48)

09916–53380

Valve guide installer attachment

)

(Page 1D-48)

09916–84511

Tweezer

)

(Page 1D-40) /

)

(Page 1D-44)

09919–28620

Sleeve protector

)

(Page 1D-40) /

)

(Page 1D-44) email: [email protected] / www.motomatrix.co.uk

09930–11950

Torx wrench (5 mm)

)

(Page 1D-13) /

)

(Page 1D-13) /

)

(Page 1D-14)

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1D-90 Engine Mechanical:

09930–11960

Torx wrench (4 mm)

)

(Page 1D-14)

09940–14990

Engine mounting adjust wrench

)

(Page 1D-23) /

)

(Page 1D-23) /

)

(Page 1D-24) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Lubrication System: 1E-1

Engine

Engine Lubrication System

Precautions

Precautions for Engine Oil

Refer to “Fuel and Oil Recommendation” in Section 0A (Page 0A-3).

B947H11500001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1E-2 Engine Lubrication System:

Schematic and Routing Diagram

Engine Lubrication System Chart Diagram

B947H11502001

CAM CHAIN TENSION ADJUSTER

OIL JET (#16)

INTAKE CAMSHAFT

INTAKE CAMSHAFT

JOURNAL HOLDER

INTAKE CAMSHAFT JOURNALS,

CAMFACES AND TAPPETS

EXHAUST CAMSHAFT

EXHAUST CAMSHAFT

JOURNAL HOLDER #1

EXHAUST CAMSHAFT JOURNALS,

CAMFACES AND TAPPETS

#1 PISTON COOLING

OIL JET

SUB GALLERY

#2 PISTON COOLING

OIL JET

#3 PISTON COOLING

OIL JET

#4 PISTON COOLING

OIL JET

ORIFICE

GENERATOR

COVER

GENERATOR

#1 PISTON AND

CYLINDER WALL

#1 CRANK PIN

BEARING

#2 PISTON AND

CYLINDER WALL

#2 CRANK PIN

BEARING

#3 PISTON AND

CYLINDER WALL

#3 CRANK PIN

BEARING

#4 PISTON AND

CYLINDER WALL

#4 CRANK PIN

BEARING

#1 CRANKSHAFT

JOURNAL BEARING

CRANKSHAFT

#2 CRANKSHAFT

JOURNAL BEARING

#3 CRANKSHAFT

JOURNAL BEARING

#4 CRANKSHAFT

JOURNAL BEARING

#5 CRANKSHAFT

JOURNAL BEARING

MAIN GALLERY

BALANCERSHAFT

RIGHT BEARING

BALANCERSHAFT

BALANCERSHAFT

LEFT BEARING

OIL PRESSURE

SWITCH

COUNTERSHAFT

LEFT BEARING

COUNTERSHAFT

PRIMARY DRIVEN

GEAR BEARING

CLUTCH PUSH

PIECE

CLUTCH PLATES

COUNTERSHAFT GEARS

AND BUSHINGS

OIL JET

(#14)

ORIFICE

OIL COOLER

COUNTERSHAFT

RIGHT BEARING

DRIVESHAFT

RIGHT BEARING

DRIVESHAFT

DRIVESHAFT GEARS

AND BUSHINGS

OIL PRESSUER

REGULATOR

OIL FILTER

OIL PUMP

OIL STRAINER

CAM CHAIN

STARTER CLUTCH

OIL PAN

email: [email protected] / www.motomatrix.co.uk

I947H1150001-03

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Lubrication System: 1E-3

Engine Lubrication Circuit Diagram

B947H11502002 email: [email protected] / www.motomatrix.co.uk

I947H1150002-03

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1E-4 Engine Lubrication System:

email: [email protected] / www.motomatrix.co.uk

I947H1150003-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Lubrication System: 1E-5

Diagnostic Information and Procedures

Engine Lubrication Symptom Diagnosis

Condition

Engine overheats

Possible cause

Insufficient amount of engine oil.

Defective oil pump.

Clogged oil circuit.

Clogged oil cooler.

Incorrect engine oil.

Excessive amount of engine oil.

Exhaust smoke is dirty or thick

Engine lacks power

Excessive amount of engine oil.

B947H11504001

Correction / Reference Item

Check level and add.

Replace.

Clean.

Clean or replace.

Change.

Check level and drain.

Check level and drain.

Oil Pressure Check

B947H11504002

Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.

NOTE

Before checking the oil pressure, check the following.

• Oil level (Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).)

• Oil leaks (If leak is found, repair it.)

• Oil quality (If oil is discolored or deteriorated, replace it.)

1) Start the engine and check if the oil pressure indicator light is turned on. If the light stays on, check the oil pressure indicator light circuit. If the circuit is

OK, check the oil pressure in the following manner.

2) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

3) Remove the oil pressure switch lead wire (1) and oil pressure switch (2).

1

2

I947H1150005-01

4) Install the special tools to the mounting hole of the oil pressure switch.

Special tool

(A): 09915–74521 (Adapter hose)

(B): 09915–17410 (Oil pressure gauge adapter) kPa))

(C): 09915–77331 (Oil pressure gauge (1000

5) Install the oil pressure switch (2) to the adapter.

2

(B)

(C)

(A)

I947H1150036-01

6) Warm up the engine as follows:

Summer: 10 min. at 2 000 r/min

Winter: 20 min. at 2 000 r/min

7) After warming up, increase the engine speed to 3

000 r/min (Observe the tachometer), and read the oil pressure gauge.

If the oil pressure is lower or higher than the specification, the following causes may be considered.

Oil pressure specification

100 – 400 kPa (1.0 – 4.0 kgf/cm

2

, 14 – 57 psi) at 3

000 r/min, Oil temp. 60

°

C (140

°

F)

High oil pressure

• Engine oil viscosity is too high

• Clogged oil passage

Low oil pressure

• Clogged oil filter

• Oil leakage from the oil passage

• Combination of the above items

• Damaged O-ring

• Defective oil pump

• Combination of the above items

Stop the engine and remove the oil pressure gauge and attachment.

9) Reinstall the oil pressure switch. Refer to “Oil

Pressure Switch Removal and Installation”

(Page 1E-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1E-6 Engine Lubrication System:

10) Check the engine oil level. Refer to “Engine Oil and

Filter Replacement” in Section 0B (Page 0B-10).

11) Install the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

Repair Instructions

6) Remove the O-ring (6).

Engine Oil and Filter Replacement

B947H11506001

Refer to “Engine Oil and Filter Replacement” in Section

0B (Page 0B-10).

Engine Oil Level Inspection

B947H11506002

Refer to “Engine Oil and Filter Replacement” in Section

0B (Page 0B-10).

Oil Pan / Oil Pressure Regulator / Oil Strainer

Removal and Installation

B947H11506003

NOTE

The oil pan/oil strainer/oil pressure regulator cannot be serviced with the engine installed in the frame.

Removal

1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal” in Section 1D

(Page 1D-20).

2) Remove the plate (1).

3) Remove the oil pan (2).

6

I947H1150008-01

Installation

Installation is in the reverse order of removal. Pay attention to the following points:

• Apply grease to new O-ring (1).

!

CAUTION

Use a new O-ring to prevent oil leakage.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Install the oil strainer (2).

2

2

1

1

I947H1150006-01

4) Remove the gasket (3).

5) Remove the oil pressure regulator (4) and oil strainer

(5).

5

3

I947H1150009-01

• Apply grease to new O-ring (3).

!

CAUTION

Use a new O-ring to prevent oil leakage.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

4

I947H1150007-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Lubrication System: 1E-7

• Push in the oil pressure regulator (4) to the oil pump as shown.

Oil Pressure Regulator

Inspect the operation of the oil pressure regulator by pushing the piston with a proper bar.

If the piston does not operate smoothly, replace the oil pressure regulator with a new one.

3

4

• Install new gasket (5).

!

CAUTION

Use new gasket to prevent oil leakage.

I947H1150010-01

I947H1150013-02

Oil Strainer

Clean the oil strainer if necessary.

Inspect the oil strainer body for damage. If necessary, replace it with a new one.

5

I947H1150011-01

• Apply thread lock to the plate bolts “A”.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

• Tighten the oil pan bolts and plate bolts diagonally to the specified torque.

Tightening torque

Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

I947H1150014-01

Oil Cooler / Oil Cooler Hose Inspection and

Cleaning

B947H11506005

Refer to “Exterior Parts Removal and Installation” in

Section 9D (Page 9D-6).

Oil Cooler Hose Inspection

Inspect the oil cooler hoses for any damage and oil leakage. If any defects are found, replace the oil cooler hose with a new one.

“A”

I947H1150012-02

Oil Pressure Regulator / Oil Strainer Inspection

B947H11506004

Refer to “Oil Pan / Oil Pressure Regulator / Oil Strainer

Removal and Installation” (Page 1E-6).

email: [email protected] / www.motomatrix.co.uk

I947H1150015-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1E-8 Engine Lubrication System:

Oil Cooler Inspection

1) Remove the oil cooler guard (1).

!

CAUTION

• Make sure not to bend the fins when using compressed air.

• If compressed air is applied from the front side, dirt will be forced into the pores of oil cooler.

1

I947H1150037-02

2) Inspect the oil cooler for oil leakage. If any defects are found, replace the oil cooler with a new one. If the fins are bent or dented, repair them by carefully straightening them with the blade of a small screwdriver.

I947H1150038-01

I947H1150040-01

4) Reinstall the removed parts.

Oil Cooler / Oil Cooler Hose Removal and

Installation

B947H11506006

Removal

1) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Drain engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

3) Remove the oil hoses (1) and (2).

3) Reinstall the removed parts.

Oil Cooler Cleaning

1) Remove the oil cooler guard (1).

2) Remove the oil cooler mounting bolts.

1

1

I947H1150039-01

3) Blow out any foreign matter that is stuck in the oil cooler fins using compressed air.

2

4) Remove the oil cooler (3).

3 email: [email protected] / www.motomatrix.co.uk

I947H1150016-01

I947H1150041-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Lubrication System: 1E-9

5) Remove the oil cooler guard (4).

4

I947H1150017-01

Installation

Install the oil cooler and oil cooler hoses in the reverse order of removal. Pay attention to the following points:

• Apply thread lock to the oil cooler mounting bolt and tighten them securely.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

I947H1150019-01

• Apply thread lock to the oil cooler hose bolts and tighten them securely.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

I947H1150045-01

• Apply engine oil to new O-rings.

!

CAUTION

Replace the O-rings with new ones to prevent oil leakage.

I947H1150044-01

• Pour engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

• Install the removed parts.

Oil Pressure Switch Removal and Installation

B947H11506007

Refer to “Electrical Components Location” in Section 0A

(Page 0A-7).

Removal

1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

3) Drain engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

4) Disconnect the oil pressure switch lead wire (1).

I947H1150018-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1E-10 Engine Lubrication System:

5) Remove the oil pressure switch (2).

3) Pour engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

4) Install the removed parts.

2

Oil Pressure Switch Inspection

B947H11506008

Refer to “Oil Pressure Indicator Inspection” in Section 9C

(Page 9C-6).

1

I947H1150020-01

Installation

1) Apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque.

NOTE

Be careful not to apply bond to the hole of thread end.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

Tightening torque

Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lbfft)

Oil Jet Removal and Installation

B947H11506009

Piston Cooling Oil Jet

Removal

1) Remove the engine assembly. Refer to “Engine

Assembly Removal” in Section 1D (Page 1D-20).

2) Remove the Crankshaft assembly. Refer to “Engine

Bottom Side Disassembly” in Section 1D (Page 1D-

49).

3) Remove the piston cooling oil jets (1) from the upper crankcase.

1

I718H1140233-01

2) Route the oil pressure switch lead wire properly and tighten the screw to the specified torque. Refer to

“Wiring Harness Routing Diagram” in Section 9A

(Page 9A-7).

Tightening torque

Oil pressure switch lead wire screw (a): 1.5 N·m

(0.15 kgf-m, 1.1 lbf-ft)

I947H1150022-01

Installation

Installation is in the reverse order of removal. Pay attention to the following points:

• Fit new O-ring (1) to each piston cooling oil jet and apply engine oil to it.

!

CAUTION

Use new O-rings to prevent oil pressure leakage.

1

(a)

I947H1150023-01

I947H1150021-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Lubrication System: 1E-11

• Apply a small quantity of thread lock to the bolts and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Piston cooling oil jet bolt (a): 10 N·m (1.0 kgf-m,

7.0 lbf-ft)

4) Remove the oil jet (2) (for cam chain tension adjuster).

2

(a)

I947H1150024-01

Oil Jet (For Cam Chain Tension Adjuster)

Removal

1) Remove the throttle body. Refer to “Throttle Body

Removal and Installation” in Section 1D (Page 1D-

10).

2) Remove the regulator/rectifier. Refer to “Regulator /

Rectifier Removal and Installation” in Section 1J

(Page 1J-7).

3) Remove the cam chain tension adjuster (1). Refer to

“Engine Top Side Disassembly” in Section 1D

(Page 1D-26).

I947H1150043-01

Installation

Installation is in the reverse order of removal. Pay attention to the following points:

• Apply engine oil to the O-ring.

!

CAUTION

Use a new O-ring to prevent oil leakage.

1

I947H1150025-01

• Install the cam chain tension adjuster. Refer to

“Engine Top Side Assembly” in Section 1D (Page 1D-

28).

• Install the regulator/rectifier. Refer to “Regulator /

Rectifier Removal and Installation” in Section 1J

(Page 1J-7).

• Install the throttle body. Refer to “Throttle Body

Removal and Installation” in Section 1D (Page 1D-

10).

I947H1150042-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1E-12 Engine Lubrication System:

Oil Jet (For Transmission)

Removal

1) Remove the engine assembly. Refer to “Engine

Assembly Removal” in Section 1D (Page 1D-20).

2) Separate the crankcases, upper and lower. Refer to

“Engine Bottom Side Disassembly” in Section 1D

(Page 1D-49).

3) Remove the oil jet (1) (for transmission) from the lower crankcase.

Oil Pump Removal and Installation

B947H11506011

NOTE

Be careful not to drop any parts into the crankcase.

Removal

1) Remove the oil pan, oil pressure regulator and oil strainer. Refer to “Oil Pan / Oil Pressure Regulator /

Oil Strainer Removal and Installation” (Page 1E-6).

2) Remove the oil pump driven gear bolt (1).

3) Remove the oil pump driven sprocket (2).

4) Remove the washer (3).

1

1

I947H1150026-01

Installation

Installation is in the reverse order of removal. Refer to

“Engine Bottom Side Assembly” in Section 1D

(Page 1D-56).

Oil Jet Inspection

B947H11506010

Refer to “Oil Jet Removal and Installation” (Page 1E-10).

Oil Jet

Make sure that the oil jets are not clogged. If they are clogged, clean their oil passage using a wire of the proper size and compressed air.

1

2

3

2

5) Remove the oil pump (4).

3

I947H1150028-01

4

6) Remove the O-ring (5) and dowel pins.

I947H1150029-01

1. Piston cooling jet

2. Oil jet (For transmission)

3. Oil jet (For cam chain tension adjuster)

I947H1150027-01

5

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Engine Lubrication System: 1E-13

Installation

1) Install the dowel pins.

2) Apply grease to new O-ring.

!

CAUTION

Use a new O-ring to prevent oil leakage.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

4) Tighten the oil pump mounting bolts to the specified torque.

Tightening torque

Oil pump mounting bolt (a): 10 N·m (1.0 kgf-m,

7.0 lbf-ft)

(a)

I947H1150031-01

3) Install the oil pump.

NOTE

Engage the oil pump shaft end with the water pump shaft slot.

I947H1150033-01

5) Install the washer (1).

6) Install the oil pump driven sprocket (2) with the chain

(3).

7) Apply a small quantity of thread lock to the oil pump driven sprocket bolt (4) and tighten it to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Oil pump driven sprocket bolt (b): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

4

(b)

I947H1150032-01

1

2

3

I947H1150034-01

Install the oil pan, oil strainer and oil pressure regulator. Refer to “Oil Pan / Oil Pressure Regulator /

Oil Strainer Removal and Installation” (Page 1E-6).

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1E-14 Engine Lubrication System:

Oil Pump Inspection

B947H11506012

Inspect the oil pump in the following procedures:

1) Remove the oil pump. Refer to “Oil Pump Removal and Installation” (Page 1E-12).

2) Rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, replace the oil pump assembly.

!

CAUTION

Do not attempt to disassemble the oil pump.

The oil pump is available only as an assembly.

I947H1150035-01

3) Install the oil pump. Refer to “Oil Pump Removal and

Installation” (Page 1E-12).

Oil Pump Drive Sprocket Removal and

Installation

B947H11506013

Refer to “Engine Bottom Side Disassembly” in Section

1D (Page 1D-49) and “Engine Bottom Side Assembly” in

Section 1D (Page 1D-56).

Specifications

Service Data

Oil Pump

Item

Oil pressure (at 60

°

C, 140

°

F)

Standard

100 – 400 kPa (1.0 – 4.0 kgf/cm

2

, 14 – 57 psi) at 3 000 r/min

B947H11507001

Limit

—

Oil

Engine oil type

Item

Engine oil capacity

Specification

SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Change

Filter change

Overhaul

2 800 ml (3.0/2.5 US/lmp qt)

3 300 ml (3.5/2.9 US/lmp qt)

3 600 ml (3.8/3.2 US/lmp qt)

Note

Tightening Torque Specifications

Fastening part

Oil pan bolt

Oil pressure switch

Oil pressure switch lead wire screw

Piston cooling oil jet bolt

Oil pump mounting bolt

Oil pump driven sprocket bolt

N

⋅

m

10

14

1.5

10

10

10

Tightening torque kgf-m

1.0

1.4

0.15

1.0

1.0

1.0

lbf-ft

7.0

10.0

1.1

7.0

7.0

7.0

B947H11507002

Note

)

(Page 1E-7)

)

(Page 1E-10)

)

(Page 1E-10)

)

(Page 1E-11)

)

(Page 1E-13)

)

(Page 1E-13)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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Engine Lubrication System: 1E-15

Special Tools and Equipment

Recommended Service Material

Grease

Sealant

Material

Thread lock cement

B947H11508001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or equivalent

SUZUKI BOND No.1207B or

Note

P/No.: 99000–25010

)

(Page 1E-6) /

)

(Page 1E-

6) /

)

(Page 1E-13)

P/No.: 99000–31140

)

(Page 1E-10) equivalent

THREAD LOCK CEMENT SUPER

“1322” or equivalent

P/No.: 99000–32110

)

(Page 1E-7) /

)

(Page 1E-

9) /

)

(Page 1E-9) /

)

(Page 1E-11) /

)

(Page 1E-13)

Special Tool

09915–17410

Oil pressure gauge adapter

)

(Page 1E-5)

09915–74521

Adapter hose

)

(Page 1E-5)

B947H11508002

09915–77331

Oil pressure gauge (1000 kPa)

)

(Page 1E-5) email: [email protected] / www.motomatrix.co.uk

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1F-1 Engine Cooling System:

Engine

Engine Cooling System

Precautions

Precautions for Engine Cooling System

!

WARNING

B947H11600001

• You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot.

After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.

• The engine must be cool before servicing the cooling system.

• Coolant is harmful:

– If it comes in contact with skin or eyes, flush with water.

– If swallowed accidentally, induce vomiting and call physician immediately.

– Keep it away from children.

Precautions for Engine Coolant

Refer to “Engine Coolant Recommendation” in Section 0A (Page 0A-4).

B947H11600002

General Description

Fig. 1: Engine coolant density-freezing point curve

Engine Coolant Description

!

CAUTION

B947H11601001

• Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze.

• Do not put in more than 60% anti-freeze or less than 50%. (Refer to Fig. 1 and 2.)

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 protection, and will protect the cooling system from freezing at temperatures above –31

°

C (–24

°

F).

If the vehicle is to be exposed to temperatures below –

31

°

C (–24

°

F), this mixing ratio should be increased up to 55% or 60% according to the figure.

Anti-freeze Proportioning Chart

Anti-freeze density

50%

55%

60%

Freezing point

–31

°

C (–24

°

F)

–40

°

C (–40

°

F)

–55

°

C (–67

°

F)

I310G1160001-01

Fig. 2: Engine coolant density-boiling point curve

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Engine Cooling System: 1F-2

Schematic and Routing Diagram

Cooling Circuit Diagram

B947H11602001

RESERVOIR

TANK

THERMOSTAT

CYLINDER HEAD ECT SENSOR

CYLINDER

RADIATOR

WATER

PUMP

I947H1160001-02 email: [email protected] / www.motomatrix.co.uk

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1F-3 Engine Cooling System:

Water Hose Routing Diagram

“ a ”

“ b ”

“A”

(a)

“D”

“C”

“E”

(b)

“F”

“H”

“B”

“G”

2

1

3

4

“I”

B947H11602002

“A”

“A”

“B”

“A”

(c)

“J”

1. Thermostat air bleeder hole

2. Cushion

3. O-ring

4. Radiator heat guard

: Be careful not to damage the pawls when removing.

“A”: Yellow marking

“B”: White marking

“C”: Clamp end should face downward.

“B”

“D”: Clamp end should face right side.

“E”: Cut off the excess tip of the clamp.

“F”: Screw head should face right side.

“G”: Screw head should face backward.

“H”: Clamp end should face upward.

“I”: Clamp end should face left side.

“J”: Screw head should face forward.

“K”

I947H1160053-03

“K”: Screw head should face left side.

“a”: 2 – 8 mm (0.08 – 0.31 in)

“b”: Clearance

: 6 N

⋅ m (0.6 kgf-m, 4.5 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 0.7 lbf-ft)

: 13 N

⋅ m (1.3 kgf-m, 9.5 lbf-ft)

: :Apply engine oil.

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Engine Cooling System: 1F-4

Diagnostic Information and Procedures

Engine Cooling Symptom Diagnosis

Condition

Engine overheats

Engine over cools

B947H11604001

Possible cause

Not enough engine coolant.

Defective cooling fan relay, or open-orshort circuited.

Correction / Reference Item

Add engine coolant.

Radiator core clogged with dirt or scale.

Clean.

Faulty cooling fan.

Repair or replace.

Repair or replace.

Clogged water passage.

Air trapped in the cooling circuit.

Defective water pump.

Use of incorrect engine coolant.

Clean.

Bleed air.

Replace.

Replace.

Defective thermostat.

Defective ECT sensor.

Defective ECM.

Damaged ISC valve.

Incorrect ISC learning.

Defective cooling fan relay, or open-orshort circuited.

Extremely cold weather.

Replace.

Replace.

Replace.

Replace.

Reset learned value.

Repair or replace.

Defective thermostat.

Defective ECT sensor.

Defective ECM.

Put on radiator cover.

Replace.

Replace.

Replace.

Repair Instructions

Cooling Circuit Inspection

!

WARNING

B947H11606001

• Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.

• When removing the radiator cap tester, put a rag on the filler to prevent the engine coolant from spraying out.

Inspect the cooling circuit in the following procedures:

1) Remove the right side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Remove the radiator cap (1) and connect the radiator tester (2) to the filler.

3) Pressurize the cooling system with 120 kPa (1.2 kgf/ cm, 17.6 psi) of pressure, and then check if it holds the pressure for 10 seconds.

!

CAUTION

Do not exceed the radiator cap release pressure, or the radiator cap and subsequently the radiator, can be damaged.

1

2

I947H1160002-02

I815H1160002-01

4) After finishing the cooling circuit inspection, reinstall the removed parts.

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1F-5 Engine Cooling System:

Radiator Cap Inspection

B947H11606002

Inspect the radiator cap in the following procedures:

1) Remove the radiator cap. Refer to “Cooling Circuit

Inspection” (Page 1F-4).

2) Attach the radiator cap (1) to the radiator tester (2) as shown.

I718H1160033-01

3) Slowly apply pressure to the radiator cap.

If the radiator cap does not hold the pressure for at least 10 seconds, replace it with a new one.

Radiator cap release pressure

93 – 123 kPa (0.9 – 1.2 kgf/cm

2

, 13.2 – 17.5 psi)

4) After finishing the radiator cap inspection, reinstall the removed parts.

Radiator Cleaning

Blow out any foreign matter that is stuck in the radiator fins using compressed air.

!

CAUTION

• Make sure not to bend the fins when using compressed air.

• Always apply compressed air from the engine side. If compressed air is applied from the front side, dirt will be forced into the pores of radiator.

1) Remove the inner under cowlings. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the cooling fan motor lead wire coupler

(1).

1

Radiator Inspection and Cleaning

B947H11606003

Radiator Hose Inspection

Refer to “Cooling System Inspection” in Section 0B

(Page 0B-12).

Radiator Inspection

Inspect the radiator for water leaks. If any defects are found, replace the radiator with a new one.

If the fins are bent or dented, repair them by carefully straightening them with the blade of a small screwdriver.

I947H1160005-01

3) Remove the oil cooler (2) from the bracket.

2

I947H1160006-02

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Engine Cooling System: 1F-6

4) Remove the radiator mounting bolts.

9) Apply thread lock to the oil cooler bolts and tighten them securely.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

I947H1160007-01

I947H1160008-02

5) Move the radiator forward.

6) Apply compressed air from the engine side.

I947H1160057-01

10) Reinstall the removed parts.

Radiator / Cooling Fan Motor Removal and

Installation

B947H11606004

Removal

1) Remove the inner under cowlings. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Drain engine coolant. Refer to “Cooling System

Inspection” in Section 0B (Page 0B-12).

3) Disconnect the reservoir tank inlet hose (1) and water air bleed hose (2).

4) Remove the radiator reservoir tank (3).

1

2

7) Tighten the upper radiator mounting bolts.

I947H1160051-01

Apply thread lock to the radiator bracket bolts and tighten all bolts securely.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

3

I947H1160004-02

5) Disconnect the radiator inlet hose (4).

6) Disconnect the cooling fan motor coupler (5).

5

4

I947H1160009-02

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1F-7 Engine Cooling System:

7) Remove the oil cooler (6) from the bracket.

Installation

Install the radiator in the reverse order of removal. Pay attention to the following points:

• Install the radiator and oil cooler to their bracket. Refer to “Radiator Inspection and Cleaning” (Page 1F-5).

• Apply thread lock to the reservoir tank bolt and tighten it securely.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

6

I947H1160010-01

Remove the radiator assembly by removing the bolts.

I947H1160011-01

I947H1160058-01

• Connect the radiator hoses securely. Refer to “Water

Hose Routing Diagram” (Page 1F-3).

• Pour engine coolant. Refer to “Cooling System

Inspection” in Section 0B (Page 0B-12).

• Bleed air from the cooling circuit. Refer to “Cooling

System Inspection” in Section 0B (Page 0B-12).

Water Hose Inspection

B947H11606005

Inspect the water hoses in the following procedures:

1) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Check the water hoses for crack, damage or engine coolant leakage. If any defect is found, replace the water hose with a new one.

I947H1160012-02

9) Remove the radiator outlet hose (7) and cooling fan motor (8) from the radiator.

8

7

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Engine Cooling System: 1F-8

3) Any leakage from the connecting section should be corrected by proper tightening. Refer to “Water Hose

Routing Diagram” (Page 1F-3).

Installation

1) Install the water hose as shown in the water hose routing diagram. Refer to “Water Hose Routing

Diagram” (Page 1F-3).

2) Install the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-9).

3) Pour engine coolant and bleed air from the cooling circuit. Refer to “Cooling System Inspection” in

Section 0B (Page 0B-12).

4) Install the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

I947H1160014-02

Radiator Reservoir Tank Inspection

B947H11606007

Inspect the radiator reservoir tank in the following procedures:

1) Remove the right side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Inspect the radiator reservoir tank (1) for leaks. If any defects are found, replace the radiator reservoir tank with a new one.

I947H1160015-01

I947H1160016-01

4) After finishing the water hoses inspection, reinstall the removed parts.

Water Hose Removal and Installation

B947H11606006

Removal

1) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Drain engine coolant. Refer to “Cooling System

Inspection” in Section 0B (Page 0B-12).

3) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

4) Remove the water hose as shown in the water hose routing diagram. Refer to “Water Hose Routing

Diagram” (Page 1F-3).

1

I947H1160017-02

3) Reinstall the removed parts.

Radiator Reservoir Tank Removal and

Installation

B947H11606008

Removal

1) Remove the right side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the reservoir tank inlet hose (1) from the reservoir tank (2) and drain the engine coolant.

3) Remove the reservoir tank (2).

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1F-9 Engine Cooling System:

4) Disconnect the reservoir tank overflow hose (3).

1

3

2

I947H1160018-03

2) Test the cooling fan motor for load current with an ammeter connected as shown in the figure.

If the fan motor does not turn, replace the cooling fan assembly with a new one. Refer to “Radiator /

Cooling Fan Motor Removal and Installation”

(Page 1F-6).

NOTE

• When making this test, it is not necessary to remove the cooling fan.

• Make sure that the battery has a capacity enough to supply the motor with 12 V.

• With the motor running at full speed, the ammeter should indicate an amperage not higher than 5 A.

Installation

1) Install the reservoir tank. Refer to “Radiator / Cooling

Fan Motor Removal and Installation” (Page 1F-6).

2) Fill the reservoir tank with engine coolant to the upper level. Refer to “Cooling System Inspection” in

Section 0B (Page 0B-12).

3) Install the right side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

4

2

3

Cooling Fan Inspection

B947H11606009

Cooling fan operating temperature

Standard

(ON

→

OFF): Approx. 100

(OFF

→

°

ON): Approx. 105

°

C (212

°

C (221

°

F)

F)

Inspect the cooling fan in the following procedures:

1) Disconnect the cooling fan motor coupler (1).

1

2. Fan motor 3. Ammeter

I718H1160048-01

4. Battery

3) Connect the cooling fan motor coupler.

Cooling Fan Relay Inspection

B947H11606010

Inspect the fan relay in the following procedures:

1) Remove the frame covers. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Remove the cooling fan relay (1).

1

I947H1160019-01

I947H1160052-01 email: [email protected] / www.motomatrix.co.uk

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Engine Cooling System: 1F-10

4) Remove the thermostat (2).

3) First check the insulation between “A” and “B” terminals with tester. Then apply 12 volts to “C” and

“D” terminals, (+) to “C” and (–) to “D”, and check the continuity between “A” and “B”.

If there is no continuity, replace it with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication set

Continuity test ( )

2

“A”

“C”

“B”

4) Reinstall the removed parts.

“D”

ECT Sensor Removal and Installation

B947H11606011

Refer to “ECT Sensor Removal and Installation” in

Section 1C (Page 1C-4).

I718H1160006-03

I947H1160021-02

Installation

Install the thermostat in the reverse order of removal.

Pay attention to the following points:

• Install the thermostat.

NOTE

Air bleeder hole “A” of the thermostat faces upside.

ECT Sensor Inspection

B947H11606012

Refer to “ECT Sensor Inspection” in Section 1C

(Page 1C-4).

Thermostat Removal and Installation

B947H11606013

Removal

1) Drain a small amount of engine coolant. Refer to

“Cooling System Inspection” in Section 0B

(Page 0B-12).

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

3) Remove the thermostat cover (1).

“A”

I947H1160022-02

• Tighten the thermostat cover bolts to the specified torque.

Tightening torque

Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

1

I947H1160020-02

(a)

I947H1160023-01

• Pour engine coolant and bleed air from the cooling circuit. Refer to “Cooling System Inspection” in

Section 0B (Page 0B-12).

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1F-11 Engine Cooling System:

Thermostat Inspection

B947H11606014

Inspect the thermostat in the following procedures:

1) Remove the thermostat. Refer to “Thermostat

Removal and Installation” (Page 1F-10).

2) Inspect the thermostat pellet for signs of cracking.

6) Read the thermometer just when opening the thermostat. If this reading, which is the temperature level at which the thermostat valve begins to open, is out of the standard value, replace the thermostat with a new one.

Thermostat valve opening temperature

Standard: Approx. 82

°

C (180

°

F)

7) Keep on heating the water to raise its temperature.

Just when the water temperature reaches specified value, the thermostat valve should have been lifted by at least 8 mm (0.31 in). A thermostat failing to satisfy either of the two requirements (start-to-open temperature and valve lift) must be replaced.

Thermostat valve lift “a”

Standard: Over 8 mm (0.31 in) and at 95

°

C (203

°

F)

I947H1160024-01

3) Test the thermostat at the bench for control action.

!

CAUTION

• Do not contact the thermostat (1) and column thermometer (2) with a pan.

• As the thermostat operating response to water temperature change is gradual, do not raise water temperature too quickly.

• The thermostat with its valve open even slightly under normal temperature must be replaced.

4) Immerse the thermostat (1) in the water contained in a beaker and note that the immersed thermostat is in suspension.

5) Heat the water by placing the beaker on a stove and observe the rising temperature on a thermometer

(2).

I705H1160031-04

9) Install the thermostat. Refer to “Thermostat Removal and Installation” (Page 1F-10).

“A”: String “B”: Water

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Engine Cooling System: 1F-12

Water Pump Components

B947H11606015

5

3

2

1

(a)

4

(c)

(d)

1. Impeller

2. Mechanical seal

3. Oil seal

4. O-ring

5. O-ring

: 8 N

⋅ m (0.8 kgf-n, 6.0 Ib-ft)

: 10 N

⋅ m (1.0 kgf-n, 7.0 Ib-ft)

: 6 N

⋅ m (0.6 kgf-n, 4.5 Ib-ft)

: 13 N

⋅ m (1.3 kgf-n, 9.5 Ib-ft)

: Apply grease.

(b)

: Apply engine coolant.

: Apply molybdenum oil solution.

: Do not reuse.

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1F-13 Engine Cooling System:

Water Pump Construction

4

1

3

B947H11606016

(a)

5

2

(b)

I947H1160054-02

1. Impeller

2. Mechanical seal

3. Oil seal

4. O-ring

5. O-ring

: 8 N

⋅ m (0.8 kgf-m, 6.0 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: Apply grease.

Water Pump Removal and Installation

B947H11606017

Removal

NOTE

Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer. Refer to

“Water Pump Related Parts Inspection”

(Page 1F-17).

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Drain engine oil and coolant. Refer to “Engine Oil and Filter Replacement” in Section 0B (Page 0B-10) and “Cooling System Inspection” in Section 0B

(Page 0B-12).

3) Disconnect the water bypass hose (1).

: Apply engine coolant.

: Apply molybdenum oil solution.

: Do not reuse.

4) Remove the water pump (2).

2

1

I947H1160025-02

Installation

Install the water pump in the reverse order of removal.

Pay attention to the following points:

• Apply grease to the O-ring.

!

CAUTION

Replace the O-ring with the a new one.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine Cooling System: 1F-14

• Install the water pump assembly with the slot of the pump shaft end “A” securely engaged with the flat “B” of the oil pump shaft.

Water Pump Disassembly and Assembly

B947H11606018

Refer to “Water Pump Removal and Installation”

(Page 1F-13).

“B”

Disassembly

1) Remove the air bleeder bolt (1) if necessary.

1

“A”

I947H1160026-01

• Tighten the water pump mounting bolts (1) to the specified torque.

Tightening torque

Water pump mounting bolt (a): 10 N·m (1.0 kgfm, 7.0 lbf-ft)

2) Remove the water pump case screws.

I947H1160028-01

1

(a)

I947H1160027-03

• Connect the water hoses securely. Refer to “Water

Hose Routing Diagram” (Page 1F-3).

• Pour engine oil and coolant. Refer to “Engine Oil and

Filter Replacement” in Section 0B (Page 0B-10) and

“Cooling System Inspection” in Section 0B (Page 0B-

12).

• Bleed air from the cooling circuit. Refer to “Cooling

System Inspection” in Section 0B (Page 0B-12).

3) Remove the O-ring (2).

2

I947H1160029-01

I947H1160030-01

4) Hold the impeller (3) with water pump pliers and remove the impeller securing bolt (4).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1F-15 Engine Cooling System:

5) Remove the impeller (3).

(A)

3

4

I947H1160031-01

6) Remove the mechanical seal ring (5) and rubber seal (6) from the impeller.

10

I947H1160034-01

9) Remove the oil seal (11).

NOTE

If there is no abnormal condition, the oil seal removal is not necessary.

11

6

5

I947H1160032-01

7) Remove the O-ring (7), impeller shaft (8) and washer

(9) from the holder.

8

9

7

I947H1160033-01

Remove the mechanical seal (10) with the special tool.

NOTE

If there is no abnormal condition, the mechanical seal removal is not necessary.

Special tool

(A): 09921–20240 (Bearing remover set)

I947H1160035-01

Assembly

1) Install the oil seal with the special tool.

!

CAUTION

The removed oil seal must be replaced with a new one.

NOTE

The stamped mark on the oil seal should face mechanical seal side.

Special tool

– 75

(A): 09913–70210 (Bearing installing set (10

Φ

))

(A)

I947H1160036-01 email: [email protected] / www.motomatrix.co.uk

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Engine Cooling System: 1F-16

2) Apply a small quantity of the grease to the oil seal lip.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

5) Install the impeller shaft (1) and washer (2) to the holder.

2

1

I947H1160037-01

3) Install a new mechanical seal using a suitable size socket wrench.

!

CAUTION

The removed mechanical seal must be replaced with a new one.

NOTE

On new mechanical seals, the sealer “A” has been applied.

6) Install the rubber seal (3) into the impeller.

I947H1160040-01

7) After wiping off the oily or greasy matter from the mechanical seal ring (4), install it into the impeller.

NOTE

The paint marked side “B” of mechanical seal ring faces the rubber seal.

3

“B”

4

“A”

I947H1160038-01

I947H1160041-01

Install the washer (5) and seal washer (6) onto the impeller securing bolt.

NOTE

The metal side “C” of seal washer and the curved side “D” of washer face the impeller securing bolt head.

5

6

I947H1160039-01

4) Apply molybdenum solution to the impeller shaft (1) and washer (2).

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

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“C” “D”

9) Install the impeller (7).

I947H1160042-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1F-17 Engine Cooling System:

10) Hold the impeller with water pump pliers and tighten the impeller securing bolt to the specified torque.

Tightening torque

Impeller securing bolt (a): 8 N·m (0.8 kgf-m, 6.0 lbf-ft)

9

(b)

7

(a)

I947H1160043-02

11) Install new O-ring (8) and apply engine coolant to it.

!

CAUTION

Use a new O-ring to prevent engine coolant leakage.

12) Tighten the water pump case screws to the specified torque.

Tightening torque

Water pump case screw: 6 N·m (0.6 kgf-m, 4.5 lbf-ft)

I947H1160045-01

Water Pump Related Parts Inspection

B947H11606019

Refer to “Water Pump Disassembly and Assembly”

(Page 1F-14).

Mechanical Seal

Visually inspect the mechanical seal for damage, with particular attention given to the sealing face.

Replace the mechanical seal that shows indications of leakage.

8

I947H1160046-01

Oil Seal

Visually inspect the oil seal for damage, with particular attention given to the lip.

Replace the oil seal that shows indications of leakage.

I947H1160044-02

13) Tighten the water pump air bleeder bolt (9) to the specified torque.

!

CAUTION

Use a new gasket washer to prevent engine coolant leakage.

Tightening torque

Water pump air bleeder bolt (b): 13 N·m (1.3 kgfm, 9.5 lbf-ft)

I947H1160047-01 email: [email protected] / www.motomatrix.co.uk

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Engine Cooling System: 1F-18

Seal Washer

Visually inspect the seal washer for damage, with particular attention given to the sealing face.

Replace the seal washer that shows indications of leakage.

Impeller / Shaft

Visually inspect the impeller and its shaft for damage.

Replace the impeller or shaft if necessary.

I947H1160048-01

I947H1160049-01

Impeller Shaft Journal

Visually inspect the journal for damage or scratch.

Replace the holder if necessary.

I947H1160050-01

Specifications

Service Data

Thermostat + Radiator + Fan + Coolant

Item

Thermostat valve opening temperature

Thermostat valve lift

ECT sensor resistance

Specification

Approx. 82

°

C (180

°

F)

Over 8 mm (0.31 in) and at 95

°

C (203

°

F)

20

°

C

Approx. 2.45 k

Ω

(68

°

F)

50

°

C

(122

°

F)

80

°

C

Approx. 0.811 k

Approx. 0.318 k

Ω

Ω

(176

°

F)

110

°

C

(230

°

F)

Approx. 0.142 k

Ω

Radiator cap valve opening pressure

93 – 123 kPa (0.9 – 1.2 kgf/cm

2

, 13.2 – 17.5 psi)

Cooling fan operating temperature

Engine coolant type

Engine coolant

OFF

→

ON

ON

→

OFF

Approx. 105

°

C (221

°

F)

Approx. 100

°

C (212

°

F)

Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

Reservoir tank side

Engine side

Approx. 250 ml (0.3/0.2 US/lmp qt)

Approx. 2 500 ml (2.6/2.2 US/lmp qt) email: [email protected] / www.motomatrix.co.uk

B947H11607001

Note

—

—

—

—

—

—

—

—

—

—

—

—

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1F-19 Engine Cooling System:

Tightening Torque Specifications

Fastening part

Thermostat cover bolt

Water pump mounting bolt

Impeller securing bolt

Water pump case screw

Water pump air bleeder bolt

N

⋅

10

10

8

6

m

13

Tightening torque kgf-m

1.0

1.0

0.8

0.6

1.3

lbf-ft

7.0

7.0

6.0

4.5

9.5

B947H11607002

Note

)

(Page 1F-10)

)

(Page 1F-14)

)

(Page 1F-17)

)

(Page 1F-17)

)

(Page 1F-17)

NOTE

The specified tightening torque is described in the following.

“Water Hose Routing Diagram” (Page 1F-3)

“Water Pump Components” (Page 1F-12)

“Water Pump Construction” (Page 1F-13)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

Grease

Material

Molybdenum oil

Thread lock cement

B947H11608001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or equivalent

MOLYBDENUM OIL SOLUTION

THREAD LOCK CEMENT SUPER

“1322” or equivalent

Note

P/No.: 99000–25010

)

(Page 1F-13) /

)

(Page 1F-16)

—

)

(Page 1F-16)

P/No.: 99000–32110

)

(Page 1F-6) /

)

(Page 1F-

6) /

)

(Page 1F-7)

NOTE

Required service material is also described in the following.

“Water Hose Routing Diagram” (Page 1F-3)

“Water Pump Components” (Page 1F-12)

“Water Pump Construction” (Page 1F-13)

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1F-10)

09913–70210

Bearing installing set (10 –

75

Φ

)

)

(Page 1F-15)

B947H11608002

09921–20240

Bearing remover set

)

(Page 1F-15) email: [email protected] / www.motomatrix.co.uk

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Fuel System: 1G-1

Engine

Fuel System

Precautions

Precautions for Fuel System

!

WARNING

B947H11700001

• Keep away from fire or spark.

• During disassembling, use care to minimize spillage of gasoline.

• Spilled gasoline should be wiped off immediately.

• Work in a well-ventilated area.

• For E-33 models, drain fuel from the fuel tank before disconnecting the fuel feed hose to prevent fuel leakage.

!

CAUTION

• To prevent the fuel system (fuel tank, fuel hose, etc.) from contamination with foreign particles, blind all openings.

• After removing the throttle body, tape the cylinder intake section to prevent foreign particles from entering.

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1G-2 Fuel System:

General Description

Fuel Injection System Description

B947H11701001

Fuel System

The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipes

(5) including fuel injectors (6) and (7), fuel pressure regulator (8). 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. Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injectors (the fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of approx. 294 kPa (2.9 kgf/cm

2

, 41.8 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the

ECM.

The fuel relieved by the fuel pressure regulator flows back to the fuel tank.

1

1. Fuel tank

2. Fuel pump

3. Fuel mesh filter

6

4. Fuel feed hose

5. Fuel delivery pipe

6. Primary fuel injector

7

5

8

2

3

4

“A”

“B”

“C”

7. Secondary fuel injector

8. Fuel pressure regulator

“A”: Pre-pressurized fuel

I947H1170019-03

“B”: Pressurized fuel

“C”: Relieved fuel email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Fuel System: 1G-3

Schematic and Routing Diagram

Fuel Tank Drain Hose and Breather Hose Routing Diagram

B947H11702001

6

“E”

1

“B”

2

“D”

“I”

“F”

“H”

“G”

“C”

4

“ c ”

3

1. Fuel tank water drain hose

2. Fuel tank breather hose No. 1

3. Fuel tank breather hose No. 2

4. Fuel tank breather hose No. 3

5. 3-way joint

6. Frame

“ b ”

2

5

“A”

“ a ”

“A”: White marking

“B”: Set the hose end to the root of tank nipple.

“C”: Match the direction of 3-way joint and hoses.

“D”: Arrange the hoses in parallel.

“E”: Face the clamp end forward. Cut off the excess tip of the clamp.

“F”: Set the hoses with the white marking inside.

I947H1170020-02

“G”: Stick the hose clamp along the line behind the cowling.

“H”: Clamp the hoses at marking point. Match the length of hoses.

“I”: Pass the hoses in front of the rear brake reservoir.

“a”: 30 – 45

°

“b”: 10 – 30 mm (0.4 – 1.2 in)

“c”: 50 mm (2.0 in) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1G-4 Fuel System:

Diagnostic Information and Procedures

Fuel System Diagnosis

B947H11704001

Condition

Engine will not start or is hard to start (No fuel reaching the intake manifold)

Engine will not start or is hard to start (Incorrect fuel/air mixture)

Engine stalls often

(Incorrect fuel/air mixture)

Engine stalls often (Fuel injector improperly operating)

Engine runs poorly in high speed range

(Defective control circuit or sensor)

Possible cause

Clogged fuel filter or fuel hose.

Defective fuel pump.

Defective fuel pressure regulator.

Defective fuel injector.

Defective fuel pump relay.

Defective ECM.

Open-circuited wiring connection.

TP sensor out of adjustment.

Defective fuel pump.

Defective fuel pressure regulator.

Defective TP sensor.

Defective CKP sensor.

Defective IAP sensor.

Defective ECM.

Defective ECT sensor.

Correction / Reference Item

Clean or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Check and repair.

Adjust.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Defective IAT sensors.

Defective AP sensors.

Clogged ISC valve air passage way.

Defective IAP sensor or circuit.

Clogged fuel filter.

Defective fuel pump.

Defective fuel pressure regulator.

Defective ECT sensor.

Replace.

Replace.

Repair or replace.

Repair or replace.

Clean or replace.

Replace.

Replace.

Replace.

Defective thermostat.

Defective IAT sensor.

Damaged or cracked vacuum hose.

Damaged or cracked ISC valve.

Replace.

Replace.

Replace.

Repair or replace.

Defective fuel injector.

No injection signal from ECM.

Open or short circuited wiring connection.

Replace.

Repair or replace.

Repair or replace.

Defective battery or low battery voltage.

Replace or recharge.

Low fuel pressure.

Defective TP sensor.

Defective IAT sensor.

Defective CMP sensor.

Defective CKP sensor.

Defective GP switch.

Defective IAP sensor.

Defective ECM.

TP sensor out of adjustment.

Defective STP sensor and/or STVA.

Repair or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

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Fuel System: 1G-5

Fuel Pressure Inspection

!

WARNING

1

Repair Instructions

B947H11706001

• Keep away from fire or spark.

• Spilled gasoline should be wiped off immediately.

• Work in a well-ventilated area.

Inspect the fuel pressure in the following procedures:

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” (Page 1G-9).

2) Place a rag under the fuel feed hose (1) and remove the fuel feed hose.

I947H1170001-01

3) Install the special tools between the fuel pump and fuel delivery pipe.

Special tool

(A): 09940–40211 (Fuel pressure gauge adapter)

(B): 09940–40220 (Fuel pressure gauge attachment)

(C): 09915–77331 (Oil pressure gauge (1000 kPa))

(D): 09915–74521 (Adapter hose)

4) Turn the ignition ON and check for fuel pressure.

Fuel pressure

Approx. 300 kPa (3.0 kgf/cm

2

, 43 psi)

If the fuel pressure is lower than the specification, check for the followings:

• Fuel hose leakage

• Clogged fuel filter

• Pressure regulator

• Fuel pump

If the fuel pressure is higher than the specification, check for the followings:

• Fuel pump

• Pressure regulator

5) Remove the special tools.

!

WARNING

Before removing the special tools, turn the ignition switch OFF and release the fuel pressure slowly.

6) Reinstall the fuel tank. Refer to “Fuel Tank Removal and Installation” (Page 1G-9).

NOTE

Connect the fuel feed hose to the fuel pump until it locks securely (a click is heard).

(C)

(B)

(D)

(A)

I947H1170021-01 email: [email protected] / www.motomatrix.co.uk

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1G-6 Fuel System:

Fuel Pump Inspection

B947H11706002

Turn the ignition switch ON and check that the fuel pump operates for a few seconds.

If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and TO sensor. Refer to “Fuel Pump

Relay Inspection” (Page 1G-7) and “DTC “C23” (P1651-

H/L): TO Sensor Circuit Malfunction” in Section 1A

(Page 1A-68).

If the fuel pump relay, TO sensor and fuel pump circuit connections are OK, the fuel pump may be faulty, replace the fuel pump with a new one. Refer to “Fuel

Pump Disassembly and Assembly” (Page 1G-11).

3) Connect a proper fuel hose (2) to the fuel pump.

4) Place the measuring cylinder and insert the fuel hose end into the measuring cylinder.

5) Disconnect the fuel pump lead wire coupler (3).

2

3

Fuel Discharge Amount Inspection

!

WARNING

B947H11706003

• Keep away from fire or spark.

• Spilled gasoline should be wiped off immediately.

• Work in a well-ventilated area.

Inspect the fuel discharge amount in the following procedures:

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” (Page 1G-9).

2) Place a rag under the fuel feed hose (1) and disconnect fuel feed hose from the fuel pump.

I947H1170022-01

6) Connect a proper lead wire into 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.

If the discharge amount is out of the specification, the probable cause may be failure of the fuel pump or clogged fuel filter.

NOTE

The battery must be in fully charged condition.

Fuel discharge amount

222 ml (7.5/7.8 US/lmp oz) and more/10 seconds

1

I947H1170002-01

I947H1170023-01

7) After finishing the fuel discharge inspection, reinstall the fuel tank. Refer to “Fuel Tank Removal and

Installation” (Page 1G-9).

NOTE

Connect the fuel feed hose to the fuel pump until it locks securely (a click is heard).

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Fuel Pump Relay Inspection

B947H11706004

Refer to “Electrical Components Location” in Section 0A

(Page 0A-7).

Inspect the fuel pump relay in the following procedures:

1) Remove the frame covers. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Remove the fuel pump relay (1).

Fuel System: 1G-7

Fuel Hose Inspection

B947H11706005

Refer to “Fuel Line Inspection” in Section 0B (Page 0B-

10).

Fuel Level Gauge Inspection

B947H11706006

Refer to “Fuel Level Gauge Inspection” in Section 9C

(Page 9C-5).

1

I947H1170024-01

3) First, check for insulation with the tester between terminals “A” and “B”. Next, check for continuity between “A” and “B” with 12 V voltage applied, positive (+) to terminal “C” and negative (–) to terminal “D”. If continuity does not exist, replace the relay with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

“A”

“C”

“B”

“D”

I718H1170013-01 email: [email protected] / www.motomatrix.co.uk

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1G-8 Fuel System:

Fuel Tank Construction

1

B947H11706007

2

“A”

3

4

“B”

4

4

“B”

“B”

1. Fuel tank heat shield

: Aluminum film side should face the engine side.

2. Fuel tank front cover

3. Fuel tank front bracket

4. Velcro fastenings

: Clean the adhesive surface before adhering the velcro fastenings.

I947H1170025-02

“A”: Insert to the bracket.

“B”: Apply adhesive agent.

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Fuel Tank Removal and Installation

B947H11706008

Removal

!

WARNING

• Keep away from fire or spark.

• Spilled gasoline should be wiped off immediately.

• Work in a well-ventilated area.

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Take out the fuel tank prop stay (1).

Fuel System: 1G-9

5) Disconnect the fuel pump lead wire coupler (2).

6) Place a rag under the fuel feed hose (3) and disconnect the fuel feed hose from the fuel tank.

!

CAUTION

When removing the fuel tank, do not leave the fuel feed hose on the fuel pump side.

7) Disconnect the fuel tank drain hose (4).

Disconnect the surge hose (5). (For E-33)

9) Disconnect the fuel tank breather hose. (Except for

E-33)

4

5

1

3

2

I947H1170026-01

I947H1170028-01

10) Remove the fuel tank by removing its bracket bolt

(6).

3) Remove the bolts.

6

I947H1170003-02

4) Lift and support the fuel tank with the prop stay.

I947H1170029-01

Installation

Install the fuel tank in the reverse order of removal.

Pay attention to the following point:

NOTE

Connect the fuel feed hose to the fuel pump until it locks securely (a click is heard).

I947H1170027-01 email: [email protected] / www.motomatrix.co.uk

1G-10 Fuel System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Fuel Pump Components

B947H11706009

1

2

3

3

4

3

6

7

5

(a)

1. Fuel level gauge

2. Fuel pressure regulator assembly

3. O-ring

3

4. Joint

5. Fuel pump

6. Fuel pump case

7. Fuel mesh filter

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: Apply engine oil.

I947H1170030-02

: Apply grease.

: Do not reuse.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Fuel System: 1G-11

Fuel Pump Disassembly and Assembly

B947H11706010

Disassembly

1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation” (Page 1G-9).

2) Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.

!

WARNING

• Spilled gasoline should be wipe off immediately.

• Keep away from fire or spark.

• Work in a well-ventilated area.

5) Remove the fuel pressure regulator assembly (4).

!

CAUTION

Never remove the fuel pressure regulator (5) from the holder.

4

1

I947H1170007-01

5

I947H1170004-01

3) Disconnect the lead wires (2).

I947H1170008-01

6) Remove the O-ring (6) and fuel pump case (7).

2

6

I947H1170005-01

7

4) Remove the fuel level gauge (3).

3

I947H1170006-01

I947H1170009-01

7) Remove the O-ring (8) and joint (9).

Remove the O-ring (10) and lead wires (11).

11

8

9

10

I947H1170010-01 email: [email protected] / www.motomatrix.co.uk

1G-12 Fuel System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9) Remove the fuel mesh filter (12).

10) Remove the fuel pump (13).

!

CAUTION

Connect all lead wires securely so as not to cause contact failure.

12

2

3

4

13

I947H1170011-01

Assembly

Refer to “Fuel Mesh Filter Inspection and Cleaning”

(Page 1G-13).

Assemble the fuel tank pump in the reverse order of the disassembly. Pay attention to the following points:

!

CAUTION

• To prevent fuel leakage, the bushing and

O-ring must be replaced with new ones.

• Apply engine oil lightly to the O-rings.

1

4

2

3

I947H1170014-01

I947H1170012-01

I947H1170018-01

1. Fuel pump (+) lead wire (Y/R)

2. Fuel level gauge (+) lead wire (R/B)

3. Fuel pump (–) lead wire (B/W)

4. Fuel level gauge (–) lead wire (B/W)

• Install a new O-ring and apply grease to it.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

!

WARNING

The O-ring must be replaced with a new one to prevent fuel leakage.

I947H1170013-01

I947H1170015-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Fuel System: 1G-13

• When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending of numbers.

Tightening torque

Fuel pump mounting bolt (a): 10 N·m (1.0 kgf-m,

7.0 lbf-ft)

Fuel Injector / Fuel Delivery Pipe / T-joint

Removal and Installation

B947H11706012

Refer to “Throttle Body Disassembly and Assembly” in

Section 1D (Page 1D-11).

(3)

(1) (6)

(4)

Fuel Injector Inspection and Cleaning

B947H11706013

Inspect the fuel injector in the following procedures:

1) Remove the fuel injector. Refer to “Throttle Body

Disassembly and Assembly” in Section 1D

(Page 1D-11).

2) Check the fuel injector for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank.

(5)

(a)

(2)

I947H1170016-01

Fuel Mesh Filter Inspection and Cleaning

B947H11706011

Inspect the fuel mesh filter in the following procedures:

1) Remove the fuel mesh filter. Refer to “Fuel Pump

Disassembly and Assembly” (Page 1G-11).

2) If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of engine power. Such a filter should be cleaned by blowing with compressed air.

NOTE

When the fuel mesh filter is dirtied excessively, replace the fuel filter cartridge with a new one.

I947H1170031-01

3) Install the fuel injector. Refer to “Throttle Body

Disassembly and Assembly” in Section 1D

(Page 1D-11).

I947H1170017-01

3) After finishing the fuel mesh filter inspection, reinstall the fuel mesh filter. Refer to “Fuel Pump

Disassembly and Assembly” (Page 1G-11).

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1G-14 Fuel System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Specifications

Service Data

Injector + Fuel Pump + Fuel Pressure Regulator

Item

Injector resistance

Fuel pump discharge amount

Fuel pressure regulator operating set pressure

Specification

11 – 13

Ω

at 20

°

C (68

°

F)

222 ml (7.5/7.8 US/lmp oz) and more/10 sec.

Approx. 300 kPa (3.0 kgf/cm

2

, 43 psi)

Fuel

Fuel type

Item

Fuel tank capacity

B947H11707001

Note

Specification

Use only unleaded gasoline of at least 90 pump octane (R/2

+ M/2).

Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Gasoline used should be graded 95 octane (Research

Method) or higher. Unleaded gasoline is recommended.

Including reserve

Fuel level indicator light lighting

16.5 L (4.4/3.6 US/lmp gal)

17.5 L (4.6/3.8 US/lmp gal)

Approx. 3.5 L (0.9/0.8 US/lmp gal)

Note

E-03, 14, 28, 33

E-02, 19, 24, 51

E-33

Others

Tightening Torque Specifications

Fastening part

Fuel pump mounting bolt

N

⋅

m

10

Tightening torque kgf-m

1.0

lbf-ft

7.0

)

B947H11707002

Note

(Page 1G-13)

NOTE

The specified tightening torque is described in the following.

“Fuel Pump Components” (Page 1G-10)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Fuel System: 1G-15

Special Tools and Equipment

Recommended Service Material

Grease

Material SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or

Note

P/No.: 99000–25010

)

(Page 1G-12) equivalent

B947H11708001

NOTE

Required service material is also described in the following.

“Fuel Pump Components” (Page 1G-10)

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1G-7)

09915–74521

Adapter hose

)

(Page 1G-5)

B947H11708002

09915–77331

Oil pressure gauge (1000 kPa)

)

(Page 1G-5)

09940–40220

Fuel pressure gauge attachment

)

(Page 1G-5)

09940–40211

Fuel pressure gauge adapter

)

(Page 1G-5) email: [email protected] / www.motomatrix.co.uk

1H-1 Ignition System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine

Ignition System

1

General Description

Immobilizer Description (For E-02, 19, 24, 51)

B947H11801001

The immobilizer, an anti-theft system, is installed as a standard equipment.

The immobilizer verifies that the key ID agrees with ECM

ID by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start.

Operation

When the ignition switch is turned ON with the engine stop switch in ON, the immobi-antenna and ECM are powered ON.

The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID.

With the signal received, the transponder transmits the key ID signal to ECM so that ECM can make comparison with its own ID, and if it matches, the engine is made ready to start.

2

1

3

OFF

ON

R O

I947H1180001-01

4

1. Immobilizer antenna

3

4

1

1. Immobilizer antenna

2. Indicator light

2

2. Indicator light

I947H1180002-01

ECM

2

1. Immobilizer antenna

2. Transponder

3. Ignition switch

4. ECM

I815H1180003-01

Also, when the ignition switch is turned ON, the indicator light flashes as many as the number of IDs registered in

ECM. Thereafter, if the IDs are in agreement, the indicator light turns on for two seconds to notify of completion in successful communication.

If the indicator light (LED) flashes fast, it notifies of communication error or disagreement of ID.

Flashing Lighting

2 registered

3 registered

4 registered

Normal

Normal

Normal

Abnormal

Approx. 1.6 sec.

Fast flashing

Approx. 2.0 sec.

I705H1180006-01

3. Transponder

4. ID

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition System: 1H-2

NOTE

If the indicator light flashes fast, turn the ignition switch OFF then ON to make judgment again as there is possible misjudgment due to environmental radio interference.

!

CAUTION

When the battery performance is lowered in winter (low temperature), the system may at times makes a re-judgment at the time of beginning the starter motor operation. In this case, the indicator light operation starts immediately after the starter operation.

5

5. Indicator light

I947H1180003-01

Operation

Drive mode is preset at A-mode when the ignition switch and engine stop switch are turned on. Follow the procedure below to operate drive mode selector.

1) Turn on the ignition switch and engine stop switch.

2) Push the drive mode selector UP or DOWN for 1 second until the drive mode indicator shows A.

3) Push the drive mode selector to change drive mode.

Pushing the UP switch can change from A to C to B to A. Pushing the DOWN switch can change from A to B to C to A. The drive mode indicator indicates actual drive mode.

NOTE

• Operating the drive mode selector while riding with the throttle opened will change the engine speed because of engine power characteristics change.

• Drive mode indicator blinks when drive mode change operation is failed.

• Turning off the ignition switch or engine stop switch will return the drive mode to Amode. Start the engine and reset the drive mode.

Drive Mode

A-mode

A-mode provides sharp throttle response at all throttle opening range to obtain maximum engine power.

Drive Mode Selector Description

B947H11801002

Engine power characteristics can be changed in 3 modes by operating the drive mode selector to meet various riding conditions and rider’s preference.

B-mode

B-mode provides softer throttle response than A-mode up to middle throttle opening range.

C-mode

C-mode provides soft throttle response at all throttle opening range by reducing engine power.

Engine power

A B

A, B

C

I947H1180015-01

Throttle opening

I838H1180001-01 email: [email protected] / www.motomatrix.co.uk

1H-3 Ignition System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Schematic and Routing Diagram

Ignition System Diagram

Refer to “Wire Color Symbols” in Section 0A (Page 0A-5).

Engine stop switch

CKP sensor

ECM

#1

#2

#3

#4

B947H11802001

Side-stand relay

Fuse

Ignition switch

Fuse

Battery

TP sensor

ECT sensor

GP switch

Ignition System Components Location

Refer to “Electrical Components Location” in Section 0A (Page 0A-7).

I947H1180004-01

B947H11802002 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition System: 1H-4

Diagnostic Information and Procedures

Ignition System Symptom Diagnosis

Condition Possible cause

Spark plug not sparking

Damaged spark plug.

Fouled spark plugs.

Wet spark plugs.

Defective ignition coil.

Defective CKP sensor.

Defective ECM.

Open-circuited wiring connections.

Engine stalls easily (No spark)

Spark plug is wet or quickly becomes fouled with carbon

Fouled spark plugs.

Defective CKP sensor.

Defective ECM.

Excessively rich air/fuel mixture.

Excessively high idling speed.

Incorrect gasoline.

Dirty air cleaner element.

Incorrect spark plug (Cold type).

Spark plug quickly becomes fouled with oil or carbon

Spark plug electrodes overheat or burn

Worn piston rings.

Worn pistons.

Worn cylinders.

Excessive valve-stem to valve-guide clearance.

Worn valve stem oil seals.

Incorrect spark plug (Hot type).

Overheated engine.

Loose spark plugs.

Excessively lean air/fuel mixture.

B947H11804001

Replace.

Correction / Reference Item

Clean or replace.

Clean and dry or replace.

Replace.

Replace.

Replace.

Repair or replace.

Clean or replace.

Replace.

Replace.

Inspect FI system.

Inspect FI system.

Change.

Clean or replace.

Change to hot type spark plug.

Replace.

Replace.

Replace.

Replace.

Replace.

Change to cold type spark plug.

Tune-up.

Tighten.

Inspect FI system.

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1H-5 Ignition System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

No Spark or Poor Spark

Troubleshooting

B947H11804002

NOTE

Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing.

Step Action

1 Check the ignition system couplers for poor connections.

Yes

Go to Step 2.

No

Poor connection of couplers.

Is there connection in the ignition system couplers?

2 Measure the battery voltage between input lead wires at the

ECM with the ignition switch in the “ON” position. (E-02, 19,

24, 51: O/G and B/W, E-03, 14, 28, 33: O/W and B/W)

Go to Step 3.

3

Is the voltage OK?

Measure the ignition coil primary peak voltage. Refer to

“Ignition Coil Inspection” (Page 1H-7).

Go to Step 4.

• Faulty ignition switch.

• Faulty turn signal/ side-stand relay.

• Faulty engine stop switch.

• Broken wire harness or poor connection of related circuit couplers.

Go to Step 5.

NOTE

This inspection method is applicable only with the multi-circuit tester and the peak volt adaptor.

Is the peak voltage OK?

4 Inspect the spark plugs. Refer to “Spark Plug Inspection and

Cleaning” in Section 0B (Page 0B-9).

Go to Step 5.

Faulty spark plug(-s).

Is the spark plug(-s) OK?

5 Inspect the ignition coil. Refer to “Ignition Coil Inspection”

(Page 1H-7).

Is the ignition coil OK?

6 Measure the CKP sensor peak voltage and its resistance.

Refer to “CKP Sensor Inspection” (Page 1H-9).

NOTE

The CKP sensor peak voltage inspection is applicable only with the multi-circuit tester and peak volt adaptor.

Are the peak voltage and resistance OK?

Go to Step 6.

• Faulty ECM.

• Open or short circuit in wire harness.

• Poor connection of ignition couplers.

• Faulty ignition coil.

• Poor connection of the ignition coil.

• Faulty CKP sensor.

• Metal particles or foreign material being stuck on the CKP sensor and rotor tip.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition System: 1H-6

Repair Instructions

Ignition Coil and Spark Plug Removal and

Installation

B947H11806001

Removal

!

WARNING

The hot engine can burn you.

Wait until the engine is cool enough to touch.

1) Turn the ignition switch OFF.

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

3) Disconnect the lead wire couplers (1).

5) Remove the spark plugs with the spark plug wrench.

Special tool

(A): 09930–10121 (Spark plug wrench set)

(A)

I947H1180007-03

1

I947H1180005-03

!

CAUTION

Disconnect the lead wire coupler before removing the ignition coil to avoid lead wire coupler damage.

4) Remove the ignition coils (2).

!

CAUTION

• Do not pry up the ignition coil with a screwdriver or a bar to avoid its damage.

• Be careful not to drop the ignition coil to prevent short/open circuit.

Installation

Install the spark plugs in the reverse order of removal.

Pay attention to the following points:

• Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque.

!

CAUTION

Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.

Special tool

(A): 09930–10121 (Spark plug wrench set)

Tightening torque

Spark plug: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

(A)

2

I947H1180008-03

I947H1180006-02 email: [email protected] / www.motomatrix.co.uk

1H-7 Ignition System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

• Install the ignition coil and connect their lead wire couplers.

!

CAUTION

Do not hit the ignition coil with a plastic hammer when installing it.

2) Disconnect all ignition coil. Refer to “Ignition Coil and

Spark Plug Removal and Installation” (Page 1H-6).

INCORRECT

I947H1180009-03

Spark Plug Inspection and Cleaning

B947H11806002

Refer to “Spark Plug Inspection and Cleaning” in Section

0B (Page 0B-9).

Ignition Coil Inspection

B947H11806003

Refer to “Electrical Components Location” in Section 0A

(Page 0A-7).

Ignition Coil Primary Peak Voltage

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

I718H1180012-01

I947H1180010-03

3) Connect the new spark plugs to each ignition coil.

4) Connect all the ignition coil lead wire couplers to the ignition coil respectively, and ground them on the cylinder head (each spark plug hole).

!

CAUTION

Avoid grounding the spark plugs and suppling the electrical shock to the cylinder head cover (magnesium parts) to prevent the magnesium material from damage.

NOTE

Be sure that all the spark plugs are connected properly and the battery used is in fully-charged condition.

1

“A”

1. New spark plug

“A”: Contact the spark plug to the cylinder head.

I823H1180011-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition System: 1H-8

5) Insert the needle pointed probe to the lead wire coupler.

!

CAUTION

Use the special tool to prevent the rubber of the water proof coupler from damage.

6) Connect the multi-circuit tester with the peak voltage adaptor as follows.

!

CAUTION

Before using the multi-circuit tester and peak voltage adaptor, refer to the appropriate instruction manual.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication: Voltage ( )

(+) Probe

Ignition coil #1 W/Bl wire terminal

(–) Probe

Ground

Ignition coil #2 Black wire terminal Ground

Ignition coil #3 Yellow wire terminal Ground

Ignition coil #4 Green wire terminal Ground

(B)

(A)

I718H1180003-02

2

2. ECM

3. Peak voltage adaptor

4. New spark plug

5. Ignition coil

“B”

3

5

4

“C”

“D”

I823H1180026-01

“B”: (+) probe

“C”: (–) probe

“D”: To engine stop switch

7) Measure the ignition coil primary peak voltage in the following procedures:

!

WARNING

Do not touch the tester probes and spark plugs to prevent an electric shock while testing.

a) Shift the transmission into neutral, turn the ignition switch ON and grasp the clutch lever.

b) Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.

Repeat the b) procedure several times and measure the highest peak voltage.

If the voltage is lower than standard range, inspect the ignition coil and the CKP sensor.

Ignition coil primary peak voltage

80 V and more

9) After measuring the ignition coil primary peak voltage, reinstall the removed parts.

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1H-9 Ignition System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition Coil Resistance

1) Remove the ignition coil. Refer to “Ignition Coil and

Spark Plug Removal and Installation” (Page 1H-6).

2) Measure the ignition coil for resistance in both primary and secondary coils. If the resistance is not within the standard range, replace the ignition coil with a new one.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

Ignition coil resistance

Primary: 1.1 – 1.9

Ω

((+) terminal – (–) terminal)

Secondary: 6.4 – 9.6 k

Ω

(Spark plug cap – (–) terminal)

2) Disconnect the CKP sensor coupler (1).

NOTE

Be sure that all of the couplers are connected properly and the battery is fully-charged.

1

(

ޓ

) (

ޓ

)

(

ޓ

)

(A)

I718H1180005-01

I947H1180011-02

3) Connect the multi-circuit tester with the peak volt adaptor as follows.

!

CAUTION

Before using the multi-circuit tester and peak voltage adaptor, refer to the appropriate instruction manual.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication: Voltage ( )

CKP sensor

(+) Probe

B

(–) Probe

Bl/Y

(

ޓ

)

I718H1180006-01

3) After measuring the ignition coil resistance, reinstall the removed parts.

2

1

3

CKP Sensor Inspection

B947H11806004

Refer to “Electrical Components Location” in Section 0A

(Page 0A-7).

(A)

I947H1180020-01

3. Peak voltage adaptor 1. CKP sensor coupler

2. CKP sensor

CKP Sensor Peak Voltage

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

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4) Measure the CKP sensor peak voltage in the following procedures: a) Shift the transmission into neutral, turn the ignition switch ON and grasp the clutch lever.

b) Press the starter button and allow the engine to crank for a few seconds, and then measure the

CKP sensor peak voltage.

5) Repeat the b) procedure several times and measure the highest CKP sensor peak voltage.

CKP sensor peak voltage

0.5 V and more (B – Bl/Y)

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition System: 1H-10

6) If the peak voltage is within the specification, check the continuity between the CKP sensor coupler and

ECM coupler.

!

CAUTION

Normally, use the needle pointed probe to the backside of the lead wire coupler to prevent the terminal bend and terminal alignment.

7) After measuring the CKP sensor peak voltage, connect the CKP sensor coupler.

CKP Sensor Resistance

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Disconnect the CKP sensor coupler (1).

CKP Sensor Removal and Installation

B947H11806005

Refer to “Generator Removal and Installation” in Section

1J (Page 1J-4).

Engine Stop Switch Inspection

B947H11806006

Inspect the engine stop switch in the following procedures:

1) Turn the ignition switch OFF.

2) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

3) Disconnect the right handlebar switch coupler (1).

1

2

1

I947H1180012-02

3) Measure the resistance between the lead wires and ground. If the resistance is not within the standard range, replace the CKP sensor with a new one.

Refer to “CKP Sensor Removal and Installation”

(Page 1H-10).

Tester knob indication

Resistance (

Ω

)

CKP sensor resistance

142 – 194

Ω

(B – Bl/Y)

∞ Ω

(B – Ground)

1

I947H1180013-01

4) Inspect the engine stop switch for continuity with a tester.

If any abnormality is found, replace the right handlebar switch assembly with a new one. Refer to

“Handlebar Removal and Installation” in Section 6B

(Page 6B-2).

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

Color

Position

OFF

( )

RUN

( )

O/B O/W

I815H1180012-01

5) After finishing the engine stop switch inspection, reinstall the removed parts.

Ignition Switch Inspection

B947H11806007

Refer to “Ignition Switch Inspection” in Section 9C

(Page 9C-7).

1. CKP sensor coupler 2. CKP sensor

I837H1180011-01

4) After measuring the CKP sensor resistance, connect the CKP sensor coupler.

5) Reinstall the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1H-11 Ignition System:

Ignition Switch Removal and Installation

Removal

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Disconnect the ignition switch lead wire coupler (1).

3) Disconnect the immobilizer lead wire coupler (2).

(For E-02, 19, 24, 51)

1

2

B947H11806008

Installation

Install the ignition switch in the reverse order of removal.

Pay attention to the following points:

• Tighten the ignition switch mounting bolts (1), right and left with the special tools.

!

CAUTION

When reusing the ignition switch bolts, clean the threaded part and apply a thread lock to them.

Special tool

(A): 09930–11920 (Torx bit (JT40H))

(B): 09930–11940 (Torx bit holder)

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

1

I947H1180014-01

4) Remove the harness clamp (3).

(A)

(B)

I947H1180018-01

3

I947H1180016-01

5) Remove the ignition switch (4) with the special tools.

Special tool

(A): 09930–11920 (Torx bit (JT40H))

(B): 09930–11940 (Torx bit holder)

4

(A)

(B)

I947H1180017-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition System: 1H-12

Drive Mode Selector Inspection

Inspect the drive mode selector in the following procedures:

1) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

2) Turn the ignition switch ON.

3) Click “Data monitor”.

4) Make sure each of “Driving mode selection” on the monitor is indicated “Open”.

B947H11806009

I947H1180021-01

5) Push each of drive mode selector (1) and (2). At this time, if the indication is changed to “GND”, the function is normal.

1

2

I947H1180019-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1H-13 Ignition System:

Specifications

Service Data

Electrical

Unit: mm (in)

Item

Firing order

Spark plug

Spark performance

CKP sensor resistance

CKP sensor peak voltage

Ignition coil resistance

Ignition coil primary peak voltage

Type

Gap

Primary

Secondary

Specification

1

⋅

2

⋅

4

⋅

3

NGK: CR9EIA-9

DENSO: IU27D

0.8 – 0.9 (0.031 – 0.035)

Over 8 (0.3) at 1 atm.

142 – 194

Ω

0.5 V and more

1.1 – 1.9

Ω

6.4 – 9.6 k

Ω

80 V and more

B947H11807001

Note

When cranking

Terminal –

Terminal

Plug cap –

Terminal

When cranking

Tightening Torque Specifications

Spark plug

Fastening part

N

⋅

m

11

Tightening torque kgf-m

1.1

lbf-ft

8.0

B947H11807002

Note

)

(Page 1H-6)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Ignition System: 1H-14

Special Tools and Equipment

Recommended Service Material

Material

Thread lock cement

SUZUKI recommended product or Specification

THREAD LOCK CEMENT SUPER

Note

P/No.: 99000–32110

)

(Page 1H-11)

“1322” or equivalent

B947H11808001

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1H-8) /

)

(Page 1H-

9) /

)

(Page 1H-9) /

)

(Page 1H-10)

09900–25009

Needle-point probe set

)

(Page 1H-8)

B947H11808002

09930–10121

Spark plug wrench set

)

(Page 1H-6) /

)

(Page 1H-

6)

09930–11920

Torx bit (JT40H)

)

(Page 1H-11) /

)

(Page 1H-11)

09930–11940

Torx bit holder

)

(Page 1H-11) /

)

(Page 1H-11) email: [email protected] / www.motomatrix.co.uk

1I-1 Starting System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Engine

Starting System

Schematic and Routing Diagram

Starting System Diagram

Refer to “Wire Color Symbols” in Section 0A (Page 0A-5).

B947H11902001

Starter motor

Starter relay

B/W

B/Y

To ignition coil

Y/G

O/W

Starter button

Engine stop switch

O/B

O

Ignition switch

R

Fuse (30 A)

Fuse

Bl

Clutch lever position switch

Turn signal/ side-stand relay

G

Side-stand switch

Gear position switch

I837H1190038-01

Component Location

Starting System Components Location

Refer to “Electrical Components Location” in Section 0A (Page 0A-7).

B947H11903001

Diagnostic Information and Procedures

Starting System Symptom Diagnosis

Condition

Engine does not turn though the starter motor runs

Starter button is not effective

Possible cause

Faulty starter clutch.

Run down battery.

Defective switch contacts.

Brushes not seating properly on starter motor commutator.

Repair or replace.

Replace.

Repair or replace.

Defective starter relay or starter interlock switch.

Defective main fuse.

Replace.

Replace.

B947H11904001

Replace.

Correction / Reference Item

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Starting System: 1I-2

Starter Motor Will Not Run

B947H11904002

NOTE

Make sure the fuses are not blown and the battery is fully-charged before diagnosing.

Troubleshooting

Step Action

1 1) Shift the transmission into neutral.

2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN” position and listen for a click from the starter relay when the starter button is pushed.

Yes

Go to Step 2.

No

Go to Step 3.

Is the click sound heard?

2 Check if the starter motor runs when its terminal is connected to the battery (+) terminal. (Do not use thin “wire” because a large amount of current flows.)

Does the starter motor run?

• Faulty starter relay.

• Loose or disconnected starter motor lead wire.

• Loose or disconnected between starter relay and battery (+) terminal.

Go to Step 4.

3 Measure the starter relay voltage at the starter relay terminal

(between Y/G (+) and B/Y (–)) when the starter button is pushed.

Faulty starter motor.

• Faulty ignition switch.

• Faulty engine stop switch.

Is the voltage OK?

• Faulty clutch lever position switch.

• Faulty gear position switch.

4 Check the starter relay. Refer to “Starter Relay Inspection”

(Page 1I-6).

Poor contact of the starter relay.

• Faulty turn signal/ side-stand relay.

• Faulty starter button.

• Faulty side-stand switch.

• Poor contact of the coupler.

• Open circuit in wire harness.

Faulty starter relay.

Is the starter relay OK?

Starter Motor Runs But Does Not Crank The Engine

B947H11904003

The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up.

Step Action

1 Check the side-stand switch. Refer to “Side-stand / Ignition

Interlock System Parts Inspection” (Page 1I-7).

Yes

Go to Step 2.

No

Faulty side-stand switch.

Is the side-stand switch OK?

2 Check the starter clutch. Refer to “Starter Clutch Removal and Installation” (Page 1I-10).

Is the starter clutch OK?

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• Open circuit in wire harness.

• Poor contact of connector.

Faulty starter clutch.

1I-3 Starting System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Repair Instructions

Starter Motor Components

1

2

B947H11906001

(b)

3

4

(a)

3

5

1. O-ring

2. Housing end (Inside)

3. O-ring

4. Starter motor case

5. Armature

6. Housing end (Outside)

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: 4 N

⋅ m (0.4 kgf-m, 3.0 lbf-ft)

6

(c)

I947H1190032-02

: 5 N

⋅ m (0.5 kgf-m, 3.5 lbf-ft)

: Apply grease to sliding surface.

: Apply moly paste to sliding surface.

: Do not reuse.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Starting System: 1I-4

Starter Motor Removal and Installation

B947H11906002

Removal

1) Turn the ignition switch OFF and disconnect the battery (–) lead wire (1).

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

3) Disconnect the starter motor lead wire (2).

4) Remove the starter motor (3).

Assembly

Reassemble the starter motor in the reverse order of removal. Pay attention to the following points:

!

CAUTION

Replace the O-rings with new ones to prevent oil leakage and moisture.

• Apply grease to the bearing and lip of the oil seal.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

2

3

1

I947H1190001-02

Installation

Install the starter motor in the reverse order of removal.

Pay attention to the following points:

• Apply grease to the O-ring.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

!

CAUTION

Replace the O-ring with a new one.

I947H1190004-01

• Apply a small quantity of moly paste to the armature shaft.

: Moly paste 99000–25140 (SUZUKI MOLY

PASTE or equivalent)

I947H1190002-01

• Install the starter motor. Refer to “Wiring Harness

Routing Diagram” in Section 9A (Page 9A-7).

Starter Motor Disassembly and Assembly

B947H11906003

Refer to “Starter Motor Removal and Installation”

(Page 1I-4).

Disassembly

Disassemble the starter motor as shown in the starter motor components diagram. Refer to “Starter Motor

Components” (Page 1I-3).

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I947H1190005-01

• Fit the depression “A” on the housing end to the projection “B” on the case.

“B”

“A”

I947H1190006-01

1I-5 Starting System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

• Tighten the starter motor housing bolts (1) to the specified torque.

Tightening torque

Starter motor housing bolt (a): 5 N·m (0.5 kgf-m,

3.5 lbf-ft)

Commutator

Inspect the commutator for discoloration, abnormal wear or undercut “A”.

If the commutator is abnormally worn, replace the armature assembly.

If the commutator surface is discolored, polish it with

#400 sandpaper and wipe it using a clean, dry cloth.

If there is no undercut, scrape out the insulator (1) with a saw blade.

“A”

1

(a)

I947H1190007-02

Starter Motor Inspection

B947H11906004

Refer to “Starter Motor Disassembly and Assembly”

(Page 1I-4).

Carbon Brush

Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.

If either carbon brush is defective, replace the brush holder set with a new one.

Measure the length “a” of the carbon brushes using a vernier calipers. If the measurement is less than the service limit, replace the housing end assembly (outside) with a new one.

Brush length “a”

Service limit: 3.5 mm (0.14 in)

Special tool

: 09900–20102 (Vernier calipers (200 mm))

1

I823H1190007-01

Armature Coil

Inspect for continuity between each segment.

Inspect for continuity between each segment and the armature shaft.

If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature assembly with a new one.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity set ( )

(A)

“ a ”

I947H1190008-01

Bearing

Check the bearings for damage.

If any damage is found, replace the housing end.

I837H1190008-01

I947H1190009-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Starting System: 1I-6

Oil Seal

Check the seal lip for damage.

If any damage is found, replace the housing end.

I947H1190010-01

Starter Relay Inspection

B947H11906006

Inspect the starter relay in the following procedures:

1) Remove the starter relay. Refer to “Starter Relay

Removal and Installation” (Page 1I-6).

2) Apply 12 V to “A” and “B” terminals and check for continuity between the positive and negative terminals using the multi-circuit tester. If the starter relay clicks and continuity is found, the relay is ok.

!

CAUTION

Do not apply battery voltage to the starter relay for five seconds and more, since the relay coil may overheat and get damaged.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

Starter Relay Removal and Installation

B947H11906005

Removal

1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

3) Disconnect the battery (–) lead wire (1) from the battery.

4) Remove the starter relay cover (2) and disconnect the starter relay coupler (3).

“A” “B”

(A)

2

I649G1190021-04

1

3

To starter motor

(–)

To battery

(+)

I947H1190011-03

5) Disconnect the starter motor lead wire (4) and battery (+) lead wire (5).

6) Remove the starter relay (6).

4

5

6

“A”

“B”

I823H1190040-02

I947H1190027-01

Installation

Install the starter relay in the reverse order of removal.

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1I-7 Starting System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3) Measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Starter relay resistance

3 – 6

Ω

(A)

Side-stand / Ignition Interlock System Parts

Inspection

B947H11906008

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

1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

3) Disconnect the side-stand switch coupler (1).

1

I649G1190023-03

4) Install the starter relay. Refer to “Starter Relay

Removal and Installation” (Page 1I-6).

Turn Signal / Side-stand Relay Removal and

Installation

B947H11906007

Removal

1) Turn the ignition switch OFF.

2) Remove the frame cover assembly. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

3) Remove the turn signal/side-stand relay (1).

1

I947H1190012-01

4) Measure the voltage between G and B/W lead wires.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Diode test ( )

G

((+) probe)

ON

(Side-stand up)

OFF

(Side-stand down)

0.4 – 0.6 V

B/W

((–) probe)

1.4 V and more

(Tester’s battery voltage)

NOTE

If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.

I947H1190028-01

Installation

Install the turn signal/side-stand relay in the reverse order of removal.

I947H1190013-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Starting System: 1I-8

5) Connect the side-stand switch coupler.

6) Install the removed parts.

Turn Signal / Side-stand Relay

The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode.

Diode inspection

1) Remove the turn signal/side-stand relay. Refer to

“Turn Signal / Side-stand Relay Removal and

Installation” (Page 1I-7).

2) Measure the voltage between the “A”, “B” and “C” terminals using the multi-circuit tester.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Diode test ( )

I649G1190027-02

Side-stand relay

1) Remove the turn signal/side-stand relay. Refer to

“Turn Signal / Side-stand Relay Removal and

Installation” (Page 1I-7).

2) Check the insulation between “D” and “E” terminals using the multi-circuit tester.

3) Apply 12 V to terminals “D” and “C” ((+) to “D” and (–

) to “C”) and check the continuity between “D” and

“E”. If there is no continuity, replace the turn signal/ side-stand relay with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

“D” “C” “B” “A”

“E” “F” “G”

SIDE-STAND RELAY

DIODE

TURN

SIGNAL

RELAY

“A”

“B”

“C”

“C” “A” “B”

I649G1190029-02

“B”, “C”

+

Probe of tester to:

“B”, “C” “A”

1.4 V and more

(Tester’s battery voltage)

“A” 0.4

– 0.6 V

I649G1190046-04

NOTE

If the multi circuit tester reads 1.4 V and below when the tester probes are not connected, replace its battery.

3) Install the turn signal/side-stand relay. Refer to “Turn

Signal / Side-stand Relay Removal and Installation”

(Page 1I-7).

Gear Position Switch

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

“A” “B” “C” “D” “E” “F” “G”

I649G1190028-02

4) Install the turn signal/side-stand relay. Refer to “Turn

Signal / Side-stand Relay Removal and Installation”

(Page 1I-7).

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1I-9 Starting System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2) Disconnect the gear position switch coupler (1).

!

CAUTION

When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged.

(B)

(A)

1

I947H1190015-01

Turn the ignition switch OFF.

9) Install the removed parts.

Starter Torque Limiter Removal and Installation

B947H11906012

Removal

1) Remove the clutch assembly. Refer to “Clutch

Removal” in Section 5C (Page 5C-5).

2) Remove the washer (1), starter idle gear No. 1 (2) and starter torque limiter (3).

I947H1190014-01

3) Check the continuity between Bl and B lead wires with the transmission in “neutral”.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity test ( )

2

1

BI B/W

ON (Neutral)

OFF (Except neutral)

I947H1190030-01

4) Connect the gear position switch coupler to the wiring harness.

5) Insert the needle pointed probes to the lead wire coupler.

6) Turn the ignition switch ON and side-stand to upright position.

7) Measure the voltage between P and B/W lead wires using the multi-circuit tester when shifting the gearshift lever from low to top.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

Gear position switch voltage (Except neutral position)

0.6 V and more ((+) P – (–) B/W)

3

I947H1190016-01

Installation

Installation is in the reverse order of removal. Pay attention to the following point:

• Apply molybdenum oil solution to the starter torque limiter shaft hole.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

I947H1190017-01

• Install the clutch assembly. Refer to “Clutch

Installation” in Section 5C (Page 5C-7).

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Starter Torque Limiter Inspection

B947H11906013

Refer to “Starter Torque Limiter Removal and

Installation” (Page 1I-9).

!

CAUTION

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Starting System: 1I-10

• Do not attempt to disassemble the starter torque limiter.

• The starter torque limiter is available only as an assembly part.

1) Hold the starter torque limiter with the special tools and vise.

Special tool

(A): 09930–73170 (Starter torque limiter holder)

(B): 09930–73181 (Starter torque limiter socket)

2) Turn the starter torque limiter with a torque wrench and check the slip torque. If the slip torque is not within the specification, replace the starter torque limiter with a new one.

Starter torque limiter slip torque

Standard: 20.6 – 36.3 N

⋅

m (2.06 – 3.63 kgf-m, 15.0

– 26.0)

3) Remove the starter idle gear No. 2 bearing (4), shaft

(5) and washer (6).

4

6

5

I947H1190019-02

4) Hold the starter clutch with the special tool and remove the starter clutch bolt.

!

CAUTION

Make sure that the pawls of the special tool are inserted into the holes of the starter clutch.

Special tool

(A): 09930–40113 (Flywheel rotor holder)

5) Remove the CKP sensor rotor (7) and starter clutch assembly.

(A)

(B)

(A)

7

I947H1190031-01

Starter Clutch Removal and Installation

B947H11906009

Removal

1) Remove the clutch cover. Refer to “Clutch Removal” in Section 5C (Page 5C-5).

2) Remove the washers (1), starter idle gear No. 1 (2) and No. 2 (3).

I947H1190020-02

Installation

Installation is in the reverse order of removal. Pay attention to the following points:

• Install the washer (1) to the crankshaft.

1

2

3

I947H1190018-01 email: [email protected] / www.motomatrix.co.uk

1

I947H1190021-01

1I-11 Starting System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

• When installing the starter clutch and CKP sensor rotor, align the wide spline tooth of them with that of crankshaft.

Starter Clutch Inspection

B947H11906010

Refer to “Starter Clutch Removal and Installation”

(Page 1I-10).

Starter Clutch

1) Install the starter driven gear onto the starter clutch.

2) Turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns in one direction only. If a large resistance is felt for rotation, inspect the starter clutch or the starter clutch contacting surface on the starter driven gear for wear or damage.

If they are found to be damaged, replace them with new ones.

I947H1190022-01

• Hold the starter clutch with the special tool and tighten the starter clutch bolt to the specified torque.

Special tool

(A): 09930–40113 (Flywheel rotor holder)

Tightening torque

Starter clutch bolt: 54 N·m (5.4 kgf-m, 39.0 lbf-ft)

(A)

I947H1190025-02

Starter Clutch Bearing and Starter Driven Gear

Inspect the starter clutch bearing and starter clutch contacting surface on the starter driven gear for wear and damage. If they are found to be damaged, replace them with new ones.

I947H1190023-01

• Apply molybdenum oil solution to the starter idle gear

No. 2 bearing, shaft and shaft hole.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

I947H1190026-02

I947H1190024-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Starting System: 1I-12

Starter Button Inspection

B947H11906011

Inspect the starter button in the following procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Disconnect the right handlebar switch coupler (1).

3) Inspect the starter button for continuity with the tester.

If any abnormality is found, replace the right handle switch assembly with a new one. Refer to

“Handlebar Removal and Installation” in Section 6B

(Page 6B-2).

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

Position

Color

O/W Y/G O/R Y/W

1

PUSH

I815H1190019-01

4) After finishing the starter button inspection, reinstall the removed parts.

I947H1190029-01

Specifications

Service Data

Electrical

Unit: mm

Item

Starter motor brush length

Starter relay resistance

Standard

Limit

Specification

7.0 (0.28)

3.5 (0.14)

3 – 6

Ω

B947H11907001

Note

Tightening Torque Specifications

Fastening part

Starter motor housing bolt

Starter clutch bolt

N

⋅

m

5

54

Tightening torque kgf-m

0.5

5.4

lbf-ft

3.5

39.0

B947H11907002

Note

)

(Page 1I-5)

)

(Page 1I-11)

NOTE

The specified tightening torque is described in the following.

“Starter Motor Components” (Page 1I-3)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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1I-13 Starting System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Special Tools and Equipment

Recommended Service Material

Grease

Material

Moly paste

Molybdenum oil

B947H11908001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or

Note

P/No.: 99000–25010

)

(Page 1I-4) /

)

(Page 1I-4) equivalent

SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140

)

(Page 1I-4)

MOLYBDENUM OIL SOLUTION —

)

(Page 1I-9) /

)

(Page 1I-

11)

NOTE

Required service material is also described in the following.

“Starter Motor Components” (Page 1I-3)

Special Tool

09900–20102

Vernier calipers (200 mm)

)

(Page 1I-5)

09900–25009

Needle-point probe set

)

(Page 1I-9)

09900–25008

Multi circuit tester set

)

(Page 1I-5) /

)

(Page 1I-6)

/

)

(Page 1I-7) /

)

(Page 1I-

7) /

)

(Page 1I-8) /

)

(Page 1I-8) /

)

(Page 1I-9)

/

)

(Page 1I-9) /

)

(Page 1I-

12)

09930–40113

Flywheel rotor holder

)

(Page 1I-10) /

)

(Page 1I-

11)

B947H11908002

09930–73170

Starter torque limiter holder

)

(Page 1I-10)

09930–73181

Starter torque limiter socket

)

(Page 1I-10) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Charging System: 1J-1

Engine

Charging System

Schematic and Routing Diagram

Charging System Diagram

B947H11A02001

Regulator/Rectifier

Generator

Ignition switch

IC

SCR

I947H11A0021-01

Component Location

Charging System Components Location

Refer to “Electrical Components Location” in Section 0A (Page 0A-7).

B947H11A03001

Diagnostic Information and Procedures

Charging System Symptom Diagnosis

B947H11A04001

charge

Condition

Generator does not

Generator does charge, but charging rate is below the specification

Possible cause

Open- or short-circuited lead wires, or loose lead connections.

Short-circuited, grounded or open generator coil.

Short-circuited or punctured regulator/ rectifier.

Lead wires tend to get short- or opencircuited or loosely connected at terminals.

Grounded or open-circuited generator coil.

Correction / Reference Item

Repair, replace or connect properly.

Replace.

Replace.

Repair or retighten.

Replace.

Defective regulator/rectifier.

Defective cell plates in the battery.

Replace.

Replace the battery.

Generator overcharges

Internal short-circuit in the battery.

Replace the battery.

Damaged or defective regulator/rectifier.

Replace.

Unstable charging

Poorly grounded regulator/rectifier.

Lead wire insulation frayed due to vibration, resulting in intermittent shortcircuiting.

Clean and tighten ground connection.

Repair or replace.

Internally short-circuited generator.

Defective regulator/rectifier.

Replace.

Replace.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1J-2 Charging System:

Condition

Battery overcharges

Possible cause

Faulty regulator/rectifier.

Faulty battery.

Poor contact of generator lead wire coupler.

Battery runs down quickly

Trouble in charging system.

Replace.

Replace.

Repair.

Correction / Reference Item

Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.

Cell plates have lost much of their active materials a result of overcharging.

Replace the battery and correct the charging system.

Battery “sulfation”

Internal short-circuit in the battery.

Too low battery voltage.

Too old battery.

Incorrect charging rate. (When not in use battery should be checked at least once a month to avoid sulfation.)

The battery was left unused in a cold climate for too long.

Replace the battery.

Recharge the battery fully.

Replace the battery.

Replace the battery.

Replace the battery if badly sulfated.

Battery Runs Down Quickly

Troubleshooting

Step Action

1 Check accessories which use excessive amounts of electricity.

Are accessories being installed?

2 Check the battery for current leakage. Refer to “Battery

Current Leakage Inspection” (Page 1J-3).

Is the battery for current leakage OK?

Go to Step 3.

3 Measure the regulated voltage between the battery terminals. Refer to “Regulated Voltage Inspection” (Page 1J-

3).

• Faulty battery.

• Abnormal driving condition.

Is the regulated voltage OK?

4 Measure the resistance of the generator coil. Refer to

“Generator Inspection” (Page 1J-3).

Go to Step 5.

Is the resistance of generator coil OK?

5 Measure the generator no-load performance. Refer to

“Generator Inspection” (Page 1J-3).

Go to Step 6.

Is the generator no-load performance OK?

6 Inspect the regulator/rectifier. Refer to “Regulator / Rectifier

Inspection” (Page 1J-8).

Go to Step 7.

Is the regulator/rectifier OK?

7 Inspect wirings.

Is the wirings OK?

Faulty battery.

B947H11A04002

Yes No

Remove accessories.

Go to Step 2.

• Short circuit of wire harness.

• Faulty electrical equipment.

Go to Step 4.

• Faulty generator coil.

• Disconnected lead wires.

Faulty generator.

Faulty regulator/rectifier.

• Short circuit of wire harness.

• Poor contact of couplers.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Charging System: 1J-3

Battery Current Leakage Inspection

B947H11A06001

Inspect the battery current leakage in the following procedures:

1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

3) Disconnect the battery (–) lead wire.

4) Measure the current between battery (–) terminal and the battery (–) lead wire using the multi-circuit tester. If the reading exceeds the specified value, leakage is evident.

!

CAUTION

• In case of a large current leak, turn the tester to high range first to avoid tester damage.

• Do not turn the ignition switch ON when measuring current.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Current ( , 20 mA)

Battery current (Leak)

Under 3 mA

(A)

Repair Instructions

3) Measure the DC voltage between the battery (+) and

(–) terminals using the multi-circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/rectifier. Refer to “Generator

Inspection” (Page 1J-3) and “Regulator / Rectifier

Inspection” (Page 1J-8).

NOTE

When making this test, be sure that the battery is in fully charged condition.

Special tool

(A): 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

Regulated voltage (Charging output)

Standard: 14.0 – 15.5 V at 5 000 r/min

Battery

(DCV)

Tester

(A)

I837H11A0026-01

4) Install the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

Generator Inspection

B947H11A06003

Generator Coil Resistance

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the generator coupler (1).

I837H11A0025-01

5) Connect the battery (–) terminal and install the front seat. Refer to “Battery Removal and Installation”

(Page 1J-11) and “Exterior Parts Removal and

Installation” in Section 9D (Page 9D-6).

Regulated Voltage Inspection

B947H11A06002

Inspect the regulated voltage in the following procedures:

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position.

1

I947H11A0001-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1J-4 Charging System:

3) Measure the resistance between the three lead wires.

If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insulated properly.

NOTE

When making this test, be sure that the battery is in fully charged condition.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

Generator coil resistance

0.12 – 0.6

Ω

(W – W)

∞ Ω

(W – Ground)

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage (~)

Generator no-load performance (When engine is cold)

85 V (AC) and more at 5 000 r/min

W

W

W

W

I947H11A0004-02

5) Connect the generator coupler.

6) Install the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

W

W

I947H11A0002-02

4) Connect the generator coupler.

5) Install the left side cowling. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

Generator Removal and Installation

B947H11A06004

Removal

1) Drain engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

2) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

3) Disconnect the generator coupler (1).

No-load Performance

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the generator coupler (1).

1

4) Remove the generator cover (2).

I947H11A0005-01

1

I947H11A0003-01

3) Start the engine and keep it running at 5 000 r/min.

4) Using the multi-circuit tester, measure the voltage between three lead wires.

If the tester reads under the specified value, replace the generator with a new one.

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2

I947H11A0006-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Charging System: 1J-5

5) Remove the gasket (3) and dowel pins.

3

(B)

(C)

I947H11A0007-01

6) Hold the generator rotor with the special tool and remove the generator rotor bolt.

Special tool

(A): 09930–44530 (Rotor holder)

9) Remove the generator stator (5).

I947H11A0022-02

(A)

I947H11A0008-01

7) Screw in the special tool to the crankshaft.

Remove the generator rotor (4) using the special tool.

Special tool

(B): 09930–30460 (Rotor remover bolt)

(C): 09930–34970 (Rotor remover)

4

(B)

(b)

5

I947H11A0010-01

Installation

Install the generator in the reverse order of removal. Pay attention to the following points:

• Tighten the generator stator set bolts and generator lead wire set bolt to the specified torque.

Tightening torque

Generator stator set bolt (a): 11 N·m (1.1 kgf-m,

8.0 lbf-ft)

Generator lead wire set bolt (b): 5.5 N·m (0.55 kgfm, 4.0 lbf-ft)

• Apply bond lightly to the generator lead wire grommet

(1).

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

1

(C)

I947H11A0009-03

(a)

I947H11A0011-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1J-6 Charging System:

• Degrease the tapered portion “A” of generator rotor and also the crankshaft “B” with nonflammable cleaning solvent.

!

CAUTION

Dry these parts naturally. Do not wipe them with a cloth or use compressed air to dry.

• Install the generator rotor onto crankshaft.

• Install the dowel pins and new gasket (2).

!

CAUTION

Use new gasket to prevent oil leakage.

2

“A”

“B”

I947H11A0023-01

• Hold the generator rotor with the special tool and tighten its bolt to the specified torque.

Special tool

(A): 09930–44530 (Rotor holder)

Tightening torque

Generator rotor bolt (c): 145 N·m (14.5 kgf-m,

105.0 lbf-ft)

I947H11A0014-01

• Install the generator cover (3) and tighten the generator cover bolts.

!

WARNING

Be careful not to pinch the finger between the generator cover and crankcase.

NOTE

Fit the clamp to the generator cover bolt “C”.

“C”

(c)

(A)

3

I947H11A0012-02

• Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

I947H11A0015-01

• Route the generator lead wire. Refer to “Wiring

Harness Routing Diagram” in Section 9A (Page 9A-7).

I947H11A0013-01 email: [email protected] / www.motomatrix.co.uk

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Charging System: 1J-7

Regulator / Rectifier Construction

B947H11A06005

3

FWD

1

(a)

4

(a)

2

FWD

5

(a)

1

1. Regulator/rectifier

2. Regulator/rectifier bracket

3. Air intake pipe (RH)

“A”

4. Spacer

5. Wiring harness

“A”: Connect the regulator/rectifier couplers under the wiring harness.

I947H11A0020-03

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

4) Remove the EVAP system purge control solenoid valve bracket bolt. (E-33 only)

Regulator / Rectifier Removal and Installation

B947H11A06006

Removal

1) Turn the ignition switch OFF.

2) Remove the right side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

3) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

I947H11A0019-01 email: [email protected] / www.motomatrix.co.uk

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1J-8 Charging System:

5) Disconnect the regulator/rectifier couplers (1).

6) Remove the regulator/rectifier as shown in the regulator/rectifier construction. Refer to “Regulator /

Rectifier Construction” (Page 1J-7).

1

Installation

1) Install the regulator/rectifier as shown in the regulator/rectifier construction. Refer to “Regulator /

Rectifier Construction” (Page 1J-7).

2) Reinstall the removed parts.

I947H11A0016-02

Regulator / Rectifier Inspection

B947H11A06007

Inspect the regulator/rectifier in the following procedures:

1) Turn the ignition switch OFF.

2) Disconnect the regulator/rectifier couplers. Refer to “Regulator / Rectifier Removal and Installation” (Page 1J-7).

3) Measure the voltage between the terminals using the multi-circuit testers as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. Refer to “Regulator /

Rectifier Removal and Installation” (Page 1J-7).

NOTE

If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Diode test ( )

B

2

B/R

1

B/R

2

B/W

1

B/W

2

B

1

B

3

I823H11A0020-04

Unit: V

B

1

0.3 – 0.6

0.3 – 0.6

—

*

*

*

*

(+) probe of tester to:

(–) probe of tester to:

B/R

1

B/R

2

B

B

1

2

B

3

B/W

1

B/R

1

—

0

*

*

*

*

B/W

2

*

*1.4 V and more (tester’s battery voltage)

*

*

*

*

B/R

2

0

—

*

4) Connect the regulator/rectifier couplers and bind the clamp.

5) Reinstall the removed parts.

B

2

0.3 – 0.6

0.3 – 0.6

*

—

*

*

*

B

3

0.3 – 0.6

0.3 – 0.6

*

*

—

*

*

B/W

1

0.6 – 0.9

0.6 – 0.9

0.3 – 0.6

0.3 – 0.6

0.3 – 0.6

—

0

B/W

2

0.6 – 0.9

0.6 – 0.9

0.3 – 0.6

0.3 – 0.6

0.3 – 0.6

0

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Charging System: 1J-9

Battery Components

3

4

5

6

7

B947H11A06008

2) Remove the caps (2) from the electrolyte container.

NOTE

• Do not remove or pierce the sealed areas

“B” of the electrolyte container.

• After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes.

8

2

1

2

1. Anode plates

2. Separator (Fiberglass plate)

3. Cathode plates

4. Upper cover breather

I649G11A0046-03

5. Stopper

6. Filter

7. Terminal

8. Safety valve

“B”

Battery Charging

Initial Charging

Filling electrolyte

B947H11A06009

NOTE

When filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground.

1) Remove the aluminum tape (1) which seals the battery filler holes “A”.

I649G11A0040-03

3) Insert the nozzles of the electrolyte container (3) into the electrolyte filler holes of the battery.

4) Hold the electrolyte container firmly so that it does not fall.

NOTE

Do not allow any of the electrolyte to spill.

3

1

“A”

I649G11A0041-03

I649G11A0039-03 email: [email protected] / www.motomatrix.co.uk

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1J-10 Charging System:

5) Make sure that air bubbles (4) rise to the top of each electrolyte container, and leave in this position for about more than 20 minutes.

2

4

Correct

I649G11A0042-03

NOTE

If no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times.

Never remove the container from the battery.

I718H11A0027-01

Incorrect

6) After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.

7) Wait for about 20 minutes.

I310G11A0024-01

Insert the caps (2) into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover.

!

CAUTION

• Once the caps are installed to the battery, do not remove the caps.

• Do not tap the caps with a hammer when installing them.

I649G11A0047-02

Charging

For initial charging, use the charger specially designed for MF battery.

!

CAUTION

• For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life.

• Do not remove the cap during charging.

• Position the battery with the cap facing upward during charging.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Charging System: 1J-11

Battery Recharging

!

CAUTION

Do not remove the caps on the battery top while recharging.

NOTE

When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.

1) Remove the battery from the motorcycle. Refer to

“Battery Removal and Installation” (Page 1J-11).

2) Measure the battery voltage using the multi-circuit tester.

If the voltage reading is less than the 12 V (DC), recharge the battery with a battery charger.

Recharging time

1.2 A for 5 to 10 hours or 5 A for 1 hour

!

CAUTION

Be careful not to permit the charging current to exceed 5 A at any time.

3) After recharging, wait at least 30 minutes and then measure the battery voltage using the multi-circuit tester.

If the battery voltage is less than 12.5 V, recharge the battery again.

If the battery voltage is still less than 12.5 V after recharging, replace the battery with a new one.

4) Install the battery to the motorcycle. Refer to “Battery

Removal and Installation” (Page 1J-11).

Battery Removal and Installation

B947H11A06010

Removal

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Disconnect the battery (–) lead wire (1).

3) Disconnect the battery (+) lead wire (2).

NOTE

Be sure to disconnect the battery (–) lead wire (1) first, then disconnect the battery (+) lead wire (2).

4) Remove the battery (3) from the motorcycle.

1

I705H11A0029-02

“A”

“B”

3

2

I947H11A0017-01

“A”: Charging period “B”: Stop charging

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1J-12 Charging System:

Installation

Install the battery in the reverse order of removal.

Pay attention to following points:

!

CAUTION

Never use anything except the specified battery.

• Tighten the battery lead wire bolts securely.

Battery Visual Inspection

B947H11A06011

Inspect the battery in the following procedures:

1) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) 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.

3) Install the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

I947H11A0018-01

Specifications

Service Data

Electrical

Unit: mm

Item

Generator coil resistance

Generator maximum output

Generator no-load voltage (When engine is cold)

Regulated voltage

Battery

Type designation

Capacity

Specification

0.12 – 0.6

Ω

Approx. 375 W at 5 000 r/min

85 V (AC) and more at 5 000 r/min

14.0 – 15.5 V at 5 000 r/min

FT12A-BS

12 V 36.0 kC (10 Ah)/10 HR

B947H11A07001

Note

!

CAUTION

Never use anything except the specified battery.

Tightening Torque Specifications

Fastening part

Generator stator set bolt

Generator lead wire set bolt

Generator rotor bolt

N

⋅

m

11

5.5

145

Tightening torque kgf-m

1.1

0.55

14.5

lbf-ft

8.0

4.0

105.0

B947H11A07002

Note

)

(Page 1J-5)

)

(Page 1J-5)

)

(Page 1J-6)

NOTE

The specified tightening torque is described in the following.

“Regulator / Rectifier Construction” (Page 1J-7)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Charging System: 1J-13

Special Tools and Equipment

Recommended Service Material

Sealant

Material

B947H11A08001

SUZUKI recommended product or Specification

SUZUKI BOND No.1207B or

Note

P/No.: 99000–31140

)

(Page 1J-5) /

)

(Page 1Jequivalent 6)

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1J-3) /

)

(Page 1J-

3) /

)

(Page 1J-4) /

)

(Page 1J-4) /

)

(Page 1J-

09930–30460

Rotor remover bolt

)

(Page 1J-5)

B947H11A08002

09930–34970

Rotor remover

)

(Page 1J-5)

09930–44530

Rotor holder

)

(Page 1J-5) /

)

(Page 1J-

6) email: [email protected] / www.motomatrix.co.uk

1K-1 Exhaust System:

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Engine

Exhaust System

Precautions

Precautions for Exhaust System

B947H11B00001

!

WARNING

To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool.

!

CAUTION

Make sure that the exhaust pipes and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.

General Description

Exhaust Control System Description

B947H11B01001

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. This system is designed to improve the engine torque at low engine rpm.

1

1. Exhaust control valve actuator (EXCVA)

2

2. Exhaust control valve (EXCV) email: [email protected] / www.motomatrix.co.uk

I947H11B0001-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exhaust System: 1K-2

Exhaust Control System Operation

B947H11B01002

The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (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. Every time the ignition switch is turned ON, the EXCVA automatically drives the EXCV and detects full close/open position voltages and sets the

EXCV to middle position.

FULL CLOSE

I947H11B0002-01 email: [email protected] / www.motomatrix.co.uk

1K-3 Exhaust System:

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FULL OPEN

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Exhaust System: 1K-4

Exhaust Control System Construction

Repair Instructions

B947H11B06001

(a)

“ a ”

“ b ”

“A”

2

1

2

1

“ c ”

1. EXCV cable No. 1 (CL)

2. EXCV cable No. 2 (OP)

“A”: When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

: 5 N

⋅ m (0.5 kgf-m, 3.5 lbf-ft)

“a”: 42 – 43 mm (1.65 – 1.69 in)

“b”: 60 – 61 mm (2.36 – 2.40 in)

I947H11B0004-02

“c”: 11 – 12 mm (0.43 – 0.47 in) email: [email protected] / www.motomatrix.co.uk

1K-5 Exhaust System:

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Exhaust System Components

6

(b)

(b)

B947H11B06002

6

(c)

(a)

4

(c)

(d)

1

(a)

5

3

2

(b)

(a)

4

(f)

(a)

(b)

“A”

(e)

8

7

(a)

(a)

4

1. Exhaust pipe gasket

2. Exhaust pipe assembly

3. HO2 sensor

4. Connector

: Install the connector so that the chamfer side faces backward.

5. Muffler chamber

6. Muffler body

7. EXCV cable No. 1

8. EXCV cable No. 2

“A”: When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 25 N

⋅ m (2.5 kgf-m, 18.0 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

!

CAUTION

Replace the gaskets and connectors with new ones when reassembling.

I947H11B0005-03

: 5.5 N

⋅ m (0.55 kgf-m, 4.0 lbf-ft)

: 5 N

⋅ m (0.5 kgf-m, 3.5 lbf-ft)

: 30 N

⋅ m (3.0 kgf-m, 21.5 lbf-ft)

: Apply muffler seal.

: Do not reuse.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exhaust System: 1K-6

EXCV Cable Removal and Installation

B947H11B06003

Removal

1) Turn the ignition switch OFF.

2) Remove the front seat. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

3) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

4) Connect the special tool (Mode select switch) to the dealer mode coupler. Refer to “Self-Diagnostic

Procedures” in Section 1A (Page 1A-12).

5) After turning the mode select switch ON, turn the ignition switch ON.

Special tool

(A): 09930–82720 (Mode selection switch)

Loosen the lock-nut (1) on the No. 2 cable (2) and turn in the cable adjuster (3) fully.

9) Loosen the lock-nut (4) on the No. 1 cable (5) and turn in the cable adjuster (6) fully.

5

6

2

4

3

1

I947H11B0008-01

10) Disconnect the No. 2 cable (2) and No. 1 cable (5) from the EXCVA pulley (7).

(A)

7

5

6) Check that the cable slots of the EXCVA pulley comes to the middle (Adjustment position) “A”.

7) Turn the ignition switch OFF.

I947H11B0006-01

!

CAUTION

Before removing the EXCV cables, be sure to set the EXCVA pulley to the adjustment position.

2

I947H11B0009-02

11) Loosen the lock-nuts.

12) Disconnect the No. 2 cable (2) and No. 1 cable (5) from the EXCV pulley (8).

2

8

“A”

5

I947H11B0010-02

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1K-7 Exhaust System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Installation

!

CAUTION

The cable slots of EXCVA pulley must be located adjustment position.

1) Temporarily connect the EXCV cable No. 1

(47H0CL) (1) and No. 2 (47H0OP) (2) to the exhaust pipe and EXCV pulley.

NOTE

The EXCV cables are identified by the letters.

No. 1 cable (1): 47H0CL

No. 2 cable (2): 47H0OP

2) Tighten the lock-nuts (3) on the No. 1 cable.

3) Adjust the inner cable length “a” of No. 1 cable in 42

– 43 mm (1.65 – 1.69 in) by turning the adjuster (4), then tighten the lock-nuts (5).

4) Turn in the adjuster (6) on the No. 2 cable fully.

5) Turn the No. 2 cable adjuster (7) in or out until the inner cable length “b” becomes 60 – 61 mm (2.36 –

2.40 in).

After adjusting the inner cable length “b”, tighten the lock-nuts (8).

6) Connect the other end of EXCV cable No. 1 (1) and

No. 2 (2) to the EXCVA pulley (9).

I947H11B0012-01

7) After connecting the No. 2 cable (2), loosen the locknut (10) and turn the adjuster (6) in or out until 11 –

12 mm (0.43 – 0.47 in) of the thread length “c” on the cable adjuster can be provided and tighten the locknut (10).

2

2

“ c ”

9

1

“ a ”

“ b ”

2

1

6

4

5

7

8

3

I947H11B0011-02

6

10

I947H11B0013-01

Inspect the EXCVA position sensor output voltage.

Refer to “EXCVA Adjustment” (Page 1K-9).

EXCVA Removal and Installation

B947H11B06004

Removal

1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

3) Connect the special tool (Mode select switch) to the dealer mode coupler. Refer to “Self-Diagnostic

Procedures” in Section 1A (Page 1A-12).

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Exhaust System: 1K-8

9) Remove the EXCVA (3) with the bracket.

4) After turning the mode select switch ON, turn the ignition switch ON.

Special tool

(A): 09930–82720 (Mode selection switch)

(A)

3

2

10) Remove the bracket from the EXCVA.

I947H11B0017-01

5) Check that the cable slots of the EXCVA pulley comes to the middle (Adjustment position) “A”.

6) Turn the ignition switch OFF.

I947H11B0014-01

!

CAUTION

Before removing the EXCVA, be sure to set the EXCVA pulley to the adjustment position.

“A”

7) Disconnect the EXCVA coupler (1).

I947H11B0015-01

I947H11B0037-01

11) Hold the pulley with an adjustable wrench, and loosen the pulley mounting bolt (4).

!

CAUTION

• When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

• Do not use the adjustable wrench to turn

EXCVA pulley so as not to cause damage to the internal gear of EXCVA.

12) Remove the pulley from the EXCVA body.

4

1

I947H11B0016-01

Remove the EXCV cables (2). Refer to “EXCV Cable

Removal and Installation” (Page 1K-6).

I947H11B0038-01 email: [email protected] / www.motomatrix.co.uk

1K-9 Exhaust System:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Installation

Install the EXCVA in the reverse order of removal. Pay attention to the following points:

• Install the EXCVA pulley to the shaft.

NOTE

Align the shaft’s line “A” and cable slots “B”.

EXCVA Pulley Inspection

B947H11B06006

Inspect the EXCVA pulley in the following procedures:

1) Remove the EXCVA pulley. Refer to “EXCV Cable

Removal and Installation” (Page 1K-6).

2) Visually inspect the EXCVA pulley for wear and damage. If there is anything unusual, replace the pulley with a new one.

“B”

“A”

I823H11B0017-02

• Hold the pulley with an adjustable wrench, and then tighten the pulley mounting bolt (1) to the specified torque.

Tightening torque

EXCVA pulley mounting bolt (a): 5 N·m (0.5 kgfm, 3.5 lbf-ft)

!

CAUTION

When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

1

(a)

I823H11B0021-01

3) Install the pulley and EXCVA. Refer to “EXCVA

Removal and Installation” (Page 1K-7).

EXCVA Adjustment

B947H11B06007

Inspect the EXCVA operation and adjust it if necessary in the following steps:

Step 1

1) Set the EXCVA to the adjustment position. Refer to

“EXCV Cable Removal and Installation” (Page 1K-

6).

Step 2

1) Turn the ignition switch OFF.

2) Turn the mode select switch OFF.

3) Turn the ignition switch ON and check the operation of EXCVA.

(EXCVA operation order: Full close

→

Full open

→

Approx. 60% open)

I947H11B0039-01

• Install the EXCV cables. Refer to “EXCV Cable

Removal and Installation” (Page 1K-6).

• Adjust the EXCVA. Refer to “EXCVA Adjustment”

(Page 1K-9).

EXCVA Inspection

B947H11B06005

Refer to “DTC “C46” (P1657-H/L or P1658): EXCV

Actuator Circuit Malfunction” in Section 1A (Page 1A-

109).

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Exhaust System: 1K-10

4) Turn the mode select switch ON. If DTC “C46” is not indicated on the LCD display, the adjustment is correctly completed. If “C46” is indicated, repeat the procedures from Step 3 to Step 4.

7) Measure the EXCVA position sensor output voltage at EXCV fully closed position.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

Tester knob indication

Voltage ( )

EXCVA position sensor output voltage

EXCV is fully closed: 0.45

≤

Output voltage

≤

1.4

V ((+) Y – (–) W)

I947H11B0019-01

Step 3

1) Turn the ignition switch OFF.

2) Set up the SDS tools. Refer to “Self-Diagnostic

Procedures” in Section 1A (Page 1A-12).

3) Turn the ignition switch ON.

4) Click “Exhaust valve operating control” (1).

5) Click “Full closed” (2).

1

I947H11B0040-01

(B)

3

(A)

I947H11B0021-02

If the measured voltage is less than specification, adjust the No. 1 cable adjuster (4) as follows: a) Set the EXCVA to the adjustment position. Refer to “EXCV Cable Removal and Installation”

(Page 1K-6).

!

CAUTION

Adjusting the No. 1 cable with the EXCV fully closed can damage the EXCVA. Be sure to adjust the No. 1 cable with the EXCV set in the adjustment position.

b) Turn the No. 1 cable adjuster (4) in or out to set the output voltage within the specified value.

NOTE

If C46 code is indicated after adjusting the voltage, increase the voltage to 0.9 V.

2

I947H11B0020-02

6) Insert the needle pointed probes into the back side of the EXCVA coupler (3). ((+) Y – (–) W)

4

I947H11B0022-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1K-11 Exhaust System:

Step 4

1) Click “Full opened” (1).

b) Turn out the No. 2 cable adjuster (2) in or out to set the output voltage within the specified value.

2

1

I947H11B0023-02

2) Measure the EXCVA position sensor output voltage at EXCV fully opened position.

Special tool

(A): 09900–25008 (Multi circuit tester set)

(B): 09900–25009 (Needle-point probe set)

EXCVA position sensor out put voltage

EXCV is fully opened: 3.6

≤

Output voltage

≤

4.55

V ((+) Y – (–) W)

(B)

I947H11B0025-02

4) After adjusting the EXCV cables, perform Step 2 to confirm DTC “46” is not indicated.

Muffler / Muffler Chamber / Exhaust Pipe

Removal and Installation

B947H11B06008

Removal

1) Loosen the muffler connecting bolts (1).

2) Remove the mufflers (2) by removing the mounting bolt and nut (3).

NOTE

Support the muffler to prevent it from falling.

(A)

3

I947H11B0024-02

3) If the measured voltage is more than specification, adjust the No. 2 cable adjuster (2) as follows: a) Set the EXCVA to the adjustment position. Refer to “EXCV Cable Removal and Installation”

(Page 1K-6).

!

CAUTION

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.

3

1

2

I947H11B0027-01

2

1

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exhaust System: 1K-12

3) Remove the side cowlings. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

4) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

5) Disconnect the HO2 sensor coupler (4).

4

I947H11B0028-01

6) Remove the muffler chamber heat guard No. 2 (5).

(RH only)

6

7

I947H11B0031-01

9) Remove the muffler chamber heat guard No. 1 (8) and HO2 sensor (9) from the muffler chamber.

!

CAUTION

• Be careful not to expose the HO2 sensor to an excessive shock.

• Be careful not to twist or damage the HO2 sensor lead wires.

8

5

I947H11B0029-01

7) Loosen the muffler chamber connecting bolt (6).

Remove the muffler chamber (7).

9

I947H11B0032-01

10) Remove the EXCV cables (10). Refer to “EXCV

Cable Removal and Installation” (Page 1K-6).

10

7

I947H11B0030-03

I947H11B0033-01

11) Move the radiator and oil cooler forward. Refer to

“Radiator Inspection and Cleaning” in Section 1F

(Page 1F-5).

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1K-13 Exhaust System:

12) Remove the exhaust pipe assembly by removing the exhaust pipe bolts.

!

CAUTION

Take care not to bend the radiator/oil cooler fins.

NOTE

Support the exhaust pipe assembly to prevent it from falling.

(a)

13) Remove the exhaust pipe gaskets (11).

I947H11B0034-01

I947H11B0036-01

• Install new gaskets and connectors and tighten each bolt to the specified torque. Refer to “Exhaust System

Components” (Page 1K-5).

!

CAUTION

Replace the gaskets and connectors with new ones.

NOTE

When installing a new connector, remove all of the old sealer. Apply the exhaust gas sealer to both the inside and outside of the new connector.

: Muffler seal (MUFFLER SEAL LOCTITE

5920 (commercially available) or equivalent)

• Install the EXCVA cables. Refer to “EXCV Cable

Removal and Installation” (Page 1K-6).

11

I947H11B0035-01

Installation

Installation is in the reverse order of removal. Pay attention to the following points:

• Tighten the HO2 sensor to the specified torque.

Tightening torque

HO2 sensor (a): 25 N·m (2.5 kgf-m, 18.0 lbf-ft)

!

CAUTION

• Be careful not to expose the HO2 sensor to an excessive shock.

• Do not use an impact wrench when installing the HO2 sensor.

• Be careful not to twist or damage the HO2 sensor lead wires.

• Do not apply oil or other materials to the sensor air holes.

Exhaust System Inspection

B947H11B06009

Inspect the exhaust pipe, muffler chamber and muffler connection for exhaust gas leakage and mounting condition. If any defect is found, replace the exhaust pipe, muffler chamber or muffler with a new one.

Check the exhaust pipe bolts, muffler connecting bolts and muffler mounting bolts are tightened to their specified torque. Refer to “Exhaust System

Components” (Page 1K-5).

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Exhaust System: 1K-14

Specifications

Service Data

FI Sensors

Item

HO2 sensor output voltage

EXCVA position sensor input voltage

EXCVA position sensor output voltage

EXCVA position sensor resistance

Closed

Opened

Standard/Specification

0.3 V and less at idle speed

0.6 V and more at 5 000 r/min

4.5 – 5.5 V

0.45 – 1.4 V

3.6 – 4.55 V

Approx. 3.1 k

Ω

B947H11B07001

Note

At adjustment position

Tightening Torque Specifications

Fastening part

EXCVA pulley mounting bolt

HO2 sensor

N

⋅

5

m

25

Tightening torque kgf-m

0.5

2.5

lbf-ft

3.5

18.0

B947H11B07002

Note

)

(Page 1K-9)

)

(Page 1K-13)

NOTE

The specified tightening torque is described in the following.

“Exhaust Control System Construction” (Page 1K-4)

“Exhaust System Components” (Page 1K-5)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

1K-15 Exhaust System:

Recommended Service Material

Special Tools and Equipment

Material

Muffler seal

SUZUKI recommended product or Specification

MUFFLER SEAL LOCTITE 5920 —

(commercially available) or equivalent

NOTE

Required service material is also described in the following.

“Exhaust System Components” (Page 1K-5)

Special Tool

09900–25008

Multi circuit tester set

)

(Page 1K-10) /

)

(Page 1K-11)

09900–25009

Needle-point probe set

)

(Page 1K-10) /

)

(Page 1K-11)

Note

)

(Page 1K-13)

B947H11B08001

B947H11B08002

09930–82720

Mode selection switch

)

(Page 1K-6) /

)

(Page 1K-

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 2- i

Section 2

Suspension

CONTENTS

Precautions ………………………………………….2-1

Precautions……………………………………………………. 2-1

Precautions for Suspension ……………………………. 2-1

Suspension General Diagnosis………….. 2A-1

Diagnostic Information and Procedures…………2A-1

Suspension and Wheel Symptom Diagnosis …… 2A-1

Front Suspension ……………………………… 2B-1

Repair Instructions ……………………………………….2B-1

Front Fork Components ……………………………….. 2B-1

Front Fork Removal and Installation ………………. 2B-2

Front Suspension Adjustment ……………………….. 2B-4

Front Fork Disassembly and Assembly…………… 2B-4

Front Fork Parts Inspection…………………………. 2B-10

Rod Guide Case Tightening Torque …………….. 2B-10

Specifications……………………………………………..2B-11

Service Data …………………………………………….. 2B-11

Tightening Torque Specifications…………………. 2B-11

Special Tools and Equipment ………………………2B-12

Recommended Service Material ………………….. 2B-12

Special Tool ……………………………………………… 2B-12

Rear Suspension ………………………………. 2C-1

Repair Instructions ……………………………………….2C-1

Rear Suspension Components ………………………2C-1

Rear Suspension Assembly Construction………..2C-2

Rear Shock Absorber Removal and

Installation …………………………………………………2C-3

Rear Suspension Inspection ………………………….2C-3

Rear Shock Absorber Inspection ……………………2C-4

Rear Shock Absorber Bearing Removal and

Installation …………………………………………………2C-4

Rear Shock Absorber Adjustment…………………..2C-5

Rear Shock Absorber Disposal ………………………2C-6

Cushion Lever Removal and Installation………….2C-7

Cushion Lever Inspection ……………………………..2C-7

Cushion Rod Removal and Installation ……………2C-7

Cushion Rod Inspection ………………………………..2C-8

Cushion Rod Bearing Removal and

Installation …………………………………………………2C-9

Swingarm Removal and Installation………………..2C-9

Swingarm Pivot Boss Removal and

Installation ……………………………………………….2C-12

Swingarm Related Parts Inspection ………………2C-12

Swingarm Bearing Removal and Installation ….2C-13

Specifications ……………………………………………..2C-15

Service Data………………………………………………2C-15

Tightening Torque Specifications………………….2C-15

Special Tools and Equipment ………………………2C-16

Recommended Service Material …………………..2C-16

Special Tool ………………………………………………2C-16

Wheels and Tires ………………………………. 2D-1

Precautions…………………………………………………..2D-1

Precautions for Wheel and Tire………………………2D-1

Repair Instructions ……………………………………….2D-2

Front Wheel Components ……………………………..2D-2

Front Wheel Assembly Construction……………….2D-3

Front Wheel Assembly Removal and

Installation …………………………………………………2D-4

Front Wheel Related Parts Inspection …………….2D-6

Front Wheel Dust Seal / Bearing Removal and Installation …………………………………………..2D-7

Rear Wheel Components………………………………2D-9

Rear Wheel Assembly Construction ……………..2D-10

Rear Wheel Assembly Removal and

Installation ……………………………………………….2D-11

Rear Wheel Related Parts Inspection ……………2D-12

Rear Wheel Dust Seal / Bearing Removal and

Installation ……………………………………………….2D-13

Tire Removal and Installation……………………….2D-14

Wheel / Tire / Air Valve Inspection and

Cleaning ………………………………………………….2D-16

Air Valve Removal and Installation ……………….2D-16

Wheel Balance Check and Adjustment………….2D-17

Specifications ……………………………………………..2D-18

Service Data………………………………………………2D-18

Tightening Torque Specifications………………….2D-18

Special Tools and Equipment ………………………2D-19

Recommended Service Material …………………..2D-19

Special Tool ………………………………………………2D-19

2

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2-1 Precautions:

Suspension

Precautions

Precautions

Precautions for Suspension

Refer to “General Precautions” in Section 00 (Page 00-1).

B947H12000001

!

WARNING

All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.

!

CAUTION

Never attempt to heat, quench or straighten any suspension part. Replace it with a new one, or damage to the part may result.

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Suspension General Diagnosis: 2A-1

Suspension

Suspension General Diagnosis

Diagnostic Information and Procedures

Suspension and Wheel Symptom Diagnosis

B947H12104001

Condition

Wobbly front wheel

Possible cause

Distorted wheel rim.

Worn front wheel bearings.

Defective or incorrect tire.

Loose front axle nut.

Loose front axle pinch bolts.

Incorrect fork oil level.

Incorrect front wheel weight balance.

Replace.

Correction / Reference Item

Replace.

Replace.

Tighten.

Tighten.

Adjust.

Adjust.

Front suspension too soft

Weak spring.

Insufficient fork oil.

Improperly set front fork damping force adjuster.

Replace.

Check level and add.

Wrong weight fork oil.

Replace.

Improperly set front fork spring adjuster.

Adjust.

Adjust.

Front suspension too stiff

Excessively viscous fork oil.

Excessive fork oil.

Front suspension too noisy

Wobbly rear wheel

Rear suspension too soft

Bent front axle.

Insufficient fork oil.

Loose front suspension bolt/nut.

Distorted wheel rim.

Worn rear wheel bearings.

Defective or incorrect tire.

Worn swingarm bearings.

Worn rear suspension bearings.

Loose rear suspension bolt/nut.

Incorrect rear wheel weight balance.

Weak rear shock absorber spring.

Rear shock absorber leaks oil.

Replace.

Check level and drain.

Replace.

Check level and add.

Tighten.

Replace.

Replace.

Replace.

Replace.

Replace.

Tighten.

Adjust.

Replace.

Replace.

Adjust.

Improperly set rear spring pre-load adjuster.

Improperly set damping force adjuster.

Adjust.

Rear suspension too stiff

Bent rear shock absorber shaft.

Replace.

Rear suspension too noisy

Bent swingarm pivot shaft.

Worn swingarm bearings.

Worn rear suspension bearings.

Improperly set rear spring pre-load

Replace.

Replace.

Replace.

Adjust.

adjuster.

Improperly set damping force adjuster.

Adjust.

Loose rear suspension bolt/nut.

Worn rear suspension bearings.

Worn swingarm bearings.

Tighten.

Replace.

Replace.

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2B-1 Front Suspension:

Suspension

Front Suspension

Repair Instructions

Front Fork Components

B947H12206001

5

(b)

11

1

7

6

(a)

12

8

(c)

2

3

9

14

13

18

20

19

17

16

10

4

21

15

22

(d)

1. Front fork cap

2. O-ring

3. Rebound damping force adjuster rod

4. Compression damping force adjuster rod

5. Piston rod nut

6. O-ring

7. Piston ring

8. Rod guide case

9. Spring

10. Piston rod

11. Spring collar B

12. Spring

13. Spring collar A

14. Slide bushing

15. Outer tube

16. Guide bushing

17. Oil seal spacer

18. Oil seal

19. Stopper ring

20. Dust seal

21. Inner tube

I947H1220001-03

22. Front axle pinch bolt

: 35 N

⋅ m (3.5 kgf-m, 25.5 lbf-ft)

: 28 N

⋅ m (2.8 kgf-m, 20.0 lbf-ft)

: 90 N

⋅ m (9.0 kgf-m, 65.0 lbf-ft)

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: Apply fork oil.

: Do not reuse.

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2

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Suspension: 2B-2

Front Fork Removal and Installation

B947H12206002

NOTE

The right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.

Removal

1) Remove the front wheel. Refer to “Front Wheel

Assembly Removal and Installation” in Section 2D

(Page 2D-4).

!

CAUTION

• Make sure that the motorcycle is supported securely.

• Do not operate the front brake lever with the front wheel removed.

2) Disconnect the brake hoses from the clamps on the front fender.

3) Remove the reflex reflectors (1). (Except for E-02,

19, 51)

4) Remove the front fender (2) by removing the bolts.

6) Loosen the handlebar clamp bolt (4).

NOTE

Slightly loosen the front fork cap (5) to facilitate later disassembly.

Special tool

: 09941–53670 (Front fork cap socket wrench (45 mm))

3

5

4

I947H1220004-01

7) Loosen the front fork lower clamp bolts (6) and remove the front fork.

NOTE

Hold the front fork by hand to prevent it sliding out of the steering stem.

1

6

I947H1220002-01

2

1

I947H1220005-01

Installation

1) Set the front fork to the steering stem lower bracket temporarily by tightening the lower clamp bolts (1).

I947H1220003-01

5) Loosen the front fork upper clamp bolt (3).

1

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2B-3 Front Suspension:

2) Tighten the front fork cap (2) to the specified torque.

Tightening torque

Front fork cap (a): 35 N·m (3.5 kgf-m, 25.5 lbf-ft)

3) Loosen the lower clamp bolts.

4) Set the front fork with the edge of the outer tube positioned 7.0 mm (0.28 in) “a” from the upper surface of the upper bracket.

7) Tighten the handlebar clamp bolt (4).

Tightening torque

Handlebar clamp bolt (d): 23 N·m (2.3 kgf-m,

16.5 lbf-ft)

3

(c)

2

(a)

4

(d)

“ a ”

I947H1220007-02

“a”: 7.0 mm (0.28 in)

5) Tighten the front fork lower clamp bolts (1).

Tightening torque

Front fork lower clamp bolt (b): 23 N·m (2.3 kgfm, 16.5 lbf-ft)

I947H1220008-01

Install the front wheel. Refer to “Front Wheel

Assembly Removal and Installation” in Section 2D

(Page 2D-4).

!

WARNING

After remounting the brake calipers, pump the brake lever until the pistons push the pads correctly.

NOTE

Before tightening the front axle bolt and front axle pinch bolts, move the front fork up and down four or five times.

1

(b)

I947H1220045-01

6) Tighten the front fork upper clamp bolt (3).

Tightening torque

Front fork upper clamp bolt (c): 23 N·m (2.3 kgfm, 16.5 lbf-ft)

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Suspension: 2B-4

Front Suspension Adjustment

B947H12206003

After installing the front fork, adjust the spring pre-load and two kinds of damping force as follows:

!

WARNING

Adjust the left and right front forks to the same setting.

Spring Pre-load Adjustment

Turn the spring pre-load adjuster (1) counterclockwise fully. From that position (softest), turn it clockwise to the specified position.

STD position

4 turns in from softest position

Compression damping force

Fully turn the compression damping force adjuster (1) clockwise. From that position (stiffest), turn it out to standard setting position.

STD position

5 turns from stiffest position

1

1

I947H1220010-01

Damping Force Adjustment

Rebound damping force

Fully turn the rebound damping force adjuster (1) clockwise. From that position (stiffest), turn it out to standard setting position.

STD position

4 turns out from stiffest position

I947H1220012-01

Front Fork Disassembly and Assembly

B947H12206004

Refer to “Front Fork Removal and Installation” (Page 2B-

2).

NOTE

The right and left front forks are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side.

Disassembly

1) Turn the spring pre-load adjuster (1) to the softest position.

1

1

I947H1220013-01

I947H1220011-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2B-5 Front Suspension:

5) Remove the spring collar B (3) and spring (4).

2) Loosen the front fork cap using the special tool and vise.

!

CAUTION

Do not clamp the outer tube too tight.

Special tool

(A): 09941–53670 (Front fork cap socket wrench (45 mm))

3

4

(A)

I947H1220017-01

6) Drain fork oil and remove the spring collar A (5).

5

I947H1220014-01

3) Loosen the rod guide case installed in the inner tube using the special tool.

Special tool

(B): 09940–84710 (Rod guide case wrench)

!

WARNING

Hold the front fork cap when removing the rod guide case, or it will jump out due to the spring pressure.

I947H1220018-01

7) Remove the dust seal (6).

Remove the oil seal stopper ring (7).

!

CAUTION

• Scratches on the inner tube could cause oil leaks.

• Avoid scratching when removing.

(B)

7

4) Remove the piston rod assembly (2).

I947H1220015-01

6

I947H1220019-01

2

I947H1220016-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Suspension: 2B-6

9) Pull out the inner tube from the outer tube.

10) Remove the slide bushing (8) from the inner tube.

11) Remove the following parts from the inner tube.

a) Guide bushing (9)

I947H1220020-01 b) Oil seal spacer (10) c) Oil seal (11) d) Oil seal stopper ring (7) e) Dust seal (6)

8

9

10

11

7

6

I947H1220021-01

12) Hold the piston rod assembly with the special tool and vise.

Special tool

(A): 09941–53670 (Front fork cap socket wrench (45 mm))

13) Loosen the piston rod nut (12) and disassemble the piston rod as shown.

I947H1220023-01

Assembly

!

CAUTION

• Clean all fork parts before reassembling.

• Replace the O-rings, seals and bushings with new ones.

• Apply specified front fork oil when installing the O-rings, slide bushing and guide bushing.

1) Cover the inner tube with a plastic film.

2) Install the following parts to the inner tube.

a) New dust seal (1) b) Stopper ring (2) c) New oil seal (3)

!

CAUTION

• Scratches on the oil seal lip may cause oil leakage. When installing the seals, place a plastic film over the slide bushing groove and edges of the inner tube to avoid damaging the seals’ lip.

• Misdirecting of the parts may cause inferior operation and oil leakage.

• Face the stamp mark side “A” of the oil seal to the dust seal side.

“A”

12

(A)

I947H1220022-01

3

2

“A”: Stamp mark

1

I947H1220024-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2B-7 Front Suspension:

3) Remove the plastic film and install the oil seal spacer

(4), guide bushing (5) and slide bushing (6) keep them free from dust.

!

CAUTION

• Face the grooved side “B” of the oil seal spacer to the outer tube side.

• Position the slit “C” of slide bushing 90

°

against the traveling direction.

7) Install the stopper ring (2).

!

CAUTION

Make sure that the stopper ring is fitted securely into the groove.

2

5

4

“C”

I947H1220027-01

Press fit the dust seal (1).

6

“B”

I947H1220025-02

“B”: Groove “C”: Slit

4) Insert the inner tube into the outer tube.

5) Press fit the guide bushing (5) using the special tools.

6) Press fit the new oil seal (3) using the special tools until the stopper ring groove on the outer tube can be seen.

Special tool

(A): 09940–52861 (Front fork oil seal installer set)

1

I947H1220028-01

9) Insert the spring collar A (7) and spring (8) into the inner tube.

7

8

(A)

5/3

I947H1220029-01

I947H1220026-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Suspension: 2B-8

10) Insert the spring collar B (9) into the inner tube.

!

CAUTION

Face the flange “D” of the collar to the spring side.

13) Assemble the piston rod and rod guide case (10).

14) Tighten the piston rod nut (11) with the special tool and vise.

Tightening torque

Piston rod nut (a): 28 N·m (2.8 kgf-m, 20.0 lbf-ft)

9

10

11

(a)

“D”

I947H1220030-01

“D”: Flange

11) Pour specified fork oil until its surface passes the side holes of inner tube.

: Fork Oil 99000–99001–SS5 (SUZUKI

FORK OIL SS-05 or equivalent)

I947H1220033-01

15) Insert the piston rod assembly into the inner tube and temporarily tighten the rod guide case by hand.

!

CAUTION

Insert the piston rod assembly into the inner tube with the outer tube lifted up. Be sure not to damage the piston ring (12) of the rod guide case.

Special tool

(B): 09940–84710 (Rod guide case wrench)

(B)

I947H1220031-01

12) Slowly stroke the outer tube more than ten times to pump out air.

NOTE

Take extreme attention to pump out air completely.

12

I947H1220034-03

I947H1220032-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2B-9 Front Suspension:

16) Tighten the rod guide case to the specified torque.

Refer to “Rod Guide Case Tightening Torque”

(Page 2B-10).

Special tool

(B): 09940–84710 (Rod guide case wrench)

Tightening torque

Rod guide case: 90 N·m (9.0 kgf-m, 65.0 lbf-ft)

19) Hold the front fork vertically and adjust the oil level using the special tool.

Special tool

(C): 09943–74111 (Front fork oil level gauge)

Fork oil level “a”

75.0 mm (2.95 in)

(C)

(B)

“ a ”

I947H1220035-01

17) Pour specified fork oil up to the top of the rod guide case.

: Fork Oil 99000–99001–SS5 (SUZUKI

FORK OIL SS-05 or equivalent)

I947H1220038-01

20) Apply fork oil to the O-ring (13).

!

CAUTION

Use new O-ring to prevent oil leakage.

21) Tighten the front fork cap to the specified torque.

!

CAUTION

Do not clamp the outer tube too tight.

Tightening torque

Front fork cap: 35 N·m (3.5 kgf-m, 25.5 lbf-ft)

Special tool

(A): 09941–53670 (Front fork cap socket wrench (45 mm))

I947H1220036-01

18) Push the front fork cap, then stroke the outer tube several times to pump out air.

NOTE

Take extreme attention to pump out the air completely.

13

(A)

I947H1220039-02

I947H1220037-01 email: [email protected] / www.motomatrix.co.uk

Front Fork Parts Inspection

B947H12206005

Refer to “Front Fork Disassembly and Assembly”

(Page 2B-4).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Suspension: 2B-10

Piston Rod / Piston Ring

Inspect the piston rod and piston ring (1) for wear or damage. If any defects are found, replace the piston rod with a new one.

Inner and Outer Tubes

Inspect the inner tube and outer tube for scratches.

1

I947H1220040-01

Slide Bushing / Guide Bushing

Inspect the slide bushing and guide bushing for wear or damage. If they are worn or damaged, replace them with new ones. If they are not clean, clean them with a nylon brush and fork oil.

I947H1220043-01

Rod Guide Case Tightening Torque

B947H12206006

Tighten the rod guide case in the following procedures:

Measure the effective length L of the torque wrench.

Calculate the reading torque on the torque wrench by use of the formula shown below.

Special tool

(A): 09940–84710 (Rod guide case wrench)

I947H1220041-01

Fork Spring

Measure the fork spring free length “a”. If it is shorter than the service limit, replace it with a new one.

Front fork spring free length “a”

Service limit: 236 mm (9.29 in)

(A)

I947H1220044-01

T: Reading torque on the torque wrench

Ts: Specified torque

Ls: 0.05 m (1.97 in)

L: Effective length of the torque wrench

I933H1310046-01

“a”

I947H1220042-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2B-11 Front Suspension:

Service Data

Suspension

Unit: mm (in)

Item

Front fork stroke

Front fork spring free length

Front fork oil level (Without spring, outer tube fully compressed)

Front fork oil type

Front fork oil capacity (Each leg)

Front fork inner tube O.D

Front fork spring adjuster

Front fork damping force adjuster

Specifications

Standard

125 (4.9)

241 (9.49)

75 (2.95)

70 (2.76) 10 min. after adjustment

SUZUKI FORK OIL SS-05 or an equivalent fork oil

476 ml (16.1/16.8 US/lmp oz)

43 (1.7)

Rebound

Compression

4 turns in from softest position

4 turns out from stiffest position

5 turns from stiffest position

B947H12207001

Limit

—

236 (9.29)

—

—

—

—

—

—

—

Tightening Torque Specifications

Front fork cap

Front fork lower clamp bolt

Front fork upper clamp bolt

Handlebar clamp bolt

Piston rod nut

Rod guide case

Fastening part

N

⋅

m

35

23

23

23

28

90

Tightening torque kgf-m

2.3

2.3

2.3

2.8

9.0

lbf-ft

16.5

16.5

16.5

20.0

65.0

B947H12207002

Note

)

(Page 2B-3)

)

(Page 2B-3)

)

(Page 2B-3)

)

(Page 2B-8)

)

(Page 2B-9)

NOTE

The specified tightening torque is described in the following.

“Front Fork Components” (Page 2B-1)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Suspension: 2B-12

Special Tools and Equipment

Recommended Service Material

Fork Oil

Material SUZUKI recommended product or Specification

SUZUKI FORK OIL SS-05 or P/No.: 99000–99001– equivalent SS5

B947H12208001

Note

)

(Page 2B-8) /

)

(Page 2B-

9)

NOTE

Required service material is also described in the following.

“Front Fork Components” (Page 2B-1)

Special Tool

09940–52861

Front fork oil seal installer set

)

(Page 2B-7)

09940–84710

Rod guide case wrench

)

(Page 2B-5) /

)

(Page 2B-

/

)

(Page 2B-9) /

)

(Page 2B-10)

B947H12208002

09941–53670

Front fork cap socket wrench (45 mm)

)

(Page 2B-2) /

)

(Page 2B-

5) /

)

(Page 2B-6) /

)

(Page 2B-9)

09943–74111

Front fork oil level gauge

)

(Page 2B-9) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-1 Rear Suspension:

Suspension

Rear Suspension

Repair Instructions

Rear Suspension Components

7

(g)

8

(f)

13

2

(a)

(c)

15

(e)

10

16

B947H12306001

12

13

1

11

5

5

6

(b)

4

(b)

14

15

(e)

16

9

(d)

2

(a)

3

4

(b)

1. Rear shock absorber

2. Rear shock absorber mounting nut

3. Cushion rod

4. Cushion rod mounting nut

5. Cushion lever

6. Cushion lever mounting nut

7. Swingarm pivot lock-nut

8. Swingarm pivot shaft

9. Swingarm pivot nut

10. Swingarm

11. Chain case

12. Plate

13. Chain adjuster

14. Chain buffer

15. Swingarm pivot boss nut

16. Swingarm pivot boss

: 50 N

⋅ m (5.0 kgf-m, 36.0 lbf-ft)

: 98 N

⋅ m (9.8 kgf-m, 71.0 lbf-ft) email: [email protected] / www.motomatrix.co.uk

: 115 N

⋅ m (11.5 kgf-m, 83.0 lbf-ft)

: 100 N

⋅ m (10.0 kgf-m, 72.5 lbf-ft)

: 65 N

⋅ m (6.5 kgf-m, 47.0 lbf-ft)

: 15 N

⋅ m (1.5 kgf-m, 11.0 lbf-ft)

: 90 N

⋅ m (9.0 kgf-m, 65.0 lbf-ft)

: Apply grease to the bearing.

: Do not reuse.

I947H1230001-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-2

Rear Suspension Assembly Construction

B947H12306002

(c)

1

(a)

1

2

(a)

6

5

(b)

“ a ” “ a ”

3

2

4

5

“ c ” “ c ”

8

(f)

4

(b)

“ b ” “ b ”

6

(d)

7

(e)

7

(e)

9

(g)

“ a ” “ a ”

3

(b)

“ a ” “ a ”

1. Rear shock absorber mounting bolt (Upper)

2. Rear shock absorber mounting nut (Lower)

3. Cushion rod mounting nut (Front)

4. Cushion rod mounting nut (Rear)

5. Cushion lever mounting nut

6. Swingarm pivot nut

7. Swingarm pivot boss nut

8. Swingarm pivot shaft

9. Swingarm pivot lock-nut

“a”: 0.5 mm (0.02 in)

“b”: 1.5 mm (0.06 in)

“c”: 0 – 0.5 mm (0 – 0.02 in)

: 50 N

⋅ m (5.0 kgf-m, 36.0 lbf-ft)

: 98 N

⋅ m (9.8 kgf-m, 71.0 lbf-ft) email: [email protected] / www.motomatrix.co.uk

: 115 N

⋅ m (11.5 kgf-m, 83.0 lbf-ft)

: 100 N

⋅ m (10.0 kgf-m, 72.5 lbf-ft)

: 65 N

⋅ m (6.5 kgf-m, 47.0 lbf-ft)

: 15 N

⋅ m (1.5 kgf-m, 11.0 lbf-ft)

: 90 N

⋅ m (9.0 kgf-m, 65.0 lbf-ft)

: Apply grease to the bearing.

I947H1230002-04

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-3 Rear Suspension:

Rear Shock Absorber Removal and Installation

B947H12306003

Removal

1) Remove the right side cowling and side frame covers. Refer to “Exterior Parts Removal and

Installation” in Section 9D (Page 9D-6).

2) Support the motorcycle with a jack to relieve load on the rear shock absorber.

3) Remove the left muffler and muffler chamber heat guard No. 2. Refer to “Muffler / Muffler Chamber /

Exhaust Pipe Removal and Installation” in Section

1K (Page 1K-11).

4) Remove the rear shock absorber lower mounting bolt and nut (1).

Installation

Install the rear shock absorber in the reverse order of removal. Pay attention to the following points:

• Tighten the rear shock absorber upper/lower mounting bolts and nuts.

Tightening torque

Rear shock absorber upper mounting nut (a): 50

N·m (5.0 kgf-m, 36.0 lbf-ft)

Rear shock absorber lower mounting nut (b): 50

N·m (5.0 kgf-m, 36.0 lbf-ft)

(a)

1

I947H1230003-02

5) Remove the rear shock absorber upper mounting bolt and nut (2).

(b)

I947H1230006-01

2

6) Remove the rear shock absorber upward.

I947H1230004-02

I947H1230007-01

• Install the left muffler and muffler chamber heat guard

No. 2. Refer to “Muffler / Muffler Chamber / Exhaust

Pipe Removal and Installation” in Section 1K

(Page 1K-11).

• Install the side frame covers and right side cowling.

Refer to “Exterior Parts Removal and Installation” in

Section 9D (Page 9D-6).

Rear Suspension Inspection

B947H12306004

Refer to “Rear Suspension Inspection” in Section 0B

(Page 0B-19).

I947H1230005-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-4

Rear Shock Absorber Inspection

B947H12306005

Refer to “Rear Shock Absorber Removal and

Installation” (Page 2C-3).

Shock Absorber

Inspect the rear shock absorber for damage and oil leakage, and absorber bushing for wear and damage. If any defect is found, replace the rear shock absorber with a new one.

!

CAUTION

Do not attempt to disassemble the rear shock absorber. It is unserviceable.

Rear Shock Absorber Bearing

1) Insert the spacer into bearing.

2) Check the play by moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. Refer to “Rear Shock Absorber Removal and Installation” (Page 2C-3).

I947H1230008-01

I947H1230011-01

Rear Shock Absorber Bearing Removal and

Installation

B947H12306017

Removal

1) Remove the rear shock absorber. Refer to “Rear

Shock Absorber Removal and Installation”

(Page 2C-3).

2) Remove the spacer (1).

1

I947H1230009-01

Spacer

1) Remove the spacer from the cushion lever.

2) Inspect the spacer for any flaws or other damage. If any defect is found, replace the spacer with a new one.

I947H1230012-01

3) Remove the rear shock absorber bearing with the special tool.

Special tool

(A): 09943–88211 (Pinion bearing installer)

(A)

I947H1230010-01 email: [email protected] / www.motomatrix.co.uk

I947H1230013-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-5 Rear Suspension:

Installation

!

CAUTION

The removed bearing must be replaced with a new one.

1) Press the bearing into the rear shock absorber at 0.5 mm (0.02 in) depth “a” from the rear shock absorber side surface with the special tool and suitable size socket wrench.

NOTE

Apply a small quantity of the grease to housing when installing the bearing.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

Special tool

(A): 09924–84521 (Bearing installer set)

Rear Shock Absorber Adjustment

B947H12306006

After installing the rear suspension, adjust the spring pre-load and damping force as follows:

Spring Pre-load Adjustment

• The set length 179.3 mm (7.06 in) provides the maximum spring pre-load.

• The set length 189.3 mm (7.45 in) provides the minimum spring pre-load.

STD position

184.3 mm (7.26 in)

(A)

“ a ”

I947H1230015-02

“a”: 0.5 mm (0.02 in)

2) Apply grease to the bearing.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1230014-01

Damping Force Adjustment

NOTE

• Turn the adjuster clockwise to stiffen the damping force and turn it counterclockwise to soften the damping force.

• Fine-tune the adjusters by turning it slightly until two punch marks align.

Rebound side

Fully turn the rebound damping force adjuster (1) clockwise. From that position (stiffest), turn it out to standard setting position.

STD position

2-3/4 turns out from stiffest position

I947H1230016-01

3) Install the rear shock absorber. Refer to “Rear Shock

Absorber Removal and Installation” (Page 2C-3).

1

I947H1230017-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-6

Compression side (Low speed)

Fully turn the compression damping force (Low speed) adjuster (1) clockwise. From that position (stiffest), turn it out to standard setting position.

STD position

2-1/4 turns out of from stiffest position

1

Gas Pressure Release

Make sure to observe the following precautions:

!

WARNING

• Never apply heat or disassemble the damper unit since it can explode or oil can splash hazardously.

• When discarding the rear cushion unit, be sure to release gas pressure from the unit following the procedures.

1) Mark the drill center at the location “A” using a center punch.

I947H1230060-01

Compression side (High speed)

Fully turn the compression damping force (High speed) adjuster (1) clockwise. From that position (stiffest), turn it out to standard setting position.

STD position

3 turns out of from stiffest position

1

I947H1230018-02

Rear Shock Absorber Disposal

B947H12306007

Refer to “Rear Shock Absorber Removal and

Installation” (Page 2C-3).

The rear shock absorber unit contains high-pressure nitrogen gas.

!

WARNING

• 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.

“ a ”

“A”

“a”: 9 mm (0.35 in) “A”: Mark the drill hole

I823H1230009-01

2) Wrap rear shock absorber (1) with a plastic bag (2) and fix it on a vise as shown in the figure.

3) Drill a 2 – 3 mm (0.08 – 0.12 in) hole at the marked drill center using a drilling machine and let out gas while taking care not to get the plastic bag entangled with the drill bit.

!

WARNING

• Be sure to wear protective glasses since drilling chips and oil may fly off with blowing gas when the drill bit has penetrated through the body.

• Make sure to drill at the specified position.

Otherwise, pressurized oil many spout out forcefully.

1

2

I823H1230010-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-7 Rear Suspension:

Cushion Lever Removal and Installation

B947H12306008

Removal

1) Remove the right side cowling and side frame covers. Refer to “Exterior Parts Removal and

Installation” in Section 9D (Page 9D-6).

2) Support the motorcycle with a jack to relieve load on the cushion levers.

3) Remove the left muffler and muffler chamber heat guard No. 2. Refer to “Muffler / Muffler Chamber /

Exhaust Pipe Removal and Installation” in Section

1K (Page 1K-11).

4) Remove the rear shock absorber. Refer to “Rear

Shock Absorber Removal and Installation”

(Page 2C-3).

5) Remove the cushion levers (1).

• Install the rear shock absorber. Refer to “Rear Shock

Absorber Removal and Installation” (Page 2C-3).

• Install the muffler chamber heat guard No. 2 and left muffler. Refer to “Muffler / Muffler Chamber / Exhaust

Pipe Removal and Installation” in Section 1K

(Page 1K-11).

• Install the side frame covers and right side cowling.

Refer to “Exterior Parts Removal and Installation” in

Section 9D (Page 9D-6).

Cushion Lever Inspection

B947H12306009

Refer to “Cushion Lever Removal and Installation”

(Page 2C-7).

Cushion Lever

Inspect the cushion levers for damage. If any defects are found, replace the cushion levers with new ones.

1

I947H1230019-01

Installation

Install the cushion levers in the reverse order of removal.

Pay attention to the following point:

• Set the cushion levers so that the arrow mark “A” points forward.

• Install the washers (1) between the cushion rod and cushion levers.

• Tighten each nut to the specified torque.

Tightening torque

Cushion lever mounting nut (a): 98 N·m (9.8 kgfm, 71.0 lbf-ft)

Cushion rod rear mounting nut (b): 98 N·m (9.8 kgf-m, 71.0 lbf-ft)

I947H1230021-01

Cushion Rod Removal and Installation

B947H12306011

Removal

1) Remove the right side cowling and side frame covers. Refer to “Exterior Parts Removal and

Installation” in Section 9D (Page 9D-6).

2) Support the motorcycle with a jack to relieve load on the cushion rod.

3) Remove the muffler chamber. Refer to “Muffler /

Muffler Chamber / Exhaust Pipe Removal and

Installation” in Section 1K (Page 1K-11).

4) Remove the cushion rod (1) and washer.

(a)

“A”

1

(b)

I947H1230020-01 email: [email protected] / www.motomatrix.co.uk

1

I947H1230022-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-8

Installation

Install the cushion rod in the reverse order of removal.

Pay attention to the following points:

• Before installing the cushion rod to the frame, insert the collar into the bearing from the left side.

• Install the washer between the cushion rod right side and frame.

Cushion Rod Inspection

B947H12306012

Refer to “Cushion Rod Removal and Installation”

(Page 2C-7).

Collar and Spacer

1) Remove the collar and spacer from the cushion rod.

2) Inspect the collar and spacer for any flaws or other damage. If any defects are found, replace it with a new one.

“A”

I947H1230023-01

“A”: Forward

• Tighten each bolts and nuts to the specified torque.

Tightening torque

Cushion rod front mounting nut (a): 98 N·m (9.8 kgf-m, 71.0 lbf-ft)

Cushion rod rear mounting nut (b): 98 N·m (9.8 kgf-m, 71.0 lbf-ft)

I947H1230025-01

Cushion Rod Bearing

1) Insert the collar and spacer into bearing.

2) Check the play by moving the collar and spacer up and down. If excessive play is noted, replace the bearing with a new one. Refer to “Cushion Rod

Bearing Removal and Installation” (Page 2C-9).

(a)

(b)

I947H1230024-01

• Install the muffler chamber. Refer to “Muffler / Muffler

Chamber / Exhaust Pipe Removal and Installation” in

Section 1K (Page 1K-11).

• Install the side frame covers and right side cowling.

Refer to “Exterior Parts Removal and Installation” in

Section 9D (Page 9D-6).

I947H1230026-02

Cushion Rod

Inspect the cushion rod for damage. If any defects are found, replace the cushion rod with a new one.

I947H1230027-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-9 Rear Suspension:

Cushion Rod Bearing Removal and Installation

B947H12306013

Removal

1) Remove the cushion rod. Refer to “Cushion Rod

Removal and Installation” (Page 2C-7).

2) Remove the cushion rod bearing with the special tool.

Special tool

(A): 09921–20240 (Bearing remover set)

2) Apply grease to the bearings.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

(A)

I947H1230028-01

Installation

!

CAUTION

The removed bearings must be replaced with new ones.

1) Press the bearings into the cushion rod at 0.5 mm

(0.02 in) depth “a” from the cushion rod side surface with the special tool and suitable size socket wrench.

NOTE

When installing the bearing, apply a small quantity of the grease to housing.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

Special tool

(A): 09924–84521 (Bearing installer set)

I947H1230030-01

3) Install the cushion rod. Refer to “Cushion Rod

Bearing Removal and Installation” (Page 2C-9).

Swingarm Removal and Installation

B947H12306014

Removal

1) Cut the drive chain. Refer to “Drive Chain

Replacement” in Section 3A (Page 3A-7).

2) Remove the rear wheel assembly. Refer to “Rear

Wheel Assembly Removal and Installation” in

Section 2D (Page 2D-11).

3) Disconnect the rear brake hose from the brake hose clamp (1).

1

I947H1230031-01

4) Remove the brake hose clamp bolt (2).

5) Remove the rear brake caliper from the swingarm.

(A)

“ a ”

“a”: 0.5 mm (0.02 in)

I947H1230029-02

2

I947H1230032-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-10

6) Remove the left muffler and muffler chamber heat guard No. 2. Refer to “Muffler / Muffler Chamber /

Exhaust Pipe Removal and Installation” in Section

1K (Page 1K-11).

7) Remove the rear shock absorber (3) and cushion lever mounting bolt and nut (4). Refer to “Rear

Shock Absorber Removal and Installation”

(Page 2C-3) and “Cushion Lever Removal and

Installation” (Page 2C-7).

10) Remove the swingarm pivot shaft.

11) Remove the swingarm assembly.

12) Remove the mudguard (7), chain case (8) and chain buffer (9) from the swingarm.

7

8

3

4

9

13) Remove the plate (10).

I947H1230035-01

I947H1230058-02

Remove the swingarm pivot shaft lock-nut with the special tool.

Special tool

(A): 09940–14940 (Swingarm pivot thrust adjuster wrench)

(A)

I947H1230033-01

9) Hold the swingarm pivot shaft (5) with the special tool and remove the swingarm pivot nut (6).

Special tool

(B): 09944–28321 (Hexagon socket (19 mm))

10

I947H1230036-01

Installation

Install the swingarm in the reverse order of removal. Pay attention to the following points:

• Install the plate.

NOTE

When reusing the removed screw (1), apply a small quantity of the thread lock to it.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

5

(B)

6

1

I947H1230037-01

I947H1230034-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-11 Rear Suspension:

• Adjust swingarm pivot thrust clearance in the following procedures:

– Insert the swingarm pivot shaft (2) and tighten it to the specified torque with the special tool.

Special tool

(A): 09944–28321 (Hexagon socket (19 mm))

Tightening torque

Swingarm pivot shaft (a): 15 N·m (1.5 kgf-m,

11.0 lbf-ft)

– Tighten the swingarm pivot lock-nut (4) to the specified torque with the special tool.

Special tool

(B): 09940–14940 (Swingarm pivot thrust adjuster wrench)

Tightening torque

Swingarm pivot lock-nut (c): 90 N·m (9.0 kgfm, 65.0 lbf-ft)

2

(a)

4

(c)

(B)

(A)

I947H1230038-01

– Hold the swingarm pivot shaft with the special tool and tighten the swingarm pivot nut (3) to the specified torque.

Special tool

(A): 09944–28321 (Hexagon socket (19 mm))

Tightening torque

Swingarm pivot nut (b): 100 N·m (10.0 kgf-m,

72.5 lbf-ft)

I947H1230040-01

• Tighten the cushion lever, cushion rod and rear shock absorber mounting bolts and nuts to the specified torque.

Tightening torque

Rear shock absorber upper mounting nut (d): 50

N·m (5.0 kgf-m, 36.0 lbf-ft)

Rear shock absorber lower mounting nut (e): 50

N·m (5.0 kgf-m, 36.0 lbf-ft)

Cushion lever mounting nut (f): 98 N·m (9.8 kgfm, 71.0 lbf-ft)

3

(b)

(A)

(d)

I947H1230039-01

(e)

(f)

I947H1230041-01

I947H1230059-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-12

Swingarm Pivot Boss Removal and Installation

B947H12306018

Removal

1) Remove the swingarm. Refer to “Swingarm Removal and Installation” (Page 2C-9).

2) Remove the swingarm pivot boss nut (1).

NOTE

Remove the swingarm pivot boss only when replacing it.

• Tighten the swingarm boss nut (2) to the specified torque.

Tightening torque

Swingarm pivot boss nut (a): 65 N·m (6.5 kgf-m,

47.0 lbf-ft)

2

(a)

2

(a)

1

1

I947H1230042-01

3) Remove the swingarm pivot boss (2) by removing its set screws.

I947H1230045-01

Swingarm Related Parts Inspection

B947H12306015

Refer to “Swingarm Removal and Installation” (Page 2C-

9).

Spacers

1) Remove the collar and spacer from the swingarm.

2) Inspect the collars and spacer for wear and damage.

If any defects are found, replace them with new ones.

2

2

I947H1230043-01

Installation

Install the swingarm pivot boss in the reverse order of removal. Pay attention to the following points:

• Install the swingarm pivot boss (1).

I947H1230046-01

Chain Buffer

Inspect the chain buffer for wear and damage. If any defect is found, replace the chain buffer with a new one.

1

1

I947H1230044-01 email: [email protected] / www.motomatrix.co.uk

I947H1230047-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-13 Rear Suspension:

Plate

Inspect the plate for damage and excessive bend. If any defect is found, replace the plate with a new one.

Swingarm Pivot Shaft

Measure the swingarm pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft.

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

(C): 09900–21304 (V blocks)

Swingarm pivot shaft runout

Service limit: 0.3 mm (0.01 in)

(A)

I947H1230048-01

Swingarm Bearing

1) Insert the collars and spacer into bearings.

2) Check the play by moving the collars and spacer up and down. If excessive play is noted, replace the bearings with new ones. Refer to “Swingarm Bearing

Removal and Installation” (Page 2C-13).

(C)

(B)

I823H1230048-01

Swingarm Bearing Removal and Installation

B947H12306016

Removal

1) Remove the swingarm. Refer to “Swingarm Removal and Installation” (Page 2C-9).

2) Remove the swingarm pivot bearings (1) using the special tool.

Special tool

(A): 09921–20240 (Bearing remover set)

I947H1230049-01

Swingarm

Inspect the swingarm for damage. If any defect is found, replace the swingarm with a new one.

(A)

I947H1230050-01

1

3) Remove the center spacer (2).

2

I947H1230051-01

I947H1230052-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-14

4) Remove the cushion lever bearing (3) using the special tool.

Special tool

(A): 09921–20240 (Bearing remover set)

(A)

3) Press the cushion lever bearing into the swingarm to the depth “b” of 1.5 mm (0.06 in) from the edge with the special tool and suitable size socket wrench.

NOTE

Apply a small quantity of the grease to housing when installing the bearing.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

Special tool

(B): 09924–84521 (Bearing installer set)

3

I947H1230053-01

Installation

!

CAUTION

The removed bearings must be replaced with new ones.

1) Install the center spacer.

2) Press the pivot bearings into the swingarm pivot to the depth “a” of 0 – 0.5 mm (0 – 0.02 in) from the edge with the special tool and suitable size socket wrench.

NOTE

When installing the bearing, stamped mark on the bearing must face outside and apply a small quantity of the grease to housing.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

Special tool

(A): 09941–34513 (Bearing installer)

“ b ”

(B)

I947H1230055-02

“b”: 1.5 mm (0.06 in)

4) Apply grease to the bearings.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1230056-01

“ a ”

“a”: 0 – 0.5 mm (0 – 0.02 in)

(A)

I947H1230054-02

I947H1230057-01

5) Install the swingarm. Refer to “Swingarm Removal and Installation” (Page 2C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2C-15 Rear Suspension:

Service Data

Specifications

Suspension

Unit: mm (in)

Item

Rear shock absorber spring pre-set length

Rear shock absorber damping force adjuster

Rebound

Compression

Rear wheel travel

Swingarm pivot shaft runout

Standard

184.3 (7.26)

2-3/4 turns from stiffed position

Lo: 2-1/4 turns from stiffest position

Hi: 3 turns from stiffest position

130 (5.12)

—

B947H12307001

Limit

—

—

—

—

0.3 (0.01)

Tightening Torque Specifications

Fastening part

Rear shock absorber upper mounting nut

N

⋅

m

50

Tightening torque kgf-m lbf-ft

B947H12307002

Note

Rear shock absorber lower mounting nut

50

Cushion lever mounting nut

98

Cushion rod rear mounting nut

Cushion rod front mounting nut

Swingarm pivot shaft

Swingarm pivot nut

Swingarm pivot lock-nut

Swingarm pivot boss nut

98

98

15

100

90

65

9.8

1.5

10.0

9.0

6.5

71.0

11.0

72.5

65.0

47.0

)

(Page 2C-8)

)

(Page 2C-11)

)

(Page 2C-11)

)

(Page 2C-11)

)

(Page 2C-12)

NOTE

The specified tightening torque is described in the following.

“Rear Suspension Components” (Page 2C-1)

“Rear Suspension Assembly Construction” (Page 2C-2)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Suspension: 2C-16

Special Tools and Equipment

Recommended Service Material

Grease

Material

Thread lock cement

B947H12308001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or equivalent

THREAD LOCK CEMENT SUPER

Note

P/No.: 99000–25010

)

(Page 2C-5) /

)

(Page 2C-

5) /

)

(Page 2C-9) /

)

(Page 2C-9) /

)

(Page 2C-

14) /

)

(Page 2C-14) /

)

(Page 2C-14)

P/No.: 99000–32110

)

(Page 2C-10)

“1322” or equivalent

NOTE

Required service material is also described in the following.

“Rear Suspension Components” (Page 2C-1)

“Rear Suspension Assembly Construction” (Page 2C-2)

Special Tool

09900–20607

Dial gauge

)

(Page 2C-13)

09900–20701

Dial gauge chuck

)

(Page 2C-13)

B947H12308002

09900–21304

V blocks

)

(Page 2C-13)

09924–84521

Bearing installer set

)

(Page 2C-5) /

)

(Page 2C-

9) /

)

(Page 2C-14)

09941–34513

Bearing installer

)

(Page 2C-14)

09944–28321

Hexagon socket (19 mm)

)

(Page 2C-10) /

)

(Page 2C-11) /

)

(Page 2C-11)

09921–20240

Bearing remover set

)

(Page 2C-9) /

)

(Page 2C-

13) /

)

(Page 2C-14)

09940–14940

Swingarm pivot thrust adjuster wrench

)

(Page 2C-10) /

)

(Page 2C-11)

09943–88211

Pinion bearing installer

)

(Page 2C-4) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-1 Wheels and Tires:

Suspension

Wheels and Tires

Precautions

Precautions for Wheel and Tire

!

WARNING

B947H12400001

• Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control.

• Under-inflated tires make smooth cornering difficult, and can result in rapid tire wear.

• Over-inflated tires have a smaller amount of tire in contact with the load, which can contribute to skidding and loss of control.

• Replace the wheel when wheel runout exceed the service limit or if find damage such as distortion, crack, nick or scratch.

• When tire replacement is necessary, the original equipment type tire should be used.

• Do not mix different types of tires on the same vehicle such as radial and bias-belted tires except in emergencies, because handling may be seriously affected and may result in loss of control.

• Replacement wheel must be equivalent to the original equivalent wheel.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-2

Repair Instructions

Front Wheel Components

B947H12406001

3

12

(b)

2

(a)

4

5

11

10

9

3

6

5

4

2

(a)

7

8

1. Front axle

2. Brake disc bolt

3. Brake disc

4. Dust seal

5. Bearing

6. Spacer

7. Air valve

8. Front wheel

9. Wheel balancer

10. Front tire

11. Collar

12. Front axle bolt

: 18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft)

: 100 N

⋅ m (10.0 kgf-m, 72.5 lbf-ft)

: Apply grease.

1

I947H1240030-01

: Apply thread lock to the thread part.

: Do not reuse.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-3 Wheels and Tires:

Front Wheel Assembly Construction

LH RH

B947H12406002

2

(b)

4

(d)

1

(a)

“ a ”

4

(d)

1

(a)

3

(c)

1. Brake disc bolt

2. Brake caliper mounting bolt

3. Front axle bolt

4. Front axle pinch bolt

“a”: Clearance

: 18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft)

: 39 N

⋅ m (3.9 kgf-m, 28.0 lbf-ft)

: 100 N

⋅ m (10 kgf-m, 72.5 lbf-ft)

I947H1240031-02

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: Apply grease.

: Apply thread lock to the thread part.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-4

Front Wheel Assembly Removal and Installation

B947H12406003

Removal

1) Remove the brake calipers, left and right.

!

CAUTION

Do not operate the brake lever with the caliper removed.

7) Remove the collar (5) (RH only).

NOTE

After removing the front wheel, fit the calipers temporarily to the original positions.

4

3

5

I947H1240001-01

2) Loosen two axle pinch bolts (1) on the right front fork leg.

3) Remove the front axle bolt (2).

I947H1240003-01

Installation

1) Install the collar (1) to the right side of the wheel.

1

2

1

I947H1240002-01

4) Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block.

!

CAUTION

Do not carry out the work with the motorcycle resting on the side-stand. Do not support the motorcycle with the exhaust pipes. Make sure that the motorcycle is supported securely.

5) Loosen two axle pinch bolts (3) on the left front fork leg.

6) Draw out the front axle (4) and remove the front wheel.

I947H1240004-01

!

WARNING

The directional arrow on the tire should point to the wheel rotation.

I947H1240005-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-5 Wheels and Tires:

2) Insert the front axle from the left side and tighten the front axle bolt temporarily.

3) Tighten the brake caliper mounting bolts (2) to the specified torque.

Tightening torque

Front brake caliper mounting bolt (a): 39 N·m (

3.9 kgf-m, 28.0 lbf-ft)

!

WARNING

After remounting the brake calipers, pump the brake lever until the pistons push the pads correctly.

5) Tighten two axle pinch bolts (4) on the right fork leg to the specified torque.

Tightening torque

Front axle pinch bolt (c): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

(A)

3

(b)

4

(c)

2

(a)

2

(a)

I947H1240027-02

6) Move the front forks up and down 4 or 5 times.

I947H1240006-01

4) Hold the front axle with the special tool and tighten the front axle bolt (3) to the specified torque.

Special tool

(A): 09900–18740 (Hexagon socket (24 mm))

Tightening torque

Front axle bolt (b): 100 N·m (10.0 kgf-m, 72.5 lbfft)

I947H1240007-01

7) Tighten two axle pinch bolts (5) on the left front fork leg to the specified torque.

Tightening torque

Front axle pinch bolt (d): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

5

(d)

I947H1240028-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-6

Front Wheel Related Parts Inspection

B947H12406004

Refer to “Front Wheel Assembly Removal and

Installation” (Page 2D-4).

Tire

Refer to “Tire Inspection” in Section 0B (Page 0B-18).

Front Brake Disc

Refer to “Front Brake Disc Inspection” in Section 4B

(Page 4B-6).

Dust Seal

Inspect the lip of dust seals for wear or damage. If any defects are found, replace the dust seal with a new one.

Refer to “Front Wheel Dust Seal / Bearing Removal and

Installation” (Page 2D-7).

Wheel

1) Remove the brake pads. Refer to “Front Brake Pad

Replacement” in Section 4B (Page 4B-2).

2) Make sure that the wheel runout checked as shown in the figure does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

Wheel rim runout

Service limit (Axial and Radial): 2.0 mm (0.08 in)

I947H1240008-02

Wheel Axle

Using a dial gauge, check the wheel axle for runout. If the runout exceeds the limit, replace the axle shaft.

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

(C): 09900–21304 (V blocks)

Wheel axle runout

Service limit: 0.25 mm (0.010 in)

I649G1240014-02

3) Install the brake pads. Refer to “Front Brake Pad

Replacement” in Section 4B (Page 4B-2).

Wheel Bearing

Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer to “Front

Wheel Dust Seal / Bearing Removal and Installation”

(Page 2D-7).

I649G1240015-02

(A)

(B)

(C)

I649G1240054-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-7 Wheels and Tires:

Front Wheel Dust Seal / Bearing Removal and

Installation

B947H12406005

4) Remove the spacer (1).

Removal

1) Remove the front wheel assembly. Refer to “Front

Wheel Assembly Removal and Installation”

(Page 2D-4).

2) Remove the dust seals using the special tool.

Special tool

(A): 09913–50121 (Oil seal remover)

1

(A)

I947H1240011-01

Installation

!

CAUTION

The removed dust seals and bearings must be replaced with new ones.

1) Apply grease to the wheel bearings.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1240009-01

3) Remove the wheel bearings using the special tool.

Special tool

(B): 09921–20240 (Bearing remover set)

(B)

I649G1240019-02

I947H1240010-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-8

2) First install the right wheel bearing, then install the spacer (1) and left wheel bearing with the special tool.

Special tool

(A): 09924–84510 (Bearing installer set)

(B): 09941–34513 (Bearing installer)

!

CAUTION

The sealed cover of the bearing must face outside.

3) Install the dust seals with the special tool.

Special tool

(C): 09913–70210 (Bearing installing set (10

– 75

Φ

))

(C)

(B)

(A)

I947H1240012-01

4) Apply grease to the lip of dust seals.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I837H1240014-01

LH RH

(B)

(A)

I947H1240013-01

5) Install the front wheel assembly. Refer to“Front

Wheel Assembly Removal and Installation”

(Page 2D-4).

“ a ”

(B)

(A)

1. Spacer

1

“a”: Clearance

I837H1240037-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-9 Wheels and Tires:

Rear Wheel Components

(b)

18

17

B947H12406006

15

9

16

13

1. Rear axel nut

2. Collar

3. Dust seal

4. Bearing

5. Retainer

6. Rear sprocket

7. Sprocket mounting drum

8. Wheel damper

9. Bearing

10. Spacer

11. Air valve

12. Rear wheel

13. Wheel balancer

14. Rear tire

15. Dust seal

16. Collar email: [email protected] / www.motomatrix.co.uk

11

12

10

9

14

7

6

8

(c)

5

4

3

2

1

(a)

17. Rear brake disc

18. Rear axle

: 100 N

⋅ m (10.0 kgf-m, 72.5 lbf-ft)

: 35 N

⋅ m (3.5 kgf-m, 25.5 lbf-ft)

: 60 N

⋅ m (6.0 kgf-m, 43.0 lbf-ft)

: Apply grease.

: Apply thread lock to the thread part.

: Do not reuse.

I947H1240033-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-10

Rear Wheel Assembly Construction

B947H12406007

LH RH

1

(a)

3

(c)

“ a ”

2

(b)

1. Rear sprocket nut

2. Rear axle nut

3. Brake disc bolt

“a”: Clearance

: 60 N

⋅ m (6.0 kgf-m, 43.0 lbf-ft)

: 100 N

⋅ m (10 kgf-m, 72.5 lbf-ft)

I947H1240034-02

: 35 N

⋅ m (3.5 kgf-m, 25.5 lbf-ft)

: Apply grease.

: Apply thread lock to the thread part.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-11 Wheels and Tires:

Rear Wheel Assembly Removal and Installation

B947H12406008

7) Remove the collars (5) and (6).

Removal

1) Loosen the axle nut (1).

2) Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block.

!

CAUTION

Make sure that the motorcycle is supported securely.

3) Remove the axle nut (1).

4) Loosen the left and right lock-nuts (2) and turn in the adjuster bolts (3).

5) Draw out the rear axle.

5

Installation

1) Install the collars (1) and (2).

6

I947H1240017-02

1

2

3

1

2

I947H1240014-02

6) Remove the rear wheel by disengaging the drive chain.

!

CAUTION

Do not operate the rear brake pedal with the rear wheel removed.

I947H1240026-02

2) Remount the rear wheel and rear axle, tighten the rear axle nut (3) temporarily.

3) Adjust the chain slack after installing the rear wheel.

Refer to “Drive Chain Inspection and Adjustment” in

Section 0B (Page 0B-14).

4) Tighten the rear axle nut (3) to the specified torque.

Tightening torque

Rear axle nut (a): 100 N·m (10.0 kgf-m, 72.5 lbfft)

!

WARNING

After remounting the rear wheel, pump the brake pedal several times to check for proper brake operation.

5) Tighten both chain adjuster lock-nut (4) securely.

I947H1240015-01

4

3

(a)

I838H1240002-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-12

Rear Wheel Related Parts Inspection

B947H12406009

Refer to “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

(A)

Tire

Refer to “Tire Inspection” in Section 0B (Page 0B-18).

(B)

Rear Brake Disc

Refer to “Rear Brake Disc Inspection” in Section 4C

(Page 4C-7).

Wheel Damper

Refer to “Drive Chain Related Parts Inspection” in

Section 3A (Page 3A-5).

Sprocket

Refer to “Drive Chain Related Components” in Section

3A (Page 3A-1).

Dust Seal

Inspect the dust seal lip for wear or damage. If any defects is found, replace the dust seal with a new one.

Refer to “Rear Wheel Dust Seal / Bearing Removal and

Installation” (Page 2D-13).

(C)

I649G1230034-03

Wheel

1) Remove the rear brake pads. Refer to “Rear Brake

Pad Replacement” in Section 4C (Page 4C-2).

2) Make sure that the wheel runout checked as shown in the figure does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

Wheel rim runout

Service limit (Axial and Radial): 2.0 mm (0.08 in)

I947H1240018-02

Wheel Axle

Using a dial gauge, check the wheel axle for runout, If the runout exceeds the limit, replace the axle shaft.

Wheel axle runout

Service limit: 0.25 mm (0.010 in)

Special tool

(A): 09900–20607 (Dial gauge)

(B): 09900–20701 (Dial gauge chuck)

(C): 09900–21304 (V blocks)

I649G1240014-02

3) Install the rear brake pads. Refer to “Rear Brake Pad

Replacement” in Section 4C (Page 4C-2).

Bearing

Inspect the play of the wheel bearings by hand while they are in the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer to “Rear

Wheel Dust Seal / Bearing Removal and Installation”

(Page 2D-13).

I649G1240015-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-13 Wheels and Tires:

Rear Wheel Dust Seal / Bearing Removal and

Installation

B947H12406010

Removal

1) Remove the rear wheel assembly. Refer to “Rear

Wheel Assembly Removal and Installation”

(Page 2D-11).

2) Remove the rear sprocket mounting drum assembly

(1) from the rear wheel.

5) Remove the bearings on both sides using the special tool.

Special tool

(B): 09921–20240 (Bearing remover set)

(B)

(B)

I947H1240022-01

3) Remove the wheel dampers (2).

1

I947H1240019-01

6) Remove the spacer (3).

3

2

2

I947H1240020-02

4) Remove the dust seal.

Special tool

(A): 09913–50121 (Oil seal remover)

I947H1240023-01

Installation

!

CAUTION

The removed dust seal and bearings must be replaced with new ones.

1) Apply grease to the wheel bearings.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

(A)

I947H1240021-01 email: [email protected] / www.motomatrix.co.uk

I649G1240019-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-14

2) First install the right wheel bearing, then install the spacer (1) and left wheel bearing with the special tools.

Special tool

(A): 09941–34513 (Bearing installer)

(B): 09924–84510 (Bearing installer set)

!

CAUTION

The sealed cover of the bearing must face outside.

3) Install new dust seal with the special tool.

Special tool

(C): 09913–70210 (Bearing installing set (10

– 75

Φ

))

(C)

(A)

(B)

I649G1240030-02

4) Install the rear sprocket mounting drum assembly

(2).

5) Apply grease to the lip of dust seals.

I947H1240024-01

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

LH RH

(B)

(A)

(B)

(A)

1. Spacer

“ a ”

1

“a”: Clearance

I947H1240032-01

2

I947H1240025-03

6) Install the rear wheel assembly. Refer to “Rear

Wheel Assembly Removal and Installation”

(Page 2D-11).

Tire Removal and Installation

B947H12406011

Removal

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

1) Removal the wheel assembly. Refer to “Front Wheel

Assembly Removal and Installation” (Page 2D-4) and “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

2) Remove the mounting drum from the rear wheel.

(For rear wheel)

Refer to “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

3) Remove the valve core.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-15 Wheels and Tires:

4) Remove the tire using the tire changer.

!

CAUTION

For operating procedures, refer to the instructions supplied by the tire changer manufacturer.

NOTE

When removing the tire in case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the valve position. Even though the tire is refitted to the original position after repairing puncture, the tire may have to be balanced again since such a repair can cause imbalance.

2) Install the tire onto the wheel.

!

CAUTION

For installation procedure of tire onto the wheel, follow the instructions given by the tire changer manufacturer.

NOTE

• When installing the tire, the arrow “A” on the side wall should point to the direction of wheel rotation.

• Align the chalk mark put on the tire at the time of removal with the valve position.

I649G1240037-02

Installation

!

CAUTION

Do not reuse the valve which has been once removed.

1) Apply tire lubricant to the tire bead.

!

CAUTION

Never use oil, grease or gasoline on the tire bead in place of tire lubricant.

“A”

3) Bounce the tire several times while rotating. This makes the tire bead expand outward to contact the wheel, thereby facilitating air inflation.

4) Install the valve core and inflate the tire.

I649G1240039-02

!

WARNING

• Do not inflate the tire to more than 400 kPa

(4.0 kgf/cm

2

, 57 psi). If inflated beyond this limit, the tire can burst and possibly cause injury. Do not stand directly over the tire while inflating.

• In the case of preset pressure air inflator, pay special care for the set pressure adjustment.

5) In this condition, check the “rim line” “B” cast on the tire side walls. The line must be equidistant from the wheel rim all around.

6) 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. Coat the bead with lubricant and fit the tire again.

I649G1240038-02

“B”

I649G1240040-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-16

7) When the bead has been fitted properly, adjust the pressure to specification.

As necessary, adjust the tire balance. Refer to

“Wheel Balance Check and Adjustment” (Page 2D-

17).

Cold inflation tire pressure

Solo riding

Dual riding

Front

250 kPa

(2.50 kgf/cm

2

, 36 psi)

250 kPa

(2.50 kgf/cm

2

, 36 psi)

Rear

290 kPa

(2.90 kgf/cm

2

, 42 psi)

290 kPa

(2.90 kgf/cm

2

, 42 psi)

9) Install the mounting drum to the rear wheel.

(For rear wheel)

Refer to “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

10) Install the wheel assembly. Refer to “Front Wheel

Assembly Removal and Installation” (Page 2D-4) and “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

I649G1240042-02

I649G1240043-02

Wheel / Tire / Air Valve Inspection and Cleaning

B947H12406012

Refer to “Tire Removal and Installation” (Page 2D-14).

Air Valve

Inspect the air valve for peeling and damage. If any defect is found, replace the air valve with a new one.

Refer to “Air Valve Removal and Installation” (Page 2D-

16).

Wheel

Wipe the wheel clean and check for the following points:

• Distortion and crack

• Any flaws and scratches at the bead seating area.

• Wheel rim runout. Refer to “Front Wheel Related

Parts Inspection” (Page 2D-6) and “Rear Wheel

Related Parts Inspection” (Page 2D-12).

I649G1240044-02

Inspect the valve core seal (1) for wear and damage. If any defect is found, replace the valve core with a new one. Refer to “Air Valve Removal and Installation”

(Page 2D-16).

1

I649G1240041-02

Tire

Tire must be checked for the following points:

• Nick and rupture on side wall

• Tire tread depth (Refer to “Tire Inspection” in Section

0B (Page 0B-18).)

• Tread separation

• Abnormal, uneven wear on tread

• Surface damage on bead

• Localized tread wear due to skidding (Flat spot)

• Abnormal condition of inner liner email: [email protected] / www.motomatrix.co.uk

I649G1240045-02

1. Seal

Air Valve Removal and Installation

B947H12406013

Removal

1) Remove the wheel assembly. Refer to “Front Wheel

Assembly Removal and Installation” (Page 2D-4) and “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

2) Remove the tire. Refer to “Tire Removal and

Installation” (Page 2D-14).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-17 Wheels and Tires:

3) Remove the air valve (1) from the wheel.

1

Installation

Install the air valve in the reverse order of removal. Pay attention to the following points:

• Any dust or rust around the valve hole (1) must be cleaned off.

1

I837H1240031-01

Wheel Balance Check and Adjustment

B947H12406014

Check and adjust the wheel balance in the following procedures:

1) Removal the wheel assembly. Refer to “Front Wheel

Assembly Removal and Installation” (Page 2D-4) and “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

2) Remove the mounting drum from the rear wheel.

(For rear wheel)

Refer to “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

3) Check the wheel balance using the balancer and adjust the wheel balance if necessary.

!

CAUTION

For operating procedures, refer to the instructions supplied by the wheel balancer manufacturer.

4) When installing the balancer weight to the wheel, set the balancer weight on center rib of the wheel.

I837H1240032-01

• Install the air valve (2) in the wheel (3).

!

CAUTION

• Be careful not to damage the valve lip (4) of the valve.

• Replace the air valve with a new one.

NOTE

To properly install the valve into the valve hole, apply a special tire lubricant or neutral soapy liquid to the valve.

3

I947H1240029-01

5) Recheck the wheel balance.

6) Install the mounting drum to the rear wheel. (For rear wheel)

Refer to “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

7) Install the wheel assembly. Refer to “Front Wheel

Assembly Removal and Installation” (Page 2D-4) and “Rear Wheel Assembly Removal and

Installation” (Page 2D-11).

2. Valve

4

3. Wheel

2

I837H1240033-01

4. Valve lip email: [email protected] / www.motomatrix.co.uk

Service Data

Wheel

Unit: mm (in)

Item

Wheel rim runout

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wheels and Tires: 2D-18

Specifications

B947H12407001

Wheel rim size

Wheel axle runout

Axial

Radial

Front

Rear

Front

Rear

Standard

—

17 M/C x MT 3.50

17 M/C x MT 6.00

—

Limit

2.0 (0.08)

—

—

0.25 (0.010)

Tire

Item

Cold inflation tire pressure

(Solo riding)

Cold inflation tire pressure

(Dual riding)

Tire size

Tire type

Tire tread depth

(Recommended depth)

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Standard

250 kPa (2.50 kgf/cm 2 , 36 psi)

290 kPa (2.90 kgf/cm 2 , 42 psi)

250 kPa (2.50 kgf/cm 2 , 36 psi)

290 kPa (2.90 kgf/cm 2 , 42 psi)

120/70 ZR17M/C (58 W)

190/50 ZR17M/C (73 W)

BRIDGESTONE BT016F N

BRIDGESTONE BT016R N

—

—

Limit

—

—

—

—

—

—

—

—

1.6 mm (0.06 in)

2.0 mm (0.08 in)

Tightening Torque Specifications

Fastening part

Front brake caliper mounting bolt

Front axle bolt

Front axle pinch bolt

N

⋅

m

39

100

23

100

Tightening torque kgf-m

3.9

10.0

lbf-ft

28.0

72.5

B947H12407002

Note

)

(Page 2D-5)

)

(Page 2D-5)

Rear axle nut 10.0 72.5

)

(Page 2D-11)

NOTE

The specified tightening torque is described in the following.

“Front Wheel Components” (Page 2D-2)

“Front Wheel Assembly Construction” (Page 2D-3)

“Rear Wheel Components” (Page 2D-9)

“Rear Wheel Assembly Construction” (Page 2D-10)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

2D-19 Wheels and Tires:

Special Tools and Equipment

Recommended Service Material

Grease

Material

B947H12408001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or equivalent

Note

P/No.: 99000–25010

)

(Page 2D-7) /

)

(Page 2D-

/

)

(Page 2D-13) /

)

(Page 2D-14)

NOTE

Required service material is also described in the following.

“Front Wheel Components” (Page 2D-2)

“Front Wheel Assembly Construction” (Page 2D-3)

“Rear Wheel Components” (Page 2D-9)

“Rear Wheel Assembly Construction” (Page 2D-10)

Special Tool

09900–18740

Hexagon socket (24 mm)

)

(Page 2D-5)

09900–20607

Dial gauge

)

(Page 2D-6) /

)

(Page 2D-

12)

B947H12408002

09900–20701

Dial gauge chuck

)

(Page 2D-6) /

)

(Page 2D-

12)

09913–50121

Oil seal remover

)

(Page 2D-7) /

)

(Page 2D-

13)

09921–20240

Bearing remover set

)

(Page 2D-7) /

)

(Page 2D-

13)

09900–21304

V blocks

)

(Page 2D-6) /

)

(Page 2D-

12)

09913–70210

Bearing installing set (10 –

75

Φ

)

)

(Page 2D-8) /

)

(Page 2D-

14)

09924–84510

Bearing installer set

)

(Page 2D-8) /

)

(Page 2D-

14)

09941–34513

Bearing installer

)

(Page 2D-8) /

)

(Page 2D-

14) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 3- i

Section 3

Driveline / Axle

CONTENTS

Precautions ………………………………………….3-1

Precautions……………………………………………………. 3-1

Precautions for Driveline / Axle ……………………….. 3-1

Drive Chain / Drive Train / Drive Shaft… 3A-1

Diagnostic Information and Procedures…………3A-1

Drive Chain and Sprocket Symptom

Diagnosis …………………………………………………. 3A-1

Repair Instructions ……………………………………….3A-1

Drive Chain Related Components………………….. 3A-1

Engine Sprocket Removal and Installation ……… 3A-2

Rear Sprocket / Rear Sprocket Mounting

Drum Removal and Installation …………………….3A-3

Drive Chain Related Parts Inspection ……………..3A-5

Sprocket Mounting Drum Dust Seal / Bearing

Removal and Installation……………………………..3A-5

Drive Chain Replacement ……………………………..3A-7

Specifications ……………………………………………..3A-10

Service Data………………………………………………3A-10

Tightening Torque Specifications………………….3A-10

Special Tools and Equipment ………………………3A-11

Recommended Service Material …………………..3A-11

Special Tool ………………………………………………3A-11

3

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3-1 Precautions:

Driveline / Axle

Precautions

Precautions

Precautions for Driveline / Axle

Refer to “General Precautions” in Section 00 (Page 00-1).

!

WARNING

Never inspect or adjust the drive chain while the engine is running.

!

CAUTION

B947H13000001

• Do not use trichloroethylene, gasoline or such similar solvent. These fluids will damage the O-rings of the drive chain.

• Clean the drive chain with a spray-type chain cleaner and blow dry with compressed air. If the drive chain cannot be cleaned with a spray cleaner, it may be necessary to use a kerosine. Always follow the chemical manufacturer’s instructions on proper use, handling and storage.

• Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant.

Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings.

• The standard drive chain is DID 50VAZ. Suzuki recommends to use this standard drive chain as a replacement.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Drive Chain / Drive Train / Drive Shaft: 3A-1

Driveline / Axle

Drive Chain / Drive Train / Drive Shaft

Diagnostic Information and Procedures

Drive Chain and Sprocket Symptom Diagnosis

Condition

Noisy Drive Chain

Possible cause

Worn sprocket.

Worn drive chain.

Stretched drive chain.

Too large drive chain slack.

Drive chain out of adjustment.

B947H13104001

Replace.

Correction / Reference Item

Replace.

Replace.

Adjust.

Adjust.

Repair Instructions

Drive Chain Related Components

B947H13106001

7

3

(b)

2

8

5

4

1. Drive chain

2. Engine sprocket

3. Rear sprocket

4. Dust seal

5. Bearing

(a)

1

6. Retainer

7. Sprocket mounting drum

8. Wheel damper

: 145 N

⋅ m (14.5 kgf-m, 105.0 lbf-ft)

: 60 N

⋅ m (6.0 kgf-m, 43.0 lbf-ft) email: [email protected] / www.motomatrix.co.uk

6

: Apply grease.

: Apply thread lock to thread part.

: Do not reuse.

I947H1310028-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3A-2 Drive Chain / Drive Train / Drive Shaft:

Engine Sprocket Removal and Installation

B947H13106002

7) Remove the speed sensor rotor (7) by removing its bolt while depressing the rear brake pedal.

Removal

1) Remove the gearshift link arm (1) from the gearshift shaft.

NOTE

Mark the gearshift shaft head at which the gearshift link arm slit set for correct reinstallation.

7

1

I947H1310021-01

Remove the engine sprocket nut (8) while depressing the rear brake pedal.

8

2) Remove the speed sensor (2).

3) Remove the engine sprocket cover (3).

I947H1310018-01

I947H1310022-01

9) Remove the washer (9).

10) Remove the engine sprocket (10).

3

2

9

I947H1310019-01

4) Support the motorcycle with a jack or wooden block.

5) Loosen the rear axle nut (4) and left and right chain adjuster lock-nuts (5).

6) Loosen the chain adjusters (6) to provide additional chain slack.

5

4

10

I947H1310023-01

Installation

Install the engine sprocket in the reverse order of removal. Pay attention to the following points:

• Apply thread lock to the driveshaft.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

6

I947H1310020-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Drive Chain / Drive Train / Drive Shaft: 3A-3

• Tighten the engine sprocket nut (1) to the specified torque.

Tightening torque

Engine sprocket nut (a): 145 N·m (14.5 kgf-m,

105.0 lbf-ft)

• Fit the gearshift link arm to the gearshift shaft so that the gearshift lever is located at height “a” below the footrest.

Gearshift lever height “a”

Standard: 65 – 75 mm (2.6 – 3.0 in)

“ a ”

1

(a)

I947H1310024-01

• Tighten the speed sensor rotor bolt (2) to the specified torque.

Tightening torque

Speed sensor rotor bolt (b): 28 N·m (2.8 kgf-m,

20.0 lbf-ft)

• Before installing the engine sprocket cover, apply a small quantity of grease to the clutch push rod.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1310001-01

• Adjust the drive chain slack. Refer to “Drive Chain

Inspection and Adjustment” in Section 0B (Page 0B-

14).

Rear Sprocket / Rear Sprocket Mounting Drum

Removal and Installation

B947H13106003

Removal

1) Remove the rear wheel assembly. Refer to “Rear

Wheel Assembly Removal and Installation” in

Section 2D (Page 2D-11).

2) Loosen the rear sprocket nuts.

3) Draw out the rear sprocket mounting drum (1) along with the rear sprocket (2) from the wheel hub.

4) Remove the rear sprocket nuts and separate the rear sprocket (2) from its mounting drum (1).

2

(b)

I947H1310025-01

• Install the engine sprocket cover (3).

• Tighten the speed sensor mounting bolt (4) to the specified torque.

Tightening torque

Speed sensor mounting bolt (c): 6.5 N·m (0.65 kgf-m, 4.5 lbf-ft)

1

2

I947H1310002-01

3

4

(c)

I947H1310026-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3A-4 Drive Chain / Drive Train / Drive Shaft:

5) Remove the retainer (3).

3

• Apply grease to the retainer.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

6) Remove the wheel dampers (4).

I947H1310003-01

4

4

I947H1310006-01

• Install the rear sprocket so that the letters “B” face outside.

“B”

I947H1310004-01

Installation

Install the rear sprocket and rear sprocket mounting drum in the reverse order of removal. Pay attention to the following points:

• Apply grease to the contacting surface between the rear wheel hub and rear sprocket mounting drum.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Apply special tire lubricant or neutral soapy liquid to the wheel damper surfaces “A”.

!

CAUTION

Never use oil, grease or gasoline on the wheel damper in place of the tire lubricant or neutral soapy liquid.

I947H1310007-01

• Tighten the rear sprocket nuts to the specified torque.

Tightening torque

Rear sprocket nut (a): 60 N·m (6.0 kgf-m, 43.0 lbfft)

(a)

I947H1310008-01

• Install the rear wheel assembly. Refer to “Rear Wheel

Assembly Removal and Installation” in Section 2D

(Page 2D-11).

“A”

I947H1310005-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Drive Chain / Drive Train / Drive Shaft: 3A-5

Drive Chain Related Parts Inspection

B947H13106004

Refer to “Rear Sprocket / Rear Sprocket Mounting Drum

Removal and Installation” (Page 3A-3).

Wheel Damper

Inspect the dampers for wear and damage. Replace the dampers if there is anything unusual.

Dust Seal

Inspect the dust seal for wear or damage. If any damage is found, replace the dust seal with a new one.

I947H1310009-01

Bearing

Inspect the play of the sprocket mounting drum bearing by hand while it is in the drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.

Replace the bearing if there is anything unusual.

I947H1310011-01

Drive Chain

Refer to “Drive Chain Inspection and Adjustment” in

Section 0B (Page 0B-14).

Sprocket Mounting Drum Dust Seal / Bearing

Removal and Installation

B947H13106005

Removal

1) Remove the rear wheel assembly. Refer to “Rear

Wheel Assembly Removal and Installation” in

Section 2D (Page 2D-11).

2) Remove the rear sprocket mounting drum assembly

(1). Refer to “Rear Sprocket / Rear Sprocket

Mounting Drum Removal and Installation” (Page 3A-

3).

I649G1310015-02

Engine Sprocket and Rear Sprocket

Inspect the sprocket teeth for wear. If they are worn as shown, replace the engine sprocket, rear sprocket and drive chain as a set.

1

“A”

“A”: Normal wear

“B”

“B”: Excessive wear

I947H1310010-01

3) Remove the retainer (2).

2

I947H1310012-01

I947H1310013-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3A-6 Drive Chain / Drive Train / Drive Shaft:

4) Remove the sprocket mounting drum dust seal with the special tool.

Special tool

(A): 09913–50121 (Oil seal remover)

(A)

2) Install the bearing and dust seal to the sprocket mounting drum with the special tools.

!

CAUTION

The sealed cover of the bearing must face wheel hub side.

Special tool

(A): 09924–84510 (Bearing installer set)

(B): 09913–70210 (Bearing installing set (10

– 75

Φ

))

(B)

(A)

I947H1310014-01

5) Remove the sprocket mounting drum bearing with the special tool.

Special tool

(B): 09921–20240 (Bearing remover set)

(B) I947H1310016-01

3) Apply grease to the retainer.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1310015-01

Installation

!

CAUTION

The removed dust seal and bearing must be replaced with new ones.

1) Apply grease to the bearing before installing.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1310017-01

4) Install the rear sprocket mounting drum assembly to rear wheel hub. Refer to “Rear Sprocket / Rear

Sprocket Mounting Drum Removal and Installation”

(Page 3A-3).

5) Install the rear wheel assembly. Refer to “Rear

Wheel Assembly Removal and Installation” in

Section 2D (Page 2D-11).

I649G1310020-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Drive Chain / Drive Train / Drive Shaft: 3A-7

Drive Chain Replacement

B947H13106006

Use the special tool in the following procedures, to cut and rejoin the drive chain.

NOTE

When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.

Special tool

: 09922–22711 (Drive chain cutting and joint tool set)

NOTE

The tip of pin remover (7) should be positioned inside “a” approximately 5 mm

(0.2 in) from the end face of pressure bolt [A]

(3) as shown in the figure.

“ a ”

I649G1310023-02

Drive Chain Cutting

1) Set up the special tool as shown in the figure.

1

6

8

7

3

4

2

5

3

7

I837H1310026-02

“a”: 5 mm (0.2 in)

2) Place the drive chain link being disjointed on the chain holder (8) of the tool.

3) Turn in both the adjuster bolt (6) and pressure bolt

[A] (3) so that each of their end hole fits over the chain joint pin properly.

4) Tighten the pressure bolt [A] (3) with the bar.

3

6

8

I649G1310024-02

1. Tool body

2. Grip handle

3. Pressure bolt [A]

4. Pressure bolt [B]

5. Bar

6. Adjuster bolt (With through hole)

7. Pin remover

8. Chain holder (Engraved mark 500) with reamer bolt M5 x 10

I837H1310027-02

5) Turn in the pressure bolt [B] (4) with the bar (5) and force out the drive chain joint pin (9).

!

CAUTION

Continue turning in the pressure bolt [B] (4) until the joint pin should been completely pushed out of the chain.

NOTE

After the joint pin (9) is removed, loosen the pressure bolt [B] (4) and then pressure bolt

[A] (3).

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3A-8 Drive Chain / Drive Train / Drive Shaft:

6) Remove the joint pin (9) of the other side of joint plate.

!

CAUTION

Never reuse joint pins, O-rings and plates.

4

5

2) Apply grease to the joint pins (8), O-rings (9) and plates (10).

!

CAUTION

Replace the joint pins (8), O-rings (9) and plates (10) with new ones.

3) Connect both ends of the drive chain with the joint pins (8) inserted from the wheel side “A” as installed on the motorcycle.

Joint set part number

DID: 27620 – 40F20

“A”

I649G1310027-02

9

8

8

9

6 9 7 3

4

I837H1310028-02

Drive Chain Connecting

!

WARNING

Do not use joint clip type of drive chain. The joint clip may have a chance to drop which may cause severe damage to motorcycle and severe injury.

Joint plate installation

1) Set up the special tool as shown in the figure.

6

4

(F50)

3

1

5

9

9

10

I837H1310029-01

4) Apply grease on the recessed portion of the joint plate holder (3) and set the joint plate (10).

NOTE

When positioning the joint plate (10) on the tool, its stamp mark must face the joint plate holder (3) side.

5) Set the drive chain on the tool as illustrated and turn in the adjuster bolt (5) to secure the wedge holder and wedge pin (4).

3

10

4

5

I649G1310031-02

6) Turn in the pressure bolt [A] (6) and align two joint pins (8) properly with the respective holes of the joint plate (10).

2

1. Tool body

2. Grip handle

3. Joint plate holder (Engraved mark “F50”)

4. Wedge holder & wedge pin

5. Adjuster bolt (Without hole)

6. Pressure bolt [A]

7. Bar

7

I947H1310027-01 email: [email protected] / www.motomatrix.co.uk

8

10

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Drive Chain / Drive Train / Drive Shaft: 3A-9

7) Turn in the pressure bolt [A] (6) further using the bar

(7) to press the joint plate over the joint pins.

6

7

2) Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [A] (3) with the bar until the pin end diameter becomes the specified dimension.

!

CAUTION

• After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.

• Should any abnormal condition be found, reassemble the chain link using the new joint parts.

Pin end diameter specification “a”

DID: 5.7 – 6.0 mm (0.22 – 0.24 in)

I837H1310030-01

Continue pressing the joint plate until the distance between the two joint plates comes to the specification.

Joint plate distance specification “a”

20.7 – 21.0 mm (0.81 – 0.83 in)

!

CAUTION

If pressing of the joint plate makes the dimension out of specification excessively, the work must be carried out again by using new joint parts.

3

I649G1310035-02

“a”

I649G1310033-03

Joint pin staking

1) Set up the special tool as shown in the figure.

3

1

5

4

“a”

I649G1310036-03

3) Adjust the drive chain slack, after connecting it.

Refer to “Drive Chain Inspection and Adjustment” in

Section 0B (Page 0B-14).

2

6

I649G1310034-02

1. Tool body

2. Grip handle

3. Pressure bolt [A]

4. Adjuster bolt (Without hole)

5. Staking pin (Stowed inside grip handle behind rubber cap)

6. Bar

NOTE

Before staking the joint pin, apply a small quantity of grease to the staking pin (5).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3A-10 Drive Chain / Drive Train / Drive Shaft:

Specifications

Service Data

Drive Train

Unit: mm (in) Except ratio

Item

Final reduction ratio

Drive chain

Drive chain slack (on side-stand)

Gearshift lever height

Type

Links

20-pitch length

Standard

2.470 (42/17)

DID 50VAZ

114 links

—

20 – 30 (0.8 – 1.2)

65 – 75 (2.6 – 3.0)

B947H13107001

Limit

—

—

—

319.4 (12.57)

—

—

Tightening Torque Specifications

Fastening part

Engine sprocket nut

Speed sensor rotor bolt

Speed sensor mounting bolt

Rear sprocket nut

N

⋅

m

145

28

6.5

60

Tightening torque kgf-m

14.5

2.8

0.65

6.0

lbf-ft

105.0

20.0

4.5

43.0

B947H13107002

Note

)

(Page 3A-3)

)

(Page 3A-3)

)

(Page 3A-3)

)

(Page 3A-4)

NOTE

The specified tightening torque is described in the following.

“Drive Chain Related Components” (Page 3A-1)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Drive Chain / Drive Train / Drive Shaft: 3A-11

Special Tools and Equipment

Recommended Service Material

Grease

Material

Thread lock cement

B947H13108001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or equivalent

Note

P/No.: 99000–25010

)

(Page 3A-3) /

)

(Page 3A-

4) /

)

(Page 3A-4) /

)

(Page 3A-6) /

)

(Page 3A-

THREAD LOCK CEMENT SUPER

6)

P/No.: 99000–32110

)

(Page 3A-2)

“1322” or equivalent

NOTE

Required service material is also described in the following.

“Drive Chain Related Components” (Page 3A-1)

Special Tool

09913–50121

Oil seal remover

)

(Page 3A-6)

09913–70210

Bearing installing set (10 –

75

Φ

)

)

(Page 3A-6)

B947H13108002

09921–20240

Bearing remover set

)

(Page 3A-6)

09924–84510

Bearing installer set

)

(Page 3A-6)

09922–22711

Drive chain cutting and joint tool set

)

(Page 3A-7) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

3A-12 Drive Chain / Drive Train / Drive Shaft:

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 4- i

Section 4

Brake

CONTENTS

Precautions ………………………………………….4-1

Precautions……………………………………………………. 4-1

Precautions for Brake System ………………………… 4-1

Brake Fluid Information ………………………………….. 4-1

Brake Control System and Diagnosis … 4A-1

Schematic and Routing Diagram……………………4A-1

Front Brake Hose Routing Diagram ……………….. 4A-1

Rear Brake Hose Routing Diagram………………… 4A-2

Diagnostic Information and Procedures…………4A-3

Brake Symptom Diagnosis……………………………. 4A-3

Repair Instructions ……………………………………….4A-3

Brake Pedal Height Inspection and

Adjustment ……………………………………………….. 4A-3

Front Brake Light Switch Inspection ………………. 4A-3

Rear Brake Light Switch Inspection ……………….. 4A-4

Rear Brake Light Switch Inspection and

Adjustment ……………………………………………….. 4A-4

Brake Fluid Level Check ………………………………. 4A-4

Brake Hose Inspection …………………………………. 4A-4

Air Bleeding from Brake Fluid Circuit ……………… 4A-4

Brake Fluid Replacement……………………………… 4A-6

Front Brake Hose Removal and Installation…….. 4A-8

Rear Brake Hose Removal and Installation …….. 4A-8

Front Brake Master Cylinder Components………. 4A-9

Front Brake Master Cylinder Assembly

Removal and Installation…………………………… 4A-10

Front Brake Master Cylinder / Brake Lever

Disassembly and Assembly ………………………. 4A-11

Front Brake Master Cylinder Parts Inspection .. 4A-13

Rear Brake Master Cylinder Components …….. 4A-14

Rear Brake Master Cylinder Assembly

Removal and Installation…………………………… 4A-15

Rear Brake Master Cylinder Disassembly and

Assembly ……………………………………………….. 4A-16

Rear Brake Master Cylinder Parts Inspection … 4A-17

Rear Brake Pedal Construction …………………… 4A-18

Rear Brake Pedal Removal and Installation ….. 4A-18

Specifications……………………………………………..4A-19

Service Data …………………………………………….. 4A-19

Tightening Torque Specifications………………….4A-19

Special Tools and Equipment ………………………4A-20

Recommended Service Material …………………..4A-20

Special Tool ………………………………………………4A-20

Front Brakes …………………………………….. 4B-1

Repair Instructions ……………………………………….4B-1

Front Brake Components ………………………………4B-1

Front Brake Pad Inspection……………………………4B-2

Front Brake Pad Replacement……………………….4B-2

Front Brake Caliper Removal and Installation…..4B-3

Front Brake Caliper Disassembly and

Assembly…………………………………………………..4B-3

Front Brake Caliper Parts Inspection ………………4B-5

Front Brake Disc Removal and Installation ………4B-6

Front Brake Disc Inspection …………………………..4B-6

Specifications ……………………………………………….4B-7

Service Data………………………………………………..4B-7

Tightening Torque Specifications……………………4B-7

Special Tools and Equipment ………………………..4B-8

Recommended Service Material …………………….4B-8

Special Tool ………………………………………………..4B-8

Rear Brakes………………………………………. 4C-1

Repair Instructions ……………………………………….4C-1

Rear Brake Components……………………………….4C-1

Rear Brake Pad Inspection ……………………………4C-2

Rear Brake Pad Replacement ……………………….4C-2

Rear Brake Caliper Removal and Installation …..4C-3

Rear Brake Caliper Disassembly and

Assembly…………………………………………………..4C-4

Rear Brake Caliper Parts Inspection……………….4C-6

Rear Brake Disc Removal and Installation……….4C-6

Rear Brake Disc Inspection……………………………4C-7

Specifications ……………………………………………….4C-7

Service Data………………………………………………..4C-7

Tightening Torque Specifications……………………4C-8

Special Tools and Equipment ………………………..4C-8

Recommended Service Material …………………….4C-8

Special Tool ………………………………………………..4C-8

4

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4-1 Precautions:

Brake

Precautions

Precautions

Precautions for Brake System

Refer to “General Precautions” in Section 00 (Page 00-1).

B947H14000001

Brake Fluid Information

!

WARNING

B947H14000002

• This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.

• Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for a long period of time.

• When storing brake fluid, seal the container completely and keep it away from children.

• When replenishing brake fluid, take care not to get dust into the fluid.

• When washing brake components, use new brake fluid. Never use cleaning solvent.

• A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent.

!

CAUTION

Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage them severely.

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Brake Control System and Diagnosis: 4A-1

Brake

Brake Control System and Diagnosis

Schematic and Routing Diagram

Front Brake Hose Routing Diagram

B947H14102001

“C”

1

3

“B”

2

(a)

“A”

5

4

“B”

(a)

2

(a)

1. Hose clamp

: Clamp end should face downward.

2. Stopper

: After the brake hose union has contacted to the stopper, tighten the union bolt.

3. Hose guide

: Pass the brake hose through the hose guide.

4. Stopper

: After positioning the clamp with the stopper, tighten the clamp bolt.

5. Hose clamp

: Insert the clamp end into the hole on the front fender.

2

I947H1410046-02

“A”: White marking

: White marking should be on right side and face upward.

“B”: Clamp the brake hose firmly.

“C”: Pass the brake hose through rear side of the throttle cables.

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-2 Brake Control System and Diagnosis:

Rear Brake Hose Routing Diagram

B947H14102002

(a)

2

4

(f)

(g)

5

(c)

1

(a)

2

(e)

“B”

“A”

(b)

“C”

1. Hose clamp

: Face the clamp end backward.

2. Stopper

: After the brake hose union has contacted to the stopper, tighten the union bolt.

3. Brake pad pin

4. Plug

5. Caliper sliding pin B

6. Caliper sliding pin A

“A”: White marking

“B”: Yellow marking

“C”: Pass the reservoir hose above the brake hose.

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: 27 N

⋅ m (2.7 kgf-m, 19.5 lbf-ft) email: [email protected] / www.motomatrix.co.uk

3

(e)

6

(d)

I947H1410047-04

: 12 N

⋅ m (1.2 kgf-m, 8.5 lbf-ft)

: 17 N

⋅ m (1.7 kgf-m, 12.5 lbf-ft)

: 2.5 N

⋅ m (0.25 kgf-m, 2.0 lbf-ft)

: 6 N

⋅ m (0.6 kgf-m, 4.5 lbf-ft)

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-3

Diagnostic Information and Procedures

Brake Symptom Diagnosis

B947H14104001

Condition Possible cause

Insufficient brake power

Leakage of brake fluid from hydraulic

Correction / Reference Item

Repair or replace.

system.

Worn pads and disc.

Replace.

Oil adhesion on friction surface of pads.

Clean disc and pads.

Brake squeaking

Air in hydraulic system.

Bleed air.

Not enough brake fluid in the reservoir.

Replenish.

Carbon adhesion on pad surface.

Tilted pad.

Repair surface with sandpaper.

Correct pad fitting or replace.

Excessive brake lever stroke

Leakage of brake fluid

Damaged wheel bearing.

Loose front wheel axle or rear wheel

Replace.

Tighten to specified torque.

axle.

Worn pads and disc.

Foreign material in brake fluid.

Replace.

Replace brake fluid.

Clogged return port of master cylinder.

Disassemble and clean master cylinder.

Air in hydraulic system.

Insufficient brake fluid.

Improper quality of brake fluid.

Insufficient tightening of connection

Bleed air.

Replenish fluid to specified level; bleed air.

Replace with correct fluid.

Tighten to specified torque.

Brake drags

joints.

Cracked hose.

Worn piston and/or cup.

Worn piston seals and dust seals.

Rusty part.

Insufficient brake lever or brake pedal pivot lubrication.

Replace.

Replace piston and/or cup.

Replace piston seals and dust seals.

Clean and lubricate.

Lubricate.

Repair Instructions

Brake Pedal Height Inspection and Adjustment

B947H14106001

Refer to “Brake System Inspection” in Section 0B

(Page 0B-16).

Front Brake Light Switch Inspection

B947H14106002

Inspect the front brake light switch in the following procedures:

1) Disconnect the front brake light switch coupler (1).

2) Inspect the front brake light switch for continuity with the tester.

If any abnormality is found, replace the front brake light switch with a new one. Refer to “Front Brake

Master Cylinder / Brake Lever Disassembly and

Assembly” (Page 4A-11).

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

1

Color

Position

OFF

ON

Terminal (B/R) Terminal (B/BI)

I815H1410006-01

3) Connect the front brake light switch coupler.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-4 Brake Control System and Diagnosis:

Rear Brake Light Switch Inspection

B947H14106003

Inspect the rear brake light switch in the following procedures:

1) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

2) Disconnect the rear brake light switch lead wire coupler (1).

Rear Brake Light Switch Inspection and

Adjustment

B947H14106004

Check the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. If the brake light switch adjustment is necessary, turn the adjuster nut (1) in or out while holding the brake pedal.

1

1

I947H1410042-01

3) Inspect the rear brake light switch for continuity with the tester.

If any abnormality is found, replace the rear brake light switch with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

Rear brake light switch

Color

Terminal (O) Terminal (W/B)

Position

OFF

ON

I837H1410002-01

4) Connect the rear brake light switch lead wire coupler.

5) Reinstall the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-9).

I947H1410002-01

Brake Fluid Level Check

B947H14106005

Refer to “Brake System Inspection” in Section 0B

(Page 0B-16).

Brake Hose Inspection

B947H14106006

Refer to “Brake System Inspection” in Section 0B

(Page 0B-16).

Air Bleeding from Brake Fluid Circuit

B947H14106007

Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:

!

CAUTION

Handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-5

Front Brake

NOTE

If air is trapped in the master cylinder, bleed air from the master cylinder first in the same manner as follows. Refer to “Front Brake

Master Cylinder Assembly Removal and

Installation” (Page 4A-10).

1) Remove the reservoir cap and diaphragm.

2) Fill the reservoir with brake fluid to the upper line of the reservoir. Place the reservoir cap to prevent dirt from entering.

Close the air bleeder valve and disconnect the hose.

Tightening torque

Air bleeder valve (Front caliper): 7.5 N·m (0.75 kgf-m, 5.5 lbf-ft)

I947H1410004-01

9) Fill the reservoir with brake fluid to the upper line of the reservoir.

I947H1410043-01

3) Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle.

4) Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it.

10) Install the diaphragm and reservoir cap.

I947H1410005-01

Rear Brake

1) Remove the right side frame cover. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Remove the rear brake fluid reservoir mounting bolt

(1).

I947H1410003-02

5) Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip.

6) Close the air bleeder valve, pump and squeeze the lever, and open the valve.

7) Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.

NOTE

While bleeding the brake system, replenish the brake fluid in the reservoir as necessary.

Make sure that there is always some fluid visible in the reservoir.

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1

I947H1410048-01

3) Remove the reservoir cap and diaphragm.

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-6 Brake Control System and Diagnosis:

4) Fill the reservoir with brake fluid to the upper line of the reservoir. Place the reservoir cap to prevent dirt from entering.

5) Fill the reservoir with brake fluid to the upper line of the reservoir.

I947H1410049-01

NOTE

The difference of bleeding operation from the front brake is that the rear master cylinder is actuated by a pedal.

Tightening torque

Air bleeder valve (Rear caliper): 6 N·m (0.6 kgfm, 4.5 lbf-ft)

6) Install the diaphragm and reservoir cap.

7) Install the removed parts.

I947H1410009-03

Brake Fluid Replacement

B947H14106008

!

CAUTION

Handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc.

Front Brake

1) Place the motorcycle on a level surface and keep the handlebars straight.

2) Remove the brake fluid reservoir cap and diaphragm.

3) Suck up the old brake fluid as much as possible.

I947H1410007-01

I947H1410008-01

I947H1410010-01

4) Fill the reservoir with new brake fluid.

BF: Brake fluid (DOT 4)

5) Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-7

6) Loosen the air bleeder valve and pump the brake lever until the old brake fluid flows out of the brake system.

Rear Brake

1) Place the motorcycle on a level surface.

2) Remove the right side frame cover. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

3) Remove the rear brake fluid reservoir mounting bolt

(1).

I947H1410011-01

1

4) Remove the brake fluid reservoir cap and diaphragm.

I947H1410050-01

5) Suck up the old brake fluid as much as possible.

I947H1410012-02

7) Close the air bleeder valve and disconnect the clear hose.

Tightening torque

Air bleeder valve (Front caliper): 7.5 N·m (0.75 kgf-m, 5.5 lbf-ft)

Fill the reservoir with brake fluid to the upper mark of the reservoir.

I947H1410014-02

6) Fill the reservoir with new brake fluid.

BF: Brake fluid (DOT 4)

7) Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.

9) Bleed air from the brake fluid circuit. Refer to “Air

Bleeding from Brake Fluid Circuit” (Page 4A-4).

10) Install the diaphragm and reservoir cap.

I947H1410013-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-8 Brake Control System and Diagnosis:

Loosen the air bleeder valve and pump the brake pedal until the old brake fluid flows out of the brake system.

Front Brake Hose Removal and Installation

Removal

B947H14106009

1) Drain brake fluid. Refer to “Brake Fluid

Replacement” (Page 4A-6).

2) Remove the front brake hoses as shown in the front brake hose routing diagram. Refer to “Front Brake

Hose Routing Diagram” (Page 4A-1).

I947H1410015-01

Installation

!

CAUTION

The seal washers should be replaced with the new ones to prevent fluid leakage.

1) Install the front brake hose as shown in the front brake hose routing diagram. Refer to “Front Brake

Hose Routing Diagram” (Page 4A-1).

2) Bleed air from the front brake system. Refer to “Air

Bleeding from Brake Fluid Circuit” (Page 4A-4).

I947H1410016-01

9) Close the air bleeder valve and disconnect the clear hose.

Tightening torque

Air bleeder valve (Rear caliper): 6 N·m (0.6 kgfm, 4.5 lbf-ft)

10) Fill the reservoir with brake fluid to the upper line of the reservoir.

Rear Brake Hose Removal and Installation

B947H14106010

Removal

1) Drain brake fluid. Refer to “Brake Fluid

Replacement” (Page 4A-6).

2) Remove the rear brake hoses as shown in the rear brake hose routing diagram. Refer to “Rear Brake

Hose Routing Diagram” (Page 4A-2).

Installation

!

CAUTION

The seal washers should be replaced with new ones to prevent fluid leakage.

1) Install the rear brake hose as shown in the rear brake hose routing diagram. Refer to “Rear Brake

Hose Routing Diagram” (Page 4A-2).

2) Bleed air from the rear brake system. Refer to “Air

Bleeding from Brake Fluid Circuit” (Page 4A-4).

I947H1410017-03

11) Bleed air from the brake fluid circuit. Refer to “Air

Bleeding from Brake Fluid Circuit” (Page 4A-4).

12) Install the diaphragm and reservoir cap.

13) Install the removed parts.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-9

Front Brake Master Cylinder Components

B947H14106011

8

9

(b)

1

11

3

2

4

10

(c)

12

(a)

13

5

(e)

(d)

12

(a)

6

12

(a)

7

1. Reservoir cap

2. PLATE

3. Diaphragm

4. Reservoir tank

5. Master cylinder

6. Dust boot

7. Piston set

8. Brake lever

9. Brake lever pivot bolt

10. Brake lever pivot bolt lock-nut

11. Brake light switch

12. Brake hose union bolt

13. Brake hose

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft) email: [email protected] / www.motomatrix.co.uk

: 1 N

⋅ m (0.1 kgf-m, 0.5 lbf-ft)

: 6 N

⋅ m (0.6 kgf-m, 4.5 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 0.7 lbf-ft)

: 6 N

⋅ m (0.6 kgf-m, 4.5 lbf-ft)

: Apply brake fluid.

: Apply silicone grease.

: Do not reuse.

I947H1410051-02

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-10 Brake Control System and Diagnosis:

Front Brake Master Cylinder Assembly Removal and Installation

B947H14106012

Removal

1) Drain brake fluid. Refer to “Brake Fluid

Replacement” (Page 4A-6).

2) Disconnect the front brake light switch coupler (1).

3) Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.

4) Remove the brake hose union bolt (2).

Installation

Install the front brake master cylinder in the reverse order of removal. Pay attention to the following points:

• When installing the master cylinder (1) onto the handlebar, align the master cylinder holder’s mating surface “A” with the punch mark “B” on the handlebar and tighten the upper holder bolt first.

Tightening torque

Front brake master cylinder holder bolt (Upper and Lower) (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

1

1

“B”

(a)

“A”

2

5) Remove the master cylinder assembly.

I947H1410018-02

I947H1410020-01

“A”

(a)

“B”

1

“C”

(a)

“C”: Up mark

“ a ”

“a”: Clearance

I947H1410041-01

I947H1410019-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-11

• After setting the brake hose union to the stopper, tighten the union bolt (2) to the specified torque.

!

CAUTION

The seal washers should be replaced with the new ones to prevent fluid leakage.

Tightening torque

Brake hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

Front Brake Master Cylinder / Brake Lever

Disassembly and Assembly

B947H14106013

Refer to “Front Brake Master Cylinder Assembly

Removal and Installation” (Page 4A-10).

Disassembly

1) Remove the reservoir cap (1), PLATE (2), diaphragm

(3) and reservoir tank (4).

4

3

2

1

2

(b)

I947H1410021-03

• Bleed air from the master cylinder in the same manner as caliper side.

NOTE

If air is trapped in the master cylinder, bleed air from the master cylinder first.

Tightening torque

Air bleeder valve (Front master cylinder): 6 N·m (

0.6 kgf-m, 4.5 lbf-ft)

I947H1410023-01

2) Remove the brake light switch (5) and brake lever

(6).

5

6

I947H1410024-01

3) Remove the dust boot (7) and push rod (8).

4) Remove the snap ring (9).

7

I947H1410022-01

• Bleed air from brake system. Refer to “Air Bleeding from Brake Fluid Circuit” (Page 4A-4).

8

9

I947H1410025-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-12 Brake Control System and Diagnosis:

5) Remove the following parts from the master cylinder.

• Piston (10)

• Return spring (11)

• Return spring guide (12)

10

11

12

I947H1410026-01

6) Remove the dust rubber (13) and snap ring (14).

Assembly

Assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points:

!

CAUTION

• Wash the master cylinder components with new brake fluid before reassembly.

• Do not wipe the brake fluid off after washing the components.

• When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.

• Apply brake fluid to the master cylinder bore and all of the master cylinder component to be inserted into the bore.

BF: Brake fluid (DOT 4)

13

14

I947H1410027-02

7) Remove the connector (15), O-ring (16) and air bleeder valve (17).

I837H1410034-01

• When install the spring guide, insert the spring guide end “A” into the hole “B” of the master cylinder.

17

15

16

“B”

I947H1410028-01

“A”

I947H1410029-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-13

• Apply grease to the push rod.

: Grease 99000–25100 (SUZUKI SILICONE

GREASE or equivalent)

• When installing the brake light switch, align the projection “C” on the switch with the hole “D” in the master cylinder.

“C”

“D”

I947H1410030-01

• Apply grease to the brake lever pivot bolt.

: Grease 99000–25100 (SUZUKI SILICONE

GREASE or equivalent)

I947H1410044-03

Front Brake Master Cylinder Parts Inspection

B947H14106014

Refer to “Front Brake Master Cylinder / Brake Lever

Disassembly and Assembly” (Page 4A-11).

Master Cylinder

Inspect the master cylinder bore for any scratches or other damage.

I947H1410031-01

• Tighten the pivot bolt (1) and lock-nut (2) to the specified torque.

Tightening torque

Brake lever pivot bolt (a): 1 N·m (0.1 kgf-m, 0.5 lbf-ft)

Brake lever pivot bolt lock-nut (b): 6 N·m (0.6 kgf-m, 4.5 lbf-ft)

2

(b)

I947H1410033-01

Piston / Rubber Parts

Inspect the piston surface for any scratches or other damage.

Inspect the primary cup, secondary cup and dust boot for wear or damage.

1

(a)

I947H1410032-02

I837H1410041-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-14 Brake Control System and Diagnosis:

Rear Brake Master Cylinder Components

1

3

2

4

7

(a)

B947H14106015

6

5

7

(a)

8

12

(c)

9

10

11

(b)

13

1. Reservoir cap

2. PLATE

3. Diaphragm

4. Reservoir tank

5. Reservoir hose

6. Brake hose

7. Brake hose union bolt

8. Brake hose connector

9. Master cylinder

10. Spring

11. Piston/Cup set

12. Push rod

13. Dust boot

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 0.7 lbf-ft)

I947H1410052-02

: 17 N

⋅ m (1.7 kgf-m, 12.5 lbf-ft)

: Apply silicone grease.

: Apply thread lock to the thread part.

: Apply brake fluid.

: Do not reuse.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-15

Rear Brake Master Cylinder Assembly Removal and Installation

B947H14106016

Refer to “Rear Brake Hose Routing Diagram” (Page 4A-

2).

Removal

1) Remove the right side frame cover. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Remove the rear brake fluid reservoir mounting bolt

(1).

1

Installation

Install the rear brake master cylinder in the reverse order of removal. Pay attention to the following points:

!

CAUTION

The seal washers should be replaced with the new ones to prevent fluid leakage.

• Apply thread lock to the master cylinder mounting bolts (1) and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

• Tighten the lock-nut (2) temporarily.

• After setting the brake hose union to the stopper, tighten the union bolt (3) to the specified torque.

Tightening torque

Rear brake master cylinder mounting bolt (a): 10

N·m (1.0 kgf-m, 7.0 lbf-ft)

Brake hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

I947H1410053-01

3) Drain brake fluid. Refer to “Brake Fluid

Replacement” (Page 4A-6).

4) Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid.

5) Remove the brake hose union bolt (2).

6) Loosen the lock-nut (3).

7) Remove the master cylinder mounting bolts (4).

Remove the master cylinder along with the reservoir by turning the push rod (5).

2

3

1

(b)

(a)

5

2

I947H1410045-02

• Bleed air from the brake system after reassembling the master cylinder. Refer to “Air Bleeding from Brake

Fluid Circuit” (Page 4A-4).

• Adjust the brake pedal height. Refer to “Brake Pedal

Height Inspection and Adjustment” (Page 4A-3).

• Install the removed parts.

4

3

I947H1410034-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-16 Brake Control System and Diagnosis:

Rear Brake Master Cylinder Disassembly and

Assembly

B947H14106017

Refer to “Rear Brake Master Cylinder Assembly

Removal and Installation” (Page 4A-15).

4) Pull out the dust boot (5) and remove the snap ring

(6).

Special tool

: 09900–06108 (Snap ring remover (Close type))

Disassembly

1) Disconnect the reservoir hose (1).

2) Remove the lock-nut (2).

5

6

2

1

I947H1410035-02

3) Remove the brake hose connector (3) and O-ring

(4).

Special tool

: 09900–06108 (Snap ring remover (Close type))

I947H1410037-02

5) Remove the push rod (7), piston/cup set (8) and spring (9).

9

8

7

I947H1410054-01

3

4

I947H1410036-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-17

Assembly

Assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points:

!

CAUTION

• Wash the master cylinder components with new brake fluid before reassembly.

• Do not wipe the brake fluid off after washing the components.

• When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.

• Apply brake fluid to the master cylinder bore and all of the master cylinder component to be inserted into the bore.

BF: Brake fluid (DOT 4)

!

CAUTION

Replace the O-ring with a new one.

1

Rear Brake Master Cylinder Parts Inspection

B947H14106018

Refer to “Rear Brake Master Cylinder Disassembly and

Assembly” (Page 4A-16).

I947H1410055-01

Master Cylinder

Inspect the master cylinder bore for any scratches or other damage.

I947H1410038-01

• Apply grease to the push rod end.

: Grease 99000–25100 (SUZUKI SILICONE

GREASE or equivalent)

I947H1410040-02

Piston / Rubber Parts

Inspect the piston surface for any scratches or other damage.

Inspect the primary cup, secondary cup and dust boot for wear or damage.

I947H1410039-02

I837H1410050-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-18 Brake Control System and Diagnosis:

Rear Brake Pedal Construction

B947H14106019

(c)

5

4

1

3

(a)

(b)

2

1. Footrest bracket No. 2

2. Footrest bracket No. 1

3. Rear brake pedal

4. Footrest holder

5. Footrest

: 35 N

⋅ m (3.5 kgf-m, 25.5 lbf-ft)

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft)

Rear Brake Pedal Removal and Installation

B947H14106020

Removal

1) Remove the master cylinder assembly. Refer to

“Rear Brake Master Cylinder Assembly Removal and Installation” (Page 4A-15).

2) Disconnect the rear brake light switch lead wire coupler. Refer to “Rear Brake Light Switch

Inspection” (Page 4A-4).

3) Remove the rear brake pedal as shown in the rear brake pedal construction. Refer to “Rear Brake

Pedal Construction” (Page 4A-18).

: Apply grease.

: Apply thread lock to the thread part.

: Do not reuse.

I947H1410056-02

Installation

!

CAUTION

Replace the snap ring with a new one.

Install the rear brake pedal as shown in the rear brake pedal construction. Refer to “Rear Brake Pedal

Construction” (Page 4A-18).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Brake Control System and Diagnosis: 4A-19

Specifications

Service Data

Brake

Unit: mm (in)

Item

Rear brake pedal height

Master cylinder bore

Master cylinder piston diam.

Brake fluid type

Front

Rear

Front

Rear

Standard

65 – 75 (2.6 – 3.0)

17.460 – 17.503 (0.6874 – 0.6891)

14.000 – 14.043 (0.5512 – 0.5529)

17.417 – 17.444 (0.6857 – 0.6868)

13.957 – 13.984 (0.5495 – 0.5506)

DOT 4

B947H14107001

Limit

—

—

—

—

—

—

Tightening Torque Specifications

Fastening part

Air bleeder valve (Front caliper)

N

⋅

m

7.5

Tightening torque kgf-m lbf-ft

B947H14107002

Note

Air bleeder valve (Rear caliper)

6

Front brake master cylinder holder bolt (Upper and Lower)

Brake hose union bolt

10

Air bleeder valve (Front master cylinder)

Brake lever pivot bolt

Brake lever pivot bolt lock-nut

Rear brake master cylinder mounting bolt

23

6

1

6

10

0.6

0.1

0.6

1.0

4.5

0.5

4.5

7.0

)

(Page 4A-11)

)

(Page 4A-13)

)

(Page 4A-13)

)

(Page 4A-15)

NOTE

The specified tightening torque is described in the following.

“Front Brake Hose Routing Diagram” (Page 4A-1)

“Rear Brake Hose Routing Diagram” (Page 4A-2)

“Front Brake Master Cylinder Components” (Page 4A-9)

“Rear Brake Master Cylinder Components” (Page 4A-14)

“Rear Brake Pedal Construction” (Page 4A-18)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4A-20 Brake Control System and Diagnosis:

Special Tools and Equipment

Recommended Service Material

Material

Brake fluid

Grease

Thread lock cement

B947H14108001

SUZUKI recommended product or Specification

DOT 4

SUZUKI SILICONE GREASE or equivalent

THREAD LOCK CEMENT SUPER

Note

—

)

(Page 4A-6) /

)

(Page 4A-

7) /

)

(Page 4A-12) /

)

(Page 4A-17)

P/No.: 99000–25100

)

(Page 4A-13) /

)

(Page 4A-13) /

)

(Page 4A-17)

P/No.: 99000–32110

)

(Page 4A-15)

“1322” or equivalent

NOTE

Required service material is also described in the following.

“Front Brake Master Cylinder Components” (Page 4A-9)

“Rear Brake Master Cylinder Components” (Page 4A-14)

“Rear Brake Pedal Construction” (Page 4A-18)

Special Tool

09900–06108

Snap ring remover (Close type)

)

(Page 4A-16) /

)

(Page 4A-16)

09900–25008

Multi circuit tester set

)

(Page 4A-3) /

)

(Page 4A-

4)

B947H14108002 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Brakes: 4B-1

Brake

Front Brakes

Repair Instructions

Front Brake Components

B947H14206001

(a)

(c)

3

(b)

2

1

5

4

(d)

1. Seal set

2. Piston and seal set

3. Brake pad spring

4. Brake pad set

5. Front brake disc

: 7.5 N

⋅ m (0.75 kgf-m, 5.5 lbf-ft)

: 15 N

⋅ m (1.5 kgf-m, 11.0 lbf-ft)

: 39 N

⋅ m (3.9 kgf-m, 28.0 lbf-ft) email: [email protected] / www.motomatrix.co.uk

: 18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft)

: Apply thread lock to the thread part.

: Apply brake fluid.

: Do not reuse.

I947H1420020-01

4B-2 Front Brakes:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Brake Pad Inspection

B947H14206002

The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Front Brake Pad

Replacement” (Page 4B-2).

!

CAUTION

Replace the brake pad as a set, otherwise braking performance will be adversely affected.

4) Clean up the caliper especially around the caliper pistons.

5) When installing the spring to caliper, bring its wider pawl “A” to top side.

“A”

“A”

I947H1420001-02

Front Brake Pad Replacement

B947H14206003

1) Loosen the pad mounting pins (1).

2) Remove the brake caliper by removing the caliper mounting bolts (2).

3) Remove the pad mounting pins (1), brake pads and spring.

!

CAUTION

Do not operate the brake lever while the pads are removed.

NOTE

When removing the pads and pad spring, push the pistons all the way into the brake caliper.

I947H1420018-01

6) Install new brake pads and temporarily tighten the pad mounting pins.

!

CAUTION

Replace the brake pads as a set, otherwise braking performance will be adversely affected.

7) Install the brake caliper.

Tighten the front brake caliper mounting bolts (2) and front brake pad mounting pins (1) to the specified torque.

Tightening torque

Front brake caliper mounting bolt (a): 39 N·m (

3.9 kgf-m, 28.0 lbf-ft)

Front brake pad mounting pin (b): 15 N·m (1.5 kgf-m, 11.0 lbf-ft)

2

(a)

1

(b)

2

1

I947H1420003-02

NOTE

After replacing the brake pads, pump the brake lever several times to check for proper brake operation and then check the brake fluid level.

I947H1420002-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Brake Caliper Removal and Installation

B947H14206004

NOTE

The right and left calipers are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.

Removal

1) Drain brake fluid. Refer to “Brake Fluid

Replacement” in Section 4A (Page 4A-6).

2) Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.

NOTE

Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.

Front Brakes: 4B-3

Installation

Install the brake caliper in the reverse order of removal.

Pay attention to the following points:

• Tighten each bolt to the specified torque.

Tightening torque

Front brake caliper mounting bolt (a): 39 N·m (3.9 kgf-m, 28.0 lbf-ft)

• After setting the brake hose union to the stopper, tighten the union bolt to the specified torque.

!

CAUTION

The seal washers should be replaced with the new ones to prevent fluid leakage.

Tightening torque

Brake hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

(a)

(b)

(a)

1

I947H1420019-01

3) Remove the brake caliper by removing its mounting bolts (2).

2

I947H1420017-02

I947H1420004-01

• Bleed air from the brake system after installing the caliper. Refer to “Air Bleeding from Brake Fluid

Circuit” in Section 4A (Page 4A-4).

• Check the brake fluid leakage and brake operation.

!

WARNING

Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.

Check the brake hose and hose joints for cracks and fluid leakage.

Front Brake Caliper Disassembly and Assembly

B947H14206005

Refer to “Front Brake Caliper Removal and Installation”

(Page 4B-3).

NOTE

The right and left calipers are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4B-4 Front Brakes:

Disassembly

1) Remove the brake pads (1) and spring from the caliper by removing the pad mounting pins.

1

I947H1420005-01

2) Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air.

!

CAUTION

Do not use high pressure air to prevent piston damage.

Assembly

Assemble the caliper in the reverse order of disassembly. Pay attention to the following points:

• Wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves.

BF: Brake fluid (DOT 4)

!

CAUTION

• Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.

• Do not wipe the brake fluid off after washing the components.

• When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or the others.

I947H1420006-01

3) Remove the dust seals (2) and piston seals (3) from both sides of the caliper.

I649G1420012-02

• Apply the brake fluid to piston seals (1) and dust seals

(2).

!

CAUTION

Replace the piston seals (1) and dust seals

(2) with new ones.

BF: Brake fluid (DOT 4)

• Install the piston seals as shown in the figure.

3

2

2

3

2

I947H1420007-01

1

I649G1420013-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

• When installing the spring to the caliper, bring its wider pawl “A” facing top side.

Front Brakes: 4B-5

Brake Caliper Piston

Inspect the surface of brake caliper pistons for any scratches or other damage. If any damage is found, replace the pistons with a new set.

“A”

“B”

I947H1420009-01

“A”: Wider pawl “B”: Top side

• Install the brake pads and temporarily tighten the pad mounting pins (3).

I947H1420012-01

Brake Pad Mounting Pin

Inspect the brake pad mounting pins for wear and other damage. If any damage is found, replace the mounting pins with new ones.

3

I947H1420010-01

Front Brake Caliper Parts Inspection

B947H14206006

Refer to “Front Brake Caliper Disassembly and

Assembly” (Page 4B-3).

Brake Caliper Cylinder

Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one.

I947H1420013-01

Brake Pad Spring

Inspect the brake pad spring for damage and excessive bend. If any damage is found, replace it with a new one.

I947H1420014-01

I947H1420011-01 email: [email protected] / www.motomatrix.co.uk

4B-6 Front Brakes:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Brake Disc Removal and Installation

B947H14206007

Removal

1) Remove the front wheel assembly. Refer to “Front

Wheel Assembly Removal and Installation” in

Section 2D (Page 2D-4).

2) Remove the front brake disc.

Front Brake Disc Inspection

B947H14206008

Brake Disc Thickness

Check the brake disc for damage or cracks and measure the thickness using the micrometer.

Replace the brake disc if the thickness is less than the service limit or if defect is found.

Special tool

(A): 09900–20205 (Micrometer (0 – 25 mm))

Brake disc thickness

Service limit (Front): 5.0 mm (0.20 in)

(A)

I947H1420015-01

Installation

Install the front brake disc in the reverse order of removal. Pay attention to the following points:

• Make sure that the brake disc is clean and free of any grease.

• Apply thread lock to the brake disc bolts (1) and tighten them to the specified torque.

: Thread lock cement 99000–32130

(THREAD LOCK CEMENT SUPER “1360” or equivalent)

Tightening torque

Brake disc bolt (Front) (a): 18 N·m (1.8 kgf-m,

13.0 lbf-ft)

I649G1420019-03

Brake Disc Runout

1) Dismount the front brake caliper. Refer to “Front

Brake Caliper Removal and Installation” (Page 4B-

3).

2) Measure the runout using the dial gauge.

Replace the disc if the runout exceeds the service limit.

Special tool

(A): 09900–20607 (Dial gauge)

: 09900–20701 (Dial gauge chuck)

Brake disc runout

Service limit: 0.30 mm (0.012 in)

1

(a)

(A)

I947H1420016-02

I649G1420020-03

3) Remount the front brake caliper. Refer to “Front

Brake Caliper Removal and Installation” (Page 4B-

3).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Brakes: 4B-7

Specifications

Service Data

Brake

Unit: mm (in)

Item

Brake disc thickness

Brake disc runout

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type

Front

Front

Front

Standard

5.3 – 5.7 (0.21 – 0.22)

—

Leading 30.280 – 30.330 (1.1921 – 1.1941)

Trailing 32.080 – 32.130 (1.2630 – 1.2650)

Leading 30.167 – 30.200 (1.1877 – 1.1890)

Trailing 31.967 – 32.000 (1.2585 – 1.2598)

DOT 4

B947H14207001

Limit

5.0 (0.20)

0.30 (0.012)

—

—

—

—

—

Tightening Torque Specifications

Fastening part

Front brake caliper mounting bolt

Front brake pad mounting pin

Brake hose union bolt

Brake disc bolt (Front)

N

⋅

m

39

15

23

18

Tightening torque kgf-m

1.5

2.3

1.8

lbf-ft

11.0

16.5

13.0

B947H14207002

Note

)

(Page 4B-2)

)

(Page 4B-3)

)

(Page 4B-6)

NOTE

The specified tightening torque is described in the following.

“Front Brake Components” (Page 4B-1)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

4B-8 Front Brakes:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Special Tools and Equipment

Recommended Service Material

Material

Brake fluid

Thread lock cement

B947H14208001

SUZUKI recommended product or Specification

DOT 4

THREAD LOCK CEMENT SUPER

—

Note

)

(Page 4B-4) /

)

(Page 4B-

4)

P/No.: 99000–32130

)

(Page 4B-6)

“1360” or equivalent

NOTE

Required service material is also described in the following.

“Front Brake Components” (Page 4B-1)

Special Tool

09900–20205

Micrometer (0 – 25 mm)

)

(Page 4B-6)

09900–20607

Dial gauge

)

(Page 4B-6)

B947H14208002

09900–20701

Dial gauge chuck

)

(Page 4B-6) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Brakes: 4C-1

.Brake

Rear Brakes

Repair Instructions

Rear Brake Components

B947H14306001

5

8

(a)

7

4

(c)

8

3

2

1

(d)

(e)

(b)

6

(f)

1. Rear brake caliper

2. Piston seal

3. Dust seal

4. Piston

5. Rear caliper bracket

6. Rear brake pad set

7. Rear brake disc

8. Brake pad spring

: 6 N

⋅ m (0.6 kgf-m, 4.5 lbf-ft)

: 27 N

⋅ m (2.7 kgf-m, 19.5 lbf-ft)

: 12 N

⋅ m (1.2 kgf-m, 8.5 lbf-ft)

: 17 N

⋅ m (1.7 kgf-m, 12.5 lbf-ft)

: 2.5 N

⋅ m (0.25 kgf-m, 2.0 lbf-ft)

: 35 N

⋅ m (3.5 kgf-m, 25.5 lbf-ft) email: [email protected] / www.motomatrix.co.uk

I947H1430026-02

: Apply silicone grease to sliding surface.

: Apply thread lock to the thread part.

: Apply thread lock to the thread part.

: Apply brake fluid.

: Do not reuse.

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4C-2 Rear Brakes:

Rear Brake Pad Inspection

B947H14306002

The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Rear Brake Pad

Replacement” (Page 4C-2).

!

CAUTION

Replace the brake pad as a set, otherwise braking performance will be adversely affected.

2) Remove the brake pads (3).

!

CAUTION

Do not operate the brake pedal while the pads are removed.

3

“A”

I947H1430027-01

Rear Brake Pad Replacement

B947H14306003

1) Remove the plug (1) and brake pad mounting pin (2).

I947H1430002-02

3) Clean up the caliper, especially around the caliper piston.

!

CAUTION

Replace the brake pads as a set, otherwise braking performance will be adversely affected.

4) Install new brake pads.

NOTE

Make sure that the detent of the pads is seated onto the retainers on the caliper bracket.

1

2

I947H1430001-02

I947H1430003-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Brakes: 4C-3

5) Remove the caliper by removing the sliding pin A (2).

5) Tighten the brake pad mounting pin (2) and plug (1) to the specified torque.

Tightening torque

Rear brake pad mounting pin (a): 17 N·m (1.7 kgf-m, 12.5 lbf-ft)

Rear brake pad mounting pin plug (b): 2.5 N·m (

0.25 kgf-m, 2.0 lbf-ft)

2

2

I947H1430007-03

6) Remove the caliper bracket (3) from the swingarm.

2

(a)

1

(b)

I947H1430005-02

NOTE

After replacing the brake pads, pump the brake pedal several times to check for proper brake operation and then check the brake fluid level.

Rear Brake Caliper Removal and Installation

B947H14306004

Removal

1) Remove the rear wheel. Refer to “Rear Wheel

Assembly Removal and Installation” in Section 2D

(Page 2D-11).

2) Drain brake fluid. Refer to “Brake Fluid

Replacement” in Section 4A (Page 4A-6).

3) Remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle.

4) Remove the brake pads. Refer to “Rear Brake Pad

Replacement” (Page 4C-2).

NOTE

Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.

I947H1430008-03

Installation

Install the brake caliper in the reverse order of removal.

Pay attention to the following points:

• Apply grease to the sliding pins.

: Grease 99000–25100 (SUZUKI SILICONE

GREASE or equivalent)

I947H1430009-03

1

I947H1430006-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4C-4 Rear Brakes:

• Tighten the caliper sliding pin A (1) to the specified torque.

Tightening torque

Rear brake caliper sliding pin A (a): 27 N·m (2.7 kgf-m, 19.5 lbf-ft)

1

(a)

• Bleed air from the brake system after installing the caliper. Refer to “Air Bleeding from Brake Fluid

Circuit” in Section 4A (Page 4A-4).

• Check the brake fluid leakage and brake operation.

!

WARNING

Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.

Check the brake hose and hose joints for cracks and fluid leakage.

Rear Brake Caliper Disassembly and Assembly

B947H14306005

Refer to “Rear Brake Caliper Removal and Installation”

(Page 4C-3).

I947H1430010-04

• Fit each boot end into the sliding pin groove.

Disassembly

1) Remove the pad spring (1) and rubber boot (2) from the caliper.

2

I947H1430011-03

• Install the rear wheel. Refer to “Rear Wheel Assembly

Removal and Installation” in Section 2D (Page 2D-11).

• Install the brake pads. Refer to “Rear Brake Pad

Replacement” (Page 4C-2).

• After setting the brake hose union to the stopper, tighten the union bolt (2) to the specified torque.

!

CAUTION

The seal washers should be replaced with the new ones to prevent fluid leakage.

Tightening torque

Brake hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

1

I947H1430013-02

2) Place a rag over the piston to prevent it from popping out and then force out the piston using compressed air.

!

CAUTION

Do not use high pressure air to prevent piston damage.

2

(b)

I947H1430014-01

I947H1430012-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Brakes: 4C-5

3) Remove the dust seal (3) and piston seal (4).

4

3

I947H1430015-02

4) Remove the rubber boot (5), pad spring (6) and sliding pin B (7) from the bracket.

5

I649G1430018-02

• Apply the brake fluid to dust seal (1).

BF: Brake fluid (DOT 4)

• Apply grease to the piston seal (2).

: Grease 99000–25100 (SUZUKI SILICONE

GREASE or equivalent)

• Install the piston seal (2) as shown in the figure.

7

1

6

I947H1430028-01

Assembly

Assemble the caliper in the reverse order of disassembly. Pay attention to the following points:

• Wash the caliper bore and piston with specified brake fluid. Particularly wash the dust seal groove and piston seal groove.

BF: Brake fluid (DOT 4)

!

CAUTION

• Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.

• Do not wipe the brake fluid off after washing the components.

• When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or the others.

• Replace the piston seal and dust seal with new ones.

2

I947H1430016-04

• Apply thread lock to the thread part and install the sliding pin B (3) to the bracket.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Rear caliper sliding pin B (a): 12 N·m (1.2 kgf-m,

8.5 lbf-ft)

3

(a)

I947H1430017-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4C-6 Rear Brakes:

• Install the rear brake caliper. Refer to “Rear Brake

Caliper Removal and Installation” (Page 4C-3).

Boot

Inspect the boots for damage and wear. If any defects are found, replace it with a new one.

Rear Brake Caliper Parts Inspection

B947H14306006

Refer to “Rear Brake Caliper Disassembly and

Assembly” (Page 4C-4).

Brake Caliper Cylinder

Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one.

I947H1430022-01

Brake Pad Spring

Inspect the brake pad spring for damage and excessive bend. If any defects are found, replace it with a new one.

I947H1430019-01

Brake Caliper Piston

Inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, replace the piston with a new one.

I947H1430020-01

Brake Caliper Sliding Pin

Inspect the brake caliper sliding pins for wear and other damage. If any damage is found, replace the sliding pin with a new one.

I947H1430023-01

Rear Brake Disc Removal and Installation

B947H14306007

Removal

1) Remove the rear wheel assembly. Refer to “Rear

Wheel Assembly Removal and Installation” in

Section 2D (Page 2D-11).

2) Remove the rear brake disc.

I947H1430024-01

I947H1430021-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Brakes: 4C-7

Installation

Install the rear brake disc in the reverse order of removal. Pay attention to the following points:

• Make sure that the brake disc is clean and free of any grease.

• Apply thread lock to the brake disc bolts (1) and tighten them to the specified torque.

: Thread lock cement 99000–32130

(THREAD LOCK CEMENT SUPER “1360” or equivalent)

Tightening torque

Brake disc bolt (Rear) (a): 35 N·m (3.5 kgf-m, 25.5 lbf-ft)

(A)

1

(a)

I649G1430027-03

Brake Disc Runout

1) Dismount the rear brake caliper. Refer to “Rear

Brake Caliper Removal and Installation” (Page 4C-

3).

2) Measure the runout using the dial gauge.

Replace the disc if the runout exceeds the service limit.

Special tool

(A): 09900–20607 (Dial gauge)

: 09900–20701 (Dial gauge chuck)

Brake disc runout

Service limit: 0.30 mm (0.012 in)

I947H1430025-01

Rear Brake Disc Inspection

B947H14306008

Brake Disc Thickness

Check the brake disc for damage or cracks and measure the thickness using the micrometer.

Replace the brake disc if the thickness is less than the service limit or if defect is found.

Special tool

(A): 09900–20205 (Micrometer (0 – 25 mm))

Brake disc thickness

Service limit (Rear): 4.5 mm (0.18 in)

(A)

I649G1430028-03

3) Remount the rear brake caliper. Refer to “Rear

Brake Caliper Removal and Installation” (Page 4C-

3).

Specifications

Service Data

Brake

Unit: mm (in)

Item

Brake disc thickness

Brake disc runout

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type

Rear

Rear

Rear

Standard

4.8 – 5.2 (0.19 – 0.20)

—

30.230 – 30.280 (1.1902 – 1.1921)

30.148 – 30.198 (1.1869 – 1.1889)

DOT 4

B947H14307001

Limit

4.5 (0.18)

0.30 (0.012)

—

—

— email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

4C-8 Rear Brakes:

Tightening Torque Specifications

Fastening part

Rear brake pad mounting pin

Rear brake pad mounting pin plug

Rear brake caliper sliding pin A

Brake hose union bolt

Rear caliper sliding pin B

Brake disc bolt (Rear)

N

⋅

m

17

2.5

27

23

12

35

Tightening torque kgf-m

1.7

0.25

2.7

2.3

1.2

3.5

lbf-ft

12.5

2.0

19.5

16.5

8.5

25.5

B947H14307002

Note

)

(Page 4C-3)

)

(Page 4C-3)

)

(Page 4C-4)

)

(Page 4C-4)

)

(Page 4C-5)

)

(Page 4C-7)

NOTE

The specified tightening torque is described in the following.

“Rear Brake Components” (Page 4C-1)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

Material

Brake fluid

Grease

Thread lock cement

B947H14308001

SUZUKI recommended product or Specification

DOT 4

SUZUKI SILICONE GREASE or

—

Note

)

(Page 4C-5) /

)

(Page 4C-

5)

P/No.: 99000–25100

)

(Page 4C-3) /

)

(Page 4Cequivalent

THREAD LOCK CEMENT SUPER

5)

P/No.: 99000–32110

)

(Page 4C-5)

“1322” or equivalent

THREAD LOCK CEMENT SUPER P/No.: 99000–32130

)

(Page 4C-7)

“1360” or equivalent

NOTE

Required service material is also described in the following.

“Rear Brake Components” (Page 4C-1)

Special Tool

09900–20205

Micrometer (0 – 25 mm)

)

(Page 4C-7)

09900–20607

Dial gauge

)

(Page 4C-7)

B947H14308002

09900–20701

Dial gauge chuck

)

(Page 4C-7) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 5- i

Section 5

Transmission / Transaxle

CONTENTS

Precautions ………………………………………….5-1

Precautions……………………………………………………. 5-1

Precautions for Transmission / Transaxle…………. 5-1

Manual Transmission………………………… 5B-1

Diagnostic Information and Procedures…………5B-1

Manual Transmission Symptom Diagnosis ……… 5B-1

Repair Instructions ……………………………………….5B-2

Transmission Components …………………………… 5B-2

Transmission Removal…………………………………. 5B-3

Transmission Installation ……………………………… 5B-5

Transmission Construction……………………………. 5B-9

Countershaft Gear / Driveshaft Gear

Disassembly and Assembly ………………………. 5B-10

Transmission Related Parts Inspection…………. 5B-12

Gear Position (GP) Switch Inspection…………… 5B-13

Gear Position (GP) Switch Removal and

Installation ………………………………………………. 5B-14

Gearshift Lever Construction ………………………. 5B-15

Gearshift Lever Removal and Installation ……… 5B-15

Gearshift Lever Height Inspection and

Adjustment ……………………………………………… 5B-16

Gearshift Shaft / Gearshift Cam Plate

Components……………………………………………. 5B-16

Gearshift Shaft Construction ……………………….. 5B-17

Gearshift Shaft / Gearshift Cam Plate

Removal and Installation…………………………… 5B-17

Gearshift Linkage Inspection ………………………. 5B-20

Gearshift Shaft Oil Seal / Bearing Removal and Installation ………………………………………… 5B-20

Specifications ……………………………………………..5B-21

Service Data………………………………………………5B-21

Tightening Torque Specifications………………….5B-22

Special Tools and Equipment ………………………5B-22

Recommended Service Material …………………..5B-22

Special Tool ………………………………………………5B-23

Clutch ………………………………………………. 5C-1

Precautions…………………………………………………..5C-1

Precautions for Clutch System……………………….5C-1

Schematic and Routing Diagram ……………………5C-1

Clutch Cable Routing Diagram……………………….5C-1

Diagnostic Information and Procedures …………5C-1

Clutch System Symptom Diagnosis ………………..5C-1

Repair Instructions ……………………………………….5C-2

Clutch Lever Position Switch Inspection ………….5C-2

Clutch Cable Inspection ………………………………..5C-2

Clutch Cable Removal and Installation ……………5C-2

Clutch Control System Components ……………….5C-3

Clutch Components………………………………………5C-4

Clutch Removal……………………………………………5C-5

Clutch Installation…………………………………………5C-7

Clutch Parts Inspection ……………………………….5C-11

Clutch Lifter Pin Inspection and Adjustment …..5C-13

Specifications ……………………………………………..5C-14

Service Data………………………………………………5C-14

Tightening Torque Specifications………………….5C-14

Special Tools and Equipment ………………………5C-15

Recommended Service Material …………………..5C-15

Special Tool ………………………………………………5C-15

5

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5-1 Precautions:

Transmission / Transaxle

Precautions

Precautions

Precautions for Transmission / Transaxle

Refer to “General Precautions” in Section 00 (Page 00-1).

B947H15000001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-1

Transmission / Transaxle

Manual Transmission

Diagnostic Information and Procedures

Manual Transmission Symptom Diagnosis

Condition

Engine is noisy (Noise seems to come from the transmission)

Transmission will not shift

Transmission will not shift back

Transmission jumps out of gear

Possible cause

Worn or rubbing gear.

Worn countershaft spline.

Worn driveshaft spline.

Worn or rubbing primary gear.

Worn bearing.

Broken gearshift cam.

Distorted gearshift fork.

Worn gearshift pawl.

Broken return spring on shift shaft.

Rubbing or stuck gearshift shaft.

Worn or distorted gearshift fork.

Worn shifting gears on driveshaft or countershaft.

Worn or distorted gearshift fork.

Weakened gearshift stopper spring.

Worn gearshift cam plate.

B947H15204001

Replace.

Correction / Reference Item

Replace countershaft.

Replace driveshaft.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Repair or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-2 Manual Transmission:

Repair Instructions

Transmission Components

19

18

B947H15206001

12

(c)

17

11

10

9

14

(b)

16

(d)

15

8

13

7

20

6

5

1. 2nd drive gear

2. 6th drive gear

3. 3rd/4th drive gear

4. 5th drive gear

5. Countershaft/1st drive gear

6. Driveshaft

7. 2nd driven gear

8. 6th driven gear

9. 3rd driven gear

10. 4th driven gear

4

3

2

1

11. 5th driven gear

12. 1st driven gear

13. Gearshift cam stopper

14. Gearshift cam plate

15. Gearshift cam

16. Gearshift fork shaft

17. Gearshift fork (For 3rd/4th drive gear)

18. Gearshift fork (For 6th driven gear)

19. Gearshift fork (For 5th driven gear)

20. GP switch

(a)

I947H1520072-02

: 145 N

⋅ m (14.5 kgf-m, 105.0 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: 13 N

⋅ m (1.3 kgf-m, 9.5 lbf-ft)

: 6.5 N

⋅ m (0.65 kgf-m, 4.7 lbf-ft)

: Apply grease to the oil seal lip.

: Apply thread lock to the thread part.

: Apply engine oil.

: Do not reuse.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-3

Transmission Removal

B947H15206002

1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal” in Section 1D

(Page 1D-20).

2) Remove the engine top side. Refer to “Engine Top

Side Disassembly” in Section 1D (Page 1D-26).

3) Separate the upper and lower crankcases. Refer to

“Engine Bottom Side Disassembly” in Section 1D

(Page 1D-49).

Gearshift Fork and Gearshift Cam

1) Remove the gearshift cam bearing retainer screws.

2) Remove the gearshift fork shaft (1).

3) Remove the gearshift cam (2) along with its bearing.

4) Remove the gearshift forks (3).

2

1

Countershaft Assembly

1) Remove the gearshift shaft plug (1) and gearshift fork/gearshift shaft (2).

2) Remove the clutch push rod oil seal (3) and countershaft assembly (4).

3

4

3

I947H1520025-01

Driveshaft Assembly

1) Remove the spacer (1).

2) Remove the driveshaft oil seal retainer (2).

1

2

1

I947H1520023-01

3) Remove the bearing pin (5) and C-ring (6).

2

I947H1520026-01

3) Remove the driveshaft left bearing case bolts.

6

5

I947H1520024-01

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-4 Manual Transmission:

4) Using suitable size bolts (3), remove the driveshaft left bearing case (4).

5) Remove the dowel pin.

3

4

I947H1520028-01

6) Remove the driveshaft right bearing case bolts.

7) Using suitable size bolts (5), remove the driveshaft right bearing assembly (6).

Bearing and Oil Seal

NOTE

If there is no abnormal condition, the oil seal and bearing removal is not necessary.

!

CAUTION

The removed oil seal and bearing must be replaced with a new one.

1) Remove the gearshift cam bearing (1) with the special tools.

!

CAUTION

Be careful not to lean the bearing remover.

Special tool

(A): 09923–74511 (Bearing remover)

(B): 09930–30104 (Rotor remover sliding shaft)

6

1

5

Remove the driveshaft assembly (7).

I947H1520029-01

(A)

(B)

I947H1520031-02

2) Remove the gearshift shaft oil seal (2). (LH only)

7

2

I947H1520030-01

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-5

3) Remove the gearshift shaft bearings (3) and (4) with the special tool.

Special tool

(C): 09921–20240 (Bearing remover set)

Transmission Installation

B947H15206003

Install the transmission in the reverse order of removal.

Pay attention to the following points:

3

(C)

(C)

4

Bearing and Oil Seal

!

CAUTION

Replace the removed bearings and oil seals with new ones.

• Install the driveshaft left bearing oil seal into the retainer using the special tool.

Special tool

– 75

(A): 09913–70210 (Bearing installing set (10

Φ

))

I947H1520033-01

4) Remove the driveshaft left bearing with the special tool.

Special tool

(D): 09913–70210 (Bearing installing set (10

– 75

Φ

))

(A)

(D)

I947H1520034-01

5) Remove the driveshaft left bearing oil seal from the retainer using the special tool.

Special tool

(D): 09913–70210 (Bearing installing set (10

– 75

Φ

))

I947H1520036-01

• Install the driveshaft left bearing with the special tool.

NOTE

The stamped mark side of the driveshaft left bearing faces outside.

Special tool

(A): 09913–70210 (Bearing installing set (10

– 75

Φ

))

(A)

(D)

I947H1520037-01

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-6 Manual Transmission:

• Install the gearshift shaft bearings (1) and (2) with the special tool.

NOTE

The stamped mark side of the gearshift shaft bearing faces outside.

Special tool

(A): 09913–70210 (Bearing installing set (10

– 75

Φ

))

• Install the gearshift cam bearing with the special tool.

Special tool

(A): 09913–70210 (Bearing installing set (10

– 75

Φ

))

(A)

(A)

2

1

I947H1520038-01

• Install the gearshift shaft oil seal (3) with the special tool.

Special tool

(A): 09913–70210 (Bearing installing set (10

– 75

Φ

))

• Apply grease to the oil seal lip.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

(A)

(A)

I947H1520040-01

Driveshaft Assembly

• Put the driveshaft assembly (1) into the lower crankcase.

• Install the driveshaft right bearing assembly (2).

• Apply thread lock to the bolts and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Driveshaft right bearing case bolt (a): 12 N·m (1.2 kgf-m, 8.7 lbf-ft)

1

2

3

(a)

I947H1520039-01

• Install the dowel pin.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-7

• Apply grease to the O-ring and install the driveshaft left bearing case (3).

!

CAUTION

Replace the O-ring with a new one.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Apply thread lock to the screws and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Driveshaft oil seal retainer screw (c): 12 N·m (1.2 kgf-m, 8.7 lbf-ft)

4

(c)

3

I947H1520042-01

• Apply thread lock to the bolts and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Driveshaft left bearing case bolt (b): 12 N·m (1.2 kgf-m, 8.7 lbf-ft)

I947H1520044-01

• Apply grease to the O-ring (5) and install it to the driveshaft.

!

CAUTION

Replace the O-ring with a new one.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Install the spacer (6).

6

5

(b)

(b)

• Apply grease to the oil seal lip and O-ring.

I947H1520043-01

!

CAUTION

Replace the O-ring with a new one.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Install the oil seal retainer (4).

Gearshift Cam and Gearshift Fork

• Install the gearshift forks (1) as shown.

1

I947H1520045-02

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-8 Manual Transmission:

• Install the gearshift cam (2) with the bearing fitted.

• Install the countershaft assembly to the upper crankcase.

NOTE

Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.

2

I947H1520047-01

• With engaging each fork end to the cam groove, insert the fork shaft (3).

• Apply thread lock to the screws and tighten them to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Gearshift cam bearing retainer screw (a): 10 N·m (

1.0 kgf-m, 7.0 lbf-ft)

I947H1520050-01

• Turn the bearing and set the bearing dowel pin in position.

3

(a)

I947H1520048-01

Countershaft

• Install the C-ring (1) and bearing pin (2) to the upper crankcase.

I947H1520051-01

• Install the clutch push rod oil seal (3).

• Install the gearshift fork/gearshift shaft (4) and gearshift shaft plug (5).

3

1

2

4

5

I947H1520052-01

I947H1520049-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-9

Transmission Construction

B947H15206004

1

2

1. Countershaft 2. Driveshaft

I947H1520060-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-10 Manual Transmission:

Countershaft Gear / Driveshaft Gear

Disassembly and Assembly

B947H15206005

Refer to “Transmission Removal” (Page 5B-3) and

“Transmission Installation” (Page 5B-5).

• Slide the 6th (3) and 2nd (4) drive gears toward the

3rd/4th drive gears (2), then remove the 2nd drive gear circlip (5).

• Remove the 2nd drive gear (4) and 6th drive gear (3).

Disassembly

!

CAUTION

Identify the position of each removed part.

Organize the parts in their respective groups

(i.e., drive or driven) so that they can be reinstalled in their original positions.

Countershaft

Disassemble the countershaft as shown in the transmission construction. Refer to “Transmission

Construction” (Page 5B-9).

Pay attention to the following points:

• Remove the 6th drive gear snap ring (1) from its groove and slide it towards the 3rd/4th drive gears (2).

Special tool

: 09900–06104 (Snap ring remover (Open type))

4

3

2

5

I947H1520062-01

• Remove the countershaft bearing (6) using hydraulic press.

2

1

I947H1520061-02

6

I947H1520063-01

Driveshaft

• Disassembly the driveshaft as shown in the transmission construction. Refer to “Transmission

Construction” (Page 5B-9).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-11

Assembly

NOTE

When reassembling the transmission gears, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, bushings, washers and snap rings. Refer to “Transmission

Construction” (Page 5B-9).

!

CAUTION

• Never reuse a snap ring. After a snap ring has been removed from the shaft, it should be discarded and a new snap ring must be installed.

• When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft.

• After installing a snap ring, make sure that it is completely seated in the groove and securely fitted.

NOTE

• Rotate the bearing by hand to inspect if there is any abnormal noise and for smooth rotation. Replace the bearing if there is anything unusual.

• Before installing the gears, apply engine oil to the driveshaft and countershaft.

• Before installing the oil seal, apply grease to the oil seal lip.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• When installing a new snap ring (1), pay attention to its direction. Fit it to the side where the thrust is as shown in the figure.

Driveshaft

• When installing the gear bushings onto the driveshaft, align the shaft oil holes “A” with the bushing oil hole

“B”.

Countershaft

• Install the countershaft bearing (1) using a hydraulic press and special tool.

Special tool

(A): 09913–70210 (Bearing installing set (10

– 75

Φ

))

1

“A”

“A”

“B”

“B”

I947H1520064-01

I947H1520065-01

“A”

1

1

(A)

I947H1520066-02

“A”: Thrust

“B”

“B”: Sharp edge

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-12 Manual Transmission:

• When installing the gear bushing onto the countershaft, align the shaft oil hole “A” with the bushing oil hole “B”.

Gearshift Fork Groove Width

Measure the gearshift fork groove width using the vernier calipers.

Special tool

(A): 09900–20102 (Vernier calipers (200 mm))

Gearshift fork groove width

Standard: 5.0 – 5.1 mm (0.197 – 0.201 in)

“B”

“A”

I947H1520067-01

Transmission Related Parts Inspection

B947H15206006

Refer to “Transmission Removal” (Page 5B-3),

“Transmission Installation” (Page 5B-5) and

“Countershaft Gear / Driveshaft Gear Disassembly and

Assembly” (Page 5B-10).

Gearshift Fork to Groove Clearance

NOTE

The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action.

Using the thickness gauge, check the gearshift fork clearance in the groove of its gear.

If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.

Special tool

(A): 09900–20803 (Thickness gauge)

Gearshift fork to gearshift fork groove clearance

Standard: 0.1 – 0.3 mm (0.004 – 0.012 in)

Service limit: 0.5 mm (0.02 in)

(A)

I649G1520057-03

Gearshift Fork Thickness

Measure the gearshift fork thickness using the vernier calipers.

Special tool

(A): 09900–20102 (Vernier calipers (200 mm))

Gearshift fork thickness

Standard: 4.8 – 4.9 mm (0.189 – 0.193 in)

(A)

I649G1520058-03

(A)

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-13

Gearshift Cam

Inspect the gearshift cam groove for abnormal wear and damage. If any defects are found, replace the gearshift cam with a new one.

Inspect the driveshaft right bearing for abnormal noise and smooth rotation.

If there is anything unusual, replace the bearing assembly. Refer to “Transmission Removal” (Page 5B-3) and “Transmission Installation” (Page 5B-5).

I947H1520053-01

Gearshift Cam Bearing

Inspect the gearshift cam bearings, left and right for abnormal noise and smooth rotation.

Replace the bearing if there is anything unusual. Refer to “Transmission Removal” (Page 5B-3) and

“Transmission Installation” (Page 5B-5).

I837H1520041-01

Driveshaft Oil Seal

Inspect the driveshaft left bearing dust seal for wear and damage.

Replace the dust seal if there is anything unusual. Refer to “Transmission Removal” (Page 5B-3) and

“Transmission Installation” (Page 5B-5).

I947H1520054-01

Driveshaft Bearing

Inspect the driveshaft left bearing for abnormal noise and smooth rotation while it is in the case.

Replace the bearing if there is anything unusual. Refer to “Transmission Removal” (Page 5B-3) and

“Transmission Installation” (Page 5B-5).

I947H1520057-01

Gear Position (GP) Switch Inspection

B947H15206007

Refer to “Side-stand / Ignition Interlock System Parts

Inspection” in Section 1I (Page 1I-7).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-14 Manual Transmission:

Gear Position (GP) Switch Removal and

Installation

Removal

B947H15206008

1) Turn the ignition switch OFF.

2) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

3) Disconnect the gear position switch lead wire coupler (1).

Installation

Install the gear position switch in the reverse order of removal. Pay attention to the following points:

• Apply grease to the O-ring.

!

CAUTION

Replace the O-ring with a new one.

NOTE

Align the gear position switch pin “A” with the gearshift cam hole “B”.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

1

“B”

4) Remove the engine sprocket cover. Refer to “Engine

Sprocket Removal and Installation” in Section 3A

(Page 3A-2).

5) Remove the GP switch (2).

I947H1520068-01

“A”

I947H1520070-01

• Tighten the gear position switch mounting bolts to the specified torque.

Tightening torque

Gear position switch mounting bolt (a): 6.5 N·m (

0.65 kgf-m, 4.5 lbf-ft)

2

I947H1520069-01

(a)

I947H1520071-01

• Route the gear position switch lead wire. Refer to

“Wiring Harness Routing Diagram” in Section 9A

(Page 9A-7).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-15

Gearshift Lever Construction

B947H15206009

“ a ”

“A”

1

2

(b)

(a)

3

4

1. Gearshift lever bracket

2. Gearshift lever shaft

3. Washer

4. Snap ring

5. Gearshift lever

“A”: Footrest top surface

Gearshift Lever Removal and Installation

B947H15206010

Removal

Remove the gearshift lever as shown in the gearshift lever construction. Refer to “Gearshift Lever

Construction” (Page 5B-15).

5

“a”: 65 – 75 mm (2.6 – 3.0 in)

: 28 N

⋅ m (2.8 kgf-m, 20.0 lbf-ft)

: 40 N

⋅ m (4.0 kgf-m, 29.0 lbf-ft)

: Apply grease.

: Do not reuse.

I947H1520058-02

Installation

1) Install the gearshift lever as shown in the gearshift lever construction. Refer to “Gearshift Lever

Construction” (Page 5B-15).

2) After installing the gearshift lever, check the gearshift lever height. Refer to “Gearshift Lever Height

Inspection and Adjustment” (Page 5B-16).

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-16 Manual Transmission:

Gearshift Lever Height Inspection and

Adjustment

B947H15206011

Inspect and adjust the gearshift lever height in the following procedures:

1) Inspect the gearshift lever height “a” between the lever top and footrest.

Adjust the gearshift lever height if necessary.

Gearshift lever height “a”

Standard: 65 – 75 mm (2.6 – 3.0 in)

2) Loosen the lock-nuts (1).

3) Turn the gearshift link rod (2) until the gearshift lever is 65 – 75 mm (2.6 – 3.0 in) below the top of the footrest.

4) Tighten the lock-nuts securely.

2

1

“ a ”

I947H1520002-01

I947H1520001-01

Gearshift Shaft / Gearshift Cam Plate Components

(c)

(a)

B947H15206012

2

(b)

3

1

(c)

1. Gearshift shaft

2. Gearshift cam drive plate

3. Gearshift cam plate

4. Gearshift cam stopper

4

: 19 N

⋅ m (1.9 kgf-m, 13.5 lbf-ft)

: 13 N

⋅ m (1.3 kgf-m, 9.5 lbf-ft)

: 8.5 N

⋅ m (0.85 kgf-m, 6.0 lbf-ft)

: Apply grease to oil seal lip.

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: Apply thread lock to the thread part.

: Apply thread lock to the thread part.

: Apply engine oil to bearing.

: Do not reuse.

I947H1520073-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-17

Gearshift Shaft Construction

B947H15206013

2

4 5

(c)

1

3

2

(a)

3

6

(b)

(a)

1. Gearshift shaft

2. Washer

3. Snap ring

4. Gearshift shaft return spring

5. Gearshift cam drive plate

6. Gearshift plate return spring

: 8.5 N

⋅ m (0.85 kgf-m, 6.0 lbf-ft)

: 13 N

⋅ m (1.3 kgf-m, 9.5 lbf-ft)

: 19 N

⋅ m (1.9 kgf-m, 13.5 lbf-ft)

: Apply grease.

Gearshift Shaft / Gearshift Cam Plate Removal and Installation

B947H15206014

Removal

1) Remove the engine sprocket cover. Refer to “Engine

Sprocket Removal and Installation” in Section 3A

(Page 3A-2).

2) Remove the clutch components. Refer to “Clutch

Removal” in Section 5C (Page 5C-5).

3) Remove the snap ring (1) and washer (2) from the gearshift shaft.

Special tool

: 09900–06107 (Snap ring remover (Open type))

1

2

I947H1520059-03

: Apply thread lock to the thread part.

: Apply thread lock to the thread part.

: Apply engine oil to bearing.

: Do not reuse.

4) Remove the gearshift shaft assembly (3).

3

I947H1520003-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-18 Manual Transmission:

5) Remove the following parts from the gearshift shaft.

Special tool

: 09900–06107 (Snap ring remover (Open type))

• Apply a small quantity of thread lock to the gearshift arm stopper and tighten it to the specified torque.

: Thread lock cement 99000–32030

(THREAD LOCK CEMENT SUPER “1303” or equivalent)

Tightening torque

Gearshift arm stopper (a): 19 N·m (1.9 kgf-m, 13.5 lbf-ft)

7

8

9

10

(a)

4

5

6

I947H1520004-01

4. Washer

5. Snap ring

6. Gearshift shaft return spring

7. Gearshift cam drive plate

8. Gearshift plate return spring

9. Washer

10. Gearshift shaft end screw

6) Remove the gearshift cam plate bolt (11) and gearshift cam plate (12).

7) Remove the gearshift cam stopper (13).

Remove the gearshift arm stopper (14).

14

I947H1520006-02

• Assemble the gearshift cam stopper (1), bolt (2), washer (3) and return spring (4).

• Tighten the gearshift cam stopper bolt (2) to the specified torque.

NOTE

Hook the return spring end “A” to the stopper.

Tightening torque

Gearshift cam stopper bolt (b): 10 N·m (1.0 kgfm, 7.0 lbf-ft)

11

1

12

13

I947H1520005-02

Installation

Install the gearshift shaft and gearshift cam plate in the reverse order of removal. Pay attention to the following points:

!

CAUTION

The removed snap rings must be replaced with new ones.

2

3

4

I947H1520007-01

“A”

2

(b)

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-19

• Check the gearshift cam stopper moves smoothly.

• Locate the gearshift cam in the neutral position.

• Install the gearshift cam plate (5).

NOTE

Align the gearshift cam pin “B” with the gearshift cam plate hole “C”.

• Apply a small quantity of thread lock to the gearshift shaft end screw and tighten it to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Gearshift shaft end screw (d): 8.5 N·m (0.85 kgfm, 6.0 lbf-ft)

“B”

5

(d)

“C”

I947H1520009-01

• Apply a small quantity of thread lock to the gearshift cam plate bolt and tighten it to the specified torque.

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

Tightening torque

Gearshift cam plate bolt (c): 13 N·m (1.3 kgf-m,

9.5 lbf-ft)

I947H1520011-01

• When installing the gearshift shaft return spring, position the stopper “D” of gearshift arm between the shaft return spring ends “E”.

“D”

(c)

I947H1520010-01

“E”

I947H1520012-01

• Install the washer (6) and gearshift shaft assembly (7).

NOTE

Pinch the gearshift arm stopper (8) with return spring ends “E”.

8

6

“E”

7

I947H1520013-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-20 Manual Transmission:

• Install a new snap ring (9).

Special tool

: 09900–06107 (Snap ring remover (Open type))

Gearshift Shaft Bearing

Inspect the gearshift shaft bearings for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual.

9

I947H1520014-01

• After installing the gearshift lever, check the gearshift lever height. Refer to “Gearshift Lever Height

Inspection and Adjustment” (Page 5B-16).

Gearshift Linkage Inspection

B947H15206015

Refer to “Gearshift Shaft / Gearshift Cam Plate Removal and Installation” (Page 5B-17).

Gearshift Shaft

Check the gearshift shaft for bend or wear.

Check the return spring for damage or fatigue.

If any defects are found, replace the defective part(-s).

I947H1520017-01

Gearshift Shaft Oil Seal / Bearing Removal and

Installation

B947H15206016

Removal

1) Remove the gearshift shaft. Refer to “Gearshift Shaft

/ Gearshift Cam Plate Removal and Installation”

(Page 5B-17).

2) Remove the gearshift shaft oil seal (1).

1

I947H1520015-01

Gearshift Shaft Oil Seal

Inspect the gearshift shaft oil seal lip for damage or wear. If any defect is found, replace the oil seal with a new one.

I947H1520018-01

3) Remove the bearings (2) and (3) with the special tools.

Special tool

(A): 09921–20210 (Bearing remover (12 mm))

(B): 09930–30104 (Rotor remover sliding shaft)

(A)

2

(A)

3

(B)

(B)

I947H1520019-01

I947H1520016-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-21

Installation

Install the oil seal and bearing in the reverse order of removal. Pay attention to the following points:

!

CAUTION

The removed oil seal and bearings must be replaced with new ones.

• Install the bearings with the special tool.

NOTE

The stamped mark side of gearshift shaft bearing faces outside.

Special tool

(A): 09913–70210 (Bearing installing set (10

– 75

Φ

))

• Install the oil seal with the special tool.

Special tool

(A): 09913–70210 (Bearing installing set (10

– 75

Φ

))

(A)

I947H1520021-01

• Apply grease to the oil seal lip.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

(A)

(A)

I947H1520020-01

Service Data

Drive Train

Unit: mm (in) Except ratio

Item

Primary reduction ratio

Final reduction ratio

Gear ratios

Low

2nd

3rd

4th

5th

Top

Gearshift fork to groove clearance

Gearshift fork groove width

Gearshift fork thickness

Gearshift lever height

Specifications

Standard

1.617 (76/47)

2.470 (42/17)

2.562 (41/16)

2.052 (39/19)

1.714 (36/21)

1.500 (36/24)

1.360 (34/25)

1.269 (33/26)

0.1 – 0.3 (0.004 – 0.012)

5.0 – 5.1 (0.197 – 0.201)

4.8 – 4.9 (0.189 – 0.193)

65 – 75 (2.6 – 3.0)

I947H1520022-01

B947H15207001

Limit

—

—

—

—

—

—

—

—

0.5 (0.02)

—

—

— email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5B-22 Manual Transmission:

Tightening Torque Specifications

Fastening part

Driveshaft right bearing case bolt

Driveshaft left bearing case bolt

Driveshaft oil seal retainer screw

Gearshift cam bearing retainer screw

Gear position switch mounting bolt

Gearshift arm stopper

Gearshift cam stopper bolt

Gearshift cam plate bolt

Gearshift shaft end screw

N

⋅

m

12

12

12

10

6.5

19

10

13

8.5

Tightening torque kgf-m

1.2

1.2

1.2

1.0

0.65

1.9

1.0

1.3

0.85

lbf-ft

8.7

8.7

8.7

7.0

4.5

13.5

7.0

9.5

6.0

B947H15207002

Note

)

(Page 5B-6)

)

(Page 5B-7)

)

(Page 5B-7)

)

(Page 5B-8)

)

(Page 5B-14)

)

(Page 5B-18)

)

(Page 5B-18)

)

(Page 5B-19)

)

(Page 5B-19)

NOTE

The specified tightening torque is described in the following.

“Transmission Components” (Page 5B-2)

“Gearshift Lever Construction” (Page 5B-15)

“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-16)

“Gearshift Shaft Construction” (Page 5B-17)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

Grease

Material

Thread lock cement

B947H15208001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or equivalent

THREAD LOCK CEMENT SUPER

Note

P/No.: 99000–25010

)

(Page 5B-6) /

)

(Page 5B-

7) /

)

(Page 5B-7) /

)

(Page 5B-7) /

)

(Page 5B-

11) /

)

(Page 5B-14) /

)

(Page 5B-21)

P/No.: 99000–32030

)

(Page 5B-18)

“1303” or equivalent

THREAD LOCK CEMENT SUPER

“1322” or equivalent

P/No.: 99000–32110

)

(Page 5B-6) /

)

(Page 5B-

7) /

)

(Page 5B-7) /

)

(Page 5B-8) /

)

(Page 5B-

19) /

)

(Page 5B-19)

NOTE

Required service material is also described in the following.

“Transmission Components” (Page 5B-2)

“Gearshift Lever Construction” (Page 5B-15)

“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-16)

“Gearshift Shaft Construction” (Page 5B-17)

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Manual Transmission: 5B-23

Special Tool

09900–06104

Snap ring remover (Open type)

)

(Page 5B-10)

09900–06107

Snap ring remover (Open type)

)

(Page 5B-17) /

)

(Page 5B-18) /

)

(Page 5B-20)

B947H15208002

09900–20102

Vernier calipers (200 mm)

)

(Page 5B-12) /

)

(Page 5B-12)

09900–20803

Thickness gauge

)

(Page 5B-12)

09913–70210

Bearing installing set (10 –

75

Φ

)

)

(Page 5B-5) /

)

(Page 5B-

5) /

)

(Page 5B-5) /

)

(Page 5B-5) /

)

(Page 5B-

6) /

)

(Page 5B-6) /

)

(Page 5B-6) /

)

(Page 5B-

11) /

)

(Page 5B-21) /

)

(Page 5B-21)

09921–20240

Bearing remover set

)

(Page 5B-5)

09921–20210

Bearing remover (12 mm)

)

(Page 5B-20)

09923–74511

Bearing remover

)

(Page 5B-4)

09930–30104

Rotor remover sliding shaft

)

(Page 5B-4) /

)

(Page 5B-

20) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5C-1 Clutch:

Transmission / Transaxle

Clutch

Precautions

Precautions for Clutch System

Refer to “General Precautions” in Section 00 (Page 00-1).

B947H15300001

Schematic and Routing Diagram

Clutch Cable Routing Diagram

Refer to “Throttle Cable Routing Diagram” in Section 1D (Page 1D-2).

B947H15302001

Diagnostic Information and Procedures

Clutch System Symptom Diagnosis

Condition

Engine is noisy (Noise seems to come from the clutch)

Clutch slips

B947H15304001

Possible cause

Worn countershaft spline.

Worn clutch hub spline.

Worn clutch plate teeth.

Distorted clutch plate.

Worn clutch release bearing.

Weakened clutch damper.

Weakened clutch spring.

Replace.

Replace.

Replace primary driven gear.

Replace.

Correction / Reference Item

Replace countershaft.

Replace clutch hub.

Replace clutch plate.

Worn or distorted clutch pressure plate.

Replace.

Distorted clutch plate.

Replace.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Clutch: 5C-2

Repair Instructions

Clutch Lever Position Switch Inspection

B947H15306001

Inspect the clutch lever position switch in the following procedures:

1) Disconnect the clutch lever position switch lead wires (1).

Clutch Cable Inspection

B947H15306002

Refer to “Clutch Cable Play Inspection and Adjustment” in Section 0B (Page 0B-14).

1

Clutch Cable Removal and Installation

B947H15306003

Removal

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the clutch cable from the clutch lever.

Refer to “Handlebar Removal and Installation” in

Section 6B (Page 6B-2).

3) Remove the clutch cable as shown in the throttle cable routing diagram. Refer to “Throttle Cable

Routing Diagram” in Section 1D (Page 1D-2).

I947H1530001-02

2) Inspect the clutch lever position switch for continuity with the tester.

If any abnormality is found, replace the switch with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

Installation

1) Install the clutch cable as shown in the throttle cable routing diagram. Refer to “Throttle Cable Routing

Diagram” in Section 1D (Page 1D-2).

2) Reinstall the removed parts.

Clutch lever position switch

Position

Color

FREE

Terminal (B/Y) Terminal (B/W)

I649G1530004-03

3) Connect the clutch lever position switch lead wires.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5C-3 Clutch:

Clutch Control System Components

B947H15306004

(a)

(c)

(b)

4

1

2

3

1. Push rod

2. Clutch release camshaft

3. Clutch release arm

4. Clutch cable

: 1 N

⋅ m (0.1 kgf-m, 0.7 lbf-ft)

: 6 N

⋅ m (0.6 kgf-m, 4.5 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 0.7 lbf-ft)

: Apply grease.

: Do not reuse.

I947H1530043-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Clutch Components

(a)

1

3

4/5

3

4/5

3

5

3

5

3

2

(b)

5

3

5

3

5

3

6

7

Clutch: 5C-4

B947H15306005

8

9

10

11

12

16

13

14

1. Clutch pressure plate

2. Clutch push piece

3. No. 1 drive plate (8 pcs.)

4. No. 3 driven plate (0 – 2 pcs.)

5. No. 1 driven plate (5 – 7 pcs.)

6. No. 2 driven plate (1 pc.)

7. No. 2 drive plate (1 pc.)

8. Spring washer

9. Spring washer seat

10. Clutch sleeve hub

11. Seat washer

12. Wave spring washer

13. Clutch lifter driven cam

14. Clutch lifter drive cam email: [email protected] / www.motomatrix.co.uk

15

15. Primary driven gear assembly

16. Push rod

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: 95 N

⋅ m (9.5 kgf-m, 68.7 lbf-ft)

: Apply engine oil.

I947H1530044-03

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5C-5 Clutch:

Clutch Removal

B947H15306006

1) Drain engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

2) Lift and support the fuel tank with the prop stay.

Refer to “Fuel Tank Removal and Installation” in

Section 1G (Page 1G-9).

3) Disconnect the CKP sensor coupler (1).

6) Remove the clutch springs and pressure plate (4).

NOTE

Loosen the clutch spring set bolts little by little and diagonally.

4

1

I947H1530042-02

I947H1530004-01

7) Remove the clutch drive plates (5) and driven plates

(6).

4) Remove the clutch cover (2).

2

5

6

5) Remove the gasket (3) and dowel pins.

I947H1530002-01

I947H1530005-01

Remove the spring washer (7) and its seat (8).

8

7

3

I947H1530006-01

I947H1530003-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9) Remove the thrust washer (9), bearing (10) and clutch push piece (11).

13) Remove the clutch sleeve hub nut.

Clutch: 5C-6

(A)

11

10

9

I947H1530007-01

10) Remove the clutch push rod (12).

NOTE

If it is difficult to pull out the push rod (12), use a magnetic hand or wire.

I947H1530010-01

14) Remove the spring washer (13), washer (14) and clutch sleeve hub (15).

15

13

14

12

I947H1530011-01

15) Remove the seat washer (16) from the clutch sleeve hub.

I947H1530008-01

11) Unlock the clutch sleeve hub nut.

16

I947H1530009-01

12) Hold the clutch sleeve hub with the special tool.

Special tool

(A): 09920–53740 (Clutch sleeve hub holder)

I947H1530012-01

16) Remove the wave spring washers (17) and clutch lifter driven cam (18).

17

18

I947H1530013-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5C-7 Clutch:

17) Remove the clutch lifter drive cam (19) and thrust washer (20).

2) Install the spacer (2) and bearing (3), and apply engine oil to them.

19

3

20

2

I947H1530014-01

18) Remove the spacer (21) and bearing (22).

19) Remove the primary driven gear assembly (23).

NOTE

If it is difficult to remove the primary driven gear, rotate the crankshaft.

3) Install the thrust washer (4).

4

I947H1530017-01

23

22

I947H1530018-01

4) Install the seat washer (5) to the clutch sleeve hub

(6).

21

5

6

I947H1530015-01

Clutch Installation

B947H15306007

1) Install the primary driven gear assembly (1).

!

CAUTION

• If it is difficult to install the primary driven gear, rotate the crankshaft.

• Be sure to engage the oil pump drive sprocket with the primary driven gear.

1

I947H1530019-01

5) Install the wave spring washers (7) and clutch lifter driven cam (8).

6) Apply engine oil to the contacting surfaces of the clutch sleeve hub, clutch lifter drive cam and clutch lifter driven cam.

I947H1530016-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

7) Install the clutch lifter drive cam (9).

9

(a)

8

Clutch: 5C-8

(A)

7

I947H1530020-02

Install the clutch sleeve hub, washer (10) and spring washer (11).

NOTE

The conical curve side of spring washer (11) faces outside.

I947H1530022-01

11) Lock the clutch sleeve hub nut with a center punch.

10

11

I947H1530023-01

12) Install the clutch push rod (12) into the countershaft.

I947H1530021-01

12

10

11

I837H1530024-02

9) Hold the clutch sleeve hub with the special tool.

Special tool

(A): 09920–53740 (Clutch sleeve hub holder)

10) Tighten the clutch sleeve hub nut to the specified torque.

Tightening torque

Clutch sleeve hub nut (a): 95 N·m (9.5 kgf-m,

68.7 lbf-ft)

I947H1530024-01

13) Install the clutch push piece (13), bearing (14) and thrust washer (15) to the countershaft.

NOTE

Thrust washer (15) is located between the pressure plate and bearing (14).

13

14

15

I947H1530025-01 email: [email protected] / www.motomatrix.co.uk

5C-9 Clutch:

14) Install the spring washer seat (16) and spring washer

(17) onto the clutch sleeve hub correctly.

16

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

17

NOTE

Two kinds of drive plate (No. 1 and No. 2) are equipped in the clutch system, they can be distinguished by inside diameter.

Drive plate

No. 1

No. 2

I.D.

112 mm (4.41 in)

122.5 mm (4.82 in)

15) Apply engine oil to the clutch drive plates.

I837H1530028-01

16) Insert the clutch drive plates and driven plate one by one into the clutch sleeve hub in the prescribed order.

NOTE

Insert the outermost No. 1 drive plate claws

“A” to the other slits “B” of clutch housing as shown in the figure.

“B”

“A”

NOTE

Three kinds of the driven plate (No. 1, No. 2 and No. 3) are equipped in the clutch system, they can be distinguished by color and thickness.

The No. 1, No. 2 and No. 3 driven plates are 8 pcs. in total.

5 – 7 pcs. of No. 1 driven plates are used with

1 pc. of No. 2 and 0 – 2 pc(-s). of No. 3 driven plate(-s) as a set. The No. 3 driven plate(-s) should be installed in pressure plate side.

Driven plate

No. 1

No. 2

No. 3

Thickness

2.3 mm (0.09 in)

2.3 mm (0.09 in)

2.6 mm (0.10 in)

Color

Silver

Gray (Heat treated)

Silver

17) Install the pressure plate (23).

NOTE

When install the pressure plate, fit the convex part “D” of the pressure plate onto the concave part “E” of the clutch sleeve hub.

18

19

I947H1530026-02

“E”

“D”

“C”

I947H1530027-01

23

18) Install the clutch springs and set bolts.

I947H1530028-02

20 21

18. No. 2 drive plate (1 pc.)

19. No. 1 drive plate (8 pcs.)

20. No. 2 driven plate (1 pc.)

21. No. 1 driven plate (5 – 7 pcs.)

22. No. 3 driven plate (0 – 2 pcs.)

“C”: Direction of outside email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

19) Tighten the clutch spring set bolts to the specified torque.

Tightening torque

Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lbfft)

NOTE

Tighten the clutch spring set bolt little by little and diagonally.

Clutch: 5C-10

22) Apply bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown in the figure.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

I947H1530029-01

20) Loosen the lock-nut (24) and turn in the clutch release adjusting screw (25) until resistance is felt.

21) From that position, turn out the clutch release adjusting screw (25) 1 turn and tighten the lock-nut

(24) while holding the screw (25).

Tightening torque

Clutch release adjusting screw lock-nut: 6 N·m (

0.6 kgf-m, 4.5 lbf-ft)

I947H1530031-01

23) Install the dowel pins and new gasket (26).

!

CAUTION

Use new gasket to prevent oil leakage.

24

25

I947H1530030-02

26

I947H1530032-01

24) Apply bond lightly to the CKP sensor grommet.

: Sealant 99000–31140 (SUZUKI BOND

No.1207B or equivalent)

25) Apply molybdenum oil solution to the starter torque limiter/idle gear No. 2 shaft holes.

M/O: Molybdenum oil (MOLYBDENUM OIL

SOLUTION)

I947H1530033-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5C-11 Clutch:

26) Install the clutch cover and tighten the clutch cover bolts.

NOTE

Fit new gasket washer to the bolt “F” and clamp to the bolt “G”.

“G”

Measure the claw width of drive plates with a vernier calipers. Replace the drive plates found to have worn down to the limit.

Special tool

(A): 09900–20102 (Vernier calipers (200 mm))

Clutch drive plate claw width

Service limit (No. 1 and No. 2 drive plates): 12.90 mm

(0.508 in)

“F”

(A)

I947H1530034-01

27) Route the CKP sensor lead wire properly. Refer to

“Wiring Harness Routing Diagram” in Section 9A

(Page 9A-7).

28) Install the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-9).

29) Pour engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

Clutch Parts Inspection

B947H15306008

Refer to “Clutch Removal” (Page 5C-5) and “Clutch

Installation” (Page 5C-7).

Clutch Drive and Driven Plate

NOTE

Wipe off the engine oil from the drive and driven plates with a clean rag.

Measure the thickness of drive plates with a vernier calipers. If the drive plate thickness is found to have reached the limit, replace it with a new one.

Special tool

(A): 09900–20102 (Vernier calipers (200 mm))

Clutch drive plate thickness

Service limit (No. 1 and No. 2 drive plates): 2.92 mm

(0.115 in)

I649G1530057-03

Measure each driven plate for distortion with a thickness gauge and surface plate.

Replace driven plates which exceed the limit.

Special tool

(B): 09900–20803 (Thickness gauge)

Clutch driven plate distortion

Service limit (No. 1, No. 2 and No.3 driven plates):

0.10 mm (0.004 in)

(B)

I649G1530058-03

Clutch Spring

Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit.

Replace all the springs if any spring is not within the limit.

Special tool

(A): 09900–20102 (Vernier calipers (200 mm))

Clutch spring free length

Service limit: 55.3 mm (2.18 in)

(A)

(A)

I649G1530056-03 email: [email protected] / www.motomatrix.co.uk

I718H1530062-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Clutch Release Bearing

Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.

Smooth engagement and disengagement of the clutch depends on the condition of this bearing.

Clutch: 5C-12

Wave Spring Washer

Measure the free height “A” of each wave spring washer with a vernier calipers.

If each wave spring washer height “A” is not within the specified limit, replace it with a new one.

Special tool

: 09900–20102 (Vernier calipers (200 mm))

Wave spring washer height “A”

Service limit: 4.30 mm (0.169 in)

I649G1530059-02

Push Rod (Right)

Inspect the push rod for wear and damage.

If any defects are found, replace the push rod with a new one.

“A”

I837H1530043-01

Clutch Lifter Drive Cam and Clutch Lifter Driven Cam

Inspect the clutch lifter drive cam and clutch lifter driven cam for wear and damage. If any defects are found, replace the clutch lifter drive cam or clutch lifter driven cam.

I947H1530035-01

Clutch Sleeve Hub and 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.

I947H1530037-01

I947H1530036-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5C-13 Clutch:

Clutch Lifter Pin Inspection and Adjustment

B947H15306009

Refer to “Clutch Removal” (Page 5C-5) and “Clutch

Installation” (Page 5C-7).

NOTE

When inspection and adjusting the clutch lifter pin, it is not necessary to install the clutch onto the countershaft.

Inspect and adjust the clutch lifter pin in the following procedures:

1) Assemble the following parts into the primary driven gear assembly.

• Clutch sleeve hub

• Spring washer seat, spring washer

• Clutch drive plates, clutch driven plates

• Pressure plate

• Clutch springs, clutch springs set bolts

Tightening torque

Clutch spring set bolt (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

NOTE

Tighten the clutch spring set bolt little by little and diagonally.

3) Inspect the height “A” of clutch lifter pin at three positions using the thickness gauge. If the measurement is out of the specification, adjust the height “A” as shown in the figure.

Special tool

: 09900–20803 (Thickness gauge)

Clutch lifter pin height “A”

Standard: 0.2 – 0.4 mm (0.008 – 0.016 in)

“A”

“A”

“A”

“A”

I837H1530044-01

4) Loosen the lock-nuts (1) and turn out the clutch lifter pin (2).

NOTE

Each clutch lifter pin height should be as closely as possible.

2

(a)

(a)

(a)

1

I947H1530038-01

2) Remove the clutch assembly from the primary driven gear assembly.

I947H1530040-01

5) Set the thickness gauge to 0.3 mm (0.012 in).

Special tool

(A): 09900–20803 (Thickness gauge)

6) Place a proper flat plate on the thickness gauges and hold them by hand.

7) Slowly turn in the clutch lifter pin (2) until resistance is felt.

I947H1530039-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Tighten the lock-nut (1).

Tightening torque

Clutch lifter pin lock-nut (b): 23 N·m (2.3 kgf-m,

16.5 lbf-ft)

2

Clutch: 5C-14

(A)

1

(b)

(A)

I947H1530041-02

I837H1530046-02

Specifications

Service Data

Clutch

Unit: mm (in)

Item

Clutch drive plate thickness

Clutch drive plate claw width

Clutch driven plate distortion

Clutch spring free length

Clutch lifter pin height

Wave spring washer height

Clutch lever play

Clutch release screw

No. 1 and 2

No. 1 and 2

Standard

3.22 – 3.38 (0.127 – 0.133)

13.7 – 13.8 (0.539 – 0.543)

—

58.18 (2.29)

0.2 – 0.4 (0.008 – 0.016)

—

10 – 15 (0.4 – 0.6)

1 turn back

B947H15307001

Limit

2.92 (0.115)

12.9 (0.508)

0.10 (0.004)

55.3 (2.18)

—

4.30 (0.169)

—

—

Tightening Torque Specifications

Fastening part

Clutch sleeve hub nut

Clutch spring set bolt

Clutch release adjusting screw lock-nut

Clutch lifter pin lock-nut

N

⋅

m

95

10

6

23

Tightening torque kgf-m

9.5

0.6

2.3

lbf-ft

68.7

4.5

16.5

)

B947H15307002

Note

(Page 5C-8)

)

(Page 5C-10)

)

(Page 5C-14)

NOTE

The specified tightening torque is described in the following.

“Clutch Control System Components” (Page 5C-3)

“Clutch Components” (Page 5C-4)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

5C-15 Clutch:

Special Tools and Equipment

Recommended Service Material

Material

Molybdenum oil

Sealant

SUZUKI recommended product or Specification

MOLYBDENUM OIL SOLUTION

SUZUKI BOND No.1207B or equivalent

Note

—

)

(Page 5C-10)

P/No.: 99000–31140

)

(Page 5C-10) /

)

(Page 5C-10)

B947H15308001

NOTE

Required service material is also described in the following.

“Clutch Control System Components” (Page 5C-3)

“Clutch Components” (Page 5C-4)

Special Tool

09900–20102

Vernier calipers (200 mm)

)

(Page 5C-11) /

)

(Page 5C-11) /

)

(Page 5C-11) /

)

(Page 5C-12)

09900–20803

Thickness gauge

)

(Page 5C-11) /

)

(Page 5C-13) /

)

(Page 5C-13)

B947H15308002

09900–25008

Multi circuit tester set

)

(Page 5C-2)

09920–53740

Clutch sleeve hub holder

)

(Page 5C-6) /

)

(Page 5C-

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 6- i

Section 6

Steering

CONTENTS

Precautions ………………………………………….6-1

Precautions……………………………………………………. 6-1

Precautions for Steering ………………………………… 6-1

Steering General Diagnosis……………….. 6A-1

Diagnostic Information and Procedures…………6A-1

Steering Symptom Diagnosis………………………… 6A-1

Steering / Handlebar………………………….. 6B-1

Repair Instructions ……………………………………….6B-1

Handlebar Components ……………………………….. 6B-1

Handlebar Removal and Installation ………………. 6B-2

Handlebars Inspection …………………………………. 6B-4

Steering Components ………………………………….. 6B-5

Steering Damper Construction……………………….6B-6

Steering / Steering Damper Removal and

Installation …………………………………………………6B-6

Steering / Steering Damper Related Parts

Inspection………………………………………………….6B-9

Steering System Inspection …………………………6B-10

Steering Stem Bearing Removal and

Installation ……………………………………………….6B-10

Steering Tension Adjustment ……………………….6B-11

Specifications ……………………………………………..6B-12

Tightening Torque Specifications………………….6B-12

Special Tools and Equipment ………………………6B-13

Recommended Service Material …………………..6B-13

Special Tool ………………………………………………6B-13

6

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6-1 Precautions:

Steering

Precautions

Precautions

Precautions for Steering

Refer to “General Precautions” in Section 00 (Page 00-1).

B947H16000001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Steering General Diagnosis: 6A-1

Steering

Steering General Diagnosis

Diagnostic Information and Procedures

Steering Symptom Diagnosis

Condition

Heavy steering

Wobbly handlebars

Possible cause

Over tightened steering stem nut.

Broken bearing in steering stem.

Distorted steering stem.

Not enough pressure in tires.

Defective steering damper unit.

Loss of balance between right and left front forks.

Distorted front fork.

Distorted front axle or crooked tire.

Loose steering stem nut.

Worn or incorrect tire or wrong tire pressure.

Worn bearing/race in steering stem.

Replace.

B947H16104001

Adjust.

Replace.

Correction / Reference Item

Replace.

Adjust.

Replace.

Replace fork, adjust fork oil level or replace spring.

Repair or replace.

Replace.

Adjust.

Adjust or replace.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6B-1 Steering / Handlebar:

Steering

Steering / Handlebar

Repair Instructions

Handlebar Components

2

4

B947H16206001

3

5

(a)

1

6

“A”

1. Throttle grip

2. Grip rubber

3. Right handlebar switch box

4. Left handlebar switch box

5. Right handlebar

6. Left handlebar

7. Handlebar expander

8. Handlebar balancer

7

8

(b)

“A”: Apply handle grip bond.

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 5.5 N

⋅ m (0.55 kgf-m, 4.0 lbf-ft)

: Apply grease.

I947H1620001-05 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Steering / Handlebar: 6B-2

Handlebar Removal and Installation

B947H16206002

Removal

1) Remove the following parts from the left handlebar.

a) Left handlebar switch box (1) b) Handlebar balancer (2) c) Grip rubber (3) d) Clutch cable (4)

3) Loosen the handlebar clamp bolts (9) and front fork upper clamp bolts (10).

10

10

9

9

2

3

1

4

I947H1620004-01

4) Remove the steering stem head nut (11) and washer

(12).

5) Remove the steering stem upper bracket assembly

(13).

NOTE

Place a rag under the steering stem upper bracket to prevent scratching the body cowling and the combination meter.

I947H1620002-01

2) Remove the following parts from the right handlebar.

a) Right handlebar switch box (5) b) Handlebar balancer (6) c) Throttle grip (7) d) Front brake master cylinder (8)

!

CAUTION

Do not turn the front brake master cylinder upside down.

11

13

12

I947H1620005-01

6) Remove the handlebars (14) upward.

7

8

6

5

I947H1620003-01

14

I947H1620006-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6B-3 Steering / Handlebar:

7) Remove the clutch lever assembly (15) from the left handlebar.

• Insert the protrusion “B” of the handlebar into the hole

“C” of the steering stem upper bracket.

15

“C”

“C”

“B”

“B”

I947H1620007-01

Installation

Install the handlebars in the reverse order of removal.

Pay attention to the following points:

• When installing the clutch lever assembly to the left handlebar, align the slit of lever holder with the punch mark “A”.

I947H1620010-01

• Tighten the front fork upper clamp bolts (4) and handlebar clamp bolts (5) to the specified torque.

Tightening torque

Front fork upper clamp bolt (a): 23 N·m (2.3 kgfm, 16.5 lbf-ft)

Handlebar clamp bolt (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

“A”

I947H1620009-01

• Install the handlebars temporarily to the front forks.

• Install the upper bracket (1), washer (2) and steering stem head nut (3) temporarily.

NOTE

Face the chamfer side of the washer downward.

4

(a)

4

(a)

5

(b)

5

(b)

I947H1620011-01

• Tighten the steering stem head nut (6) to the specified torque.

Tightening torque

Steering stem head nut (c): 90 N·m (9.0 kgf-m,

65.0 lbf-ft)

3

2

1

1

2

3

6

(c)

I947H1620012-01

I947H1620008-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Steering / Handlebar: 6B-4

• Install the front brake master cylinder. Refer to “Front

Brake Master Cylinder Assembly Removal and

Installation” in Section 4A (Page 4A-10).

• Apply grease to the end of the throttle cables and cable pulley.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Insert the projection “D” of the right handlebar switch box into the hole of the right handlebar.

• After installing the steering, the following adjustments are required before driving.

– Throttle cable routing (Refer to “Throttle Cable

Routing Diagram” in Section 1D (Page 1D-2))

– Clutch cable routing (Refer to “Throttle Cable

Routing Diagram” in Section 1D (Page 1D-2))

– Throttle cable play (Refer to “Throttle Cable Play

Inspection and Adjustment” in Section 1D

(Page 1D-7))

– Clutch cable play (Refer to “Clutch Cable Play

Inspection and Adjustment” in Section 0B

(Page 0B-14))

“D”

Handlebars Inspection

B947H16206003

Refer to “Handlebar Removal and Installation” (Page 6B-

2).

Inspect the handlebars for distortion and damage.

If any defect is found, replace the handlebar with a new one.

I947H1620013-01

• Apply a handle grip bond “E” onto the left handlebar before installing the handlebar grip.

: Handle grip bond (Handle Grip Bond

(commercially available))

“E”

I947H1620016-01

I947H1620014-01

• Insert the projection “F” of the left handlebar switch box into the hole of the left handlebar.

“F”

I947H1620015-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6B-5 Steering / Handlebar:

Steering Components

1

(a)

2

7

5

3

(c)

4

(b)

6

(d)

9

8

B947H16206004

12

10

11

1. Steering stem head nut

2. Steering stem upper bracket

3. Steering stem lock-nut

4. Washer

5. Steering stem nut

6. Dust seal cover

7. Dust seal

8. Steering stem upper bearing

9. Steering stem lower bearing

10. Lower seal

11. Steering stem lower bracket

12. Steering stem lower bearing inner race

I947H1620017-04

: 90 N

⋅ m (9.0 kgf-m, 65.0 lbf-ft)

: 80 N

⋅ m (8.0 kgf-m, 58.0 lbf-ft)

: 45 N

⋅ m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/2 – 1/4

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: Apply grease.

: Do not reuse.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Steering / Handlebar: 6B-6

Steering Damper Construction

B947H16206005

2

1

3

2

1. Steering damper 2. Dust seal 3. Bearing

Steering / Steering Damper Removal and

Installation

B947H16206006

Removal

Steering damper

1) Turn the ignition switch OFF.

2) Disconnect the steering damper solenoid coupler

(1).

(a)

I837H1620040-01

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft) : Apply grease.

5) Remove the steering damper mounting bolt (5).

6) Remove the steering damper (6).

6

4

1

3) Remove the lower bracket cover (2).

2

I947H1620018-01

I947H1620019-01

4) Remove the steering damper mounting nut (3) while holding the lock-nut (4).

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5

3

I947H1620020-01

Steering

1) Support the motorcycle with a jack or wooden block.

!

CAUTION

Do not work by using side stand. Do not support the motorcycle with exhaust pipe.

Make sure that the motorcycle is supported securely.

2) Remove the front wheel assembly. Refer to “Front

Wheel Assembly Removal and Installation” in

Section 2D (Page 2D-4).

3) Remove the front forks. Refer to “Front Fork

Removal and Installation” in Section 2B (Page 2B-2).

4) Remove the steering damper. Refer to “Steering /

Steering Damper Removal and Installation”

(Page 6B-6).

5) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-

9).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6B-7 Steering / Handlebar:

6) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

7) Disconnect the ignition switch lead wire coupler (1) and immobilizer antenna lead wire coupler (For E-

02, 19, 24, 51) (2).

11) Remove the steering stem lock-nut (7), washer and steering stem nut (8) with the special tools.

NOTE

When loosening the stem nuts, hold the steering stem lower bracket to prevent it from falling.

Special tool

(A): 09940–14911 (Steering stem nut socket wrench)

(B): 09940–14960 (Steering stem nut socket wrench)

2

(A)

1

Remove the brake hose clamp bolt (3).

I947H1620021-01

(B)

7

8

3

I947H1620041-01

9) Remove the steering stem head nut (4) and washer

(5).

10) Remove the steering stem upper bracket assembly

(6).

I947H1620023-01

12) Remove the steering stem lower bracket.

13) Remove the dust seal cover (9), dust seal (10), upper bearing inner race (11) and upper bearing

(12).

9

10

11

12

6

I947H1620024-01

4

5

I947H1620022-01

NOTE

It is not necessary to remove the ignition switch from the upper bracket when servicing the steering system.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Steering / Handlebar: 6B-8

Installation

Install the steering in the reverse order of removal.

Pay attention to the following points:

Bearing

• Apply grease to the bearings, bearing races and dust seals before remounting the steering stem.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings seat properly.

• Loosen the steering stem nut 1/4 – 1/2 turn “a”.

NOTE

This adjustment will vary from motorcycle to motorcycle.

“ a ”

I947H1620025-01

I947H1620028-01

• When installing the washer (2), align the lug of the washer to the groove of the steering stem.

2

I947H1620026-01

Steering stem nut

• Tighten the steering stem nut (1) to the specified torque with the special tools.

Special tool

(A): 09940–14911 (Steering stem nut socket wrench)

(B): 09940–14960 (Steering stem nut socket wrench)

Tightening torque

Steering stem nut (a): 45 N

⋅

m (4.5 kgf-m, 32.5 lbfft) then turn back 1/4 – 1/2

I947H1620029-01

• Tighten the steering stem lock-nut (3) to the specified torque with the special tools.

Special tool

(A): 09940–14911 (Steering stem nut socket wrench)

(B): 09940–14960 (Steering stem nut socket wrench)

Tightening torque

Steering stem lock-nut (b): 80 N·m (8.0 kgf-m,

58.0 lbf-ft)

(A)

(B)

(A)

(B)

1

(a)

I947H1620027-01 email: [email protected] / www.motomatrix.co.uk

3

(b)

I947H1620030-01

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6B-9 Steering / Handlebar:

Steering stem upper bracket

Install the front forks and steering stem upper bracket in the following points:

• Temporarily install the upper bracket (1), washer (2) and steering stem head nut (3). Refer to “Handlebar

Removal and Installation” (Page 6B-2).

• Install the steering damper and tighten the bolt (1) and nut (2).

Tightening torque

Steering damper bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

Steering damper nut (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

1

3

2

1

2

3

1

(a)

2

(b)

I947H1620031-01

• Temporarily install the front forks.

• Tighten the steering stem head nut (3) to the specified torque.

Tightening torque

Steering stem head nut (a): 90 N·m (9.0 kgf-m,

65.0 lbf-ft)

I947H1620033-02

Inspection after installation

• Check the steering tension. Refer to “Steering Tension

Adjustment” (Page 6B-11).

Steering / Steering Damper Related Parts

Inspection

B947H16206007

Refer to “Steering / Steering Damper Removal and

Installation” (Page 6B-6).

Inspect the removed parts for the following abnormalities:

Steering Stem

• Distortion of the steering stem and brackets.

3

(a)

I947H1620032-01

• Tighten the front fork upper and lower clamp bolts.

Refer to “Front Fork Removal and Installation” in

Section 2B (Page 2B-2).

Steering damper

• Apply grease to the bearings and dust seals.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

I947H1620034-01

I823H1620019-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Steering / Handlebar: 6B-10

Bearing

• Bearing wear or damage

• Abnormal bearing noise

• Race wear or damage

• Bearing lower seal damage

Steering System Inspection

B947H16206008

Refer to “Steering System Inspection” in Section 0B

(Page 0B-18).

Steering Stem Bearing Removal and Installation

B947H16206009

Removal

1) Remove the steering stem upper bearing and steering stem lower bracket. Refer to “Steering /

Steering Damper Removal and Installation”

(Page 6B-6).

2) Remove the steering stem lower bearing inner race using a chisel.

I947H1620035-01

I649G1620033-02

3) Remove the steering stem upper and lower bearing races using the steel rod.

I947H1620036-01

Steering Damper

• Inspect the steering damper body, bearing and oil seal for damage and oil leaking.

• Move the steering damper rod by hand to inspect for a smooth movement.

• If any defects are found, replace the steering damper with a new one.

NOTE

The steering damper operation can be checked without removing it. Refer to “DTC

“C93” (P1769): Steering Damper Solenoid

Valve Circuit Malfunction” in Section 1A

(Page 1A-134).

I837H1620033-01

Installation

Install the steering stem bearings in the reverse order of removal. Pay attention to the following points:

!

CAUTION

The removed bearings and races should be replaced with new ones.

I947H1620037-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6B-11 Steering / Handlebar:

Outer race

• Press in the upper and lower outer races using the special tool.

Special tool

(A): 09941–34513 (Bearing installer)

– 75

(B): 09913–70210 (Bearing installing set (10

Φ

))

4) With the front wheel in the straight ahead state, hitch the spring scale (special tool) on one handlebar grip end as shown in the figure and read the graduation when the handlebar starts moving.

Initial force

200 – 500 grams

Special tool

(A): 09940–92720 (Spring scale)

(A)

(B)

(A)

(A)

(B)

I947H1620038-01

Inner race

• Press in the lower bearing inner race using the special tool.

Special tool

(A): 09925–18011 (Bearing installer)

(A)

I947H1620039-01

• Install the steering. Refer to “Steering / Steering

Damper Removal and Installation” (Page 6B-6).

Steering Tension Adjustment

B947H16206010

Check the steering movement in the following procedures:

1) By supporting the motorcycle with a jack, lift the front wheel unit is off the floor 20 – 30 mm (0.8 – 1.2 in).

2) Remove the steering damper. Refer to “Steering

Damper Construction” (Page 6B-6).

3) Check to make sure that the cables and wire harnesses are properly routed.

I649G1620040-02

5) Do the same on the other grip end.

6) If the initial force read on the scale when the handlebar starts turning is either too heavy or too light, adjust it till it satisfies the specification.

a) First, loosen the front fork upper clamp bolts, handlebar clamp bolts, steering stem head nut and steering stem lock-nut, and then adjust the steering stem nut by loosening or tightening it.

b) Tighten the steering stem lock-nut, stem head nut, handlebar clamp bolts and front fork upper clamp bolts to the specified torque and re-check the initial force with the spring scale according to the previously described procedure.

c) If the initial force is found within the specified range, adjustment has been completed.

NOTE

Hold the front fork legs, move them back and forth and make sure that the steering is not loose.

I947H1620040-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Steering / Handlebar: 6B-12

Specifications

Tightening Torque Specifications

Fastening part

Front fork upper clamp bolt

Handlebar clamp bolt

Steering stem head nut

Steering stem nut

N

⋅

m

23

23

Tightening torque kgf-m

2.3

2.3

lbf-ft

16.5

16.5

90

45 N

⋅ m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/4 – 1/2

80

23

23

8.0

2.3

2.3

58.0

16.5

16.5

B947H16207001

Note

)

(Page 6B-3)

)

(Page 6B-3)

)

(Page 6B-8)

Steering stem lock-nut

Steering damper bolt

Steering damper nut

)

(Page 6B-8)

)

(Page 6B-9)

)

(Page 6B-9)

NOTE

The specified tightening torque is described in the following.

“Handlebar Components” (Page 6B-1)

“Steering Components” (Page 6B-5)

“Steering Damper Construction” (Page 6B-6)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

6B-13 Steering / Handlebar:

Special Tools and Equipment

Recommended Service Material

Grease

Material

Handle grip bond

B947H16208001

SUZUKI recommended product or Specification

SUZUKI SUPER GREASE “A” or equivalent

Handle Grip Bond (commercially

Note

P/No.: 99000–25010

)

(Page 6B-4) /

)

(Page 6B-

/

)

(Page 6B-9)

—

)

(Page 6B-4) available)

NOTE

Required service material is also described in the following.

“Handlebar Components” (Page 6B-1)

“Steering Components” (Page 6B-5)

“Steering Damper Construction” (Page 6B-6)

Special Tool

09913–70210

Bearing installing set (10 –

75

Φ

)

)

(Page 6B-11)

09925–18011

Bearing installer

)

(Page 6B-11)

B947H16208002

09940–14911

Steering stem nut socket wrench

)

(Page 6B-7) /

)

(Page 6B-

/

)

(Page 6B-8)

09940–92720

Spring scale

)

(Page 6B-11)

09940–14960

Steering stem nut socket wrench

)

(Page 6B-7) /

)

(Page 6B-

/

)

(Page 6B-8)

09941–34513

Bearing installer

)

(Page 6B-11) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Table of Contents 9- i

Section 9

Body and Accessories

CONTENTS

Precautions ………………………………………….9-1

Precautions……………………………………………………. 9-1

Precautions for Electrical System ……………………. 9-1

Component Location ……………………………………… 9-1

Electrical Components Location ……………………… 9-1

Specifications ……………………………………………..9B-13

Service Data………………………………………………9B-13

Tightening Torque Specifications………………….9B-13

Special Tools and Equipment ………………………9B-13

Recommended Service Material …………………..9B-13

Special Tool ………………………………………………9B-13

Wiring Systems…………………………………. 9A-1

Schematic and Routing Diagram……………………9A-1

Wiring Diagram …………………………………………… 9A-1

Wiring Harness Routing Diagram…………………… 9A-7

Specifications……………………………………………..9A-11

Service Data …………………………………………….. 9A-11

Tightening Torque Specifications…………………. 9A-11

Special Tools and Equipment ………………………9A-11

Recommended Service Material ………………….. 9A-11

Lighting Systems………………………………. 9B-1

Repair Instructions ……………………………………….9B-1

Headlight Components ………………………………… 9B-1

Headlight Removal and Installation ……………….. 9B-1

Headlight Bulb and Position Light Bulb

Replacement …………………………………………….. 9B-2

Headlight Beam Adjustment …………………………. 9B-3

Front Turn Signal Light Components ……………… 9B-3

Front Turn Signal Light Removal and

Installation ………………………………………………… 9B-4

Front Turn Signal Light Bulb Replacement ……… 9B-4

Rear Lighting System Construction………………… 9B-5

Rear Combination Light Removal and

Installation ………………………………………………… 9B-6

Rear Combination Light Replacement ……………. 9B-6

License Plate Light Components …………………… 9B-7

License Plate Light Removal and Installation ….. 9B-7

License Plate Light Bulb Replacement …………… 9B-8

Rear Turn Signal Light Components………………. 9B-9

Rear Turn Signal Light Removal and

Installation ………………………………………………… 9B-9

Rear Turn Signal Light Bulb Replacement…….. 9B-10

Reflex Reflector Construction ……………………… 9B-10

Turn Signal / Side-Stand Relay Inspection ……. 9B-11

Turn Signal / Side-Stand Relay Removal and

Installation ………………………………………………. 9B-11

Hazard Switch Inspection …………………………… 9B-11

Turn Signal Switch Inspection……………………… 9B-12

Dimmer / Passing Light Switch Inspection …….. 9B-12 email: [email protected] / www.motomatrix.co.uk

Combination Meter / Fuel Meter / Horn.. 9C-1

General Description ………………………………………9C-1

Combination Meter System Description …………..9C-1

Repair Instructions ……………………………………….9C-2

Combination Meter Components ……………………9C-2

Combination Meter Removal and Installation …..9C-2

Combination Meter Disassembly and

Assembly…………………………………………………..9C-3

Combination Meter Inspection ……………………….9C-3

Engine Coolant Temperature Indicator Light

Inspection………………………………………………….9C-4

ECT Sensor Removal and Installation …………….9C-4

Fuel Level Indicator Inspection ………………………9C-5

Fuel Level Gauge Inspection …………………………9C-5

Speedometer Inspection ……………………………….9C-5

Speed Sensor Removal and Installation ………….9C-5

Speed Sensor Inspection ………………………………9C-6

Oil Pressure Indicator Inspection ……………………9C-6

Oil Pressure Switch Removal and Installation ….9C-7

Oil Pressure Switch Inspection ………………………9C-7

Ignition Switch Inspection………………………………9C-7

Ignition Switch Removal and Installation………….9C-7

Horn Inspection ……………………………………………9C-8

Horn Removal and Installation ……………………….9C-8

Specifications ……………………………………………….9C-9

Service Data………………………………………………..9C-9

Tightening Torque Specifications……………………9C-9

Special Tools and Equipment ………………………..9C-9

Special Tool ………………………………………………..9C-9

Exterior Parts ……………………………………. 9D-1

Repair Instructions ……………………………………….9D-1

Exterior Parts Construction ……………………………9D-1

Rear Fender Construction……………………………..9D-2

Frame Cover Construction …………………………….9D-3

Rear View Mirror Construction ……………………….9D-4

Fastener Removal and Installation………………….9D-5

Exterior Parts Removal and Installation …………..9D-6

9

9-ii Table of Contents

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Specifications……………………………………………..9D-12

Tightening Torque Specifications………………….9D-12

Body Structure …………………………………..9E-1

Repair Instructions ………………………………………. 9E-1

Body Frame Construction …………………………….. 9E-1

Front Footrest Bracket Construction ………………. 9E-2

Side-stand Construction……………………………….. 9E-3

Pillion Footrest Construction ………………………….9E-4

Side-stand Removal and Installation……………….9E-4

Specifications ……………………………………………….9E-5

Tightening Torque Specifications ……………………9E-5

Special Tools and Equipment ………………………..9E-5

Recommended Service Material …………………….9E-5 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Precautions: 9-1

Body and Accessories

Precautions

Precautions

Precautions for Electrical System

B947H19000001

Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00

(Page 00-2).

Component Location

Electrical Components Location

Refer to “Electrical Components Location” in Section 0A (Page 0A-7).

B947H19003001 email: [email protected] / www.motomatrix.co.uk

9A-1 Wiring Systems:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Body and Accessories

Wiring Systems

Schematic and Routing Diagram

Wiring Diagram

Refer to “Wire Color Symbols” in Section 0A (Page 0A-5).

For E-02, 19, 24, 51

METER

SWITCH

HANDLEBAR SWITCH (RH)

UP

FREE

DOWN ENGINE

STOP

SWITCH

FREE

PUSH

STARTER

BUTTON

OFF

RUN

FRONT BRAKE

SWITCH

OFF

ON

SIDE-STAND

SWITCH

PUSH

FREE

IMMOBILIZER

SPEED

SENSOR

IGNITION SWITCH

ON

OFF

LOCK

P

BRAKE LIGHT

SWITCH

IGNITION

ON

OFF

COIL #1

IGNITION

COIL #2

IGNITION

COIL #3

IGNITION

COIL #4

PAIR

CONTROL

SOLENOID

VALVE

B947H19102001

HEADLIGHT (HI)

COMBINATION METER

FRONT TURN SIGNAL LIGHT (RH)

B

B

B/Bl

B/W

POSITION LIGHT (RH)

Br

B/W

B/Br

B/W

POSITION LIGHT (LH)

Br

B/W

B/Br

B/W

FRONT TURN SIGNAL LIGHT (LH)

B

B

B

B/W

HEADLIGHT (LO) W

B/W

B/Bl

B/O

STEERING

DAMPER

SOLENOID

VALVE

Dg

Dbr

B/R

P

Y/Bl

B/G

G/Y

B/Lg

Bl/B

W

Br

O/G

Br/Y

R/Bl

Lg

W

B

Br

B/W

Y

1 2 3 4 5 6

HORN

ON

OFF

OIL

PRESSURE

SWITCH

COOLING

FAN RELAY

M

FUSE BOX

FUEL PUMP

1. HEAD HI

2. HEAD LO

3. IGNITION

4. SIGNAL

5. FUEL

6. FAN

10 A

10 A

15 A

10 A

10 A

15 A

PUSH

DOWN

PUSH

UP

PUSH

HORN

BUTTON

OFF

ON

HAZARD

SWITCH

L

PUSH

R

TURN SIGNAL

LIGHT SWITCH

HI

LO

PASS

FREE

CLUTCH

SWITCH

DIMMER & PASS

SWITCH

HANDLEBAR SWITCH (LH)

B Bl

1

1: MAIN FUSE (30 A)

STARTER

MOTOR

BATTERY

GENERATOR

I947H1910901-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wiring Systems: 9A-2

ECM

Br

Bl

LICENSE PLTE LIGHT

Gr

B

Lg

B/W

W/B

B/W

Br

Bl

B/W

Lg

B

Br

B/Bl

W/B

B

B/W

REAR TURN SIGNAL LIGHT (RH)

B

B/W

Br

B/W

W/B

REAR COMBINATION LIGHT

B

B/W

REAR TURN SIGNAL LIGHT (LH)

TO SENSOR

GEAR

CMP

SENSOR

POSITION

SWITCH

ECT

SENSOR

EXCVA

AP

SENSOR

CKP

SENSOR

COOLING

FAN RELAY

COOLING

FAN MOTOR

HO2 SENSOR

REGULATOR/

RECTIFIER

IAP

SENSOR

STVA

TP

SENSOR

ISC

VALVE

IAT

SENSOR

STP

SENSOR

PRIMARY

INJECTOR #1

PRIMARY

INJECTOR #3

PRIMARY

INJECTOR #2

SECONDARY

INJECTOR #1

PRIMARY

INJECTOR #4

SECONDARY

INJECTOR #3

SECONDARY

INJECTOR #2

SECONDARY

INJECTOR #4

I947H1910902-03 email: [email protected] / www.motomatrix.co.uk

9A-3 Wiring Systems:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

For E-03, 28

METER

SWITCH

UP

FREE

DOWN

HANDLEBAR SWITCH (RH)

ENGINE

STOP

SWITCH

OFF

RUN

STARTER

BUTTON

FREE

PUSH

FRONT BRAKE

SWITCH

OFF

ON

SIDE-STAND

SWITCH

PUSH

FREE

SPEED

SENSOR

IGNITION SWITCH

ON

OFF

LOCK

P

BRAKE LIGHT

SWITCH

IGNITION

ON

OFF

COIL #1

IGNITION

COIL #2

IGNITION

COIL #4

IGNITION

COIL #3

PAIR

CONTROL

SOLENOID

VALVE

HEADLIGHT (HI)

COMBINATION METER

FRONT TURN SIGNAL LIGHT (RH)

B

B

B/Bl

B/W

POSITION LIGHT (RH)

Br

B/W

B/Br

B/W

POSITION LIGHT (LH)

Br

B/W

B/Br

B/W

FRONT TURN SIGNAL LIGHT (LH)

B

B

B

B/W

HEADLIGHT (LO)

W

B/W

B/Bl

B/O

STEERING

DAMPER

SOLENOID

VALVE

Dg

Dbr

B/R

P

Y/Bl

B/G

G/Y

B/Lg

Bl/B

W

Br

O/G

R/Bl

Lg

W

B

Br

B/W

Y

1 2 3 4 5

HORN

ON

OFF

OIL

PRESSURE

SWITCH

PUSH

DOWN

COOLING

FAN RELAY

PUSH

UP

M

FUEL PUMP

FUSE BOX

1. HEAD HI

2. HEAD LO

3. IGNITION

4. SIGNAL

5. FUEL

6. FAN

10 A

10 A

15 A

10 A

10 A

15 A

PUSH

HORN

BUTTON

OFF

ON

HAZARD

SWITCH

L

PUSH

R

TURN SIGNAL

LIGHT SWITCH

HI

LO

PASS

DIMMER & PASS

SWITCH

FREE

CLUTCH

SWITCH

6

HANDLEBAR SWITCH (LH)

B Bl

STARTER

MOTOR

1

1: MAIN FUSE (30 A)

BATTERY GENERATOR

I947H1910903-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wiring Systems: 9A-4

ECM

Br

Bl

LICENSE PLTE LIGHT

Gr

B Lg

B/W

W/B

B/W

Br

Bl

B/W

Lg

B

Br

B/Bl

W/B

B

B/W

REAR TURN SIGNAL LIGHT (RH)

B

B/W

Br

B/W

W/B

REAR COMBINATION LIGHT

B

B/W

REAR TURN SIGNAL LIGHT (LH)

TO SENSOR

GEAR

POSITION

SWITCH

CMP

SENSOR

ECT

SENSOR

EXCVA

CKP

SENSOR

AP

SENSOR

COOLING

FAN RELAY

COOLING

FAN MOTOR

HO2 SENSOR

REGULATOR/

RECTIFIER

IAP

SENSOR

STVA

TP

SENSOR

ISC

VALVE

IAT

SENSOR

STP

SENSOR

PRIMARY

INJECTOR #1

PRIMARY

INJECTOR #3

PRIMARY

INJECTOR #2

SECONDARY

INJECTOR #1

PRIMARY

INJECTOR #4

SECONDARY

INJECTOR #3

SECONDARY

INJECTOR #2

SECONDARY

INJECTOR #4

I947H1910904-03 email: [email protected] / www.motomatrix.co.uk

9A-5 Wiring Systems:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

For E-14, 33

METER

SWITCH

UP

FREE

DOWN

HANDLEBAR SWITCH (RH)

ENGINE

STOP

SWITCH

OFF

RUN

STARTER

BUTTON

FREE

PUSH

FRONT BRAKE

SWITCH

OFF

ON

SIDE-STAND

SWITCH

PUSH

FREE

SPEED

SENSOR

IGNITION SWITCH

ON

OFF

LOCK

P

BRAKE LIGHT

SWITCH

IGNITION

ON

OFF

COIL #1

IGNITION

COIL #2

IGNITION

COIL #4

IGNITION

COIL #3

PAIR

CONTROL

SOLENOID

VALVE

HEADLIGHT (HI)

COMBINATION METER

FRONT TURN SIGNAL LIGHT (RH)

B

B

B/Bl

B/W

POSITION LIGHT (RH)

Br

B/W

POSITION LIGHT (LH)

Br

B/W

B/Br

B/W

B/Br

B/W

FRONT TURN SIGNAL LIGHT (LH)

B

B

B

B/W

HEADLIGHT (LO)

W

B/W

B/Bl

B/O

STEERING

DAMPER

SOLENOID

VALVE

Dg

Dbr

B/R

P

Y/Bl

B/G

G/Y

B/Lg

Bl/B

W

Br

O/G

R/Bl

Lg

W

B

Br

B/W

Y

1 2 3 4 5

HORN

ON

OFF

OIL

PRESSURE

SWITCH

PUSH

DOWN

COOLING

FAN RELAY

PUSH

UP

M

FUEL PUMP

FUSE BOX

1. HEAD HI

2. HEAD LO

3. IGNITION

4. SIGNAL

5. FUEL

6. FAN

10 A

10 A

15 A

10 A

10 A

15 A

PUSH

HORN

BUTTON

OFF

ON

HAZARD

SWITCH

L

PUSH

R

TURN SIGNAL

LIGHT SWITCH

HI

LO

PASS

DIMMER & PASS

SWITCH

FREE

CLUTCH

SWITCH

6

HANDLEBAR SWITCH (LH)

B Bl

STARTER

MOTOR

1

1: MAIN FUSE (30 A)

BATTERY GENERATOR

I947H1910905-03 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wiring Systems: 9A-6

ECM

EVAP

SYSTEM

PURGE

CONTROL

SOLENOID

VALVE

Br

Bl

LICENSE PLTE LIGHT

Gr

B Lg

B/W

W/B

B/W

Br

Bl

B/W

Lg

B

Br

B/Bl

W/B

B

B/W

REAR TURN SIGNAL LIGHT (RH)

B

B/W

Br

B/W

W/B

REAR COMBINATION LIGHT

B

B/W

REAR TURN SIGNAL LIGHT (LH)

TO SENSOR

GEAR

POSITION

SWITCH

CMP

SENSOR

ECT

SENSOR

EXCVA

CKP

SENSOR

AP

SENSOR

COOLING

FAN RELAY

COOLING

FAN MOTOR

HO2 SENSOR

REGULATOR/

RECTIFIER

IAP

SENSOR

STVA

TP

SENSOR

ISC

VALVE

IAT

SENSOR

STP

SENSOR

PRIMARY

INJECTOR #1

PRIMARY

INJECTOR #3

PRIMARY

INJECTOR #2

SECONDARY

INJECTOR #1

PRIMARY

INJECTOR #4

SECONDARY

INJECTOR #3

SECONDARY

INJECTOR #2

SECONDARY

INJECTOR #4

I947H1910906-03 email: [email protected] / www.motomatrix.co.uk

9A-7 Wiring Systems:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wiring Harness Routing Diagram

B947H19102002

“A”, “B”

2

“A”

“C”

1

“D”

3

1

4

“E”

“F”

1. Wiring harness No. 2

2. Tapping clamp

: Insert the clamp from the front side. Place the turn signal and position light couplers in front of the clamp.

3. Steel clamp

: Clamp the wiring harness at the blue taping point. Bend the steel clamps to the front side.

4. Clamp:

Face the clamp end upward.

“A”: Take care not pinch the position light lead wires between the headlight assembly and cowling brace.

I947H1910907-03

“B”: Pass the left position light lead wires under the wiring harness No. 2.

“C”: Route the steering damper lead wire under the wiring harness No. 2.

Do not pass it over the harness.

“D”: Pass the wiring harness No. 2 in front of the air intake pipe mounting fastener.

“E”: Place the small coupler inside and the big one outside.

“F”: Pass the right handlebar switch lead wire above the ignition switch lead wire.

email: [email protected] / www.motomatrix.co.uk

2

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wiring Systems: 9A-8

“C”

“B”

1

Upside

“A”

3

4

5

“D”

“E”

“ a ”

16

13

17

1. Clamp

: Pass the side-stand switch lead wire left side of the water bypass hose and clamp them in this range. Cut off the excess tip of the clamp.

2. Clamp

: Bind the lead wires at the blue taping point and face the clamp end to the engine side.

3. IAT sensor

4. ISC valve

5. Clamp

: Bind the lead wires with throttle body at blue taping point and face the clamp end forward.

6. White coupler (for ignition coil #1)

7. Clamp:

Face the clamp end upward.

8. STVA lead wire

9. Wiring harness

10. ISC valve lead wire

11. Regulator/rectifier lead wire

12. EVAP system purge control solenoid valve lead wire (E-33 only)

15

6

13

8

9

10

14

7

12

9

14

11

I947H1910908-03

13. Battery negative lead wire

: Pass the battery negative lead wire in front of the PCV hose. (For E-33, pass the lead wire below the EVAP solenoid hoses, and between the EVAP solenoid lead wire and wiring harness.)

14. Rear brake light switch lead wire

: Pass the rear brake light switch lead wire below the wiring harness and battery negative lead wire at the frame bridge part, then above the wiring harness at the fuel tank rail part. (For E-33, pass the brake light switch lead wire between

EVAP solenoid bracket and frame.)

15. Crankcase breather (PCV) hose

16. Starter motor lead wire

17. CKP sensor lead wire

: Route the CKP sensor lead wire in front of the PCV hose and above the battery negative lead wire.

“A”: Pass the side-stand switch lead wire between the water hoses.

“B”: Plate the joint coupler to the engine side and pass the side-stand switch lead wire and speed sensor lead wire left side of the water by-pass hose.

“C”: Pass the rear brake light switch lead wire between the frame and drain hose, and under the clamp.

“D”: Pass the CMP sensor lead wire between ignition coil #1 and #2.

“E”: Pass the wiring harness above the air cleaner duct.

“a”: 60

±

5

° email: [email protected] / www.motomatrix.co.uk

9A-9 Wiring Systems:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

“B”

Upside

“A”

1

4

2

“D”

3

“C”

4

5

6

7

1. Steel clamp

: Set the clamp facing downward and bend it to outside.

2. Clamp

: Bind the wiring harness and battery negative lead wires at blue taping point and face the clamp end outside and downward. Be sure not to slacken the rear brake light switch lead wire.

3. Clamp

: Bind the wiring harness and starter motor lead wire at blue taping point and cut off the excess tip of the clamp.

4. ECM cushion

5. FP relay

6. Turn signal/side-stand relay

7. Cooling fan relay

“E”

8

I947H1910909-03

8. Clamp

: Put the coupler in the frame rib and face the clamp end inside.

“A”: Be sure not to pinch the CKP sensor lead wire between engine and water hose.

“B”: Put the coupler between the rear turn signal and frame cover.

“C”: Do not twist the wiring harness.

“D”: Bring the part number sticker on the wiring harness upward.

Do not twist the wiring harness.

“E”: Put the turn signal/side-stand relay lead wires inside the frame.

email: [email protected] / www.motomatrix.co.uk

7

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Wiring Systems: 9A-10

FWD

1

(a)

2

(a)

3

FWD

4

4

(b)

“ a ”

“ b ”

“A”

(c)

“ d ”

“ c ”

(e)

6

5

(d)

(h)

FWD

1. Cylinder head cover

2. CMP sensor

3. Battery negative lead wire

4. Starter motor lead wire

5. Oil pressure switch

6. GP switch

7. CKP sensor

8. Speed sensor

(f)

(g)

“A”: Pass the oil pressure switch lead wire between cylinder and generator lead wires.

“a”: 90

°

“b”: 45

°

“c”: 30

°

“d”: 15

°

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: 4 N

⋅ m (0.4 kgf-m, 3.0 lbf-ft)

: 1.5 N

⋅ m (0.15 kgf-m, 1.0 lbf-ft)

8

(f)

I947H1910910-02

: 14 N

⋅ m (1.4 kgf-m, 10.0 lbf-ft)

: 145 N

⋅ m (14.5 kgf-m, 105.0 lbf-ft)

: 6.5 N

⋅ m (0.65 kgf-m, 4.5 lbf-ft)

: 11 N

⋅ m (1.1 kgf-m, 8.0 lbf-ft)

: 5.5 N

⋅ m (0.55 kgf-m, 4.0 lbf-ft)

: Apply bond.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9A-11 Wiring Systems:

Specifications

Service Data

Electrical

Fuse size

Item

Headlight

Ignition

Signal

Fuel

Fan

Main

HI

LO

Specification

10 A

10 A

15 A

10 A

10 A

15 A

30 A

B947H1910S001

Note

Tightening Torque Specifications

B947H1910S002

NOTE

The specified tightening torque is described in the following.

“Wiring Harness Routing Diagram” (Page 9A-7)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

NOTE

Required service material is also described in the following.

“Wiring Harness Routing Diagram” (Page 9A-7)

B947H1910T001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Lighting Systems: 9B-1

Body and Accessories

Lighting Systems

Repair Instructions

Headlight Components

B947H19206001

1

2

3

1. Headlight Low beam bulb (12 V 55 W, H11)

Headlight Removal and Installation

2. Headlight High beam bulb (12 V 65 W, H9)

I947H1920001-02

3. Position light bulb (12 V 5 W) x 2

3) Remove the wiring harness No. 2 (2) by disconnecting the couplers and clamps.

B947H19206002

Removal

1) Remove the body cowling assembly. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

2) Remove the air intake pipes (1). Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2

1

I947H1920002-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9B-2 Lighting Systems:

4) Remove the intake pipe covers (3).

3

5) Remove the intake cover (4).

6) Remove the body cowling (5).

I947H1920003-01

Headlight Bulb and Position Light Bulb

Replacement

B947H19206003

!

CAUTION

When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

Low Beam Bulb

1) Remove the combination meter. Refer to

“Combination Meter Removal and Installation” in

Section 9C (Page 9C-2).

2) Disconnect the headlight (Low beam) coupler (1).

3) Remove the headlight bulb/socket (Low beam) (2) by turning it counterclockwise.

5

2

4

“A”

I947H1920005-01

I947H1920006-01

“A”: Velcro fastening

Installation

Installation is in the reverse order of removal. Pay attention to the following point:

• Route the wiring harness properly. Refer to “Wiring

Harness Routing Diagram” in Section 9A (Page 9A-7).

• After installing, be sure to inspect the headlight beam.

Refer to “Headlight Beam Adjustment” (Page 9B-3).

1

I947H1920007-01

4) Replace the headlight bulb (Low beam) with a new one.

5) Reinstall the removed parts.

High Beam Bulb

1) Remove the body cowling cover. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the headlight (High beam) coupler (1).

3) Remove the headlight bulb/socket (High beam) (2) by turning it counterclockwise.

2

1

4) Replace the headlight bulb (High beam) with a new one.

5) Reinstall the removed parts.

I947H1920008-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Lighting Systems: 9B-3

Position Light Bulb

1) Disconnect the position light socket (1).

1

Headlight Beam Adjustment

B947H19206004

Adjust the headlight beam, both horizontally and vertically.

NOTE

• To adjust the headlight beam, adjust the beam horizontally first, then vertically.

• It is not necessary to remove the combination meter to turn the adjusters.

I947H1920009-01

2) Replace the position light bulb (2) with a new one.

“A”

“B”

2

3) Reinstall the position light socket.

Front Turn Signal Light Components

I947H1920010-01

3

2

1

“A”: Horizontal adjuster “B”: Vertical adjuster

I947H1920011-02

B947H19206005

1. Turn signal light bulb (12 V 21 W) 2. Front turn signal light 3. Socket

I947H1920012-01 email: [email protected]x.co.uk / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9B-4 Lighting Systems:

Front Turn Signal Light Removal and

Installation

B947H19206006

Removal

1) Remove the screw.

Front Turn Signal Light Bulb Replacement

1) Remove the turn signal light assembly.

2) Remove the socket (1) by turning it counterclockwise.

B947H19206007

!

CAUTION

When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

1

I947H1920013-01

2) Disconnect the front turn signal coupler (1).

3) Remove the turn signal light assembly (2).

1

2

I947H1920014-01

Installation

Install the front turn signal light in the reverse order of removal.

3) Replace the front turn signal light bulb (2).

I947H1920015-01

2

I947H1920016-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Lighting Systems: 9B-5

Rear Lighting System Construction

B947H19206008

(a)

(b)

2

2

3

1

(c)

1. License plate light assembly

2. Reflex reflector (E-03, 28, 33 only)

3. Clamp

: Clamp the license plate light lead wire so as not to be slack.

4

4. Rear combination light

5. Rear turn signal light assembly (LH/RH)

: 5 N

⋅ m (0.5 kgf-m, 3.5 lbf-ft)

5

I947H1920017-01

: 1.8 N

⋅ m (0.18 kgf-m, 1.5 lbf-ft)

: 2.8 N

⋅ m (0.28 kgf-m, 2.0 lbf-ft)

: Apply thread lock to thread part.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9B-6 Lighting Systems:

Rear Combination Light Removal and

Installation

B947H19206009

Removal

1) Remove the frame cover assembly. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

2) Remove the clamps (1).

3) Disconnect the combination light coupler (2).

4) Remove the rear combination light assembly (3).

3

Installation

Install the rear combination light in the reverse order of removal. Pay attention to the following point:

• Tighten the combination light mounting bolts (1) to the specified torque.

NOTE

When reusing the removed bolts (1), apply a small quantity of the thread lock to them.

Tightening torque

Rear combination light mounting bolt (a): 2.8 N·m

(0.28 kgf-m, 2.0 lbf-ft)

: Thread lock cement 99000–32110

(THREAD LOCK CEMENT SUPER “1322” or equivalent)

1

2

5) Remove the combination light bracket (4).

I947H1920018-01

4

1

(a)

I947H1920019-01

I947H1920020-01

Rear Combination Light Replacement

B947H19206010

!

CAUTION

If LED operation is abnormal, replace the rear combination light with a new one.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Lighting Systems: 9B-7

License Plate Light Components

B947H19206011

(a)

1

2

3

1. License plate light bulb (12 V 5 W)

2. Lens cover

License Plate Light Removal and Installation

B947H19206012

Removal

1) Remove the frame cover. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Disconnect the license plate light coupler (1).

3. Lens

: 5 N

⋅ m (0.5 kgf-m, 3.5 lbf-ft)

3) Remove the nuts.

I947H1920021-01

1

I947H1920022-01

I947H1920023-01

4) Remove the license plate light assembly (2).

2

I947H1920024-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9B-8 Lighting Systems:

2) Remove the lens cover (1) by removing the screws.

Installation

Install the license plate light in the reverse order of removal. Pay attention to the following point:

• Tighten the license plate light mounting nuts (1) to the specified torque.

Tightening torque

License plate light mounting nut (a): 5 N·m (0.5 kgf-m, 3.5 lbf-ft)

1

3) Replace the bulb (2) with a new one.

I947H1920027-01

1

(a)

I947H1920025-01

License Plate Light Bulb Replacement

B947H19206013

!

CAUTION

When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

1) Remove the license plate light mounting nuts.

2

I947H1920028-01

4) Reinstall the removed parts.

5) Tighten the license plate light mounting nuts (3) to the specified torque.

Tightening torque

License plate light mounting nut (a): 5 N·m (0.5 kgf-m, 3.5 lbf-ft)

I947H1920026-01

3

(a)

I947H1920029-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Lighting Systems: 9B-9

Rear Turn Signal Light Components

B947H19206014

1

3

2

I947H1920030-01

Rear Turn Signal Light Removal and Installation

Removal

1. Rear turn signal light lens 2. Rear turn signal light bulb (12 V 21 W)

B947H19206015

1) Remove the frame cover assembly. Refer to

“Exterior Parts Removal and Installation” in Section

9D (Page 9D-6).

2) Remove the rear combination light. Refer to “Rear

Combination Light Removal and Installation”

(Page 9B-6).

3) Disconnect the lead wire coupler (1).

(LH: White, RH: Black)

4) Remove the screws (2).

3. Socket

5) Remove the side frame cover (3) from the center frame cover (4). Refer to “Frame Cover

Construction” in Section 9D (Page 9D-3).

4

3

“A”

2

I947H1920032-01

“A”: Bushing

1

I947H1920031-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9B-10 Lighting Systems:

6) Remove the rear turn signal light (5).

1) Remove the rear turn signal light lens (1).

5

I947H1920033-02

Installation

Install the rear turn signal light in the reverse order of removal.

Rear Turn Signal Light Bulb Replacement

B947H19206016

!

CAUTION

When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

2) Replace the bulb (2).

2

3) Reinstall the removed parts.

1

Reflex Reflector Construction

I947H1920034-01

I947H1920035-01

B947H19206017

(a)

2

2

1

1. Front reflex reflector x 2 pcs. (For E-03, 24, 28, 33) 2. Rear reflex reflector x 2 pcs. (For E-03, 28, 33)

I947H1920036-01

: 1.8 N

⋅ m (0.18 kgf-m, 1.5 lbf-ft) email: [email protected] / www.motomatrix.co.uk

(Page 0A-7).

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Lighting Systems: 9B-11

Turn Signal / Side-Stand Relay Inspection

B947H19206019

Refer to “Electrical Components Location” in Section 0A

NOTE

Make sure that the battery is fully charged.

Before removing the turn signal/side-stand relay, check the operation of the turn signal light.

If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

If the bulb, turn signal switch and circuit connection are

OK, the turn signal relay may be faulty; therefore, replace the turn signal/side-stand relay with a new one.

Refer to “Turn Signal / Side-Stand Relay Removal and

Installation” (Page 9B-11).

Hazard Switch Inspection

B947H19206021

Inspect the hazard switch in the following procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Disconnect the left handlebar switch coupler (1).

(Yellow)

1

Turn Signal / Side-Stand Relay Removal and

Installation

B947H19206020

Removal

1) Remove the frame cover. Refer to “Exterior Parts

Removal and Installation” in Section 9D (Page 9D-

6).

2) Remove the turn signal/side-stand relay (1).

1

I947H1920038-01

3) Inspect the hazard switch for continuity with the tester.

If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to

“Handlebar Removal and Installation” in Section 6B

(Page 6B-2).

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

I947H1920037-02

Installation

Install the turn signal/side-stand relay in the reverse order of removal.

Color

Position

OFF

B/R Bl Dg

ON

I947H1920039-01

4) After finishing the hazard switch inspection, reinstall the removed parts.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9B-12 Lighting Systems:

Turn Signal Switch Inspection

Inspect the turn signal switch in the following

B947H19206022 procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Disconnect the left handlebar switch coupler (1).

(Yellow)

Dimmer / Passing Light Switch Inspection

B947H19206023

Inspect the dimmer/passing light switch in the following procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Disconnect the left handlebar switch coupler (1).

(Yellow)

1 1

I947H1920040-02

3) Inspect the turn signal switch for continuity with the tester. If any abnormality is found, replace the left handlebar switch assembly with a new one.

Refer to “Handlebar Removal and Installation” in

Section 6B (Page 6B-2).

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

Color

Position

L

PUSH

B Lbl Lg

R

I947H1920041-01

4) After finishing the turn signal switch inspection, reinstall the removed parts.

I947H1920042-02

3) Inspect the dimmer/passing light switch for continuity with the tester.

If any abnormality is found, replace the left handlebar switch assembly with a new one.

Refer to “Handlebar Removal and Installation” in

Section 6B (Page 6B-2).

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

Position

Color

HI

LO

Y O W

PASS

I947H1920043-01

4) After finishing the passing light switch inspection, reinstall the removed parts.

email: [email protected] / www.motomatrix.co.uk

Service Data

Wattage

Unit: W

Item

Headlight

Position light

Brake light/Taillight

Turn signal light

License plate light

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Lighting Systems: 9B-13

Specifications

HI

LO

Specification

65

55

5 x 2

LED

21 x 4

5

B947H19207001

Tightening Torque Specifications

Fastening part

Rear combination light mounting bolt

License plate light mounting nut

N

⋅

m

2.8

5

Tightening torque kgf-m

0.28

lbf-ft

2.0

B947H19207002

Note

)

(Page 9B-6)

NOTE

The specified tightening torque is described in the following.

“Rear Lighting System Construction” (Page 9B-5)

“License Plate Light Components” (Page 9B-7)

“Reflex Reflector Construction” (Page 9B-10)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

Material

Thread lock cement

SUZUKI recommended product or Specification

THREAD LOCK CEMENT SUPER

Note

P/No.: 99000–32110

)

(Page 9B-6)

“1322” or equivalent

B947H19208001

NOTE

Required service material is also described in the following.

“Rear Lighting System Construction” (Page 9B-5)

Special Tool

09900–25008

Multi circuit tester set

)

(Page 9B-11) /

)

(Page 9B-12) /

)

(Page 9B-12)

B947H19208002 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9C-1 Combination Meter / Fuel Meter / Horn:

Body and Accessories

Combination Meter / Fuel Meter / Horn

General Description

Combination Meter System Description

B947H19301001

This combination meter mainly consists of a stepping motor, LCD (Liquid Crystal Display) and LEDs (Light Emitting

Diode).

The tachometer pointer is driven by the stepping motor.

The LCDs indicate followings:

Speed, Odo / Trip 1 / Trip 2 / Fuel reserve trip / Clock / FI (DTC) / Lap time counter / Panel light brightness, Gear position, Engine RPM indicator, Oil pressure indicator, Engine coolant temperature and Drive mode position.

LED (Light Emitting Diode)

LED is used for the illumination light and each indicator light.

LED is maintenance free. LED is less power consuming and more resistant to vibration resistance compared to the bulb.

Engine RPM Indicator Light

This speedometer is equipped the engine revolution indicator light. The engine revolution indicator light is adjustable from 5 000 – 13 750 r/min. (from 5 000 r/min to 10 000 r/min, every 250 r/min and 10 000 r/min to 13 750 r/min, every

50 r/min: Initial setting: 11 000 r/min)

12

2

17

12

4

18 14

13

16

1

3

6

5

8

1. ADJ button

2. Tachometer

3. LCD (Speedometer)

4. LCD (Engine RPM indicator)

5. SEL button

6. LCD (Odo / Trip 1 / Trip 2 / Fuel reserve trip / Clock /

FI (DTC) / Lap time counter / Panel light brightness)

7. LED (Engine RPM indicator light)

8. LCD (Engine coolant temperature)

9. LCD (Drive mode indicator)

9

10

11 7

15

I947H1930001-02

10. LED (Oil pressure indicator light / Engine coolant temperature indicator light)

11. LCD (Oil pressure indicator / Engine coolant temperature indicator)

12. LED (Turn signal indicator light)

13. LED (Neutral indicator light)

14. LED (Fuel indicator light)

15. LED (Immobilizer indicator light) (For E-02, 19, 24, 51)

16. LED (High-beam indicator light)

17. LCD (Gear position indicator)

18. LED (FI / Sd) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Combination Meter / Fuel Meter / Horn: 9C-2

Repair Instructions

Combination Meter Components

B947H19306001

2

1

3

I947H1930002-01

1. Combination meter unit 2. Combination meter case

Combination Meter Removal and Installation

B947H19306002

Removal

1) Remove the combination meter mounting bolt (1).

3. Combination meter cover

2) Disconnect the coupler (2) and remove the combination meter assembly (3).

“A”

3

2

“A”: Bushing

1

I947H1930003-01

I947H1930004-01

Installation

Install the combination meter in the reverse order of removal.

NOTE

Fix the boot of the combination meter coupler firmly.

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9C-3 Combination Meter / Fuel Meter / Horn:

Combination Meter Disassembly and Assembly

B947H19306003

Refer to “Combination Meter Removal and Installation”

(Page 9C-2).

Disassembly

Disassemble the combination meter as shown in the combination meter components. Refer to “Combination

Meter Components” (Page 9C-2).

Assembly

Assemble the combination meter as shown in the combination meter components. Refer to “Combination

Meter Components” (Page 9C-2).

NOTE

• The pointers may not return to the proper position even turning the ignition switch on under low temperature condition. In that case, you can reset the pointers to the proper position by the following instruction.

• Complete the operation within 10 seconds after the ignition switch has been turned on.

2) With the ADJ button (1) pressed, turn the ignition switch ON.

3) Keep pushing the ADJ button for more than 3 to 5 sec.

Combination Meter Inspection

B947H19306004

LED Inspection

Check that the LEDs “A” (FI, fuel, engine RPM, oil pressure/engine coolant, immobilizer (E-02, 19, 24, 51) and meter panel illumination) immediately light up when the ignition switch is turned ON.

Check that the other LEDs “B” (neutral, high-beam and turn signal indicator lights) light up/go off by operating each switch.

If abnormal condition is found, replace the combination meter assembly with a new one after checking its wire harness/coupler. Refer to “Combination Meter Removal and Installation” (Page 9C-2).

1

4) Release the ADJ button, then tap it twice.

I947H1930007-02

“B”

“A”

“B” “A”

“B”

I947H1930005-01

Stepping Motor Inspection and Adjustment

1) Check that the pointers calibrate immediately after turning the ignition switch ON and stop at zero point.

If abnormal condition is found, replace the combination meter assembly with a new one after checking its wire harness/coupler.

Time Ignition switch

OFF

Adjuster button (1)

PUSH

0

ON

•

•

•

•

•

•

3 sec.

•

5 sec.

Release

Push

Push

→

Reset

10 sec.

I837H1930023-01

Pointers will return to the proper position right after the completion of the operation. In the case of the pointers not returning to the proper position after doing above, replace the combination meter unit.

Refer to “Combination Meter Removal and

Installation” (Page 9C-2).

I947H1930006-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Combination Meter / Fuel Meter / Horn: 9C-4

Engine Coolant Temperature Indicator Light Inspection

B947H19306005

Inspect the engine coolant temperature meter and indicator light (LED) in the following procedures:

1) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6).

2) Disconnect the ECT sensor coupler (1).

1

3) Connect a variable resistor (2) between the terminals.

I947H1930008-01

2

I718H1930009-05

4) Turn the ignition switch ON.

5) Check the engine coolant temperature meter (LCD) (3) and indicator light (LED) (4) operations when the resistance is adjusted to the specified values.

If either one or both indications are abnormal, replace the combination meter assembly with a new one. Refer to

“Combination Meter Removal and Installation” (Page 9C-2).

5

3

4

I947H1930009-02

Resistance “A”

°

C

LCD (3)

°

F

2.45 k

Ω

and more

Approx. 0.318 k

0.1108 k

Ω

0

Ω

Ω

(Jumper wire)

“- — -”

“80”

“- — -”

and less “120” – “139” flicker “248” – “282” flicker

“HI”

“177”

“HI”

LED (4) LCD (5) Engine coolant temperature

OFF

OFF

ON

ON

—

Flicker

19

°

C (67

—

Flicker 120 – 139

°

°

F) and below

Approx. 80

°

C (177

°

F)

C (248 – 282

°

140

°

C (283

°

F) and over

F)

6) Connect the ECT sensor coupler.

7) Install the removed parts.

ECT Sensor Removal and Installation

Refer to “ECT Sensor Removal and Installation” in Section 1C (Page 1C-4).

email: [email protected] / www.motomatrix.co.uk

B947H19306006

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9C-5 Combination Meter / Fuel Meter / Horn:

Fuel Level Indicator Inspection

B947H19306007

If the fuel level indicator light (1) does not function properly, check the fuel level gauge and its lead wire/ coupler.

If the fuel level gauge and its lead wire/coupler are functioning properly, replace the combination meter with a new one.

1

3) Install the fuel pump. Refer to “Fuel Pump

Disassembly and Assembly” in Section 1G

(Page 1G-11).

Speedometer Inspection

B947H19306009

If the speedometer, odometer or tripmeter does not function properly, inspect the speed sensor and the coupler connections. If the speed sensor and coupler connections are OK, replace the combination meter unit with a new one. Refer to “Combination Meter Removal and Installation” (Page 9C-2).

Speed Sensor Removal and Installation

B947H19306010

Removal

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the speed sensor lead wire coupler (1).

I947H1930010-01

Fuel Level Gauge Inspection

B947H19306008

Inspect the fuel level gauge in the following procedures:

1) Remove the fuel pump. Refer to “Fuel Pump

Disassembly and Assembly” in Section 1G

(Page 1G-11).

2) Measure the resistance at each fuel level gauge in float position. If the resistance is incorrect, replace fuel level gauge with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Resistance (

Ω

)

Float position

Full “a”

Empty “b”

Resistance

3 – 5

Ω

179 – 185

Ω

1

3) Remove the speed sensor (2).

I947H1930012-01

2

“ a ”

I947H1930013-01

“ b ”

“a”: 186.5

±

5 mm (3.34

±

0.2 in)

I947H1930011-01

“b”: 59.7

±

5 mm (2.35

±

0.2 in) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Combination Meter / Fuel Meter / Horn: 9C-6

Installation

Install the speed sensor in the reverse order of removal.

Pay attention to the following points:

• Tighten the speed sensor mounting bolt (1) to the specified torque.

Tightening torque

Speed sensor mounting bolt (a): 6.5 N·m (0.65 kgf-m, 4.5 lbf-ft)

3) Move a screwdriver back and forth across the pickup surface of the speed sensor. The voltage readings should cycle as follows (0 V

→

12 V or 12 V

→

0 V). If the voltage reading does not change, replace the speed sensor with a new one.

NOTE

While testing, the highest voltage reading should be the same as the battery voltage (12

V).

1

(a)

I947H1930014-01

• Route the speed sensor lead wire. Refer to “Wiring

Harness Routing Diagram” in Section 9A (Page 9A-7).

Speed Sensor Inspection

B947H19306011

Inspect the speed sensor in the following procedures:

1) Remove the speed sensor. Refer to “Speed Sensor

Removal and Installation” (Page 9C-5).

2) Connect a 12 V battery (between B and B/W), 10 k

Ω resistor (between B/R and B) and multi-circuit tester

(tester (+) probe to B and tester (–) probe to B/R) as shown in the figure.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Voltage ( )

I649G1930017-02

Oil Pressure Indicator Inspection

B947H19306012

Inspect the oil pressure indicator in the following procedures:

NOTE

Before inspecting the oil pressure switch, check if the engine oil level is correct. Refer to “Engine Oil and Filter Replacement” in

Section 0B (Page 0B-10).

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the oil pressure switch lead wire (1) from the oil pressure switch.

B B/R

1

1. Speed sensor

I649G1930016-02

1

3) Turn the ignition switch ON.

I947H1930015-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9C-7 Combination Meter / Fuel Meter / Horn:

4) Check if the oil pressure indicator (LED) (2) will light up and LCD (3) will flicker when grounding the lead wire (1).

If the oil pressure indicator does not light up, replace the combination meter assembly with a new one after checking the connection of couplers.

Ignition Switch Inspection

B947H19306015

Inspect the ignition switch in the following procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Disconnect the ignition switch lead wire coupler (1).

1

1

2

3

I947H1930016-01

Oil Pressure Switch Removal and Installation

B947H19306013

Refer to “Oil Pressure Switch Removal and Installation” in Section 1E (Page 1E-9).

Oil Pressure Switch Inspection

B947H19306014

Inspect the oil pressure switch in the following procedures:

NOTE

Before inspecting the oil pressure switch, check if the engine oil level is correct. Refer to “Engine Oil and Filter Replacement” in

Section 0B (Page 0B-10).

1) Remove the left side cowling. Refer to “Exterior

Parts Removal and Installation” in Section 9D

(Page 9D-6).

2) Disconnect the oil pressure switch lead wire from the oil pressure switch.

3) Inspect the oil pressure switch for continuity with the tester. If any abnormality is found, replace the oil pressure switch with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

Color

Position

ON

(Engine is at stop.)

G/Y Ground

OFF

(Engine is running.)

I823H1930033-01

4) After finishing the oil pressure switch inspection, reinstall the removed parts.

I947H1930017-01

3) Inspect the ignition switch for continuity with a tester.

If any abnormality is found, replace the ignition switch with a new one.

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

E-02, 19, 24, 51

Position

ON

Color

OFF

LOCK

P

R O G/Y Br

I947H1930018-01

E-03, 14, 28, 33

Position

ON

Color

OFF

R O O/Y Gr Br

LOCK

P

I837H1930021-01

4) After finishing the ignition switch inspection, reinstall the removed parts.

Ignition Switch Removal and Installation

B947H19306016

Refer to “Ignition Switch Removal and Installation” in

Section 1H (Page 1H-11).

email: [email protected] / www.motomatrix.co.uk

Horn Inspection

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Combination Meter / Fuel Meter / Horn: 9C-8

Horn Inspection

1) Disconnect the horn coupler (1).

B947H19306017

NOTE

If the horn sound condition is normal, it is not necessary to inspect the horn button continuity.

Horn Button Inspection

1) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D

(Page 1D-7).

2) Disconnect the left handlebar switch lead wire coupler (1).

1

I947H1930022-01

2) Connect a 12 V battery to the horn terminals. If the sound is not heard from the horn, replace the horn with a new one.

1

I947H1930020-01

3) Inspect the horn button for continuity with a tester.

If any abnormality is found, replace the left handlebar switch assembly with a new one.

Refer to “Handlebar Removal and Installation” in

Section 6B (Page 6B-2).

Special tool

: 09900–25008 (Multi circuit tester set)

Tester knob indication

Continuity ( )

I947H1930023-01

3) Connect the horn coupler.

Horn Removal and Installation

B947H19306018

Removal

1) Disconnect the horn coupler (1).

2) Remove the horn (2) by removing the mounting bolts.

1

I718H1930028-03

2

I947H1930024-01

Installation

Install the horn in the reverse order of removal.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

9C-9 Combination Meter / Fuel Meter / Horn:

Specifications

Service Data

Wattage

Unit: W

Item

Combination meter light

Turn signal indicator light

High beam indicator light

Neutral position indicator light

Oil pressure indicator light/Engine coolant temp. indicator light

FI indicator light/Sd indicator light

Fuel level indicator light

Engine RPM indicator light

Immobilizer indicator light

E-02, 19, 24, 51

LED

LED

LED

LED

LED

LED

LED

LED

LED

Specification

E-03, 14, 28, 33

←

←

←

←

←

←

←

←

—

B947H19307001

Tightening Torque Specifications

Fastening part

Speed sensor mounting bolt

N

⋅

m

6.5

Tightening torque kgf-m

0.65

lbf-ft

4.5

B947H19307002

Note

)

(Page 9C-6)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Special Tool

09900–25008

Multi circuit tester set

)

(Page 9C-5) /

)

(Page 9C-

6) /

)

(Page 9C-7) /

)

(Page 9C-7) /

)

(Page 9C-

B947H19308001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exterior Parts: 9D-1

Body and Accessories

Exterior Parts

Repair Instructions

Exterior Parts Construction

B947H19406001

2

“B”

“A”

“C”

1

“A”

1. Upper cowling bracket

: Set the punch mark to the front and upper side.

2. Rear view mirror cushion

: Set the dent side to inside.

“A”: To frame

“B”: To headlight assembly email: [email protected] / www.motomatrix.co.uk

“D”

“C”: To sprocket cover

“D”: To side-stand bracket

I947H1940001-01

9D-2 Exterior Parts:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear Fender Construction

B947H19406004

3

1

2

4

3

1. Electric parts holder bracket

2. Rear fender (Front)

5

3. Rear fender (Rear)

4. Rear fender (Lower)

5. Rear fender guard (E-24 only)

I947H1940002-02 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exterior Parts: 9D-3

Frame Cover Construction

B947H19406005

2

1

3

1. Frame cover (Center) 2. Frame cover (Rear), LH/RH 3. Frame cover (LH/RH)

I947H1940003-01 email: [email protected] / www.motomatrix.co.uk

9D-4 Exterior Parts:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Rear View Mirror Construction

B947H19406008

1

3

2

6

7

5

(a)

4

1. Body cowling

2. Cowling brace

3. Cushion

4. Turn signal lead wire

5. Turn signal lead wire coupler

: Locate the turn signal lead wire coupler (5) between the mirror cover (6) and mirror body (7).

6. Mirror cover

I947H1940004-01

7. Mirror body

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft) email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exterior Parts: 9D-5

Fastener Removal and Installation

B947H19406010

Type A

Removal

1) Depress the head of fastener center piece (1).

2) Pull out the fastener (2).

Type B

Removal

1) Pry up the head of fastener center piece (1) with a screw driver.

2) Pull out the fastener “A”.

“A”

1

1

2

I649G1940005-02

Installation

1) Let the center piece stick out toward the head so that the pawls “A” closes.

“A”

I823H1940001-01

Installation

1) Insert the fastener into the installation hole.

NOTE

To prevent the pawl (1) from damage, insert the fastener all the way into the installation hole.

1

I649G1940006-02

2) Insert the fastener into the installation hole.

NOTE

To prevent the pawl “A” from damage, insert the fastener all the way into the installation hole.

3) Push in the head of center piece until it becomes flush with the fastener outside face.

2) Push in the head of center piece.

I947H1940005-01

I823H1940003-01

I649G1940007-02 email: [email protected] / www.motomatrix.co.uk

9D-6 Exterior Parts:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exterior Parts Removal and Installation

Side Frame Cover

Removal

B947H19406011

NOTE

The left and right side frame covers are installed symmetrically and therefore the removal/installation procedure for one side is the same as that for the other side.

1) Remove the bolt (1).

2) Remove the side frame cover (2).

Installation

1) Slide the seat hooks into the seat hook retainers on the frame and tighten the bolts.

1

“A”

2

I947H1940008-01

2) Install the side frame covers.

Rear Seat / Seat Tail Cover

Removal

Remove the rear seat or seat tail cover with the ignition key.

Rear Seat

“B”

I947H1940006-02

“A”: Velcro fastening “B”: Bushing

Installation

Installation is in the reverse order of removal.

Front Seat

Removal

1) Remove the side frame covers.

2) Remove the front seat by removing the bolts.

I947H1940009-01

Seat Tail Cover

I947H1940007-01

I947H1940010-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exterior Parts: 9D-7

Installation

Slide the hook into the hook retainer and push down firmly until the rear seat/seat tail cover snaps into the locked position.

Installation

Install the windscreen in the reverse order of removal.

Pay attention to the following point:

• Insert two nuts into the hole of cowling brace.

I947H1940011-01

Windscreen

Removal

1) Loosen the rear view mirror mounting nuts.

I947H1940014-01

• Insert four nuts (top and bottom ones) into the windscreen.

I947H1940012-01

2) Remove the windscreen (1) by removing the screws.

1

I947H1940015-01

• Tighten the screws.

NOTE

The screws “A” are 3 mm shorter than the others.

“A”

I947H1940013-01

I947H1940016-01 email: [email protected] / www.motomatrix.co.uk

9D-8 Exterior Parts:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

• Tighten the rear view mirror mounting nuts to the specified torque.

Tightening torque

Rear view mirror mounting nut (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

Side Cowling

Removal

1) Remove the fasteners and cowling bracket (1).

1

(a)

(a)

I947H1940019-01

Body Cowling Cover

Removal

1) Remove the fasteners (8 pcs.).

2) Remove the body cowling cover (1).

I947H1940017-01

1

2) Remove the bolts.

3) Remove the side cowling (2). (LH/RH)

“A”

I947H1940020-01

I947H1940018-01

Installation

Install the body cowling cover in the reverse order of removal.

2

I947H1940021-04

“A”

“A”: Bushing

2

I947H1940036-01 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exterior Parts: 9D-9

Installation

Install side cowling in the reverse order of removal.

Pay attention to the following points:

• When installing the right side cowling, make sure that the fuel tank drain hose and breather hose are routed properly. Refer to “Fuel Tank Drain Hose and Breather

Hose Routing Diagram” in Section 1G (Page 1G-3).

• When installing the bracket, set the punch mark “A” to the front and upper side.

6) Remove the combination meter. Refer to

“Combination Meter Removal and Installation” in

Section 9C (Page 9C-2).

7) Disconnect the turn signal lead wire couplers (1).

1

“A”

I947H1940023-01

Disconnect the steering damper lead wire coupler

(2).

I947H1940035-01

Inner Under Cowling

Removal

NOTE

The left and right inner under cowlings are installed symmetrically and therefore the removal/installation procedure for one side is the same as that for the other side.

1) Remove the side cowling.

2) Remove the inner under cowling (1).

2

9) Disconnect the lead wire couplers (3).

10) Remove the air intake pipe bolts.

I947H1940034-01

3

1

I947H1940022-02

Installation

Install the inner under cowling in the reverse order of removal.

Body Cowling

Removal

1) Remove the body cowling cover.

2) Remove the left and right side cowlings.

3) Remove the inner under cowlings.

4) Remove the rear view mirror.

5) Remove the windscreen.

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11) Remove the screws.

I947H1940024-01

I947H1940025-01

9D-10 Exterior Parts:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

12) Remove the body cowling assembly (4) forward.

4

Cowling Brace

Removal

1) Remove the body cowling.

2) Remove the cowling brace (1).

1

I947H1940026-01

13) Disassemble the body cowling assembly. Refer to

“Headlight Removal and Installation” in Section 9B

(Page 9B-1).

Installation

Install the body cowling in the reverse order of removal.

Pay attention to the following point:

• Adjust the headlight beam if necessary. Refer to

“Headlight Beam Adjustment” in Section 9B

(Page 9B-3).

Intake Pipe

Removal

1) Remove the body cowling.

2) Remove the intake pipes (1). (LH & RH)

I947H1940028-01

Installation

Install the cowling brace in the reverse order of removal.

Pay attention to the following point:

• Tighten the cowling brace mounting bolts (1) to the specified torque.

Tightening torque

Cowling brace mounting bolt (a): 23 N·m (2.3 kgfm, 16.5 lbf-ft)

1

(a)

I947H1940029-01

1

I947H1940027-01

Installation

Install the intake pipes in the reverse order of removal.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Exterior Parts: 9D-11

Frame Cover

Removal

1) Remove the front and rear seats.

2) Remove the bolts and fasteners.

4) Disconnect the rear combination light coupler (2).

5) Remove the frame cover assembly from the frame.

2

“A”

“A”: Bushing

3) Disconnect the seat lock cable (1).

I947H1940030-02

I947H1940031-04

I947H1940033-02

6) Disassemble the frame cover assembly. Refer to

“Rear Combination Light Removal and Installation” in Section 9B (Page 9B-6).

Installation

Install the frame cover assembly in the reverse order of removal.

Front Fender

Removal

Refer to “Front Fork Removal and Installation” in Section

2B (Page 2B-2).

Installation

Refer to “Front Fork Removal and Installation” in Section

2B (Page 2B-2).

Rear Fender

Removal

Refer to “Rear Fender Construction” (Page 9D-2).

Installation

Refer to “Rear Fender Construction” (Page 9D-2).

1

I947H1940032-01 email: [email protected] / www.motomatrix.co.uk

9D-12 Exterior Parts:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Specifications

Tightening Torque Specifications

Fastening part

Rear view mirror mounting nut

Cowling brace mounting bolt

N

⋅

m

10

23

Tightening torque kgf-m

1.0

2.3

lbf-ft

7.0

16.5

B947H19407001

Note

)

(Page 9D-8)

)

(Page 9D-10)

NOTE

The specified tightening torque is described in the following.

“Rear View Mirror Construction” (Page 9D-4)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Body Structure: 9E-1

Body and Accessories

Body Structure

Repair Instructions

Body Frame Construction

B947H19506001

2

1

6

(c)

5

(b)

3

(a)

2

7

(b)

4

1. Frame

2. Seat rail

3. Seat rail bolt

4. Collar

5

(b)

6

(c)

5. Engine mounting thrust adjuster

6. Engine mounting thrust adjuster lock-nut

7. Engine mounting pinch bolt

: 50 N

⋅ m (5.0 kgf-m, 36.0 lbf-ft)

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 45 N

⋅ m (4.5 kgf-m, 32.5 lbf-ft)

I947H1950001-01 email: [email protected] / www.motomatrix.co.uk

9E-2 Body Structure:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Front Footrest Bracket Construction

B947H19506002

“A”

11

(d)

8

6

“ a ”

7

3

(c)

5

8

12

(e)

2

10

(b)

1

(a)

1. Footrest bracket bolt

2. Rear brake master cylinder mounting bolt

3. Footrest guard bolt

4. Footrest bracket No. 1 (LH)

5. Footrest bracket No. 1 (RH)

6. Footrest

7. Footrest holder

1

(a)

4

9

8. Rear brake pedal

9. Footrest bracket No. 2 (LH)

10. Footrest bracket No. 2 (RH)

11. Bank sensor bolt

12. Footrest holder bolt

“A”: Align the cutaway when installing.

“a”: 65 – 75 mm (2.6 – 3.0 in)

I947H1950002-02

: 23 N

⋅ m (2.3 kgf-m, 16.5 lbf-ft)

: 10 N

⋅ m (1.0 kgf-m, 7.0 lbf-ft)

: 4.5 N

⋅ m (0.45 kgf-m, 3.0 lbf-ft)

: 18 N

⋅ m (1.8 kgf-m, 13.0 lbf-ft)

: 35 N

⋅ m (3.5 kgf-m, 25.5 lbf-ft)

: Apply grease to the sliding surface.

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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Body Structure: 9E-3

Side-stand Construction

B947H19506003

3

2

1

(b)

(a)

(a)

3

1. Frame

2. Side-stand bracket

3. Washer

4. Side-stand

4

: 50 N

⋅ m (5.0 kgf-m, 36.0 lbf-ft)

: 40 N

⋅ m (4.0 kgf-m, 29.0 lbf-ft)

I947H1950003-03

: Apply grease to sliding surface.

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9E-4 Body Structure:

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Pillion Footrest Construction

B947H19506004

7

1

6

5

4

2

1. Pillion footrest

2. Spring

3. Ball

4. E-ring

3

5. Washer

6. O-ring

7. Footrest pin

: Apply grease.

: Do not reuse.

I947H1950004-02

Side-stand Removal and Installation

Removal

1) Support the motorcycle with a jack or wooden block.

!

CAUTION

B947H19506005

• Do not support the motorcycle with the exhaust pipes.

• Make sure that the motorcycle is supported securely.

2) Remove the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction” (Page 9E-3).

Installation

Install the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction” (Page 9E-3).

email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Body Structure: 9E-5

Specifications

Tightening Torque Specifications

B947H19507001

NOTE

The specified tightening torque is described in the following.

“Body Frame Construction” (Page 9E-1)

“Front Footrest Bracket Construction” (Page 9E-2)

“Side-stand Construction” (Page 9E-3)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C

(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

NOTE

Required service material is also described in the following.

“Front Footrest Bracket Construction” (Page 9E-2)

“Side-stand Construction” (Page 9E-3)

“Pillion Footrest Construction” (Page 9E-4)

B947H19508001 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

Prepared by

March, 2009

Part No. 99500-39380-01E

Printed in Japan

640 email: [email protected] / www.motomatrix.co.uk

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

TOP

GSX-R1000

SERVICE MANUAL

email: [email protected] / www.motomatrix.co.uk

Printed in Japan

K9

No. 1298 GSX-R1000 S/M 99500-39380-01E For PS printing 2009.3.3 (Back: 23 mm) 5/0

BOTTOM

DIC255

9 9 5 0 0 — 3 9 3 8 0 — 0 1 E