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GSR600

9 9 5 0 0 — 3 6 1 6 0 — 0 1 E

FOREWORD

This manual contains an introductory description on the SUZUKI GSR600 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.



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.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FI SYSTEM DIAGNOSIS

FUEL SYSTEM AND THROTTLE

BODY

EXHAUST SYSTEM

COOLING AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

EMISSION CONTROL

INFORMATION

WIRING DIAGRAM

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

4. The contents are listed on the first page of each section to help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

Front axle

Brake disc

Dust seal

Bearing

Front wheel

Spacer

Collar

Brake disc bolt



ITEM N·m kgf-m

100 10.0

23 2.3

SYMBOL

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 SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified torque.

Apply THREAD LOCK SUPER “1360”.

99000-32130

Use engine coolant.

99000-99032-11X

Apply oil. Use engine oil unless otherwise specified.

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Apply SUZUKI SUPER GREASE “A” or equivalent grease.

99000-25010

Apply SUZUKI MOLY PASTE.

99000-25140

Use fork oil.

99000-99044-10G

Apply or use brake fluid.

Measure in voltage range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Apply SUZUKI BOND “1215” or equivalent bond.

99000-31110

Apply SUZUKI BOND “1207B”

99000-31140

Measure in current range.

Measure in resistance range.

Measure in diode test range.

Apply THREAD LOCK SUPER “1303”.

99000-32030

Apply THREAD LOCK SUPER “1322” or equivalent thread lock.

99000-32110

Apply THREAD LOCK “1342”.

99000-32050

Measure in continuity test range.

Use special tool.

Indication of service data.

ABBREVIATIONS USED IN THIS

MANUAL

A

ABDC

ACL

API

ATDC

: After Bottom Dead Center

: Alternating Current

: Air Cleaner, Air Cleaner Box

: American Petroleum Institute

: After Top Dead Center

ATM Pressure : Atmospheric Pressure

A/F

: Atmospheric Pressure sensor

(APS, AP Sensor)

: Air Fuel Mixture

B

BBDC

BTDC

B+

: Before Bottom Dead Center

: Before Top Dead Center

: Battery Positive Voltage

E

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

F

FPR

FP Relay

: Fuel Injection, Fuel Injector

: Fuel Pump

: Fuel Pressure Regulator

: Fuel Pump Relay

G

GEN

GND

GP Switch

: Generator

: Ground

: Gear Position Switch

C

CKP Sensor : Crankshaft Position Sensor

CKT

(CKPS)

: Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CMP Sensor : Camshaft Position Sensor

CPU

(CMPS)

: Carbon Monoxide

: Central Processing Unit

H

HC : Hydrocarbons

HO2 Sensor : Heated Oxygen Sensor

I

IAP Sensor : Intake Air Pressure Sensor (IAPS)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

: Ignition

D

DMC

DOHC

DRL

DTC

: Direct Current

: Dealer Mode Coupler

: Double Over Head Camshaft

: Daytime Running Light

: Diagnostic Trouble Code

L

LCD

LED

: Liquid Crystal Display

: Light Emitting Diode

(Malfunction Indicator Lamp)

: Left Hand

M

MAL-Code

Max

MIL

Min

: Malfunction Code

(Diagnostic Code)

: Maximum

: Malfunction Indicator Lamp

(LED)

: Minimum

N

NOX

O

OHC

OPS

P

PCV

: Nitrogen Oxides

: Over Head Camshaft

: Oil Pressure Switch

: Positive Crankcase

Ventilation (Crankcase Breather)

R

ROM

T

TO Sensor

TP Sensor

: Right Hand

: Read Only Memory

S

SAE

SDS

: Society of Automotive Engineers

: Suzuki Diagnosis System

STC System : Secondary Throttle Control System

(STCS)

STP Sensor : Secondary Throttle Position Sensor

ST Valve

(STPS)

: Secondary Throttle Valve (STV)

STV Actuator : Secondary Throttle Valve Actuator

(STVA)

: Tip Over Sensor (TOS)

: Throttle Position Sensor (TPS)

WIRE COLOR

B : Black

Bl : Blue

Br : Brown

Dg : Dark green

Dgr : Dark gray

B/Bl : Black with Blue tracer

B/G : Black with Green tracer

B/R : Black with Red tracer

B/Y : Black with Yellow tracer

Bl/G : Blue with Green tracer

Bl/W : Blue with White tracer

Br/Y : Brown with Yellow tracer

G/Bl : Green with Blue tracer

G/W : Green with White tracer

Gr/B : Gray with Black tracer

Gr/W : Gray with White tracer

Lg/BI : Light green with Blue tracer

Lg/W : Light green with White tracer

O/BI : Orange with Blue tracer

O/R : Orange with Red tracer

O/Y : Orange with Yellow tracer

P/W : Pink with White tracer

R/Bl : Red with Blue tracer

R/W : Red with White tracer

W/Bl : White with Blue tracer

W/R : White with Red tracer

Y/B : Yellow with Black tracer

Y/G : Yellow with Green tracer

Y/W : Yellow with White tracer

G : Green

Gr : Gray

Lbl : Light blue

Lg : Light green

O : Orange

: Pink

: Red

W : White

Y : Yellow

B/Br : Black with Brown tracer

B/Lg : Black with Light green tracer

B/W : Black with White tracer

Bl/B : Blue with Black tracer

Bl/R : Blue with Red tracer

Bl/Y : Blue with Yellow tracer

G/B : Green with Black tracer

G/R : Green with Red tracer

G/Y : Green with Yellow tracer

Gr/R : Gray with Red tracer

Gr/Y : Gray with Yellow tracer

Lg/G : Light green with Green tracer

O/B : Orange with Black tracer

O/G : Orange with Green tracer

O/W : Orange with White tracer

P/B : Pink with Black tracer

R/B : Red with Black tracer

R/Y : Red with Yellow tracer

W/B : White with Black tracer

W/G : White with Green tracer

W/Y : White with Yellow tracer

Y/Bl : Yellow with Blue tracer

Y/R : Yellow with Red tracer

GENERAL INFORMATION

GENERAL INFORMATION 1-1

1

WARNING/CAUTION/NOTE ……………………………………………………………….1- 2

GENERAL PRECAUTIONS …………………………………………………………………1- 2

SUZUKI GSR600K6 (’06-MODEL) ……………………………………………………….1- 4

SERIAL NUMBER LOCATION …………………………………………………………….1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION …………………..1- 5

FUEL ………………………………………………………………………………………….1- 5

ENGINE OIL ……………………………………………………………………………….1- 5

BRAKE FLUID …………………………………………………………………………….1- 5

FRONT FORK OIL ………………………………………………………………………1- 5

ENGINE COOLANT …………………………………………………………………….1- 6

WATER FOR MIXING ………………………………………………………………….1- 6

ANTI-FREEZE/ENGINE COOLANT ……………………………………………….1- 6

LIQUID AMOUNT OF WATER/ENGINE COOLANT ………………………..1- 6

BREAK-IN PROCEDURES …………………………………………………………………1- 7

CYLINDER IDENTIFICATION ……………………………………………………………..1- 7

INFORMATION LABELS …………………………………………………………………….1- 8

SPECIFICATIONS ……………………………………………………………………………..1- 9

COUNTRY AND AREA CODES

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

MODEL

GSR600

GSR600UE

CODE COUNTRY or AREA

E-02

E-19

E-24

U.K.

Australia

E-19 EU

EFECTIVE FRAME NO.

JS1B9111100 100001 –

JS1B9111300 100001 –

JS1B9121100 100001 –

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

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



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



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 WARN-

INGS 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



* 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 in forced outdoors.

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

* Never use gasoline as a 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.

GENERAL INFORMATION 1-3



* 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 not require use of battery power, disconnect the negative cable the battery.

* When tightening the cylinder head and 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, self-locking 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.

* 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.

1-4 GENERAL INFORMATION

SUZUKI GSR600K6 (’06-MODEL)

RIGHT SIDE

LEFT SIDE

• Difference between illustration and actual motorcycle may exist depending on the markets.

SERIAL NUMBER LOCATION

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

is stamped on the right side of the steering head pipe. The engine serial number

is located on the rear side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

GENERAL INFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended.

ENGINE OIL

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

SF/SG or SH/SJ with JASO MA.

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 right chart.

BRAKE FLUID

Specification and classification: DOT 4



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 re-use brake fluid left over from a previous servicing, which has been stored for a long period.

FRONT FORK OIL

Use fork oil G-10 or an equivalent fork oil.

1-6 GENERAL INFORMATION

ENGINE COOLANT

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

WATER FOR MIXING

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

ANTI-FREEZE/ENGINE COOLANT

The 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 anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

LIQUID AMOUNT OF WATER/ENGINE COOLANT

Solution capacity (total): Approx. 2 800ml

For engine coolant mixture information, refer to cooling system section, page 7-2



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.

GENERAL INFORMATION 1-7

BREAK-IN PROCEDURES

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

• Keep to these break-in engine speed limits:

Initial 800 km: Below 7 000 r/min

Up to 1 600 km: Below 10 500 r/min

Over to 1 600 km: Below 14 000 r/min

• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation.

However, do not exceed 14 000 r/min at any time.

CYLINDER IDENTIFICATION

The four cylinders of this engine are identified as No.1, No.2, No.3 and No.4 cylinder, as counted from left to right (as viewed by the rider on the seat.)

1-8 GENERAL INFORMATION

INFORMATION LABELS

Noise label

Fuel caution label

Tire information label

General information label

General warning label

ID plate

A: Attached

E-02

GSR600

E-19

E-24

GSR600U

E-19

Chain cover

GENERAL INFORMATION 1-9

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ………………………………………………………………..

2 090 mm

Overall width …………………………………………………………………

795 mm

Overall height ………………………………………………………………..

1 075 mm

Wheelbase ……………………………………………………………………

1 440 mm

Ground clearance…………………………………………………………..

130 mm

Seat height ……………………………………………………………………

785 mm

Dry mass ………………………………………………………………………

183 kg

ENGINE

Type …………………………………………………………………………….

Four stroke, liquid-cooled, DOHC

Number of cylinders ……………………………………………………….

Bore……………………………………………………………………………..

67.0 mm

Stroke …………………………………………………………………………..

42.5 mm

Displacement ………………………………………………………………..

599 cm³

Compression ratio ………………………………………………………….

12.5:1

Fuel system …………………………………………………………………..

Fuel injection

Air cleaner …………………………………………………………………….

Paper element

Starter system ……………………………………………………………….

Electric

Lubrication system …………………………………………………………

Wet sump

Idle speed……………………………………………………………………..

1 300 ± 100 r/min

DRIVE TRAIN

Clutch …………………………………………………………………………..

Wet multi-plate type

Transmission …………………………………………………………………

6-speed constant mesh

Gearshift pattern ……………………………………………………………

1-down, 5-up

Primary reduction ratio ……………………………………………………

1.926 (79/41)

Gear ratios, Low …………………………………………………………….

2.785 (39/14)

2nd……………………………………………………………..

2.000 (32/16)

3rd………………………………………………………………

1.600 (32/20)

4th………………………………………………………………

1.363 (30/22)

5th………………………………………………………………

1.208 (29/24)

Top……………………………………………………………..

1.086 (25/23)

Final reduction ratio………………………………………………………..

3.000 (48/16)

Drive chain ……………………………………………………………………

RK525SMOZ7Y, 114 links

1-10 GENERAL INFORMATION

CHASSIS

Front suspension …………………………………………………………..

Telescopic, coil spring, oil damped

Rear suspension ……………………………………………………………

Link type, coil spring, oil damped

Front fork stroke…………………………………………………………….

130 mm

Rear wheel travel …………………………………………………………..

134 mm

Steering angle……………………………………………………………….

33° (Right and left)

Caster ………………………………………………………………………….

25°15’

Trail ……………………………………………………………………………..

104 mm

Turning radius ……………………………………………………………….

2.9 m

Front brake……………………………………………………………………

Disc brake, twin

Rear brake ……………………………………………………………………

Disc brake

Front tire size ………………………………………………………………..

120/70 ZR 17 M/C (58 W), tubeless

Rear tire size…………………………………………………………………

180/55 ZR 17 M/C (73 W), tubeless

ELECTRICAL

Ignition type…………………………………………………………………..

Electronic ignition (Transistorized)

Ignition timing………………………………………………………………..

6° B.T.D.C. at 1 300 r/min

Spark plug…………………………………………………………………….

NGK CR9E or DENSO U27ESR-N

Battery………………………………………………………………………….

12 V 28.8 kC (8 Ah)/10 HR

Generator……………………………………………………………………..

Three-phase A.C. generator

Main fuse ……………………………………………………………………..

30 A

Fuse …………………………………………………………………………….

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

Headlight………………………………………………………………………

12 V 60/55 W H4

Turn signal light……………………………………………………………..

12 V 10 W

Brake light/Taillight…………………………………………………………

LED

Position light………………………………………………………………….

12 V 5 W × 2

License plate light ………………………………………………………….

12 V 5 W

Speedometer light………………………………………………………….

LED

Tachometer light ……………………………………………………………

LED

Neutral indicator light ……………………………………………………..

LED

High beam indicator light ………………………………………………..

LED

Turn signal indicator light ………………………………………………..

LED

Oil pressure/Engine coolant temp. warning indicator light……….

LED

Fl warning indicator light …………………………………………………

LED

Immobilizer indicator light ……………………………………………….

LED

CAPACITIES

Fuel tank ………………………………………………………………………

16.5 L

Engine oil,oil change………………………………………………………

3 200 ml with filter change …………………………………………….

3 600 ml overhaul ………………………………………………………..

3 900 ml

Coolant…………………………………………………………………………

2.8 L

These specifications are subject to change without notice.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE SCHEDULE ……………………………………………. 2- 2

PERIODIC MAINTENANCE CHART…………………………………………….. 2- 2

LUBRICATION POINTS ……………………………………………………………… 2- 3

MAINTENANCE AND TUNE-UP PROCEDURES ………………………………… 2- 4

AIR CLEANER…………………………………………………………………………… 2- 4

SPARK PLUG……………………………………………………………………………. 2- 5

VALVE CLEARANCE…………………………………………………………………. 2- 7

ENGINE OIL AND OIL FILTER ……………………………………………………. 2-13

FUEL LINE………………………………………………………………………………… 2-14

ENGINE IDLE SPEED ………………………………………………………………… 2-15

PAIR (AIR SUPPLY) SYSTEM …………………………………………………….. 2-15

THROTTLE CABLE PLAY ………………………………………………………….. 2-15

CLUTCH …………………………………………………………………………………… 2-16

COOLING SYSTEM……………………………………………………………………. 2-17

DRIVE CHAIN ……………………………………………………………………………. 2-19

BRAKE …………………………………………………………………………………….. 2-22

TIRES……………………………………………………………………………………….. 2-26

STEERING………………………………………………………………………………… 2-26

FRONT FORK……………………………………………………………………………. 2-27

REAR SUSPENSION …………………………………………………………………. 2-27

EXHAUST PIPE BOLT AND NUT ………………………………………………… 2-28

CHASSIS BOLTS AND NUTS …………………………………………………….. 2-29

COMPRESSION PRESSURE CHECK ……………………………………………….. 2-31

COMPRESSION TEST PROCEDURE ………………………………………….. 2-31

OIL PRESSURE CHECK ………………………………………………………………….. 2-32

SDS CHECK……………………………………………………………………………………. 2-33

2

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, miles and time for your convenience.

NOTE:

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

PERIODIC MAINTENANCE CHART

Item

Air cleaner element

Spark plugs

Valve clearance

Engine oil

Engine oil filter

Fuel line

Idle speed

Throttle valve synchronization

PAIR (air supply) system

Throttle cable play

Clutch cable play

Radiator hoses

Engine coolant

Drive chain

Brakes

Brake hoses

Brake fluid

Interval km months

1 000

—-

Tires

Steering

Front forks

Rear suspension

Exhaust pipe bolts and muffler bolt and nut

Chassis bolts and nuts

—-

NOTE:

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

R = Replace

T = Tighten

6 000 12 000 18 000

—-

Replace every 2 years.

I I I

Clean and lubricate every 1 000 km.

I I I

—-

I I

Replace every 4 years.

I I

Replace every 2 years.

—I

I I

—-

24 000

—-

PERIODIC MAINTENANCE 2-3

LUBRICATION POINTS

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

Major lubrication points are indicated below.

Brake lever holder

Brake pedal pivot and footrest pivot

Clutch lever holder

Side-stand pivot and spring hook

Footrest pivot and gearshift lever pivot

Drive chain

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.

2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP

PROCEDURES

This section describes the servicing procedures for each item of the Periodic Maintenance requirements.

AIR CLEANER

Inspect every 6 000 km (12 months).

Replace every 18 000 km (36 months).

• Lift and support the fuel tank. (



5-3)

• Remove the air cleaner box cover

by removing the screws and IAP sensor.

• Remove the air cleaner element.

• Inspect the air cleaner element for clogging.

If the air cleaner element is clogged with dust, replace the air cleaner element with a new one.



Do not blow the air cleaner element with compressed air.

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.

• Install a new air cleaner element in the reverse order of removal.

• Remove the drain plug

from the air cleaner box to allow any water to drain out.

SPARK PLUG

Inspect every 6 000 km (12 months). replace every 12 000 km (24 months).

SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL

• Lift and support the fuel tank. (



5-3)

• Remove the air cleaner box. (



5-13)

• Disconnect all lead wire couplers

from ignition coil/plug caps.



Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler damage.

• Remove the ignition coil/plug caps.



* Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage.

* Be careful not to drop the ignition coil/plug cap to prevent short/open circuit.

• Remove the spark plugs.



09930-10121: Spark plug wrench set

HEAT RANGE

• 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.

NGK

Hot type

CR8E

U24ESR-N

Standard

CR9E

U27ESR-N

Cold type

CR10E

U31ESR-N

NOTE:

“R” type spark plug has a resistor built into at the center electrode to prevent radio noise.

CARBON DEPOSITS

• Check carbon deposits on the spark plug.

• If carbon is deposited, remove it using a spark plug cleaner machine.

PERIODIC MAINTENANCE 2-5

2-6 PERIODIC MAINTENANCE

SPARK PLUG GAP

• Measure the spark plug gap with a thickness gauge.

• Adjust the spark plug gap if necessary.



Spark plug gap:

Standard: 0.7 – 0.8 mm



09900-20803: Thickness gauge

ELECTRODE’S CONDITION

• Check the condition of the electrode.

• If it is extremely worn or burnt, replace the spark plug.

Replace the spark plug if it has a broken insulator, damaged thread, etc.



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.

SPARK PLUG AND IGNITION COIL/PLUG CAP

INSTALLATION

• Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque.



Spark plug: 11 N·m (1.1 kgf-m)



Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.

• Install the ignition coil/plug caps and connect their lead wire couplers.



* Do not hit the ignition coil/plug cap with a plastic hammer when installing it.

* Place the ignition coil/spark plug cap so that the coupler does not touch the cylinder head cover.

CONTACT

INCORRECT INCORRECT

PERIODIC MAINTENANCE 2-7

VALVE CLEARANCE

Inspect every 24 000 km (48 months).

• Lift and support the fuel tank. (



5-3)

• Remove the air cleaner box. (



5-13)

• Disconnect the CMP sensor coupler

• Remove the PAIR control solenoid valve

• Remove the spark plugs. (



2-5)

• Loosen the throttle body clamp screws at the intake pipe side.

(



5-14)

• Move the throttle body assembly.

• Remove the frame bridge bar

• Remove the cylinder head cover. (



3-14)

The valve clearance specification is different for intake and exhaust valves. Valve clearance must be checked and adjusted,

1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing.



Valve clearance (when cold):

Standard: IN. : 0.10 – 0.20 mm

EX. : 0.20 – 0.30 mm

NOTE:

* The cam must be at positions,

, when checking or adjusting the valve clearance. Clearance readings should not be taken with the cam in any other position than these two positions.

* The clearance specification is for COLD state.

* To turn the crankshaft for clearance checking, be sure to use a wrench, and rotate in the normal running direction. All spark plugs should be removed.

EX.

IN.

2-8 PERIODIC MAINTENANCE

• Remove the valve timing inspection plug

• Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches

on the left ends of both camshafts (Ex. and In.) to the positions as shown.

• In this condition, read the valve clearance at the valves

(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.

(



2-9)



09900-20803: Thickness gauge

• Turn the crankshaft 360 degrees (one rotation) to bring the

“TOP” line on the starter clutch to the index mark of valve timing inspection hole and also to bring the notches

to the position as shown.

• Read the clearance at the rest of the valves

and adjust the clearance if necessary. (

 below)

Cam position

Notch

position

Exhaust Camshaft Intake Camshaft

←

Front

←

Front

←

Front

←

Front

PERIODIC MAINTENANCE 2-9

VALVE CLEARANCE ADJUSTMENT

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

• Remove the intake or exhaust camshafts. (



3-15)

• Remove the tappet and shim by fingers or magnetic hand.

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

• Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 25 sizes of tappet shim are available ranging from 1.20 to

2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure its size. Refer to the tappet shim selection table (



2-11 and -12) for details.

170

1.70 mm

2-10 PERIODIC MAINTENANCE

NOTE:

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

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

NOTE:

Reinstall the camshafts in the specified manner. (



3-97)

• After replacing the tappet shim and camshafts, 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 valve clearance adjustment, reinstall the following items.

* Cylinder head cover (



3-101)

* Spark plugs and plug caps (



2-6)

* Throttle body assembly (



5-19)



Valve timing inspection plug: 11 N·m (1.1 kgf-m)

(INTAKE SIDE)

PERIODIC MAINTENANCE 2-11

2-12 PERIODIC MAINTENANCE

(EXHAUST SIDE)

ENGINE OIL AND OIL FILTER

(ENGINE OIL)

Replace initially at 1 000 km (2 months) and every

6 000 km (12 months) thereafter.

(OIL FILTER)

Replace initially at 1 000 km (2 months) and every

18 000 km (36 months) thereafter.

ENGINE OIL REPLACEMENT

• Keep the motorcycle upright.

• Place an oil pan below the engine, and drain oil by removing the oil drain plug

and filler cap

• Tighten the drain plug

to the specified torque, and pour fresh oil through the oil filler. The engine will hold about 3.2 L of oil. Use of API SF/SG or SH/SJ with JASO MA.



Oil drain plug: 23 N·m (2.3 kgf-m)

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

• Turn off the engine and wait about three minutes, then check the oil level through the inspection window. If the level is below lower line

, add oil to full line

. If the level is above full line, drain oil to full line.

: Full line

: Lower line

PERIODIC MAINTENANCE 2-13

2-14 PERIODIC MAINTENANCE

OIL FILTER REPLACEMENT

• Drain the engine oil as described in the engine oil replacement procedure.

• Remove the oil filter

with the special tool.



09915-40610: Oil filter wrench

• Apply engine oil lightly to the gasket of the new oil filter before installation.

• Install the new oil filter. Turn it by hand until you feel that the oil filter gasket contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) with the special tool.

NOTE:

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



Oil filter: 20 N·m (2.0 kgf-m)

• 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 : 3.2 L

Oil and filter change : 3.6 L

Engine overhaul



: 3.9 L

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.

FUEL LINE

Inspect initially 6 000 km (12 months).

• Lift and support the fuel tank. (



5-3)

• Inspect the fuel feed hose

for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.

ENGINE IDLE SPEED

Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter.

NOTE:

Warm up the engine before adjusting the engine idle speed.

• Start the engine, turn the throttle stop screw

and set the engine idle speed as follows.



Engine idle speed: 1 300 ± 100 r/min

THROTTLE VALVE SYNCHRONIZATION

Inspect initially at 1 000 km (2 months) (E-33 only) and every 12 000 km (24 moths).

Inspect the throttle valve synchronization periodically. (



5-24)

PAIR (AIR SUPPLY) SYSTEM

Inspect every 12 000 km (24 months).

Inspect the PAIR (air supply) system periodically. (



11-6)

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter.

Adjust the throttle cable play

as follows.

• Loosen the lock-nut

of the throttle pulling cable

• Turn the adjuster

in or out until the throttle cable play (at the throttle grip)

is between 2.0 – 4.0 mm.

• Tighten the lock-nut

while holding the adjuster



Throttle cable play

: 2.0 – 4.0 mm



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.

PERIODIC MAINTENANCE 2-15

2-16 PERIODIC MAINTENANCE

CLUTCH

Inspect every 6 000 km (12 months).

• Loosen the lock-nut

and turn in the adjuster

all the way into the clutch lever assembly.

• From that position, turn out the adjuster screw 3 rotations.

• Lift and support the fuel tank. (



5-3)

• Loosen the lock-nut

and fully turn in the clutch cable adjuster

• Remove the clutch release adjuster cap

• Loosen the lock-nut

and turn in the adjusting screw

until it stop.

• From this position, turn out the adjusting screw

1/2 rotation, and tighten the lock-nut

while holding the adjusting screw

• Turn the cable adjuster

to obtain 10 – 15 mm of free play

at the clutch lever end.

• Tighten the lock-nut

and



Clutch lever play

: 10 – 15 mm

Clutch release screw: 1/2 turn out



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

COOLING SYSTEM

Inspect every 6 000 km (12 months).

Replace engine coolant every 2 years.

ENGINE COOLANT LEVEL CHECK

• Keep the motorcycle upright.

• Check the engine coolant level by observing the engine coolant reservoir.

Full line

Lower line

• If the level is below the lower line, Lift and support the fuel tank (



5-3) and add engine coolant to the full line from the engine coolant reservoir filler.

ENGINE COOLANT CHANGE

• Remove the right fuel tank side cover.

• Remove the radiator cap

• Drain engine coolant by disconnecting the radiator hose

2 from the pump.



* 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!

• Flush the radiator with fresh water if necessary.

• Connect the radiator hose

securely.

• Pour the specified engine coolant up to the radiator inlet.



Engine coolant capacity (total): 2 800 ml

• Bleed the air from the engine coolant circuit. (



2-18)

ENGINE COOLANT INFORMATION (



7-2)

PERIODIC MAINTENANCE 2-17

2-18 PERIODIC MAINTENANCE

AIR BLEEDING THE COOLING CIRCUIT

• Add engine coolant up to the radiator inlet.

• Support the motorcycle upright.

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

• Add engine coolant up to the radiator inlet.

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

• Add engine coolant up to the radiator inlet.

• Repeat the above procedure until no air bleeds from the radiator inlet.

• Loosen the air bleeding bolt

and check that the engine coolant flows out.



Air bleeder bolt: 0.5 N·m (0.05 kgf-m)

• Close the radiator cap securely.

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



Repeat the above procedure several times and make sure that the radiator is filled with engine coolant up to the reservoir full level.

RADIATOR HOSES

• Check the radiator hoses for crack, damage or engine coolant leakage.

• If any defect is found, replace the radiator hose with new one.

DRIVE CHAIN

Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter.

Clean and lubricate every 1 000 km.

Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.)

* Loose pins

* Damaged rollers

* Dry or rusted links

* Kinked or binding links

* Excessive wear

* Improper chain adjustment

* Missing O-ring seals

If any defect is found, the drive chain must be replaced.

NOTE:

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

: O-ring

: Grease

CHECKING

• Loosen the axle nut

• Loosen the chain adjuster lock-nuts

• Give tension to the drive chain fully by turning both chain adjuster bolts

PERIODIC MAINTENANCE 2-19

2-20 PERIODIC MAINTENANCE

• 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: 336.5 mm

1 2 3

ADJUSTING

• Loosen or tighten both chain adjuster bolts

until there is 20

– 30 mm of slack at the middle of the chain between the engine and rear sprockets as shown. The chain adjuster position relative to the reference marks

on both sides of the swingarm must be equal to ensure that the front and rear wheels are correctly aligned.



Drive chain slack:

Standard: 20 – 30 mm

• Place the motorcycle on its side-stand for accurate adjustment.

• After adjusting the drive chain, tighten the axle nut

to the specified torque.

• Tighten both chain adjuster lock-nuts

securely.



Rear axle nut: 100 N·m (10.0 kgf-m)

• Recheck the drive chain slack after tightening the axle nut.

20 – 30 mm

19 20 21

CLEANING AND LUBRICATING

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



Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings. Use only kerosine to clean the drive chain.

• After washing and drying the chain, oil it with a heavyweight motor oil.



* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings.

* The standard drive chain is RK525SMOZ7Y. Suzuki recommends to use this standard drive chain as a replacement.

PERIODIC MAINTENANCE 2-21

2-22 PERIODIC MAINTENANCE

BRAKE

(BRAKE)

Inspect initially at 1 000 km (2 months) and every 6 000 km (12 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID)

Inspect every 6 000 km (12 months).

Replace hoses every 4 years. Replace fluid every 2 years.

BRAKE FLUID LEVEL CHECK

• Keep the motorcycle upright and place the handlebars straight.

• Remove the right frame cover. (



8-4)

• Check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs.

• When the level is below the lower limit line, replenish with brake fluid that meets the following specification.



Specification and classification: DOT 4



* 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 re-use 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 fluid leakage before riding.

BRAKE PADS

Front brake

The extent of brake pad wear can be checked by observing the grooved limit line

on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (



8-54)



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

Rear brake

The extent of brake pad wear can be checked by observing the limit line

on the pad. When the wear exceeds the limit line, replace the pads with new ones. (



8-65)



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

BRAKE PEDAL HEIGHT

• Remove the front footrest bracket bolts

• Loosen the lock-nut

• Turn the push rod

until the brake pedal height

becomes

45 – 55 mm below the top of the footrest.

• Tighten the lock-nut

and front footrest bracket bolts

to the specified torque.



Brake pedal height

Standard: 45 – 55 mm



Rear brake master cylinder rod lock-nut: 18 N·m (1.8 kgf-m)

Front footrest bracket bolt: 23 N·m (2.3 kgf-m)

PERIODIC MAINTENANCE 2-23

2-24 PERIODIC MAINTENANCE

BRAKE LIGHT SWITCH

• Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed.

AIR BLEEDING FROM BRAKE FLUID CIRCUIT

Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master 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:

FRONT BRAKE

• Fill the reservoir with brake fluid to the top of the inspection window. Place the reservoir cap to prevent dirt from entering.

• Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle.

• Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it.

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. Then, close the air bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process until 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.

• Close the air bleeder valve and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window.



Specification and classification: DOT 4



Air bleeder valve: 7.5 N·m (0.75 kgf-m)



* 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 fluid leakage before riding.

REAR BRAKE

• Bleed air from the rear brake system in the same manner as front brake.



Air bleeder valve: 7.5 N·m (0.75 kgf-m)

NOTE:

The only difference of bleeding operation from the front brake is that the rear master cylinder is actuated by the pedal.

PERIODIC MAINTENANCE 2-25

2-26 PERIODIC MAINTENANCE

TIRES

Inspect every 6 000 km (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.



09900-20805: Tire depth gauge



Tire tread depth:

Service Limit: Front : 1.6 mm

Rear : 2.0 mm

TIRE PRESSURE

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



Cold inflation tire pressure

Solo riding: Front: 250 kPa (2.50 kgf/cm 2 )

Rear: 250 kPa (2.50 kgf/cm 2 )

Dual riding: Front: 250 kPa (2.50 kgf/cm 2 )

Rear: 290 kPa (2.90 kgf/cm 2 )



The standard tire fitted on this motorcycle is 120/70

ZR17 M/C (58 W) for the front and 180/55 ZR17 M/C (73

W) for the 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: BT014F SN, Rear: BT014R N)

STEERING

Inspect initially at 1 000 km (2 months) and every 12

000 km (24 months) thereafter.

The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. 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. (



8-26)

FRONT FORK

Inspect every 12 000 km (24 months).

Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (



8-14)

REAR SUSPENSION

Inspect every 12 000 km (24 months).

Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm. Replace any defective parts if necessary. (



8-46)

PERIODIC MAINTENANCE 2-27

2-28 PERIODIC MAINTENANCE

EXHAUST PIPE BOLT AND NUT

Tighten initially at 1 000 km (2 months) and every

12 000 km (24 months) thereafter.

• Tighten the exhaust pipe bolts, muffler mounting bolts and muffler connecting bolts to the specified torque.

Muffler

Apply PERMATEX 1372.

Set chamfer side to muffler side.

Muffler joint

Set chamfer side to muffler joint side.

Gasket

HO2 sensor

Exhaust pipe bolt

Muffler mounting bolt

Muffler connecting bolt



Replace the gaskets and connectors with new ones.



ITEM

ABC

N·m kgf-m

4.8

2.3

PERIODIC MAINTENANCE 2-29

CHASSIS BOLTS AND NUTS

Tighten initially at 1 000 km (2 months) and every

6 000 km (12 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-30 for the locations of the following nuts and bolts on the motorcycle.)

Item

Steering stem head nut

Steering stem lock-nut

Front fork upper clamp bolt

Front fork lower clamp bolt

Front fork cap bolt

Front axle

Front axle pinch bolt

Handlebar clamp bolt

Front brake master cylinder mounting bolt

Front brake caliper mounting bolt

Front brake caliper housing bolt

Front brake pad mounting pin

Brake hose union bolt

Air bleeder valve

Brake disc bolt

Rear brake caliper mounting bolt

Rear brake caliper sliding pin

Rear brake pad mounting pin

Rear brake master cylinder mounting bolt

Rear brake master cylinder rod lock-nut

Front footrest bracket mounting bolt

Swingarm pivot shaft

Swingarm pivot nut

Swingarm pivot lock-nut

Rear shock absorber mounting bolt/nut (Upper & Lower)

Cushion rod nut

Cushion lever mounting nut

Rear axle nut

Rear sprocket nut

N·m

100

7.5

100

132

100

9.0

5.0

7.8

13.2

10.0

6.0

1.8

3.3

1.6

1.0

1.8

2.3

1.5

10.0

2.3

1.0

2.5

2.2

1.6

2.3

0.75

2.3

kgf-m

9.0

8.0

2.3

10.0

2.3

2-30 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-31

COMPRESSION PRESSURE CHECK

The compression pressure reading of a cylinder is a good indicator of its internal condition.

The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.

COMPRESSION PRESSURE SPECIFICATION

Standard

1 100 – 1 500 kPa

(11 – 15 kgf/cm

)

Limit

900 kPa

(9 kgf/cm

)

Difference

200 kPa

(2 kgf/cm

)

Low compression pressure can indicate any of the following conditions:

* Excessively worn cylinder wall

* Worn piston or piston ring

* Piston ring stuck in groove

* 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 900 kPa (9 kgf/cm 2 ) and less.

* The difference in compression pressure between any two cylinders is 200 kPa (2 kgf/cm 2 ) and more.

* All compression pressure readings are below 1 100 kPa (11 kgf/cm 2 ) even when they measure 900 kPa (9 kgf/cm 2 ) and more.

COMPRESSION TEST PROCEDURE

NOTE:

* Before testing 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.

* Have the engine warmed up before testing.

* Make sure that the battery is fully-charged.

Remove the related parts and test the compression pressure in the following manner.

• Lift and support the fuel tank. (



5-3)

• Remove all the spark plugs. (



2-5)

• Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.

• Keep the throttle grip in the fully opened position.

• 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.



09915-64512: Compression gauge set

09913-10750: Adaptor

2-32 PERIODIC MAINTENANCE

OIL PRESSURE CHECK

Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.

OIL PRESSURE SPECIFICATION

200 – 500 kPa (2.0 – 5.0 kgf/cm

) at 3 000 r/min, Oil temp. at 60 °C

If the oil pressure is lower or higher than the specification, the following causes may be considered.

LOW OIL PRESSURE

* Clogged oil filter

* Oil leakage from the oil passage

* Damaged O-ring

* Defective oil pump

* Combination of the above items

HIGH OIL PRESSURE

* Engine oil viscosity is too high

* Clogged oil passage

* Combination of the above items

OIL PRESSURE TEST PROCEDURE

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.

• Remove the main oil gallery plug

• Install the oil pressure gauge and adaptor into the main oil gallery.

• Warm up the engine as follows:

Summer : 10 min at 2 000 r/min

Winter : 20 min at 2 000 r/min

• After warming up, increase the engine speed to 3 000 r/min

(observe the tachometer), and read the oil pressure gauge.



09915-74521: Oil pressure gauge hose

09915-74540: Oil pressure gauge attachment

09915-77331: Meter (for high pressure)



Oil gallery plug (M16): 35 N·m (3.5 kgf-m)

PERIODIC MAINTENANCE 2-33

SDS CHECK

Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership.

Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.

For example, when a motorcycle is brought in for service but the troubleshooting is difficult, comparison with the normal data that have been saved or filed can allow the specific engine failure to be determined.

• Remove the left frame cover. (



8-4)

• Set up the SDS tools. (



4-46)



09904-41010: SDS set tool

99565-01010-007: CD-ROM Ver. 7

NOTE:

* Before taking the sample of data, check and clear the Past DTC. (



4-26)

* A number of different data under a fixed condition as shown below should be saved or filed as sample.

SAMPLE:

Data sampled from cold starting through warm-up

Fast idle section

Check the fast idle time.

Approx. XX sec.

Check the engine r/min.

XXXX r/min

Check the engine r/min.

XXXX r/min

Check the manifold absolute pressure.

XXXX mmHg

Check the secondary throttle valve operation in according with the engine r/min.

2-34 PERIODIC MAINTENANCE

Data at 3 000 r/min under no load

Data at the time of racing

Throttle:

Quick wide open

Throttle:

Slowly open

Secondary throttle valve opens closes in according with the engine r/min.

3 000 r/min

Check the manifold absolute pressure.

XXX mmHg

Data of intake negative pressure during idling (100 °C)

PERIODIC MAINTENANCE 2-35

Check the manifold absolute pressure.

Approx. XXX mmHg

Data of secondary throttle valve operation at the time of starting

Closes fully in approx. XX sec.

ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE …………3- 2

ENGINE REMOVAL AND INSTALLATION……………………………………………3- 3

ENGINE REMOVAL ……………………………………………………………………..3- 3

ENGINE INSTALLATION ………………………………………………………………3- 9

ENGINE DISASSEMBLY…………………………………………………………………….3-14

ENGINE COMPONENTS INSPECTION

AND SERVICE …………………………………………………………………………………..3-27

CYLINDER HEAD COVER…………………………………………………………….3-27

CMP SENSOR ……………………………………………………………………………..3-27

PAIR REED VALVE ……………………………………………………………………..3-27

PCV HOSE ………………………………………………………………………………….3-28

CAMSHAFT …………………………………………………………………………………3-28

CAM CHAIN TENSION ADJUSTER ……………………………………………….3-30

CAM CHAIN TENSIONER …………………………………………………………….3-31

CAM CHAIN GUIDE ……………………………………………………………………..3-31

CYLINDER HEAD AND VALVE……………………………………………………..3-31

CLUTCH ……………………………………………………………………………………..3-40

OIL PUMP……………………………………………………………………………………3-41

STARTER CLUTCH ……………………………………………………………………..3-41

GENERATOR ………………………………………………………………………………3-42

WATER PUMP …………………………………………………………………………….3-43

GEARSHIFT SYSTEM ………………………………………………………………….3-43

OIL PRESSURE REGULATOR ……………………………………………………..3-44

OIL STRAINER…………………………………………………………………………….3-44

TRANSMISSION ………………………………………………………………………….3-45

CYLINDER…………………………………………………………………………………..3-48

PISTON AND PISTON RING …………………………………………………………3-49

CRANKCASE ………………………………………………………………………………3-51

CRANKSHAFT AND CONROD ……………………………………………………..3-58

CRANKSHAFT JOURNAL BEARING …………………………………………….3-62

CRANKSHAFT THRUST BEARING ……………………………………………….3-65

ENGINE REASSEMBLY……………………………………………………………………..3-67

ENGINE 3-1

3

3-2 ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions.

ENGINE CENTER

ITEM

PAIR reed valve

Starter motor

Crankcase breather cover

Thermostat

Cylinder head cover

Camshaft

Intake pipe

Oil filter

Oil cooler

Oil pan

REMOVAL



3-14



3-14



3-23



3-16



3-14



3-16



3-39



3-23



3-23



3-23

INSPECTION



3-17



9-14

———-



7-9



3-27



3-28

———-

REINSTALLATION



3-100



3-101



3-79



3-93



3-100



3-93



3-39



3-78



3-78



3-78

ENGINE RIGHT SIDE

ITEM

Exhaust pipe and muffler joint

Cam chain tension adjuster

Clutch cover

Clutch (plates)

Primary driven gear

Oil pump

Gearshift shaft

Starter idle gear cover

Starter idle gear

Starter clutch cover

Starter clutch

CKP sensor

Oil pump driven gear

Cam chain tensioner

Cam chain guide

REMOVAL



3-5



3-15



3-17



3-17



3-18



3-19



3-19



3-20



3-20



3-21



3-21



3-21



3-19



3-21



3-21

INSPECTION



6-2



3-30

———-



3-40



3-41



3-41



3-43

———-



3-41



4-34

———-



3-31



3-31

REINSTALLATION



3-13



3-97



3-91



3-90



3-88



3-87



3-85



3-85



3-84



3-84



3-84



3-82



3-87



3-83



3-83

ENGINE LEFT SIDE

ITEM

Engine sprocket

Gear position switch

Generator (cover)

Generator rotor

Water pump

REMOVAL



3-8



3-23



3-22



3-22



3-22

INSPECTION

———-



4-72



3-42

———-



7-13

REINSTALLATION



3-12



3-79



3-82



3-80



3-79

ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL

Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure.

• Remove the under covers. (



8-5)

• Lift and support the fuel tank. (



5-3)

• Drain engine oil. (



2-13)

• Drain engine coolant. (



2-17)

• Disconnect the battery

—

lead wire

• Remove the air cleaner box

. (



5-13)

• Remove the throttle body assembly

. (



5-13)

ENGINE 3-3

3-4 ENGINE

RADIATOR

• Disconnect the radiator inlet hoses

and

• Disconnect the oil cooler water hose

• Open the hose clamp

• Remove the radiator mounting bolts.

• Move the radiator forward.



Be careful not to bent the radiator fins.

• Disconnect the radiator hose

• Disconnect the cooling fan coupler

• Disconnect the horn coupler

• Remove the radiator.

• Remove the front engine cover

EXHAUST PIPE AND MUFFLER JOINT

• Remove the exhaust pipe and muffler joint. (



6-3)

• Remove the O2 sensor. (



6-3)

• Remove the radiator mounting bracket

ELECTRIC PARTS AND PAIR HOSE

• Remove the regulator/rectifier

• Disconnect the oil pressure switch lead wire

ENGINE 3-5

3-6 ENGINE

• Disconnect the starter motor lead wire

• Disconnect the engine ground lead wire

• Disconnect the respective lead wire couplers.

CKP sensor

Generator

Side-stand

GP switch

ECT sensor

• Disconnect the ignition coil/plug cap lead wire couplers

and

CMP sensor lead wire coupler



Do not remove the ignition coil/plug cap before disconnecting its coupler.

• Remove the ignition coil/plug caps



* Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage.

* Be careful not to drop the ignition coil/plug cap to prevent its short or open circuit.

• Disconnect the PAIR hoses

ENGINE SPROCKET AND GEAR SHIFT LEVER

• Disengage the gearshift lever

• Remove the engine sprocket cover

• Remove the clamp

• Remove the clutch push rod

• Remove the speed sensor rotor

• Remove the engine sprocket nut

and its washer.

NOTE:

When loosening the engine sprocket nut

, depress the brake pedal.

• Loosen the rear axle nut

• Loosen the chain adjuster lock-nuts.

• Loosen the chain adjusters

• Push the rear wheel forward and make sure that the drive chain has enough slack.

• Disengage the drive chain from the rear sprocket.

ENGINE 3-7

3-8 ENGINE

• Remove the engine sprocket

ENGINE MOUNTING

• Support the engine using an engine jack.

• Remove the engine mounting bolts

• Remove the engine mounting bolt

• Remove the engine mounting bolt/nut

• Remove the engine mounting nut

• Loosen the engine mounting thrust adjuster lock-nut

with the special tool.

• Loosen the engine mounting thrust adjuster



09940-14980: Engine mounting thrust adjuster socket wrench

NOTE:

Do not remove the engine mounting bolt

at this stage.

• Remove the engine mounting bolt

. Then, take off the drive chain from the driveshaft.

• Remove the engine assembly.

ENGINE INSTALLATION

Install the engine in the reverse order of removal.

Pay attention to the following points:

NOTE:

Be careful not to damage the frame and engine when installing the engine.

• Before installing the engine, install the engine mounting thrust adjuster

• Gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft.

• Install all engine mounting bolts and tighten them temporarily.

(



3-11)



Be careful not to catch the wiring harness between the frame and the engine.

ENGINE 3-9

3-10 ENGINE

• Tighten the engine mounting thrust adjuster

to the specified torque.



Engine mounting thrust adjuster: 23 N·m (2.3 kgf-m)

• Tighten the engine mounting thrust adjuster lock-nut

to the specified torque with the special tool.



Engine mounting thrust adjuster lock-nut:

45 N·m (4.5 kgf-m)

ENGINE 3-11

• Tighten all engine mounting bolts and nuts to the specified torque.

NOTE:

The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.

Left

Right



ITEM

abc

N·m

kgf-m

5.5

7.5

4.5

2.3

LENGTH

ITEM

Bolt

Adjuster ac b d e

305

204

3-12 ENGINE

• Install the engine sprocket and its washer.

• Apply a small quantity of THREAD LOCK to the driveshaft thread portion.



99000-32050: THREAD LOCK “1342”

• Tighten the engine sprocket nut

to the specified torque.



Engine sprocket nut: 115 N·m (11.5 kgf-m)

• Install the speed sensor rotor

• Tighten the speed sensor rotor bolt

to the specified torque.



Speed sensor rotor bolt: 23 N·m (2.3 kgf-m)

• Apply SUZUKI SUPER GREASE “A” to the clutch push rod end.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the engine sprocket cover.

NOTE:

When installing the engine sprocket cover, align the clutch release cylinder hole with the end of clutch push rod.

• Install the gearshift lever as shown.

Footrest

35 – 45 mm

• Replace the exhaust pipe gaskets and muffler connectors with new ones.

NOTE:

Be sure to face the tabs

on the exhaust pipe gaskets

to the engine side when installing them.

• Tighten the exhaust pipe bolts, muffler mounting bolts and muffler connecting bolts to the specified torque.



Exhaust pipe bolt: 23 N·m (2.3 kgf-m)

Muffler mounting bolt: 23 N·m (2.3 kgf-m)

Muffler connecting bolt: 23 N·m (2.3 kgf-m)

• Install the HO2 sensor



HO2 sensor: 48 N·m (4.8 kgf-m)

• Perform service and adjustment in the following items.

* Engine oil (



2-13)

* Engine coolant (



2-17)

* Throttle cable play (



2-15)

* Clutch (



2-16)

* Idling adjustment (



2-15)

* Throttle valve synchronization (



5-24)

* Drive chain slack (



2-20)

* Wiring harness, cables and hoses (



10-17 to -23)

ENGINE 3-13

3-14 ENGINE

ENGINE DISASSEMBLY



Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions.

• Remove the spark plugs. (



2-5)

STARTER MOTOR

• Remove the starter motor

CYLINDER HEAD COVER AND PAIR REED VALVE

• Remove the cylinder head cover

and its gaskets.

• Remove the PAIR reed valves

and their gaskets.

CAMSHAFTS

• Remove the valve timing inspection cap

• Turn the crankshaft to bring the line

on the starter clutch to the index mark

of the valve timing inspection hole and also to bring the cams to the position as shown.

ENGINE 3-15

• Remove the cam chain tension adjuster cap bolt

• Remove the cam chain tension adjuster

with the spring.

• Remove the cam chain guide

• Remove the camshaft journal holders



Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.

3-16 ENGINE

• Remove the intake camshaft

• Remove the exhaust camshaft

• Remove the dowel pins.

CYLINDER HEAD

• Remove the water hose

• Remove the thermostat cover

and thermostat.

THERMOSTAT INSPECTION (



7-9)

• Remove the ECT sensor

ECT SENSOR INSPECTION (



7-7)

• Remove the cylinder head bolts (M6)

and side face bolt

• Remove the O-rings

• Remove the cylinder head bolts and washers.

NOTE:

When loosening the cylinder head bolts, loosen each bolt little by little diagonally.

• Remove the cylinder head.

• Remove the dowel pins and cylinder head gasket.

CLUTCH

• Remove the clutch cover

• Remove the dowel pins and gasket.

• Hold the clutch housing with the special tool.



Do not damage the clutch plates by the special tool.



09920-53740: Clutch sleeve hub holder

• Remove the clutch springs.

NOTE:

Loosen the clutch spring set bolts little by little and diagonally.

• Remove the pressure plate

• Remove the clutch drive plates and driven plates.

• Remove the spring washer

and washer

• Remove the clutch push piece

, bearing

and thrust washer

ENGINE 3-17

3-18 ENGINE

• Remove the clutch push rod

NOTE:

If it is difficult to pull out the push rod

, use a magnetic hand or a wire.

• Unlock the clutch sleeve hub nut.

• Hold the clutch sleeve hub with the special tool.



09920-53740: Clutch sleeve hub holder

• Remove the clutch sleeve hub nut.

• Remove the concaved washer

, washer

and clutch sleeve hub

• Remove the washer

, spacer

and bearing

• Remove the primary driven gear assembly

• Remove the thrust washer

• Remove the oil pump drive gear

from the primary driven gear assembly

OIL PUMP

• Remove the snap ring

• Remove the oil pump driven gear

NOTE:

Do not drop the snap ring

into the crankcase.



09900-06107: Snap ring priers

• Remove the pin

and washer

• Remove the oil pump

NOTE:

Do not drop the pin

and washer

into the crankcase.

GEARSHIFT SYSTEM

• Remove the snap ring

and washer



09900-06107: Snap ring priers

ENGINE 3-19

3-20 ENGINE

• Remove the gearshift shaft assembly

and washer

NOTE:

Do not drop the washer

into the crankcase.

• Remove the gearshift cam plate bolt

and gearshift cam plate

• Remove the gearshift cam stopper

STARTER IDLE GEAR

• Remove the starter idle gear cover

• Remove the dowel pins and gasket.

• Remove the concaved washer

, washer

and starter idle gear No.1

• Remove the shaft

, bearing

and thrust washer

• Remove the starter clutch cover

• Remove the dowel pins and gasket.

• Remove the concaved washer

, starter idle gear No.2

0 and shaft

STARTER CLUTCH

• Hold the starter clutch with the special tool.



09920-34830: Starter clutch holder

• Remove the starter clutch bolt and washer.

• Remove the starter clutch assembly and washer.

CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN

GUIDE

• Remove the cam chain tensioner

, washer

and cam chain guide

• Remove the cam chain

and cam chain drive sprocket

CKP SENSOR

• Remove the CKP sensor

CKP SENSOR INSPECTION (



4-34)

ENGINE 3-21

3-22 ENGINE

GENERATOR COVER

• Remove the generator cover

• Remove the dowel pins and gasket.

GENERATOR ROTOR

• Hold the generator rotor with the special tool.



09930-44520: Rotor holder

• Remove the generator rotor bolt.

• Install a bolt

of suitable size to the left end of crankshaft.

SUITABLE BOLT

[M12, length: 28 – 38 mm]

• Remove the generator rotor with the special tool.



09930-34980: Rotor remover

28 – 38 mm

WATER PUMP

• Remove the water hose

and water inlet cover

• Remove the water pump

WATER PUMP SERVICING (



7-11)

GEAR POSITION SWITCH

• Remove the gear position switch

CRANKCASE BREATHER (PCV) COVER

• Remove the crankcase breather cover

OIL FILTER

• Remove the oil filter with the special tool.



09915-40610: Oil filter wrench

OIL COOLER

• Remove the oil cooler

OIL PAN

• Remove the oil pan

ENGINE 3-23

3-24 ENGINE

OIL PRESSURE REGULATOR

• Remove the oil pressure regulator case

• Remove the oil pressure regulator

OIL PRESSURE SWITCH

• Remove the oil pressure switch

• Remove the oil pipe

OIL STRAINER

• Remove the oil strainer

and its O-ring.

LOWER CRANK CASE

• Remove the lower crankcase bolts (M6).

• Remove the lower crankcase bolts (M8).

• Remove the lower crankcase assembly.

TRANSMISSION

• Remove the transmission assemblies

• Remove the O-rings and dowel pins.

MIDDLE CRANKCASE

• Remove the crankcase bolts (M6).

• Remove the crankcase bolts (M6), clamp

and regulator/rectifier backet

• Remove the crankshaft journal bolts (M9).

NOTE:

Loosen the crankcase bolts diagonally with the smaller sizes first.

CRANKSHAFT

• Loosen the bearing cap bolts using a 10 mm, 12 point-socket wrench, and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap.

• Remove the dowel pins.

• Remove the O-ring

• Remove the crankshaft and thrust washers

PISTON AND CONROD

• Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase.



Be careful not to damage the cylinder wall by the conrod.

ENGINE 3-25

3-26 ENGINE

• Remove the piston pin circlip

• Separate the piston and conrod by driving out the piston pin.

NOTE:

Scribe the cylinder number on the piston head.

ENGINE COMPONENTS INSPECTION

AND SERVICE



Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations.

CYLINDER HEAD COVER

• Clean and check the gasket groove

and PAIR reed valve gasket mating surfaces

of cylinder head cover.

• If it is damaged, replace the cylinder head cover with a new one.

CMP SENSOR

REMOVAL

• Remove the CMP sensor

from the cylinder head cover.

INSPECTION

• Inspect the CMP sensor. (



4-32)

INSTALLATION

• Install the oil seal

and CMP sensor.

NOTE:

When installing, clean the CMP sensor’s surface.



CMP sensor bolt: 11 N·m (1.1 kgf-m)

PAIR REED VALVE

REMOVAL

• Remove the PAIR reed valve

from the gasket.

ENGINE 3-27

3-28 ENGINE

INSPECTION

• Inspect the reed valve for the carbon deposit.

• If the carbon deposit is found in the reed valve, replace the

PAIR reed valve with a new one.

INSTALLATION

• Set new gasket to the PAIR reed valve as shown.

PCV HOSE

• Remove the PCV hose from the crankcase breather cover.

• Inspect the PCV hose for wear or damage.

• If it is worn or damaged, replace the PCV hose with a new one.

CAMSHAFT

CAMSHAFT IDENTIFICATION

The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against letters “IN” (for intake).

CAM WEAR

• Check the camshaft for wear or damage.

• Measure the cam height

with a micrometer.



Cam height

Service Limit: (IN.) : 35.48 mm

(EX.) : 34.68 mm



09900-20202: Micrometer (25 – 50 mm)

CAMSHAFT JOURNAL WEAR

• Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.

• Use the plastigauge

to read the clearance at the widest portion, which is specified as follows:



Camshaft journal oil clearance:

Service Limit: (IN & EX): 0.150 mm



09900-22301: Plastigauge

09900-22302: Plastigauge

NOTE:

Install camshaft journal holders to their original positions.

(



3-96)

• Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque.



Camshaft journal holder bolt: 10 N·m (1.0 kgf-m)

NOTE:

Do not rotate the camshaft with the plastigauge in place.

• Remove the camshaft holders, and read the width of the compressed plastigauge with envelope scale.

• This measurement should be taken at the widest part.

ENGINE 3-29

3-30 ENGINE

• If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal.

• Replace the camshaft or the cylinder head depending upon which one exceeds the specification.



Camshaft journal holder I.D.:

Standard: (IN & EX): 24.012 – 24.025 mm



09900-20602: Dial gauge (1/1 000, 1 mm)

09900-22403: Small bore gauge (18 – 35 mm)



Camshaft journal O.D.:

Standard (IN & EX): 23.959 – 23.980 mm



09900-20205: Micrometer (0 – 25 mm)

CAMSHAFT RUNOUT

• Measure the runout using the dial gauge.

• Replace the camshaft if the runout exceeds the limit.



Camshaft runout:

Service Limit (IN & EX): 0.10 mm



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)

CAM SPROCKET

• Inspect the sprocket teeth for wear.

• If they are worn, replace the sprocket/camshaft assembly and cam chain as a set.

CAM CHAIN TENSION ADJUSTER

INSPECTION

• Remove the cam chain tension adjuster cap bolt, washer and spring.

• Check that the push rod slides smoothly when releasing stopper

• If it does not slide smoothly, replace the cam chain tension adjuster with a new one.

CAM CHAIN TENSIONER

INSPECTION

• Check the contacting surface of the cam chain tensioner.

• If it is worn or damaged, replace it with a new one.

CAM CHAIN GUIDE

INSPECTION

• Check the contacting surfaces of the cam chain guides.

• If they are worn or damaged, replace them with the new ones.

CYLINDER HEAD AND VALVE

VALVE AND VALVE SPRING DISASSEMBLY

• Remove the tappet

and shim

by fingers or magnetic hand.



Identify the position of each removed part.

ENGINE 3-31

3-32 ENGINE

• Install the special tool

between the valve spring and cylinder head.

• Using the special tools, compress the valve spring and remove the two cotter halves from the valve stem.



09916-14510: Valve lifter

09916-14530: Valve lifter attachment

09916-84511: Tweezers

09919-28610: Sleeve protector



To prevent damage of the tappet sliding surface with the special tool, use the protector.

• Remove the valve spring retainer

and valve spring

• Pull out the valve

from the combustion chamber side.

• Remove the oil seal

and spring seat



Do not reuse the removed oil seal.

• Remove the other valves in the same manner as described previously.

CYLINDER HEAD DISTORTION

• Decarbonize the combustion chambers.

• Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated.

• If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.



Cylinder head distortion:

Service Limit: 0.20 mm



09900-20803: Thickness gauge

VALVE STEM RUNOUT

• Support the valve using V-blocks and check its runout using the dial gauge as shown.

• If the runout exceeds the service limit, replace the valve.



Valve stem runout:

Service Limit: 0.05 mm



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)



Be careful not to damage the valve and valve stem when handling it.

VALVE HEAD RADIAL RUNOUT

• Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout.

• If it measures more than the service limit, replace the valve.



Valve head radial runout:

Service Limit: 0.03 mm



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)



Be careful not to damage the valve and valve stem when handling it.

VALVE FACE WEAR

• Visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve face

. If it is out of specification, replace the valve with a new one.



Valve head thickness

Service Limit: 0.5 mm



09900-20102: Vernier calipers

ENGINE 3-33

3-34 ENGINE

VALVE STEM DEFLECTION

• Lift the valve about 10 mm from the valve seat.

• Measure the valve stem deflection in two directions, perpendicular to each other, by positioning the dial gauge as shown.

• If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.



Valve stem deflection (IN & EX):

Service Limit: 0.35 mm



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

VALVE STEM WEAR

• If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve.

• If the stem is within the limit, then replace the guide.

• After replacing valve or guide, be sure to recheck the deflection.



Valve stem O.D.:

Standard (IN) : 3.975 – 3.990 mm

(EX): 3.955 – 3.970 mm



09900-20205: Micrometer (0 – 25 mm)

NOTE:

If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing. (

 below)

VALVE GUIDE SERVICING

• Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side.



09916-53310: Valve guide remover/installer

NOTE:

* Discard the removed valve guide subassemblies.

* Only oversized valve guides are available as replacement parts. (Part No. 11115-11D70)

• Re-finish the valve guide holes in cylinder head with the reamer and handle.



09916-49030: Valve guide reamer

09916-34542: Reamer handle



When refinishing or removing the reamer from the valve guide hole, always turn it clockwise.

• Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 °C – 150 °C with a hot plate.



Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.

• Apply engine oil to the valve guide hole.

• Drive the valve guide into the hole using the valve guide installer

and attachment



09916-53310: Valve guide installer/remover

09916-53330: Attachment

09916-53360: Attachment

NOTE:

Install the valve guide until the attachment

contacts with the cylinder head

: 13.6 mm (IN)

12.2 mm (EX)



Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head.

• After installing the valve guides, re-finish their guiding bores using the reamer.

• Clean and oil the guides after reaming.



09916-33310: Valve guide reamer (4 mm)

09916-34542: Reamer handle

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.

VALVE SEAT WIDTH INSPECTION

• Visually check for valve seat width on each valve face.

• If the valve face has worn abnormally, replace the valve.

• Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure.

• Check that the transferred blue on the valve face is uniform all around and in center of the valve face.



09916-10911: Valve lapper set

ENGINE 3-35

3-36 ENGINE

• If the seat width

measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter.



Valve seat width

Standard: 0.9 – 1.1 mm

If the valve seat is out of specification, re-cut the seat.

VALVE SEAT SERVICING

• The valve seats

for both the intake valve

and exhaust valve

are machined to four different angles. The seat contact surface is cut at 45°.

60 ˚

Seat angle

Seat width

INTAKE

30°, 45°, 60°

0.9 – 1.1 mm

EXHAUST

15°, 45°, 60°

0.9 – 1.1 mm

Valve diameter 27.2 mm 22 mm

Valve guide I.D.

4.000 – 4.012 mm 4.000 – 4.012 mm



* 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.

NOTE:

After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (



2-7)

• Clean and assemble the head and valve components. 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.



Always use extreme caution when handling gasoline.

VALVE SPRING

The force of the coil spring keeps the valve seat tight. Weakened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism.

• Check the valve spring for proper strength by measuring its free length and also by the force required to compress it.

• If the spring length is less than the service limit, or if the force required to compress the spring does not fall within the range specified, replace the spring.



Valve spring free length:

Service limit: (IN) : 36.2 mm

(EX): 36.0 mm



09900-20102: Vernier calipers



Valve spring tension:

Standard:

(IN) :155 – 179 N (15.8 – 18.3 kgf) 32.55 mm

(EX) :146 – 168 N (14.9 – 17.1 kgf) 32.55 mm

VALVE AND VALVE SPRING REASSEMBLY

• Install the valve spring seat.

• Apply MOLYBDENUM OIL SOLUTION to the oil seal

, and press-fit it into position.



MOLYBDENUM OIL SOLUTION



Do not reuse the removed oil seal.

• Insert the valve, with its stem coated with MOLYBDENUM

OIL SOLUTION all around and along the full stem length without any break.



When inserting the valve, take care not to damage the lip of the oil seal.



MOLYBDENUM OIL SOLUTION

ENGINE 3-37

3-38 ENGINE

• Install the valve spring with the small-pitch portion

facing cylinder head.

Large-pitch portion

UPWARD

Paint

• Put on the valve spring retainer

, and using the special tool

, press down the spring, fit the cotter halves

to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.



09916-14510: Valve lifter

09916-14530: Valve lifter attachment

09916-84511: Tweezers

09919-28610: Sleeve protector

• Be sure that the rounded lip

of the cotter fits snugly into the groove

in the stem end.

• Install the other valves and springs in the same manner as described previously.



Be sure to restore each spring and valve to their original positions.



Be careful not to damage the valve and valve stem when handling it.

Valve spring retainer

Cotter

• 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.

INTAKE PIPE

• Remove the intake pipes

• Apply SUZUKI SUPER GREASE to the O-rings.

• Install the intake pipes.

WATER BYPASS UNION

• Remove the water bypass union

• Apply SUZUKI BOND to the thread part of water bypass union and tighten it to the specified torque.



99000-31140: SUZUKI BOND “1207B”



Water bypass union: 12 N·m (1.2 kgf-m)

ENGINE 3-39

3-40 ENGINE

CLUTCH

CLUTCH DRIVE PLATES INSPECTION

NOTE:

* Wipe off engine oil from the clutch drive plates with a clean rag.

* Clutch drive plate No.1: 40 friction pieces

* Clutch drive plate No.2 and No.3: 48 friction pieces

Friction piece

• Measure the thickness of drive plates with a vernier calipers.

• If each drive plate thickness is the limit and less, replace it with a new one.



Drive plate thickness:

Service Limit: 2.62 mm



09900-20102: Vernier calipers

• Measure the claw width of drive plates with a vernier calipers.

• Replace the drive plates found to have worn down to the limit.



Drive plate claw width:

Service Limit: 12.90 mm



09900-20102: Vernier calipers

CLUTCH DRIVEN PLATES INSPECTION

NOTE:

Wipe off engine oil from the clutch driven plates with a clean rag.

• Measure each driven plate for distortion with a thickness gauge and surface plate.

• Replace driven plates which exceed the limit.



Driven plate distortion (No.1 and No.2):

Service Limit: 0.10 mm



09900-20803: Thickness gauge

CLUTCH SPRING INSPECTION

• 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.



Clutch spring free length:

Service Limit: 52.4 mm



09900-20102: Vernier calipers

CLUTCH BEARING INSPECTION

• Inspect the clutch release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be replaced.

• Smooth engagement and disengagement of the clutch depends on the condition of this bearing.

CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY

• Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one.

OIL PUMP

INSPECTION

• Rotate the oil pump by hand and check that it moves smoothly.

• If it does not move smoothly, replace the oil pump assembly.



* Do not attempt to disassemble the oil pump assembly.

* The oil pump is available only as an assembly.

STARTER CLUTCH

INSPECTION

• Install the starter driven gear

onto the starter clutch

• Turn the starter driven gear by hand.

• Inspect the starter clutch for a smooth movement.

• Inspect that the gear turns one direction only.

ENGINE 3-41

3-42 ENGINE

• If a large resistance is felt for rotation, inspect the starter clutch bearing or the starter clutch contacting surface on the starter driven gear for wear and damage.

• If they are found to be damaged, replace them with the new ones.

GENERATOR

INSPECTION (



9-10)

REASSEMBLY

• When installing the generator stator set bolts, tighten them to the specified torque.



Generator stator set bolt: 10 N·m (1.0 kgf-m)

NOTE:

Be sure to install the grommet

to the generator cover.

WATER PUMP

DISASSEMBLY/INSPECTION (



7-12)

GEARSHIFT SYSTEM

GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY

• Remove the following parts from the gearshift shaft/gearshift arm.

Washer

Snap ring

Gearshift shaft return spring

Gearshift cam drive plate

Plate return spring

GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION

• Inspect the gearshift shaft/gearshift arm for wear or bend.

• Inspect the return springs for damage or fatigue.

• Replace the arm or spring if there is anything unusual.

GEARSHIFT SHAFT/GEARSHIFT ARM REASSEMBLY

• Install the following parts to the gearshift shaft/gearshift arm as shown in the illustration.

Washer

Snap ring

Gearshift shaft return spring

Gearshift cam drive plate

Plate return spring

ENGINE 3-43

NOTE:

When installing the gearshift shaft return spring, position the stopper

of gearshift arm between the shaft return spring ends

3-44 ENGINE

OIL PRESSURE REGULATOR

• Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar.

• If the piston does not operate, replace the oil pressure regulator with a new one.

OIL STRAINER

• Inspect the oil strainer body for damage.

• Clean the oil strainer if necessary.

TRANSMISSION

DISASSEMBLY

Disassemble the countershaft and driveshaft. Pay attention to the following points:

• Remove the 6th drive gear snap ring

from its groove and slide it towards the 3rd/4th drive gears

• Slide the 6th

and 2nd

drive gears toward the 3rd/4th drive gears

, then remove the 2nd drive gear circlip

ENGINE 3-45

Countershaft/1st drive gear

5th drive gear

3rd/4th drive gear

6th drive gear

2nd drive gear

Driveshaft

2nd driven gear

6th driven gear

3rd driven gear

4th driven gear

5th driven gear

1st driven gear

Engine sprocket

Engine sprocket nut



ITEM

N·m

115

kgf-m

11.5

3-46 ENGINE

REASSEMBLY

Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points:

NOTE:

* Rotate the bearings by hand to inspect for smooth rotation.

Replace the bearings if there is anything unusual.

* Before installing the gears, apply engine oil to the driveshaft and countershaft.

* When installing the oil seal, apply SUZUKI SUPER GREASE “

A” to it.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)



* Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.

* 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 its groove and securely fitted.

NOTE:

When reassembling the transmission, 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. (



3-47)

• When installing a new snap ring, pay attention to its direction.

Fit it to the side where the thrust is as shown in the illustration.

Thrust

Sharp edge



When installing the gear bushing onto the countershaft

and driveshaft

, align the shaft oil hole

with the bushing oil hole

TRANSMISSION PARTS LOCATION

ENGINE 3-47

Countershaft

Driveshaft

3-48 ENGINE

CYLINDER

CRANKCASE SERVICING (



3-51)

CYLINDER DISTORTION

• Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated.

• If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set.



Cylinder distortion:

Service Limit: 0.02 mm



09900-20803: Thickness gauge

CYLINDER BORE

• Inspect the cylinder wall for any scratches, nicks or other damage.

• Measure the cylinder bore diameter at six places.



Cylinder bore:

Standard: 67.000 – 67.015 mm



09900-20508: Cylinder gauge set

PISTON AND PISTON RING

PISTON DIAMETER

• Using a micrometer, measure the piston outside diameter at

15 mm

from the piston skirt end.

• If the measurement is less than the limit, replace the piston.



Piston diameter:

Service Limit: 66.845 mm at 15 mm from the skirt end



09900-20203: Micrometer (50 – 75 mm)

PISTON-TO-CYLINDER CLEARANCE

• Subtract the piston diameter from the cylinder bore diameter.

(



3-48)

• If the piston-to-cylinder clearance exceeds the service limit, replace the crankcase set or the piston, or both.



Piston-to-cylinder clearance:

Service Limit: 0.120 mm

PISTON PIN AND PIN BORE

• Measure the piston pin bore inside diameter using the small bore gauge.

• If the measurement is out of specifications replace the piston.



Piston pin bore I.D.:

Service Limit: 14.030 mm



09900-20602: Dial gauge (1/1 000 mm)

09900-22401: Small bore gauge (10 – 18 mm)

• 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.



Piston pin O.D.:

Service Limit: 13.980 mm



09900-20205: Micrometer (0 – 25 mm)

ENGINE 3-49

3-50 ENGINE

PISTON RING-TO-GROOVE CLEARANCE

• Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge.

• If any of the clearances exceed the limit, replace both the piston and piston rings.



09900-20803: Thickness gauge

09900-20205: Micrometer (0 – 25 mm)



Piston ring-to-groove clearance:

Service Limit (1st) : 0.180 mm

(2nd) : 0.150 mm



Piston ring groove width:

Standard (1st) : 1.01 – 1.03 mm

(2nd) : 0.81 – 0.83 mm

(Oil) : 1.51 – 1.53 mm



Piston ring thickness:

Standard (1st) : 0.97 – 0.99 mm

(2nd) : 0.77 – 0.79 mm

PISTON RING FREE END GAP AND PISTON RING END GAP

• Measure the piston ring free end gap using the 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.



Piston ring free end gap:

Service Limit (1st) : 4.4 mm

(2nd): 6.8 mm



09900-20102: Vernier calipers



Piston ring end gap:

Service Limit (1st) : 0.50 mm

(2nd): 0.50 mm



09900-20803: Thickness gauge

CRANKCASE

GEARSHIFT FORK AND GEARSHIFT CAM

Removal

• Remove the gearshift cam bearing retainer screws

and gearshift fork shaft retainer

from the lower crankcase.

• Remove the gearshift fork shafts

and gearshift

forks from the lower crankcase.

• Remove the gearshift cam

and its bearing

GEARSHIFT FORK-TO-GROOVE CLEARANCE

• Using a thickness gauge, check the gearshift fork clearance in the groove of its gear.

• The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action.



Shift fork-to-groove clearance:

Service Limit: 0.5 mm



09900-20803: Thickness gauge

• If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.

GEARSHIFT FORK GROOVE WIDTH

• Measure the gearshift fork groove width using the vernier calipers.



Shift fork groove width:

Standard: 5.0 – 5.1 mm



09900-20102: Vernier calipers

ENGINE 3-51

3-52 ENGINE

GEARSHIFT FORK THICKNESS

• Measure the gearshift fork thickness using the vernier calipers.



Shift fork thickness:

Standard: 4.8 – 4.9 mm



09900-20102: Vernier calipers

GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT

BEARING

Inspection

• Inspect the gearshift cam bearing for abnormal noise and smooth rotation.

• Replace the bearings if there is anything unusual.

• Inspect the gearshift cam bearing

, gearshift shaft bearings

and

for abnormal noise and smooth rotation while they are in the crankcase.

• Replace the bearing if there is anything unusual.

Removal

• Remove the gearshift shaft bearing with the special tools.



09921-20210: Bearing remover

09930-30104: Sliding shaft

• Remove the gearshift cam bearing with the special tools.



09923-74511: Bearing remover

09930-30104: Sliding shaft



Be careful not to lean the bearing remover.

• Remove the oil seal

• Remove the gearshift shaft bearing with the special tool.



09921-20240: Bearing remover set (15 mm)

Installation

• Install the bearings with the special tool.



09913-70210: Bearing installer set (



22)

(



32)

NOTE:

The stamped mark side of the gearshift shaft bearing faces outside.

• Install the oil seal with the special tool.



09913-70210: Bearing installer set (



22)

• Apply SUZUKI SUPER GREASE “A” to the oil seal lip.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the gearshift cam

with the bearing

NOTE:

The stamped mark side of the gearshift cam bearing faces outside.

ENGINE 3-53

3-54 ENGINE

• Install the gearshift forks and their shafts as shown.

For 3rd/4th drive gears (17E-3W)

For 6th driven gear (17E-1E)

For 5th driven gear (17E-1F)

• Apply a small quantity of THREAD LOCK to the bearing retainer screws

• Tighten the bearing retainer screws

and gearshift fork shaft retainer bolt

to the specified torque.



99000-32050: THREAD LOCK “1342”



Bearing retainer screw: 10 N·m (1.0 kgf-m)

Gearshift fork shaft retainer bolt: 10 N·m (1.0 kgf-m)

OIL JET

Removal

• Remove the piston cooling oil jets

from the upper crankcase.

ENGINE 3-55

• Remove the oil jet

(for transmission) from the lower crankcase.

• Remove the oil jet

(for cam chain tension adjuster) from the cylinder head.

Inspection and cleaning

• Check the oil jets for clogging.

• If they are clogged, clean their oil passage with a proper wire and compressed air.

Piston cooling oil jet

Oil jet (#14) (For transmission)

Oil jet (#8) (For cam chain tension adjuster)

3-56 ENGINE

Installation

• Fit new O-ring

to each piston cooling oil jet as shown and apply engine oil to them.



Use new O-rings to prevent oil pressure leakage.

• Install each piston cooling oil jet with the bolt.

NOTE:

Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque.



99000-32050: THREAD LOCK “1342”



Piston cooling oil jet bolt: 10 N·m (1.0 kgf-m)

• Install the oil jet (for transmission).

• Apply engine oil to the O-ring.

• Install the oil jet (for cam chain tension adjuster).

PLUG

Removal

• Remove the oil gallery plugs

and

(for cylinder head side)

(for upper crankcase side)

• Remove the water jacket plugs

• Remove the oil gallery plugs

(for lower crankcase side).

Installation

• Apply engine coolant to the O-rings of the water jacket plugs



99000-99032-11X: SUZUKI COOLANT

• Apply THREAD LOCK to the oil gallery plug



99000-32050: THREAD LOCK “1342”

NOTE:

It is not required to apply THREAD LOCK when installing the other removed oil gallery plugs.

• Tighten each plug to the specified torque.



Water jacket plug: 9.5 N·m (0.95 kgf-m)

Oil gallery plug (upper crankcase): 11 N·m (1.1 kgf-m)

Oil gallery plug (lower crankcase): 35 N·m (3.5 kgf-m)

Oil gallery plug (cylinder head): 10 N·m (1.0 kgf-m)



Use new gasket or O-ring for each plug.

ENGINE 3-57

3-58 ENGINE

CRANKSHAFT AND CONROD

CRANKSHAFT RUNOUT

• Support the crankshaft with “V” blocks as shown, with the two end journals resting on the blocks.

• Set up the dial gauge, as shown.

• Rotate the crankshaft slowly to read the runout.

• Replace the crankshaft if the runout is greater than the limit.



Crankshaft runout:

Service Limit: 0.05 mm



09900-20607: Dial gauge (1/100 mm, 10 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)

CONROD SMALL END I.D.

• Using a small bore gauge, measure the inside diameter of the conrod small end.



Conrod small end I.D.:

Service Limit: 14.040 mm



09900-20602: Dial gauge (1/1 000 mm, 1 mm)

09900-22401: Small bore gauge (10 – 18 mm)

• If the inside diameter of the conrod small end exceeds the limit, replace the conrod.

CONROD BIG END SIDE CLEARANCE

• Inspect the conrod side clearance by using a thickness gauge.

• If the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width.

• If the width exceed the limit, replace conrod or crankshaft.



Conrod big end side clearance:

Service Limit: 0.30 mm



09900-20803: Thickness gauge



Conrod big end width:

Standard: 19.95 – 20.00 mm



09900-20205: Micrometer (0 – 25 mm)



Crank pin width:

Standard: 20.10 – 20.15 mm



09900-20605: Dial calipers (1/100 mm, 10 – 34 mm)

CONROD-BIG END BEARING INSPECTION

• Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings.

CONROD-BIG END BEARING SELECTION

• Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown.



09900-22301: Plastigauge

• Tighten the conrod bearing cap bolts to the specified torque, in two stages. (



3-70)



* Apply engine oil to the bearing cap bolt.

* Never rotate the crankshaft or conrod when a piece of plastigauge is installed.

*1: Face the intake side.

ENGINE 3-59

3-60 ENGINE

• Remove the bearing caps 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.



Conrod big end oil clearance:

Standard: 0.032 – 0.056 mm

Service Limit: 0.080 mm

• If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.

• Check the corresponding conrod I.D. code number (“1” or “2”)

• Check the corresponding crank pin O.D. code number (“1”,

“2” or “3”)



Bearing selection table

Conrod

I.D

Code



Conrod I.D.

Green

Black

Crank pin O.D.

Black

Brown

Yellow

Code

I.D. specification

34.000 – 34.008 mm

34.008 – 34.016 mm



Crank pin O.D.

Code

O.D. specification

30.992 – 31.000 mm

30.984 – 30.992 mm

30.976 – 30.984 mm



09900-20202: Micrometer (25 – 50 mm)



Bearing thickness

Color

(Part No.)

Yellow

(12164-29G00-0D0)

Brown

(12164-29G00-0C0)

Black

(12164-29G00-0B0)

Green

(12164-29G00-0A0)

Thickness

1.492 – 1.496 mm

1.488 – 1.492 mm

1.484 – 1.488 mm

1.480 – 1.484 mm



The bearings must be replaced as a set.

ENGINE 3-61

3-62 ENGINE

CRANKSHAFT JOURNAL BEARING

INSPECTION

• Inspect each bearing of upper and middle crankcases for any damage.

SELECTION

• Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown.



09900-22301: Plastigauge



Never rotate the crankshaft when a piece of plastigauge is installed.

• Mate the middle crankcase with the upper crankcase, and tighten the crankshaft journal bolts (M9) in the following two steps in the indicated order.



Crankshaft journal bolt (9 mm)

Initial : 18 N·m (1.8 kgf-m)

Final : 50°

• Remove the middle 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.



Crankshaft journal oil clearance:

Standard: 0.016 – 0.040 mm

Service Limit: 0.080 mm

• If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.

• Check the corresponding crankcase journal I.D. code number

, “A” or “B” which is stamped on the rear of upper crankcase.

• Check the corresponding crankshaft journal O.D. code number

, “A”, “B” or “C” which is stamped on the crankshaft.



Bearing selection table

Crankcase

I.D.

Code

Crankshaft journal O.D.

Green

Black



Crankcase I.D. specification

Black

Brown

Yellow

Code

I.D. specification

33.000 – 33.008 mm

33.008 – 33.016 mm

ENGINE 3-63

3-64 ENGINE



Crankshaft journal O.D. specification

Code

O.D. specification

29.992 – 30.000 mm

29.984 – 29.992 mm

29.976 – 29.984 mm



09900-20202: Micrometer (25 – 50 mm)



Bearing thickness specification

Color (Part No.)

Yellow

(12229-29G00-0D0)

Brown

(12229-29G00-0C0)

Black

(12229-29G00-0B0)

Green

(12229-29G00-0A0)

Thickness

1.500 – 1.504 mm

1.496 – 1.500 mm

1.492 – 1.496 mm

1.488 – 1.492 mm

NOTE:

Upper and middle crankshaft journal bearings are the same.

INSTALLATION

• When fitting the crankshaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part

first and press the other end.



Do not touch the bearing surfaces with your hands.

Grasp by the edge of the bearing shell.

CRANKSHAFT THRUST BEARING

• With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge.

: Left-side thrust bearing

: Right-side thrust bearing

NOTE:

Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.



Thrust clearance:

Standard: 0.055 – 0.110 mm



09900-20803: Thickness gauge

• If the thrust clearance exceeds the standard range, adjust the thrust clearance by the following procedures.

CRANKSHAFT THRUST CLEARANCE ADJUSTMENT

• Remove the right-side thrust bearing and measure its thickness with a micrometer.

• If the thickness of the right-side thrust bearing is below standard, replace it with a new one and once again perform the thrust clearance measurement listed above, checking to make sure it is within standard.



Right-side thrust bearing thickness:

Standard: 2.425 – 2.450 mm



09900-20205: Micrometer (0 – 25 mm)

• If the right-side thrust bearing is within the standard range, reinsert the right-side thrust bearing and remove the left-side thrust bearing.

• As shown in the illustration, measure the clearance by using a thickness gauge before inserting of the left-side thrust bearing.

• Select a left-side thrust bearing from the selection table.

(



3-66)

ENGINE 3-65

3-66 ENGINE



Thrust bearing selection table

Clearance before inserting left-side thrust bearing

Color

(Part No.)

2.560 – 2.585 mm

2.535 – 2.560 mm

2.510 – 2.535 mm

2.485 – 2.510 mm

2.460 – 2.485 mm

2.430 – 2.460 mm

White

(12228-17E00-0F0)

Yellow

(12228-17E00-0E0)

Green

(12228-17E00-0D0)

Blue

(12228-17E00-0C0)

Black

(12228-17E00-0B0)

Red

(12228-17E00-0A0)

• After selecting a left-side thrust bearing, insert it and again perform the thrust clearance measurement to make sure it falls within the standard range.

Color code

NOTE:

Right-side thrust bearing has the same specification as the

GREEN (12228-17E00-0D0) of left-side thrust bearing.

Thrust bearing thickness

2.475 – 2.500 mm

2.450 – 2.475 mm

2.425 – 2.450 mm

2.400 – 2.425 mm

2.375 – 2.400 mm

2.350 – 2.375 mm

Thrust clearance

0.060 – 0.110 mm

0.055 – 0.110 mm

ENGINE REASSEMBLY

• Reassemble the engine in the reverse order of disassembly.

• The following steps require special attention or precautionary measures should be taken.

NOTE:

Apply engine oil to each running and sliding part before reassembling.

• Be sure to install the following items to the crankcase.

* Crankshaft journal bearing (



3-62)

* Gearshift fork (



3-54)

* Gearshift fork shaft (



3-54)

* Gearshift shaft bearing (



3-53)

* Gearshift cam bearing (



3-53)

* Gearshift cam (



3-53)

* Bearing retainer (



3-54)

* Oil jets (



3-55)

PISTON RING

• Install the piston rings in the order of oil ring, 2nd ring and 1st ring.

• The first member to go into the oil ring groove is a spacer

After placing the spacer, fit the two side rails

NOTE:

Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way.



When installing the spacer, be careful not to allow its two ends to overlap in the groove.

INCORRECT

CORRECT

• Install the 2nd ring

and the 1st ring

to the piston.

NOTE:

1st ring and 2nd ring differ in shape.

ENGINE 3-67

3-68 ENGINE

• 1st ring

and 2nd ring

have letters “IT” and “T” marked on the side. Be sure to bring the marked side to the top when fitting them to the piston.

• Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located.

2nd ring and lower side rail

Upper side rail

1st ring and spacer

PISTON AND CONROD

• Rub a small quantity of MOLYBDENUM OIL SOLUTION onto each piston pin.



MOLYBDENUM OIL SOLUTION

• Assemble the piston and conrod.

NOTE:

When installing the pistons, the indent

on the piston head must be brought to the other side of ID code

on the conrod big end.

• Install the piston pin circlips



Use new piston pin circlips to prevent circlip failure which will occur with a bend one.

NOTE:

End gap of the circlip should not be aligned with the cutaway in the piston pin bore.

• Apply engine oil to the sliding surface of the pistons and cylinder walls.

NOTE:

Be sure to install the pistons in the cylinders from which they were removed in disassembly, refering to the cylinder numbers,

“1” through “4”, scribed on the piston.

120˚

120˚ 120˚

• Install the pistons and conrods into the cylinders from upside.

NOTE:

When installing the pistons, the indent

of each piston head must be brought to the exhaust side.



Be careful not to damage the cylinder wall and piston jet by the conrod.

• Check that ID code

on each conrod faces intake side.



Be sure to clean the conrod big end.

• Apply MOLYBDENUM OIL SOLUTION to the crank pin bearings surface.



MOLYBDENUM OIL SOLUTION

CRANKSHAFT

• Position the No.2 and No.3 conrod big ends on the same side, and the No.1 and No.4 conrod big ends on the opposite side of No.2 and No.3.

ENGINE 3-69

3-70 ENGINE

• Set the crankshaft to the conrods and upper crankcase.

• Apply MOLYBDENUM OIL SOLUTION to the crank pin and bearing surface.



MOLYBDENUM OIL SOLUTION



Be sure to clean the conrod big end.

• When fitting the conrod cap, make sure that I.D. code

on each conrod faces intake side.

• Apply engine oil to the bearing cap bolts.

• Tighten the bearing cap bolt by using a 10 mm, 12 point socket wrench in the following two steps.



Conrod bearing cap bolt:

Initial : 15 N·m (1.5 kgf-m)

Final : 90° (1/4 turn)

• Apply engine oil to the conrod big end side surfaces.

• Check the conrod movement for smooth turning.

• Apply MOLYBDENUM OIL SOLUTION to each crankshaft journal bearing lightly.



MOLYBDENUM OIL SOLUTION

• Insert the right and left thrust bearings with oil groove

facing the crank web.

NOTE:

Right thrust bearing has green painting.

CRANKCASE

• Clean the mating surfaces of the crankcases.

• Install the dowel pins

and O-ring

to the upper crankcase.

ENGINE 3-71

3-72 ENGINE

• Apply SUZUKI BOND to the mating surface of the middle crankcase.



99000-31140: SUZUKI BOND “1207B”

NOTE:

Use of SUZUKI BOND is as follows:

* Make surfaces free from moisture, oil, dust and other foreign materials.

* Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.

* Take extreme care not to apply any BOND to the oil hole, oil groove and bearing.

* Apply to distorted surfaces as it forms a comparatively thick film.

Gasket bolt

Lower crankcase

Middle crankcase

• Tighten the crankshaft journal bolts (9 mm) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure in the following two steps.



Crankshaft journal bolt: (M9)

Initial: 18 N·m (1.8 kgf-m)

Final : 50°

10 6 2 4 8

9 5

3 4

• Install the regulator/rectifier bracket

and tighten the other crankcase bolts a little at a time to equalize the pressure.



Crankcase bolt: (M6) Initial : 6 N·m (0.6 kgf-m)

Final : 11 N·m (1.1 kgf-m)

NOTE:

Fit the clamp to the crankcase bolt

NOTE:

Fit a new gasket to the crankcase bolt

NOTE:

After the crankshaft journal bolts and crankcase bolts have been tightened, check if the crankshaft rotates smoothly.

ENGINE 3-73

3-74 ENGINE

TRANSMISSION

• Install the bearing pins

and the C-rings

on the middle crankcase.

• Install the countershaft assembly on the middle crankcase.

NOTE:

Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.

• Install the driveshaft assembly on the middle crankcase.

NOTE:

Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.

• Install the oil seal

• Turn the bearings to install the bearing dowel pins

in the respective positions.

• Install O-rings.

• Install the dowel pins



Replace the O-rings with new ones.

• Apply SUZUKI BOND to the mating surface.



99000-31140: SUZUKI BOND “1207B”

NOTE:

Use of SUZUKI BOND is as follows:

* Make surfaces free from moisture, oil, dust and other foreign materials.

* Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.

* Take extreme care not to apply any BOND to the oil hole, oil groove and bearing.

* Apply to distorted surfaces as it forms a comparatively thick film.

ENGINE 3-75

Gasket bolt

Lower crankcase

Middle crankcase

Oil pan

• Match the middle and lower crankcases.

NOTE:

Align the gearshift forks

with their grooves

3-76 ENGINE

• Tighten the crankcase bolts a little at a time to equalize the pressure.



Crankcase bolt: (M6) Initial : 6 N·m (0.6 kgf-m)

Final : 11 N·m (1.1 kgf-m)

(M8) Initial : 15 N·m (1.5 kgf-m)

Final : 26 N·m (2.6 kgf-m)

NOTE:

* Fit new copper washer to the crankcase bolts

* Fit new gasket washer to the crankcase bolts

• Check that the driveshaft and countershaft rotate smoothly.

OIL STRAINER

• Install the O-ring.

• Apply SUZUKI SUPER GREASE “A” to the O-ring.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)



Use new O-ring to prevent oil leakage.

• Install the oil strainer

as shown and tighten the oil strainer bolts to the specified torque.



Oil strainer bolt: 10 N·m (1.0 kgf-m)

OIL PRESSURE REGULATOR

• Apply SUZUKI SUPER GREASE “A” to the O-rings.

• Press in the oil pipe

to the crankcase.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)



Use new O-ring to prevent oil leakage.

• Apply SUZUKI SUPER GREASE “A” to the O-ring.

• Press in the pipe

to the oil pan.

• Install the oil pressure regulator case

and tighten the bolts

to the specified torque.



Oil pressure regulator case bolt

: 10 N·m (1.0 kgf-m)

OIL PRESSURE SWITCH

• Apply SUZUKI BOND to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque.



99000-31140: SUZUKI BOND “1207B”



Oil pressure switch: 14 N·m (1.4 kgf-m)

NOTE:

Be careful not to apply SUZUKI BOND to the hole of thread end.

ENGINE 3-77

3-78 ENGINE

OIL PAN

• Apply SUZUKI BOND to the mating surface. (



3-75)



99000-31140: SUZUKI BOND “1207B”

• Install the oil pan.

NOTE:

Fit the gasket washer to the oil pan bolt

• Tighten the oil pan bolts diagonally to the specified torque.



Oil pan bolt: 10 N·m (1.0 kgf-m)

OIL COOLER

• Apply SUZUKI SUPER GREASE “A” to the O-ring.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)



Use new O-ring to prevent oil leakage.

• Apply THREAD LOCK to the oil cooler mounting bolts and install the oil cooler.



99000-32050: THREAD LOCK “1342”

• Tighten the oil cooler mounting bolts to the specified torque.



Oil cooler mounting bolt: 10 N·m (1.0 kgf-m)

OIL FILTER

• Install the oil filter with the special tool. (



2-14)



09915-40610: Oil filter wrench

CRANKCASE BREATHER COVER

• Apply SUZUKI BOND to the mating surface.



99000-31140: SUZUKI BOND “1207B”

• Install the crankcase breather cover



Crankcase breather cover bolt: 10 N·m (1.0 kgf-m)

• Apply SUZUKI SUPER GREASE “A” to the O-ring.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the gear position switch as shown.

• Apply THREAD LOCK to the gear position switch bolts.



99000-32110: THREAD LOCK SUPER “1322”

(or equivalent thread lock)

WATER PUMP

• Apply SUZUKI SUPER GREASE “A” to the O-ring.



Use new O-ring to prevent oil leakage.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

ENGINE 3-79

3-80 ENGINE

• Tighten the water pump mounting bolts to the specified torque.



Water pump mounting bolt: 10 N·m (1.0 kgf-m)

NOTE:

Pass the gear position switch lead wire

under the water pump lib.

• Apply engine coolant to the O-ring.

• Install the water inlet cover



Water inlet cover bolt: 10 N·m (1.0 kgf-m)

GENERATOR ROTOR

• Degrease the tapered portion

of generator rotor and also the crankshaft

. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry.

• Install the generator rotor onto the crankshaft.

• Install the rotor bolt with the washer.

• Hold the generator rotor with the special tool and tighten its bolt to the specified torque.



09930-44520: Rotor holder



Generator rotor bolt: 120 N·m (12.0 kgf-m)

• Apply SUZUKI BOND to the mating surfaces.



99000-31140: SUZUKI BOND “1207B”

NOTE:

Use of SUZUKI BOND is as follows:

* Make surfaces free from moisture, oil, dust and other foreign materials.

* Spread on surfaces thinly to form an even layer, and assemble the covers within few minutes.

* Take extreme care not to apply any BOND to the oil hole, oil groove and bearing.

* Apply to distorted surfaces as it forms a comparatively thick film.

ENGINE 3-81

Starter clutch cover

Clutch cover

Magnet cover

Lower crankcase

Upper crankcase

Gasket bolt

3-82 ENGINE

GENERATOR COVER

• Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper and middle crankcases as shown.



99000-31140: SUZUKI BOND “1207B”

• Install the dowel pins

and new gasket



Use new gasket to prevent oil leakage.

• Install the generator cover and tighten the generator cover bolts to the specified torque.



Generator cover bolt: 10 N·m (1.0 kgf-m)



Be careful not to pinch the finger between the generator cover and the crankcase.

NOTE:

Fit the gasket washer to the bolts

• Install the CKP sensor

• Apply SUZUKI BOND lightly to the groove of CKP sensor lead wire gromet.



99000-31140: SUZUKI BOND “1207B”

CAM CHAIN DRIVE SPROCKET

• Install the cam chain drive sprocket onto the crankshaft.

NOTE:

When installing the cam chain drive sprocket, align the wide spline teeth

and

CAM CHAIN TENSIONER AND CAM CHAIN GUIDE

• Install the cam chain.

• Apply a small quantity of THREAD LOCK to the cam chain tensioner bolt and cam chain guide bolt.

• Install the cam chain tensioner

along with the washer

• Install the cam chain guide



99000-32050: THREAD LOCK “1342”



Cam chain tensioner bolt: 10 N·m (1.0 kgf-m)

Cam chain guide bolt: 10 N·m (1.0 kgf-m)

ENGINE 3-83

3-84 ENGINE

STARTER CLUTCH

• Install the washer

• Install the starter clutch assembly onto the crankshaft.

NOTE:

When installing the starter clutch assembly, align the wide spline teeth

and

• Install the starter clutch bolt with the washer.

• Hold the starter clutch with the special tool and tighten its bolt to the specified torque.



09920-34830: Starter clutch holder



Starter clutch bolt: 54 N·m (5.4 kgf-m)

STARTER IDLE GEAR

• Install the starter idle gear No.2

, its shaft

and concaved washer

• Apply SUZUKI BOND lightly to the mating surfaces

at the parting line between the upper and middle crankcases and surface

as shown.



99000-31140: SUZUKI BOND “1207B”

• Install new gasket

and dowel pins



Use a new gasket to prevent oil leakage.

• Install the starter clutch cover and tighten its bolt as shown.

NOTE:

Fit a new gasket washer to the starter clutch cover bolt

as shown.



Use new gasket washer to prevent oil leakage.



Starter clutch cover bolt: 10 N·m (1.0 kgf-m)

• Install the starter idle gear No.1 shaft

, thrust washer

, bearing

, starter idle gear No.1

, washer

, and concaved washer

• Install the dowel pins

and new gasket



Use a new gasket to prevent oil leakage.

• Install the starter idle gear cover and tighten its bolts to the specified torque.



Starter idle gear cover bolt: 10 N·m (1.0 kgf-m)

NOTE:

Fit the gasket washer to the bolt

GEARSHIFT SYSTEM

• Install the gearshift cam stopper

, its bolt

, washer

and return spring

NOTE:

Apply a small quantity of THREAD LOCK to the gearshift cam stopper bolt

and tighten it to the specified torque.



99000-32050: THREAD LOCK “1342”



Gearshift cam stopper bolt: 10 N·m (1.0 kgf-m)

ENGINE 3-85

3-86 ENGINE

NOTE:

Hook the return spring end

to the stopper

• Check the gearshift cam stopper moves smoothly.

• Locate the gearshift cam in the neutral position.

• Install the gearshift cam stopper plate

NOTE:

Align the gearshift cam pin

with the gearshift cam stopper plate hole

• Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque.



99000-32050: THREAD LOCK “1342”



Gearshift cam stopper plate bolt: 13 N·m (1.3 kgf-m)

• Install the gearshift shaft assembly

and washer

as shown.

NOTE:

Pinch the gearshift arm stopper

with return spring ends

• Install the washer

and snap ring

OIL PUMP

• Install the O-ring to the oil pump and apply SUZUKI SUPER

GREASE “A” to it.



Use new O-ring to prevent oil leakage.

NOTE:

Set the oil pump shaft end

to the water pump shaft.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the oil pump with the oil pump mounting bolts and then tighten them to the specified torque.



Oil pump mounting bolt: 10 N·m (1.0 kgf-m)

• Install the washer

and pin

NOTE:

Be careful not to drop the washer

and pin

into the crankcase.

• Install the oil pump driven gear

• Install the snap ring

CLUTCH

• Install the thrust washer onto the countershaft.

NOTE:

The chamfer side

of thrust washer faces inner side.

ENGINE 3-87

3-88 ENGINE

• Install the oil pump drive gear

to the primary driven gear assembly.

• Install the primary driven gear assembly.

NOTE:

Be sure to engage the oil pump driven gear with drive gear and primary driven gear with drive gear.

• Install the bearing

and spacer

and apply engine oil to them.

• Install the thrust washer

• Install the clutch sleeve hub

onto the countershaft.

• Install the washer

and spring washer

NOTE:

The convex side of spring washer

faces outside.

• Hold the clutch sleeve hub with the special tool.



09920-53740: Clutch sleeve hub holder

• Tighten the clutch sleeve hub nut to the specified torque.



Clutch sleeve hub nut: 150 N·m (15.0 kgf-m)

• Lock the clutch sleeve hub nut with a center punch.

• Install the spring washer seat

and spring washer

onto the clutch sleeve hub correctly.

• Install the clutch push rod

into the countershaft.

• Install the clutch push piece

, bearing

and thrust washer

to the countershaft.

NOTE:

Thrust washer

is located between the pressure plate and bearing

ENGINE 3-89

3-90 ENGINE

• Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order.

NOTE:

Insert the outermost drive plate claws

to the other slits

of clutch housing as shown.

*1: Direction of outside

DRIVE PLATE: a

No.2 Drive plate…1 pc [48 friction pieces/I.D. 101 mm] b

No.1 Drive plate…6 pcs [40 friction pieces/I.D. 101 mm] c

No.3 Drive plate…1 pc [48 friction pieces/I.D. 108 mm]

Friction piece

NOTE:

No.2 and No.3 drive plates can be distinguished by the inside diameter.

DRIVEN PLATE: d

No.1 Driven plate (Thickness: 2.6 mm)…5-7 pcs e

No.2 Driven plate (Thickness: 2.3 mm)…0-2 pcs ( d

+ e

= Total 7 pcs)

• Install the pressure plate

• Install the clutch springs.

• Hold the clutch housing with the special tool.



Be careful not to damage the clutch housing or clutch plates.



09920-53740: Clutch sleeve hub holder

• Tighten the clutch spring set bolts to the specified torque.



Clutch spring set bolt: 10 N·m (1.0 kgf-m)

NOTE:

Tighten the clutch spring set bolts diagonally.

CLUTCH COVER

• Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper, middle and lower crankcases as shown.



99000-31140: SUZUKI BOND “1207B”

• Install the dowel pins and gasket



Use new gasket to prevent oil leakage.

• Install the clutch cover and tighten its bolts to the specified torque.



Clutch cover bolt: 10 N·m (1.0 kgf-m)

NOTE:

* Fit the clamp to the bolt

as shown.

* Fit the gaskets to the bolts

as shown.

ENGINE 3-91

3-92 ENGINE

CYLINDER HEAD

• Fit the dowel pins

and new cylinder head gasket

to the cylinder.



Use new gasket to prevent gas leakage.

• Place the cylinder head on the cylinder.

NOTE:

When installing the cylinder head, keep the cam chain taut.

• Tighten the cylinder head bolts (M10) in the following four-step.

Step 1:

• Tighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagonally.

Step 2:

• Loosen all the cylinder head bolts diagonally.

Step 3:

• Retighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagonally.

Step 4:

• Tighten the cylinder head bolts to the specified angles diagonally with an angular torque gauge.



Cylinder head bolt (M10): Step 1/Step 3: 31 N·m (3.1 kgf-m)

Final Step: 60°

NOTE:

Apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts.

• Tighten the cylinder head bolts to the specified torque.



Cylinder head bolt (M6): 10 N·m (1.0 kgf-m)

Cylinder head side face bolt: 14 N·m (1.4 kgf-m)

• Apply SUZUKI SUPER GREASE “A” to the O-rings and install them into the cylinder head.



Replace the O-rings with new ones.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Fit the gasket

and tighten the ECT sensor.



ECT sensor: 18 N·m (1.8 kgf-m)

• Install the thermostat

NOTE:

The jiggle valve

of thermostat faces upside.

• Install the thermostat cover



Thermostat cover bolt: 10 N·m (1.0 kgf-m)

• Install the water hose

. (



10-23)

CAMSHAFT

• Turn the crankshaft clockwise with the box wrench and align the line

on the starter clutch with the index mark

of valve timing inspection hole while keeping the cam chain pulled upward.

ENGINE 3-93

3-94 ENGINE



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

with the index mark

and hold this position when installing the camshafts.

• The camshafts are identified by the embossed letters.

• Before replacing the camshafts on cylinder head, apply

MOLYBDENUM OIL SOLUTION to their journals and cam faces.

• Apply MOLYBDENUM OIL SOLUTION to the camshaft journal holders.



MOLYBDENUM OIL SOLUTION

NOTE:

Before installing the camshaft, check that the tappets are installed correctly.

• Pull the cam chain lightly.

• The exhaust camshaft sprocket has an arrow marked “1”

Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.

• Engage the cam chain with the exhaust camshaft sprocket.

• Bind the cam chain and sprocket with a proper wire clamp

1 to prevent the cam chain disengagement while installing the camshaft journal holders.

• The other arrow marked “2”

should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked “2”

, count out 12 roller pins (from the exhaust camshaft side going towards the intake camshaft side).

• Engage the 12 roller pin

on the cam chain with the arrow marked “3” on the intake sprocket.

• Bind the cam chain and sprocket with a proper wire 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.

ENGINE 3-95

3-96 ENGINE

• Install the dowel pins

• Install the O-rings

to the camshaft journal holders.



Replace the O-rings with new ones.

• Install the camshaft journal holders.

NOTE:

* Each camshaft journal holder is identified with an embossed letter.

“A”: No.1 and No.2 cylinders

“B”: No.3 and No.4 cylinders

* Check that embossed letter on each holder faces exhaust side.



Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.

• Install the can chain guide

• Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts lightly, in the ascending order of numbers.

NOTE:

* Fit the copper washer to the camshaft journal holder bolts

* The ascending order of numbers are indicated on the camshaft journal holders.

“B”

“A”

• Tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque.



Camshaft journal holder bolt: 10 N·m (1.0 kgf-m)



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.

(5) 23

(6) 24

(1) 21

(2) 22

15 11

(3) 17

(4) 18

ENGINE 3-97

Cam chain tension adjuster

• Retract the push rod by pushing the stopper

• Install new gasket.



Use new gasket to prevent oil leakage.

• Install the cam chain tension adjuster

and tighten its mounting bolts.



Cam chain tension adjuster mounting bolt:

10 N·m (1.0 kgf-m)

• Install the spring

3-98 ENGINE

• Install the gasket

and cam chain tension adjuster cap bolt

NOTE:

Click sound is heard when the cam chain tension adjuster cap bolt is installed.

• Tighten the cam chain tension adjuster cap bolt to the specified torque.



Cam chain tension adjuster cap bolt: 23 N·m (2.3 kgf-m)



After installing the cam chain tension adjuster, check to be sure that the adjuster works properly by checking the slack of cam chain.

• Cut the wire clamps

• After installing the cam chain tension adjuster, rotate the crankshaft (some turns), and recheck the positions of the camshafts. (



3-99)

Cam chain tension adjuster mounting bolt

Cam chain tension adjuster cap bolt



ITEM

N·m

kgf-m

1.0

2.3

ENGINE 3-99

3-100 ENGINE

• Tighten the valve timing inspection plug

to the specified torque.



Valve timing inspection plug: 11 N·m (1.1 kgf-m)

CYLINDER HEAD COVER AND PAIR REED VALVE

• Pour engine oil in each oil pocket in the cylinder head.

NOTE:

Be sure to check the valve clearance. (



2-7)

• Install the PAIR reed valves

along with the gaskets.



Replace the gaskets with new ones.

• Install new gasket

to the cylinder head cover.

• Apply SUZUKI BOND to the cam end caps of the gasket as shown.



99000-31140: SUZUKI BOND “1207B”



Use new gasket to prevent oil leakage.

• Place the cylinder head cover on the cylinder head.

• Fit new gasket

to each head cover bolt.



Use new gasket to prevent oil leakage.

• Tighten the head cover bolts to the specified torque.



Head cover bolt: Initial: 10 N·m (1.0 kgf-m)

Final : 14 N·m (1.4 kgf-m)

STARTER MOTOR

• Install the new O-ring

to the starter motor.



Use new O-ring to prevent oil leakage.

• Apply SUZUKI SUPER GREASE “A” to the O-ring.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the starter motor



Starter motor mounting bolt: 10 N·m (1.0 kgf-m)

• Install the spark plugs. (



2-6)

ENGINE 3-101

FI SYSTEM DIAGNOSIS

FI SYSTEM DIAGNOSIS 4-1

PRECAUTIONS IN SERVICING ………………………………………………………… 4- 3

ELECTRICAL PARTS ………………………………………………………………… 4- 3

FUSE………………………………………………………………………………………… 4- 4

ECM/VARIOUS SENSORS …………………………………………………………. 4- 4

ELECTRICAL CIRCUIT INSPECTION PROCEDURE …………………….. 4- 6

USING THE MULTI-CIRCUIT TESTER…………………………………………. 4- 9

FI SYSTEM TECHNICAL FEATURES………………………………………………… 4-10

INJECTION TIME (INJECTION VOLUME) ……………………………………. 4-10

COMPENSATION OF INJECTION TIME (VOLUME) ……………………… 4-11

INJECTION STOP CONTROL …………………………………………………….. 4-11

FI SYSTEM PARTS LOCATION ………………………………………………….. 4-12

FI SYSTEM WIRING DIAGRAM…………………………………………………… 4-14

ECM TERMINAL ……………………………………………………………………………… 4-15

SELF-DIAGNOSIS FUNCTION………………………………………………………….. 4-16

USER MODE …………………………………………………………………………….. 4-16

DEALER MODE…………………………………………………………………………. 4-17

TPS ADJUSTMENT……………………………………………………………………. 4-19

FAIL-SAFE FUNCTION ……………………………………………………………………. 4-20

FI SYSTEM TROUBLESHOOTING ……………………………………………………. 4-22

CUSTOMER COMPLAINT ANALYSIS …………………………………………. 4-22

VISUAL INSPECTION ………………………………………………………………… 4-23

SELF-DIAGNOSTIC PROCEDURES ……………………………………………. 4-24

SELF-DIAGNOSIS RESET PROCEDURE…………………………………….. 4-24

USE OF SDS DIAGNOSTIC PROCEDURES ………………………………… 4-25

USE OF SDS DIAGNOSIS RESET PROCEDURE …………………………. 4-26

SHOW DATA WHEN TROUBLE

(DISPLAING DATA AT THE TIME OF DTC) …………………………………. 4-27

MALFUNCTION CODE AND DEFECTIVE CONDITION …………………. 4-28

“C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION ………………. 4-32

“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION ………………. 4-34

“C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION ………….. 4-36

“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION …………… 4-42

“C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION …………. 4-47

“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION ………….. 4-51

“C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION …………… 4-55

“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION …………… 4-60

“C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354)

IGNITION SYSTEM MALFUNCTION ……………………………………………. 4-63

“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION …………… 4-64

“C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION …………. 4-67

4

4-2 FI SYSTEM DIAGNOSIS

FI SYSTEM DIAGNOSIS

“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION ………………….. 4-72

“C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204)

FUEL INJECTOR CIRCUIT MALFUNCTION………………………………… 4-74

“C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION ……………… 4-76

“C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION

(Only for Immobilizer) ……………………………………………………………….. 4-78

“C44” (P0130/P0135) HO2 SENSOR (HO2S)

CIRCUIT MALFUNCTION …………………………………………………………… 4-79

“C49” (P1656) PAIR CONTROL SOLENOID VALVE

CIRCUIT MALFUNCTION …………………………………………………………… 4-83

“C60” (P0480) COOLING FAN RELAY

CIRCUIT MALFUNCTION …………………………………………………………… 4-85

SENSORS ………………………………………………………………………………………. 4-87

CMP SENSOR INSPECTION ………………………………………………………. 4-87

CMP SENSOR REMOVAL AND INSTALLATION ………………………….. 4-87

CKP SENSOR INSPECTION ………………………………………………………. 4-87

CKP SENSOR REMOVAL AND INSTALLATION ………………………….. 4-87

IAP SENSOR INSPECTION ………………………………………………………… 4-87

IAP SENSOR REMOVAL AND INSTALLATION ……………………………. 4-87

TP SENSOR INSPECTION …………………………………………………………. 4-87

TP SENSOR REMOVAL AND INSTALLATION …………………………….. 4-87

TPS ADJUSTMENT……………………………………………………………………. 4-87

ECT SENSOR INSPECTION……………………………………………………….. 4-88

ECT SENSOR REMOVAL AND INSTALLATION…………………………… 4-88

IAT SENSOR INSPECTION ………………………………………………………… 4-88

IAT SENSOR REMOVAL AND INSTALLATION ……………………………. 4-88

AP SENSOR INSPECTION …………………………………………………………. 4-88

AP SENSOR REMOVAL AND INSTALLATION …………………………….. 4-88

TO SENSOR INSPECTION …………………………………………………………. 4-89

TO SENSOR REMOVAL AND INSTALLATION …………………………….. 4-89

STP SENSOR INSPECTION ……………………………………………………….. 4-89

STP SENSOR REMOVAL AND INSTALLATION …………………………… 4-89

STP SENSOR ADJUSTMENT …………………………………………………….. 4-89

HO2 SENSOR INSPECTION……………………………………………………….. 4-89

HO2 SENSOR REMOVAL/INSTALLATION ………………………………….. 4-90

PRECAUTIONS IN SERVICING

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

ELECTRICAL PARTS

CONNECTOR/COUPLER

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

• With a lock type coupler, be sure to release the lock when disconnecting, and push 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.

• Inspect each terminal for corrosion and contamination.

The terminals must be clean and free of any foreign material which could impede proper terminal contact.

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

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

Coupler

Probe

FI SYSTEM DIAGNOSIS 4-3

Click

4-4 FI SYSTEM DIAGNOSIS

• 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.

Coupler

Probe

Where male terminal fits

FUSE

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

• Do not use a fuse of a different capacity.

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

ECM/VARIOUS SENSORS

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

INCORRECT

• Be careful not to touch the electrical terminals of the ECM.

The static electricity from your body may damage this part.

• When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch

, or electronic parts may get damaged.

• 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.

• 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 ECM which may result in serious damage.

• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagnosis.

• Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECM when its coupler is disconnected.

Otherwise, damage to ECM may result.

• Never connect an ohmmeter to the ECM 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.

FI SYSTEM DIAGNOSIS 4-5

INCORRECT

4-6 FI SYSTEM DIAGNOSIS

ELECTRICAL CIRCUIT INSPECTION

PROCEDURE

While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

• 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.

• Disconnect the negative cable from the battery.

• 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.

Sensor

ECM

*1 Check for loose connection.

• 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.

*1 Check contact tension by inserting and removing.

*2 Check each terminal for bend and proper alignment.

• Using continuity inspect or voltage check procedure as described on next page, inspect the wire harness terminals for open circuit and poor connection.

Looseness of crimping

Open

Thin wire (a few strands left)

FI SYSTEM DIAGNOSIS 4-7

Continuity check

• Measure resistance across coupler

(between

and

in the figure).

If no continuity is indicated (infinity or over limit), the circuit is open between terminals

and

ECM

• Disconnect the coupler

and measure resistance between couplers

and

If no continuity is indicated, the circuit is open between couplers

and

. If continuity is indicated, there is an open circuit between couplers

’ and

or an abnormality in coupler

’ or coupler

ECM

VOLTAGE CHECK

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

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

If measurements were taken as shown in the figure at the right and results are as listed below, it means that the circuit is open between terminals

and

Voltage Between:

and body ground: Approx. 5 V

and body ground: 0 V

Also, if measured values are as listed below, a resistance

(abnormality) exists which causes the voltage drop in the circuit between terminals

and

Voltage Between:

and body ground: Approx. 5 V

and body ground: 3 V

2 V voltage drop

0 V

5 V

4-8 FI SYSTEM DIAGNOSIS

SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)

• Disconnect the negative cable from the battery.

• Disconnect the connectors/couplers at both ends of the circuit to be checked.

NOTE:

If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts. Otherwise, diagnosis will be misled.

• 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

and

Other parts

*1: To other parts

• Disconnect the connector/coupler included in circuit (coupler

) and measure resistance between terminal

and body ground.

If continuity is indicated, the circuit is shorted to the ground between terminals

and

ECM

*1: To other parts

5 V

USING THE MULTI-CIRCUIT TESTER

• Use the Suzuki multi-circuit tester set (09900-25008).

• Use well-charged batteries in the tester.

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

USING THE TESTER

• Incorrectly connecting the

and

—

probes may cause the inside of the tester to burnout.

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

• When measuring the resistance with the multi-circuit tester

∞

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.



09900-25008: Multi-circuit tester set

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.



09900-25009: Needle pointed probe set

FI SYSTEM DIAGNOSIS 4-9

4-10 FI SYSTEM DIAGNOSIS

FI SYSTEM TECHNICAL FEATURES

INJECTION TIME (INJECTION VOLUME)

The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations.

These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

ECM

Intake Air Pressure

Sensor (IAP Sensor)

Crankshaft Position

Sensor (CKP Sensor)

Throttle Position

Sensor (TP Sensor)

Various

Sensors

Intake air pressure signal

Engine speed signal

Throttle opening signal

Various signals

Basic fuel injection time

Compensation

Injectors

Injection signal

Ultimate fuel injection time

FI SYSTEM DIAGNOSIS 4-11

COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensation of the fuel injection time (volume).

SIGNAL

ATMOSPHERIC PRESSURE SENSOR

SIGNAL

ENGINE COOLANT TEMPERATURE SEN-

SOR SIGNAL

INTAKE AIR TEMPERATURE SENSOR

SIGNAL

HEATED OXYGEN SENSOR SIGNAL

BATTERY VOLTAGE SIGNAL

ENGINE RPM SIGNAL

STARTING SIGNAL

ACCELERATION SIGNAL/

DECELERATION SIGNAL

DESCRIPTION

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 gasses. 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.

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

DESCRIPTION

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.

4-12 FI SYSTEM DIAGNOSIS

FI SYSTEM PARTS LOCATION

ECM

Speedometer

Intake air pressure sensor (IAPS)

Engine coolant temperature sensor (ECTS)

Intake air temperature sensor (IATS)

Ignition coil

Speed sensor

Cam shaft position sensor (CMPS)

Fuel injector

HO2 sensor

FI SYSTEM DIAGNOSIS 4-13

ECM

Secondary throttle valve actuator (STVA)

Fuel pump (FP)

Secondary throttle position sensor (STPS)

Fuel pump relay (FP relay)

Throttle position sensor (TPS)

Crankshaft position sensor (CKP)

Atmospheric pressure sensor (APS)

Tip-over sensor (TOS)

4-14 FI SYSTEM DIAGNOSIS

FI SYSTEM WIRING DIAGRAM

I 1

FI SYSTEM DIAGNOSIS 4-15

ECM TERMINAL

TERMINAL

NO.

CIRCUIT

STVA signal (STVA. 2A)

STVA signal (STVA. 1A)

Immobilizer indicator light

Immobilizer communication

Serial data for speedometer

Blank

TP sensor signal (TP)

IAP sensor signal (IAP)

ECT sensor signal (ECT)

Power source for sensors (VCC)

HO2 sensor signal (HO2)

CMP sensor signal (CMP+)

CKP sensor signal (CKP+)

Cooling fan relay (FAR)

Power source for back-up

Power source

STVA signal (STVA. 2B)

STVA signal (STVA. 1B)

STP sensor signal (STP)

—

TO sensor signal (TOS)

GP switch signal (GP)

Blank

AP sensor signal (AP)

IAT sensor signal (IAT)

Blank

Sensor ground (E2)

CMP sensor signal (CMP–)

ECM couplers p q r s t l m n o h i j k d e f g

TERMINAL

NO.

^ a b c

[

]

CKP sensor signal (CKP–)

Serial data for self-diagnosis

Power source for fuel injector (VM)

ECM ground (E1)

Tachometer

HO2 sensor heater

Fuel pump relay (FP Relay)

Starter relay

Fuel injector #4

Fuel injector #3

Fuel injector #2

Fuel injector #1

Ignition coil #3

Ignition coil #2

Ignition coil #1

HO2 sensor control selector

Test switch

PAIR control solenoid valve (PAIR)

Ground

Ground for ignition system

Ignition coil #4

CIRCUIT

Mode select switch

—

Gear position switch signal

Clutch switch signal

4-16 FI SYSTEM DIAGNOSIS

SELF-DIAGNOSIS FUNCTION

The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and

“Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is provided. In this check, the special tool is necessary to read the code of the malfunction items.

USER MODE

MALFUNCTION

“NO”

“YES”

LCD (DISPLAY)

INDICATION

Odd, trip or clock

Odd, trip or clock and

“FI” letters

*1 Engine can start

Engine can not start “FI” letter

FI LIGHT

INDICATION

—-

FI light turns ON.

FI light turns ON and blinks.

INDICATION MODE

—-

Each 2 sec., odd, trip or clock and “FI” is indicated alternately.

“FI” is indicated continuously.

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 or clock are indicated in the LCD panel and motorcycle can run.

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 can 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.

NOTE:

Until starting the engine, the FI light turns ON.

FI SYSTEM DIAGNOSIS 4-17

DEALER MODE

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



09930-82720: Mode select switch



Before checking the malfunction code, do not disconnect the ECM lead wire couplers.

If the couplers from the ECM are disconnected, the malfunction code memory is erased and the malfunction code can not be checked.

MALFUNCTION

“NO”

“YES”

LCD (DISPLAY)

INDICATION

C00

C**code is indicated from small numeral to large one.

FI LIGHT INDICATION

FI light turns OFF.

INDICATION MODE

—-

For each 2 sec., code is indicated.

4-18 FI SYSTEM DIAGNOSIS

CODE

C23

C24

C25

C26

C27

C28

C29

C31

C00

C11

C12

C13

C14

C15

C21

C22

C32

C33

C34

C35

C41

C42

C44

C49

C60

MALFUNCTION PART

None

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)

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)

Injector signal #1 (FI #1)

Injector signal #2 (FI #2)

Injector signal #3 (FI #3)

Injector signal #4 (FI #4)

Fuel pump control system (FP control system)

Ignition switch signal (IG switch signal: Only for immobilizer)

HO2 Sensor

PAIR control solenoid valve

Cooling fan control system

No defective part

REMARKS

Pick-up coil signal, signal generator

For #1 cylinder

For #2 cylinder

For #3 cylinder

For #4 cylinder

For #1 cylinder

For #2 cylinder

For #3 cylinder

For #4 cylinder

Fuel pump, Fuel pump relay

Anti-theft

Cooling fan relay

In the LCD (DISPLAY) panel, the malfunction code is indicated from small code to large code.

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 1 300 r/min, slightly turn the throttle position sensor and bring the line to the middle.

In the normal condition, the throttle valve stop screw pushes throttle valves slightly, and the middle line will be indicated.

When the secondary throttle valve actuator and secondary throttle position sensor signals are not sent to

ECM. In this case, C28 and C29 are indicated alternately.

TPS ADJUSTMENT

1. Adjust the engine rpm to 1 300 r/min. (



2-15)

2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness.

3. If the throttle position sensor adjustment is necessary, remove the air cleaner box (



5-13) and follow the procedure below.

4. Loosen the screw and turn the throttle position sensor

and bring the line to the middle.

5. Then, tighten the screw to fix the throttle position sensor.



09930-11950: Torx wrench

09930-82720: Mode select switch

The LCD displays the line for 0.4 sec. at a time, and when such a display repeats two times, it indicates the current position where the sensor is fixed.

Incorrect

Correct position

FI SYSTEM DIAGNOSIS 4-19

4-20 FI SYSTEM DIAGNOSIS

FAIL-SAFE FUNCTION

FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.

CMP sensor

ITEM

IAP sensor

TP sensor

ECT sensor

IAT sensor

AP sensor

Ignition signal

Injection signal

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 is fixed to 760 mmHg.

The throttle opening is fixed to half open position.

Ignition timing is also fixed.

Engine coolant temperature value is fixed to 80 °C.

Cooling fan is fixed on position.

Intake air temperature value is fixed to 40 °C.

Atmospheric pressure is fixed to 760 mmHg.

#1 Ignition-off

STARTING

ABILITY

RUNNING

ABILITY

“NO” “YES”

Motorcycle can run, but once engine stops, engine can not start.

“YES”

#2 Ignition-off

#3 Ignition-off

#4 Ignition-off

“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.

#1 Fuel-cut

#2 Fuel-cut

#3 Fuel-cut

#4 Fuel-cut

“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.

FI SYSTEM DIAGNOSIS 4-21

ITEM FAIL-SAFE MODE

STARTING

ABILITY

RUNNING

ABILITY

Secondary throttle valve actuator

STP sensor

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 close position.

Gear position signal

HO2 sensor

Gear position signal is fixed to 6th gear.

Feedback compensation is inhibited.

(Air/fuel ratio is fixed to normal.)

PAIR control solenoid valve ECM stops controlling PAIR control solenoid valve.

“YES”

The engine can start and can run even if the above signal 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.

4-22 FI SYSTEM DIAGNOSIS

FI SYSTEM TROUBLESHOOTING

CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name:

Date of issue:

Model:

Date Reg.

VIN:

Date of problem: Mileage:

Malfunction indicator lamp 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 warm

Other always)

Poor Idling

Poor fast Idle

Abnormal idling speed

( High Low) ( r/min)

Unstable

Hunting ( r/min to r/min)

Other

OTHERS:

PROBLEM SYMPTOMS

Poor Driveability

Hesitation on acceleration

Back fire/ After fire

Lack of power

Surging

Abnormal knocking

Engine rpm jumps briefly

Other

Engine Stall when

Immediately after start

Throttle valve is opened

Throttle valve is closed

Load is applied

Other

FI SYSTEM DIAGNOSIS 4-23

Weather

Temperature

Frequency

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition

Fair Cloudy Rain Snow Always Other

Hot Warm Cool Cold ( °C) Always

Always Sometimes ( times/ day, month) Only once

Road

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

NOTE:

The above form is a standard sample. The form should be modified according to conditions and characteristics of each market.

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 panel with the use of mode select switch or SDS.

* Engine oil level and leakage (



2-13)

* Engine coolant level and leakage (



2-17 and -18)

* Fuel level and leakage (



2-14 and 9-33 )

* Clogged air cleaner element (



2-4)

* Battery condition (



9-42)

* Throttle cable play (



2-15)

* Vacuum hoses looseness, bend and disconnection

* Burnt fuse

* FI light operation (



4-16, 9-29 and -31)

* Each warning light operation (



9-31)

* Speedometer operation (



9-34)

* Exhaust gas leakage and noise (



2-28)

* Each coupler disconnection

* Clogged radiator fins (



7-4)

4-24 FI SYSTEM DIAGNOSIS

SELF-DIAGNOSTIC PROCEDURES

NOTE:

* Do not disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

* Malfunction code stored in ECM memory can be checked by the special tool.

* Before checking malfunction code, read SELF-DIAGNOSIS

FUNCTION “USER MODE and DEALER MODE” (



4-16 to

-18) carefully to have good understanding as to what functions are available and how to use it.

* Be sure to read “PRECAUTIONS IN SERVICING” (



4-3) before inspection and observe what is written there.

• Remove the left frame cover. (



8-4)

• Connect the special tool to the dealer mode coupler at the wiring harness, and start the engine or crank the engine for more than 4 seconds.

• Turn the special tool’s switch ON and check the malfunction code to determine the malfunction part.



09930-82720: Mode select switch

SELF-DIAGNOSIS RESET PROCEDURE

• After repairing the trouble, turn OFF the ignition switch and turn ON again.

• If the malfunction code indicates (C00), the malfunction is cleared.

• Disconnect the special tool from the dealer mode coupler.

NOTE:

* Even though the malfunction code (C00) is indicated, the previous malfunction history code still remains stored in the ECM.

Therefore, erase the history code memorized in the ECM using

SDS.

* The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.

USE OF SDS DIAGNOSTIC PROCEDURES

* Do not disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

* Malfunction code stored in ECM memory can be checked by the SDS.

* Be sure to read “PRECAUTIONS IN SERVICING” (



4-3) before inspection and observe what is written there.

• Remove the left frame cover. (



8-4)

• Set up the SDS tool. (Refer to the SDS operation manual for further details.)

• 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 used not only for detecting Diagnostic Trouble Codes but also for reproducing and checking on screen the failure condition as described by customers using the trigger.

• How to use trigger. (Refer to the SDS operation manual for further details.)



09904-41010: SDS set tool

99565-01010-007: CD-ROM Ver. 7

FI SYSTEM DIAGNOSIS 4-25

4-26 FI SYSTEM DIAGNOSIS

USE OF SDS DIAGNOSIS RESET

PROCEDURE

• After repairing the trouble, turn OFF the ignition switch and turn ON again.

• Click the DTC inspection button

• Check the DTC.

• The previous malfunction history code (Past DTC) still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS tool.

NOTE:

The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.

• Click “Clear”

to delete history code (Past DTC).

• Follow the displayed instructions.

• Check that both “Current DTC”

and “Past DTC”

are deleted (NIL).

FI SYSTEM DIAGNOSIS 4-27

SHOW DATA WHEN TROUBLE

(DISPLAING DATA AT THE TIME OF DTC)

ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”.

Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble. 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 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.

• Click “Show data when trouble”

to display the data. By clicking the drop down button

, either “Failure

#1” or “Failure #2” can be selected.

4-28 FI SYSTEM DIAGNOSIS

MALFUNCTION CODE AND DEFECTIVE CONDITION

DTC No.

C00

C11

P0340

C12

P0335

C13

P0105

C14

P0120

C15

P0115

DETECTED

ITEM

DETECTED FAILURE CONDITION

NO FAULT –––––––––––

CMP sensor The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

CKP sensor The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

IAP sensor The sensor should produce following voltage.

CHECK FOR

–––––––––––

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

IAP sensor, lead wire/coupler connection

TP sensor

0.5 V sensor voltage < 4.85 V

In other than the above range, C13

(P0105) is indicated.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

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.

TP sensor, lead wire/coupler connection

ECT sensor

0.2 V sensor voltage < 4.80 V

In other than the above range, C14

(P0120) is indicated.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

The sensor voltage should be the following.

TP sensor circuit shorted to

VCC or ground circuit open

TP sensor circuit open or shorted to ground or VCC circuit open

ECT sensor, lead wire/coupler connection

0.15 V sensor voltage < 4.85 V

In other than the above range, C15

(P0115) is indicated.

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

FI SYSTEM DIAGNOSIS 4-29

DTC No.

C21

P0110

C22

P1450

C23

P1651

C24/C25

C26/C27

P0351/P0352

P0353/P0354

C28

P1655

DETECTED

ITEM

IAT sensor

AP sensor

TO sensor

Ignition signal

Secondary throttle valve actuator

DETECTED FAILURE CONDITION CHECK FOR

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.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

The sensor voltage should be the following.

IAT sensor, lead wire/coupler connection

IAT sensor circuit open or ground circuit open

IAT sensor circuit shorted to ground

AP sensor, wiring/coupler connection

0.5 V sensor voltage < 4.85 V

In other than the above range, C22

(P1450) is indicated.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.

AP sensor circuit shorted to

VCC or ground circuit open

AP sensor circuit open or shorted to ground or VCC circuit open

TO sensor, lead wire/coupler connection

0.2 V sensor voltage < 4.8 V

In other than the above value, C23

(P1651) is indicated.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

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.

TO sensor circuit shorted to

VCC or ground circuit open

TO sensor circuit open or shorted to ground or VCC circuit open

Ignition coil, wiring/coupler connection, power supply from the battery

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.

STVA motor, STVA lead wire/coupler

4-30 FI SYSTEM DIAGNOSIS

DTC No.

C29

P1654

C31

P0705

C32/C33

C34/C35

P0201/P0202

P0203/P0204

C41

P0230

C42

P1650

DETECTED

ITEM

DETECTED FAILURE CONDITION

STP sensor The sensor should produce following voltage.

Gear position signal value.

Sensor voltage is lower than specified value.

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

CHECK FOR

STP sensor, lead wire/coupler connection

0.15 V sensor voltage < 4.85 V

In other than the above range, C29

(P1654) is indicated.

Sensor voltage is higher than specified STP sensor circuit shorted to

VCC or ground circuit open

STP sensor circuit open or shorted to ground or VCC circuit open

GP switch, wiring/coupler connection, gearshift cam, etc.

(P0705) is indicated.

Fuel injector 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)

Fuel injector, wiring/coupler connection, power supply to the injector

Fuel pump relay

Ignition switch

(Only for

Immobilizer) is indicated.

No voltage is applied to the fuel pump, although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned

OFF.

Fuel pump relay, lead wire/coupler connection, power source to fuel pump relay and fuel injectors

Voltage is applied to fuel pump although fuel pump relay is turned

OFF.

No voltage is applied to the fuel pump, although fuel pump relay is turned ON.

Fuel pump relay switch circuit shorted to power source

Fuel pump relay (switch side)

Fuel pump relay circuit open or short

Fuel pump relay (coil side).

Immobilizer/anti-theft system When the I.D. agreement is not verified.

ECM does not receive communication signal from the immobilizer antenna.

FI SYSTEM DIAGNOSIS 4-31

P0130

C44

P0135

C49

P1656

C60

P0480

DTC No.

C44

DETECTED

ITEM

DETECTED FAILURE CONDITION

HO2 sensor HO2 sensor output voltage is not input to ECM during engine operation and running condition.

CHECK FOR

HO2 sensor circuit open or shorted to ground

PAIR control solenoid valve

Cooling fan relay

(Sensor voltage 0.1 V)

In other than the above value, C44

(P0130) is indicated.

The Heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit, C44

(P0135) is indicated.

PAIR control solenoid valve voltage is not input to ECM.

Cooling fan relay signal is not input to

ECM.

HO2 sensor lead wire/coupler connection

Battery voltage supply to the

HO2 sensor

PAIR control solenoid valve, lead wire/coupler

Cooling fan relay, lead wire/coupler connection

4-32 FI SYSTEM DIAGNOSIS

“C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION

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 CMP sensor and rotor tip

• CMP sensor circuit open or short

• CMP sensor malfunction

• ECM malfunction

ECM

CMP sensor

G/Y

CMP

INSPECTION

Step 1

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Remove the air cleaner box. (



5-13)

4) Check the CMP sensor coupler for loose or poor contacts.

If OK, then measure the CMP sensor resistance.

5) Disconnect the CMP sensor coupler and measure the resistance.



CMP sensor resistance: 0.9 – 1.7 k

Ω

(Terminal – Terminal)



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)

6) If OK, then check the continuity between each terminal and ground.



CMP sensor continuity:

∞ Ω

(Infinity)

(Terminal – Ground)

Are the resistance and continuity OK?

YES

Go to step 2.

Replace the CMP sensor with a new one.

7) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

FI SYSTEM DIAGNOSIS 4-33

Step 2

1) Crank the engine a few seconds with the starter motor, and measure the CMP sensor peak voltage at the coupler.

2) Repeat the above test procedure a few times and measure the highest peak voltage.



CMP sensor peak voltage: 0.7 V and more

(

B/Y –

—

B/Br)



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Peak volt adaptor

Is the voltage OK?

YES

• G/Y or Brown wire open or shorted to ground

• Loose or poor contacts on the CKP sensor coupler or ECM coupler (terminal

)

• 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.

• Inspect that metal particles or foreign material stuck on the CMP sensor and rotor tip.

• If there are no metal particles and foreign material, then replace the CMP sensor with a new one.

3) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

4-34 FI SYSTEM DIAGNOSIS

“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION

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

ECM

CKP sensor

G/W

G/BI

CKP

INSPECTION

Step 1

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the CKP sensor coupler for loose or poor contacts.

If OK, then measure the CKP sensor resistance.

4) Disconnect the CKP sensor coupler and measure the resistance.



CKP sensor resistance: 142 – 194

Ω

(Black – Green)



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)

FI SYSTEM DIAGNOSIS 4-35

5) If OK, then check the continuity between each terminal and ground.



CKP sensor continuity:

∞ Ω

(Infinity)

(Black – Ground)

(Green – Ground)

Are the resistance and continuity OK?

YES

Go to step 2.

Replace the CKP sensor with a new one.

6) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 2

1) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler.

2) Repeat the above test procedure a few times and measure the highest peak voltage.



CKP sensor peak voltage: 0.5 V and more

(

Black –

—

Green)



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Peak volt adaptor

Is the voltage OK?

YES

• G/W or G/BI wire open or shorted to ground.

• Loose or poor contacts on the CKP sensor coupler or ECM coupler (terminal

• 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.

• 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.

3) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

4-36 FI SYSTEM DIAGNOSIS

“C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION

C13

P0105

DETECTED CONDITION

IAP sensor voltage is not within the following range.

0.5 V Sensor voltage < 4.85 V

NOTE:

Note that atmospheric pressure varies depending on weather conditions as well as altitude.

Take that into consideration when inspecting voltage.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

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.

• IAP sensor circuit open or shorted to VCC or ground circuit open.

• IAP sensor circuit shorted to ground or VCC circuit open.

ECM

IAP sensor

B/Br

G/B

VCC

IAP

INSPECTION

Step 1 (When indicating C13:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the IAP sensor coupler for loose or poor contacts.

If OK, then measure the IAP sensor input voltage.

4) Disconnect the IAP sensor coupler.

5) Turn the ignition switch to ON.

6) Insert the needle pointed probes to the lead wire coupler.

7) Measure the voltage at the Red wire and ground.

If OK, then measure the voltage at the Red wire and B/Br wire.



IAP sensor input voltage: 4.5 – 5.5 V

(

Red –

—

Ground)

(

Red –

—

B/Br)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler

(terminal

• Open or short circuit in the Red wire or B/Br wire.

Step 1 (When indicating P0105-H:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the IAP sensor coupler for loose or poor contacts.

If OK, then check the IAP sensor lead wire continuity.

FI SYSTEM DIAGNOSIS 4-37

4) Disconnect the IAP sensor coupler.

5) Check the continuity between Red wire

and G/B wire

If the sound is not heard from the tester, the circuit condition is OK.

]

4-38 FI SYSTEM DIAGNOSIS

6) Disconnect the ECM coupler.

7) Check the continuity between G/B wire

and terminal

If OK, then check the continuity between B/Br wire

and terminal



IAPS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

G/B wire shorted to VCC, or B/Br wire open.

9) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 1 (When indicating P0105-L:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the IAP sensor coupler for loose or poor contacts.

If OK, then check the IAP sensor lead wire continuity.

ECM couplers (Harness side)

]

4) Disconnect the IAP sensor coupler.

5) Check the continuity between G/B wire

and ground.

6) Also, check the continuity between G/B wire

and B/Br wire

. If the sound is not heard from the tester, the circuit condition is OK.

]

FI SYSTEM DIAGNOSIS 4-39

7) Disconnect the ECM coupler.

Check the continuity between Red wire

and terminal

9) Also, check the continuity between G/B wire

and terminal



IAPS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 1 (



4-36) and go to Step 2.

Red wire or G/B wire open, or G/B wire shorted to ground

10)After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 2

1) Connect the IAP sensor coupler and ECM coupler.

2) Insert the needle pointed probes to the IAP sensor lead wire coupler as shown.

3) Start the engine at idle speed and measure the IAP sensor output voltage between G/B and B/Br wires.



IAP sensor output voltage: Approx. 2.7 V at idle speed

(

G/B –

—

B/Br)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

Go to Step 3.

• Check the vacuum hose for crack or damage.

• Open or short circuit in the G/B wire

• If vacuum hose and wire are OK, replace the

IAP sensor with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

4-40 FI SYSTEM DIAGNOSIS

Step 3

1) Turn the ignition switch to OFF.

2) Remove the IAP sensor.

3) Connect the vacuum pump gauge to the vacuum port of the

IAP sensor.

Arrange 3 new 1.5 V batteries in series

(check that total — voltage is 4.5 – 5.0 V) and connect

—

terminal to the ground terminal

and

terminal to the VCC terminal

4) Check the voltage between Vout

and ground. Also, check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge. (



4-41)



09917-47011: Vacuum pump gauge

09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

• G/B, Red or B/Br wire open or shorted to ground, or poor

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.

If check result is not satisfactory, replace the IAP sensor with a new one.

5) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

3 v

ECM couplers (Harness side)

Output voltage

(VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C)

ALTITUDE

(Reference)

(m)

ATMOSPHERIC

PRESSURE

(mmHg)

760 kPa

100

OUTPUT

VOLTAGE

(V)

3.1 – 3.6

610

611

708

707

2.8 – 3.4

1 524

1 525

635

634

2.6 – 3.1

2 438

2 439

568

567

2.4 – 2.9

3 048 526 70

FI SYSTEM DIAGNOSIS 4-41

4-42 FI SYSTEM DIAGNOSIS

“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION

C14

P0120

DETECTED CONDITION

Output voltage is not within the following range.

Difference between actual throttle opening and opening calculated by ECM is larger than specified value.

0.2 V Sensor voltage < 4.8 V

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• TP sensor maladjusted

• TP sensor circuit open or short

• TP sensor malfunction

• ECM malfunction

• TP sensor circuit shorted to VCC or ground circuit open

• TP sensor circuit open or shorted to ground or

VCC circuit open

ECM

TP sensor

P/B

B/Br

VCC

INSPECTION

Step 1 (When indicating C14:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Remove the air cleaner box and lift up the throttle body.

(



5-13)

4) Check the TP sensor coupler for loose or poor contacts.

If OK, then measure the TP sensor input voltage.

5) Disconnect the TP sensor coupler.

6) Turn the ignition switch ON.

7) Measure the voltage at the Red wire

and ground.

If OK, then measure the voltage at the Red wire

and B/Br wire



TP sensor input voltage: 4.5 – 5.5 V

(

Red –

—

Ground)

(

Red –

—

B/Br)



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler

(terminal

• Open or short circuit in the Red wire or B/Br wire.

Step 1 (When indicating P0120-H:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Remove the air cleaner box and lift up the throttle body.

(



5-13)

4) Check the TP sensor coupler for loose or poor contacts.

If OK, then check the TP sensor lead wire continuity.

5) Disconnect the TP sensor coupler.

6) Check the continuity between P/B wire

and Red wire

If the sound is not heard from the tester, the circuit condition is OK.

FI SYSTEM DIAGNOSIS 4-43

]

7) Disconnect the ECM coupler.

Check the continuity between P/B wire

and terminal

9) Also, check the continuity between B/Br wire

and terminal



TPS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

P/B wire shorted to VCC, or B/Br wire open

10) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

4-44 FI SYSTEM DIAGNOSIS

Step 1 (When indicating P0120-L:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Remove the air cleaner box and lift up the throttle body.

(



5-13)

4) Check the TP sensor coupler for loose or poor contacts.

If OK, then check the TP sensor lead wire continuity.

5) Disconnect the TP sensor coupler.

6) Check the continuity between P/B wire

and ground.

7) Also, check the continuity between P/B wire

and B/Br wire

. If the sound is not heard from the tester, the circuit condition is OK.

]

Disconnect the ECM coupler.

9) Check the continuity between P/B wire

and terminal

10) Also, check the continuity between Red wire

and terminal



TPS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 1 (



4-42) and go to Step 2.

Red wire or P/B wire open, or P/B wire shorted to ground

11) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

Step 2

1) Turn the ignition switch to OFF.

2) Disconnect the TP sensor coupler.

3) Install the test harness to the TP sensor.

4) Check the continuity between terminal

and ground.



TP sensor continuity:

∞ Ω

(Infinity)

(Terminal

– Ground)



09900-25008: Multi-circuit tester set

09900-28630: TPS test wire harness



Tester knob indication: Continuity test (



)

5) If OK, then measure the TP sensor resistance at the test harness terminals (between terminal

and terminal

6) Turn the throttle grip and measure the resistance.



TP sensor resistance

Throttle valve is closed: Approx. 1.1 k

Ω

Throttle valve is opened: Approx. 4.4 k

Ω

TPS

7) If OK, then measure the TP sensor resistance at the test harness terminals (between terminal

and terminal



TP sensor resistance: Approx. 4.68 k

Ω

(Terminal

– Terminal

)



Tester knob indication: Resistance (

Ω

)

FI SYSTEM DIAGNOSIS 4-45

P/B

B/Br

ECM

4-46 FI SYSTEM DIAGNOSIS

Are the continuity and resistance OK?

YES

Go to Step 3.

• Reset the TP sensor position correctly.

• Replace the TP sensor with a new one.

After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

TPS

Step 3

1) Connect the TP sensor coupler

to the test harness.

2) Turn the ignition switch to ON.

3) Measure the TP sensor output voltage at the coupler

(between

P/B and

—

B/Br) by turning the throttle grip.

P/B

B/Br

ECM



TP sensor output voltage

Throttle valve is closed: Approx. 1.1 V

Throttle valve is opened: Approx. 4.4 V





09900-25008: Multi-circuit tester set

Tester knob indication: Voltage (



)

TPS

P/B

B/Br

ECM

Is the voltage OK?

YES

• P/B, Red or B/Br wire open or shorted to ground, or poor

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.

If check result is not satisfactory, replace TP sensor with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

FI SYSTEM DIAGNOSIS 4-47

“C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION

C15

P0115

DETECTED CONDITION

Output voltage is not within the following range.

0.15 V Sensor voltage < 4.85

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 open or ground circuit open

• ECT sensor circuit shorted to ground

ECT sensor

ECM

B/BI

B/Br

ECT

INSPECTION

Step 1 (When indicating C15:)

1) Turn the ignition switch to OFF.

2) Check the ECT sensor coupler for loose or poor contacts.

If OK, then measure the ECT sensor voltage at the wire side coupler.

3) Disconnect the coupler and turn the ignition switch ON.

4) Measure the voltage between B/Bl wire terminal

and ground.

5) If OK, then measure the voltage between B/Bl wire terminal

and B/Br wire terminal



ECT sensor voltage: 4.5 – 5.5 V

(

B/Bl –

—

Ground)

(

B/Bl –

—

B/Br)



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler

(terminal

• Open or short circuit in the B/Bl wire or B/Br wire

4-48 FI SYSTEM DIAGNOSIS

Step 1 (When indicating P0115-H:)

1) Turn the ignition switch to OFF.

2) Check the ECT sensor coupler for loose or poor contacts.

If OK, then check the ECT sensor lead wire continuity.

3) Disconnect the ECT sensor coupler and ECM coupler.

4) Check the continuity between B/Bl wire

and terminal

5) Also, check the continuity between B/Br wire

and terminal



ECTS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

B/Bl or B/Br wire open

6) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

Step 1 (When indicating P0115-L:)

1) Turn the ignition switch to OFF.

2) Check the ECT sensor coupler for loose or poor contacts.

If OK, then measure the output voltage.

3) Disconnect the ECT sensor coupler.

4) Check the continuity between B/Bl wire

and ground.

If the sound is not heard from the tester, the circuit condition is OK.



Tester knob indication: Continuity test (



)

5) Connect the ECT sensor coupler and turn the ignition switch to ON.

6) Measure the voltage between B/Bl wire

and ground.



ECT sensor output voltage: 0.15 – 4.85 V

(

B/BI –

—

Ground)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Voltage (



)

Are the continuity and voltage OK?

YES

Go to Step 2.

• B/BI wire shorted to ground

• If wire is OK, go to Step 2.

7) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

FI SYSTEM DIAGNOSIS 4-49

]

4-50 FI SYSTEM DIAGNOSIS

Step 2

1) Turn the ignition switch to OFF.

2) Disconnect the ECT sensor coupler.

3) Measure the ECT sensor resistance.



ECT sensor resistance:

Approx. 2.3 – 2.6 k

Ω

at 20 °C

(Terminal – Terminal)



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)

Refer to page 7-7 for details.

Is the resistance OK?

YES

• B/Bl or B/Br wire open or shorted to ground, or poor

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.

Replace the ECT sensor with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)



ECT sensor specification

Engine Coolant Temp

20 °C

50 °C

80 °C

110 °C

Resistance

Approx. 2.45 k

Ω

Approx. 0.811 k

Ω

Approx. 0.318 k

Ω

Approx. 0.142 k

Ω

ECM couplers (Harness side)

FI SYSTEM DIAGNOSIS 4-51

“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION

C21

P0110

DETECTED CONDITION

Output voltage is not within the following range.

0.15 V Sensor voltage < 4.85 V

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

ECM

IAT sensor

B/Br

IAT

INSPECTION

Step 1 (When indicating C21:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the IAT sensor coupler for loose or poor contacts.

If OK, then measure the IAT sensor voltage at the wire side coupler.

4) Disconnect the coupler and turn the ignition switch ON.

5) Measure the voltage between Dg wire terminal

and ground.

6) If OK, then measure the voltage between Dg wire terminal

A and B/Br wire terminal



IAT sensor input voltage: 4.5 – 5.5 V

(

Dg –

—

Ground)

(

Dg –

—

B/Br)



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler

(terminal

)

• Open or short circuit in the Dg wire or B/Br wire

4-52 FI SYSTEM DIAGNOSIS

Step 1 (When indicating P0110-H:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the IAT sensor coupler for loose or poor contacts.

If OK, then check the IAT sensor lead wire continuity.

4) Disconnect the IAT sensor coupler and ECM coupler.

5) Check the continuity between Dg wire

and terminal

6) Also, check the continuity between B/Br wire

and terminal



IATS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

Dg wire or B/Br wire open

7) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

Step 1 (When indicating P0110-L:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the IAT sensor coupler for loose or poor contacts.

If OK, then check the IAT sensor lead wire continuity.

4) Disconnect the IAT sensor coupler.

5) Check the continuity between Dg wire

and ground. If the sound is not heard from the tester, the circuit condition is OK.



Tester knob indication: Continuity test (



)

6) Connect the IAT sensor coupler and turn the ignition switch

ON.

7) Measure the voltage between Dg wire

and ground.



IAT sensor output voltage: 0.15 – 4.85 V

(

Dg –

—

Ground)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Voltage (



)

Are the continuity and voltage OK?

YES

Go to Step 2.

• Dg wire shorted to ground

• If wire is OK, go to Step 2.

After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

FI SYSTEM DIAGNOSIS 4-53

]

4-54 FI SYSTEM DIAGNOSIS

Step 2

1) Turn the ignition switch to OFF.

2) Measure the IAT sensor resistance.



IAT sensor resistance: Approx. 2.45 k

Ω

at 20 °C

(Terminal – Terminal)



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)

Is the resistance OK?

YES

• Dg or B/Br wire open or shorted to ground, or poor

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.

Replace the IAT sensor with a new one.



IAT sensor specification

Intake Air Temp

20 °C

50 °C

80 °C

110 °C

Resistance

Approx. 2.45 k

Ω

Approx. 0.808 k

Ω

Approx. 0.322 k

Ω

Approx. 0.148 k

Ω

NOTE:

IAT sensor resistance measurement method is the same way as that of the ECT sensor. Refer to page 7-7 for details.

ECM couplers (Harness side)

FI SYSTEM DIAGNOSIS 4-55

“C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION

C22

P1450

DETECTED CONDITION

AP sensor voltage is not within the following range.

0.5 V Sensor voltage < 4.85 V

NOTE:

Note that atmospheric pressure varies depending on weather conditions as well as altitude.

Take that into consideration when inspecting voltage.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• Clogged air passage with dust

• AP sensor circuit open or shorted to ground

• AP sensor malfunction

• ECM malfunction

• AP sensor circuit shorted to VCC or ground circuit open

• AP sensor circuit open or shorted to ground or

VCC circuit open

ECM

AP sensor

G/Y

E2 B/Br

VCC

INSPECTION

Step 1 (When indicating C22:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the AP sensor coupler for loose or poor contacts.

If OK, then measure the AP sensor input voltage.

4-56 FI SYSTEM DIAGNOSIS

4) Disconnect the AP sensor coupler.

5) Turn the ignition switch to ON.

6) Measure the voltage at the R wire and ground.

7) If OK, then measure the voltage at the Red wire

and B/Br wire



AP sensor input voltage: 4.5 – 5.5 V

(

R –

—

Ground)

(

R –

—

B/Br)



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler

(terminal

)

• Open or short circuit in the R wire or B/Br wire

Step 1 (When indicating P1450-H:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the AP sensor coupler for loose or poor contacts.

If OK, then check the AP sensor lead wire continuity.

4) Disconnect the AP sensor coupler.

5) Check the continuity between R wire

and G/Y wire

. If the sound is not heard from the tester, the circuit condition is

OK.

]

FI SYSTEM DIAGNOSIS 4-57

6) Disconnect the ECM coupler.

7) Check the continuity between G/Y wire

and terminal

If OK, then check the continuity between B/Br wire

and terminal



APS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

G/Y wire shorted to VCC, or B/Br wire open

9) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 1 (When indicating P1450-L:)

1) Turn the ignition switch to OFF.

2) Remove the front seat. (



8-3)

3) Check the AP sensor coupler for loose or poor contacts.

If OK, then check the AP sensor lead wire continuity.

ECM couplers (Harness side)

]

4) Disconnect the AP sensor coupler.

5) Check the continuity between G/Y wire

and ground.

6) Also, check the continuity between G/Y wire

and B/Br wire

. If the sound is not heard from the tester, the circuit condition is OK.

4-58 FI SYSTEM DIAGNOSIS

7) Disconnect the ECM coupler.

Check the continuity between R wire

and terminal

9) If OK, then check the continuity between G/Y wire

and terminal



APS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 1 (



4-56) and go to Step 2.

Red or G/Y wire open, or G/Y wire shorted to ground

10) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 2

1) Connect the AP sensor coupler and ECM coupler.

2) Insert the needle pointed probes to the lead wire coupler.

Turn the ignition switch ON.

3) Measure the AP sensor output voltage at the wire side coupler (between G/Y and B/Br wires).



AP sensor output voltage: Approx. 3.6 V at

100 kPa (760 mmHg)

(

G/Y –

—

B/Br)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Voltage (



)

YES

Go to Step 3.

• Check the air passage for clogging.

• Open or short circuit in the G/Y wire

• Replace the AP sensor with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

FI SYSTEM DIAGNOSIS 4-59

Step 3

1) Remove the AP sensor.

2) Connect the vacuum pump gauge to the vacuum port of the

AP sensor.

Arrange 3 new 1.5 V batteries in series

(check that total voltage is 4.5 – 5.0 V) and connect

—

terminal to the ground terminal

and

terminal to the VCC terminal

3) Check the voltage between Vout

and ground. Also, check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge. (



Below)



09917-47011: Vacuum pump gauge

09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

• R, G/Y or B/Br wire open or shorted to ground, or poor

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.

If check result is not satisfactory, replace AP sensor with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Output voltage

(VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C)

ALTITUDE

(Reference)

(m)

ATMOSPHERIC

PRESSURE

(mmHg)

760 kPa

100

OUTPUT

VOLTAGE

(V)

3.1 – 3.6

610

611

708

707

2.8 – 3.4

1 524

1 525

635

634

2.6 – 3.1

2 438

2 439

568

567

2.4 – 2.9

3 048 526 70

ECM couplers (Harness side)

4-60 FI SYSTEM DIAGNOSIS

“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION

C23

P1651

DETECTED CONDITION

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

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• TO sensor circuit open or short

• TO sensor malfunction

• ECM malfunction

• TO sensor circuit shorted to VCC or ground circuit open

• TO sensor circuit open or shorted to ground or

VCC circuit open

TO sensor

B/Br

ECM

VCC

TOS

INSPECTION

Step 1 (When indicating C23:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the TO sensor coupler for loose or poor contacts.

If OK, then measure the TO sensor resistance.

4) Disconnect the TO sensor coupler.

5) Measure the resistance between terminal

and terminal



TO sensor resistance: 16.5 – 22.3 k

Ω

(Terminal

– Terminal

)



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)

Is the resistance OK?

YES

Go to Step 2.

Replace the TO sensor with a new one.

FI SYSTEM DIAGNOSIS 4-61

Step 1 (When indicating P1651-H:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the TO sensor coupler for loose or poor contacts.

If OK, then check the TO sensor lead wire continuity.

4) Disconnect the TO sensor coupler.

5) Check the continuity between R wire

and B wire

If the sound is not heard from the tester, the circuit condition is

OK.

]

6) Disconnect the ECM coupler.

7) Check the continuity between B wire

and terminal

Also, check the continuity between B/Br wire

and terminal



TOS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

Black wire shorted to VCC, or B/Br wire open.

9) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

]

ECM couplers (Harness side)

4-62 FI SYSTEM DIAGNOSIS

Step 1 (When indicating P1651-L:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Check the TO sensor coupler for loose or poor contacts.

If OK, then check the TO sensor lead wire continuity.

4) Disconnect the TO sensor coupler.

5) Check the continuity between B wire

and ground.

6) Also, check the continuity between B wire

and B/Br wire

. If the sound is not heard from the tester, the circuit condition is OK.

]

7) Disconnect the ECM coupler.

Check the continuity between R wire

and terminal

9) Also, then check the continuity between B wire

B and terminal



TOS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

R or B wire open, or B wire shorted to ground.

10) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

]

ECM couplers (Harness side)

FI SYSTEM DIAGNOSIS 4-63

Step 2

1) Connect the TO sensor coupler and ECM coupler.

2) Insert the needle pointed probes to the lead wire coupler.

3) Turn the ignition switch to ON.

4) Measure the voltage at the wire side coupler between B and

B/Br wires.



TO sensor voltage (Normal): 0.4 – 1.4 V

(

B –

—

B/Br)

Also, measure the voltage when leaning the motorcycle.

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.



TO sensor voltage (Leaning): 3.7 – 4.4 V

(

B –

—

B/Br)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

• R, B or B/Br wire open or shorted to ground, or poor

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.

• Loose or poor contacts on the ECM coupler

• Open or short circuit

• Replace the TO sensor with a new one.

6) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

65˚

ECM couplers (Harness side)

“C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354) IGNITION

SYSTEM MALFUNCTION

* Refer to the IGNITION SYSTEM for details. (



9-20)

4-64 FI SYSTEM DIAGNOSIS

“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION

DETECTED CONDITION

The operation voltage does not reach the STVA.

ECM does not receive communication signal from the STVA.

POSSIBLE CAUSE

• STVA malfunction

• STVA circuit open or short

• STVA motor malfunction

STVA

B/Lg

P/W

W/B

ECM

STVA. 1B

STVA. 1A

STVA. 2B

STVA. 2A

INSPECTION

Step 1

1) Lift and support the fuel tank. (



5-3)

2) Remove the air cleaner box. (



5-13)

3) Check the STVA lead wire coupler for loose or poor contacts.

4) Turn the ignition switch to ON to check the STV operation.

(STV operating order: Full open

→

95% open)

Is the operating OK?

YES

Go to Step 2.

• Loose or poor contacts on the STVA coupler

• Open or short circuit in the B/Lg, P/W, W/B or

Green wires

• If wire and connection are OK, go to Step 2.

5) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

FI SYSTEM DIAGNOSIS 4-65

Step 2

1) Turn the ignition switch to OFF.

2) Disconnect the STVA lead wire coupler.

3) Check the continuity between each terminal and ground.



STVA continuity:

∞ Ω

(Infinity)

(Terminal – Ground)

4) If OK, then measure the STVA resistance (between terminal

and terminal

) and (between terminal

and terminal



STVA resistance: Approx. 7.0

Ω

(Terminal

– Terminal

)

(Terminal

– Terminal

)



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)

Is the resistance OK?

YES

• W/B, P/W, G and B/Lg wire open or shorted to ground, or poor

and

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.

• Loose or poor contacts on the ECM coupler.

• Replace the STVA with a new one.

5) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

4-66 FI SYSTEM DIAGNOSIS

ACTIVE CONTROL INSPECTION

1) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

2) Turn the ignition switch to ON.

3) Click “Secondary throttle operating control”

4) Click each button

At this time, if an operation sound is heard from the STVA, the function is normal.

FI SYSTEM DIAGNOSIS 4-67

“C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION

C29

P1654

DETECTED CONDITION

Signal voltage is not within the following range.

Difference between actual throttle opening and opening calculated by ECM is larger than specified value.

0.15 V Sensor voltage < 4.85 V

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• STP sensor maladjusted

• STP sensor circuit open or short

• STP sensor malfunction

• ECM malfunction

• STP sensor circuit shorted to VCC or ground circuit open

• STP sensor circuit open or shorted to ground or

VCC circuit open

ECM

VCC

STP

Y/W

B/Br

STP sensor

INSPECTION

Step 1 (When indicating C29:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Remove the air cleaner box and lift up the throttle body.

(



5-13)

4) Check the STP sensor coupler for loose or poor contacts.

If OK, then measure the STP sensor input voltage.

5) Disconnect the STP sensor coupler.

6) Turn the ignition switch ON.

7) Measure the voltage at the R wire

A and ground.

Also, measure the voltage at the R wire

and B/Br wire

4-68 FI SYSTEM DIAGNOSIS



STP sensor input voltage: 4.5 – 5.5 V

(

R –

—

Ground)

(

R –

—

B/Br)



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler

(terminal

)

• Open or short circuit in the R wire or B/Br wire

Step 1 (When indicating P1654-H:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Remove the air cleaner box and lift up the throttle body.

(



5-13)

4) Check the STP sensor coupler for loose or poor contacts.

If OK, then check the STP sensor lead wire continuity.

5) Disconnect the STP sensor coupler.

6) Check the continuity between Y/W wire

and R wire

If the sound is not heard from the tester, the circuit condition is OK.

]

7) Disconnect the ECM coupler.

Check the continuity between Y/W wire

and terminal

9) Also, check the continuity between B/Br wire

and terminal



STPS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 2.

Y/W wire shorted to VCC, or B/Br wire open

10) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

FI SYSTEM DIAGNOSIS 4-69

Step 1 (When indicating P1654-L:)

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank. (



5-3)

3) Remove the air cleaner box and lift up the throttle body.

(



5-13)

4) Check the STP sensor coupler for loose or poor contacts.

If OK, then check the STP sensor lead wire continuity.

5) Disconnect the STP sensor coupler.

6) Check the continuity between Y/W wire

and ground.

7) Also, check the continuity between Y/W wire

and B/Br wire

. If the sound is not heard from the tester, the circuit condition is OK.

]

Disconnect the ECM coupler.

9) Check the continuity between Y/W wire

and terminal

10) Also, check the continuity between R wire

and terminal



STPS lead wire continuity: Continuity (



)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Continuity test (



)

Is the continuity OK?

YES

Go to Step 1 (



4-67) and go to Step 2.

Red or Y/W wire open, or Y/W wire shorted to ground

11) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

]

4-70 FI SYSTEM DIAGNOSIS

Step 2

1) Turn the ignition switch to OFF.

2) Remove the air cleaner box and lift up the throttle body.

(



5-13)

3) Disconnect the STP sensor coupler.

4) Install the test harness to the STP sensor.

5) Check the continuity between each terminal and ground.



STP sensor continuity:

∞ Ω

(Infinity)

(Terminal – Ground)



09900-25008: Multi-circuit tester set

09900-28630: TPS test wire harness

6) If OK, then measure the STP sensor resistance at the wire terminals (between terminal

and terminal

7) Close and open the secondary throttle valve by finger, and measure the valve closing and opening resistance.

STP



STP sensor resistance

Secondary throttle valve is closed: Approx. 0.5 k

Ω

Secondary throttle valve is opened: Approx. 3.9 k

Ω



Tester knob indication: Resistance (

Ω

)

2 2

Y/W

B/Br

ECM

FI SYSTEM DIAGNOSIS 4-71

If OK, then measure the STP sensor resistance at the wire terminals (between terminal

and terminal



STP sensor resistance: Approx. 4.69 k

Ω



09900-25008: Multi-circuit tester set

09900-28630: TPS test wire harness



Tester knob indication: Resistance (

Ω

)

Are the continuity and resistance OK?

YES

Go to Step 3.

• Reset the STP sensor position correctly.

• Replace the STP sensor with a new one.

9) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 3

1) Turn the ignition switch to OFF.

2) Connect the STP sensor coupler to the test harness.

3) Disconnect the STVA lead wire coupler.

4) Turn the ignition switch to ON.

5) Measure the STP sensor output voltage at the wire terminal

(between

terminal

and

—

terminal

) by turning the secondary throttle valve (close and open) with a finger.

STP



STP sensor output voltage

Secondary throttle valve is closed : Approx. 0.5 V

Secondary throttle valve is opened : Approx. 3.9 V



Tester knob indication: Voltage (



)

Y/W

B/Br

ECM

Y/W

B/Br

ECM

Is the voltage OK?

YES

• R, Y/W or B/Br wire open or shorted to ground, or poor

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.

If check result is not satisfactory, replace STP sensor with a new one.

After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

4-72 FI SYSTEM DIAGNOSIS

“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION

DETECTED CONDITION

No Gear Position switch voltage

Switch voltage is not within the following range.

Switch voltage > 0.6 V

POSSIBLE CAUSE

• Gear Position switch circuit open or short

• Gear Position switch malfunction

• ECM malfunction

ECM

B/W

To engine stop switch

Side-stand relay

B/W

GP switch

Neutral indicator light

Side-stand switch

Ignition switch

INSPECTION

Step 1

1) Turn the ignition switch to OFF.

2) Check the GP switch coupler for loose or poor contacts.

If OK, then measure the GP switch voltage.

3) Support the motorcycle with a jack.

4) Fold the side-stand to up position.

5) Make sure the engine stop switch is in the “RUN” position.

6) Insert the needle pointed probe to the lead wire coupler.

7) Turn the ignition switch to ON.

Measure the voltage at the wire side coupler between P wire and B/W wire, when shifting the gearshift lever from 1st to

Top.



GP switch voltage: 0.6 V and more

(

P –

—

B/W)



09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set



Tester knob indication: Voltage (



)

FI SYSTEM DIAGNOSIS 4-73

Is the voltage OK?

YES

• P wire open or 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.

• P or B/W wire open, or P wire shorted to ground

• Loose or poor contacts on the ECM coupler

(terminal

)

• If wire and connection are OK, replace the GP switch with a new one.

9) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

4-74 FI SYSTEM DIAGNOSIS

“C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) FUEL

INJECTOR CIRCUIT MALFUNCTION

DETECTED CONDITION

CKP signal is produced but fuel injector signal is interrupted by 4 times or more continuously.

POSSIBLE CAUSE

• Injector circuit open or short

• Injector malfunction

• ECM malfunction

ECM

Y/R

Fuel pump relay

To engine stop switch

#11

#21

#31

#41

Gr/W

Gr/B

Gr/Y

Gr/R

#4 #3 #2

Primary fuel injector

INSPECTION

Step 1

1) Turn the ignition switch to OFF.

2) Lift and support the fuel tank (



5-3)

3) Check the injector coupler for loose or poor contacts.

If OK, then measure the injector resistance.

4) Disconnect the injector coupler and measure the resistance between terminals.



Injector resistance: 11 – 13

Ω

at 20 °C

(Terminal – Terminal)



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)

FI SYSTEM DIAGNOSIS 4-75

5) If OK, then check the continuity between each terminal and ground.



Injector resistance:

∞ Ω

(Infinity)

Are the resistance and continuity OK?

YES

Go to Step 2.

Replace the injector with a new one. (



5-14)

6) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 2

1) Turn the ignition switch to ON.

2) Measure the injector voltage between Y/R wire and ground.



Injector voltage: Battery voltage

(

Y/R –

—

Ground)

NOTE:

Injector voltage can be detected only 3 for seconds after ignition switch is turned ON.



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)

Is the voltage OK?

YES

• Gr/W wire open or shorted to ground, or poor d connection (#1 cylinder side)

• Gr/B wire open or shorted to ground, or poor c connection (#2 cylinder side)

• Gr/Y wire open or shorted to ground, or poor b connection (#3 cylinder side)

• Gr/R wire open or shorted to ground, or poor a 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.

Open circuit in the Y/R wire

3) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

4-76 FI SYSTEM DIAGNOSIS

“C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION

C41

P0230

DETECTED CONDITION

No voltage is applied to 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.

No voltage is applied to fuel pump although fuel pump relay is turned ON.

POSSIBLE CAUSE

• Fuel pump relay circuit open or short

• Fuel pump relay malfunction

• ECM malfunction

• Fuel pump relay switch circuit shorted to power source

• Faulty fuel pump relay (switch side)

• Fuel pump relay coil circuit open or short

• Faulty fuel pump relay (coil side)

ECM

FP Relay

Y/R

Y/B

Fuel pump

Fuel pump relay

R/BI

O/W

Engine stop switch

To side-stand switch

Side-stand relay

INSPECTION

Step 1 (When indicating C41:)

1) Turn the ignition switch to OFF.

2) Remove the seat tail cover. (



8-4)

3) Check the FP relay coupler for loose or poor contacts.

If OK, then check the FP relay. (



5-6)

Ignition switch

Is the FP relay OK?

YES

• Y/B or O/W wire open or short or poor

]

connection

• Y/R or R/Bl wire open, shorted or poor

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.

Replace the FP relay with a new one.

ECM couplers (Harness side)

FI SYSTEM DIAGNOSIS 4-77

Step 1 (When indicating P0230-H:)

1) Turn the ignition switch to OFF.

2) Remove the seat tail cover. (



8-4)

3) Check the FP relay coupler for loose or poor contacts.

If OK, then check the FP relay. (



5-6)

Is the FP relay OK?

YES

• Y/R 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.

Replace the FP relay with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

Step 1 (When indicating P0230-L:)

1) Turn the ignition switch to OFF.

2) Remove the seat tail cover. (



8-4)

3) Check the FP relay coupler for loose or poor contacts.

If OK, then check the FP relay. (



5-6)

ECM couplers (Harness side)

Is the FP relay OK?

YES

• Y/B wire open or poor

]

connection

• O/W wire open or shorted to ground

• R/BI or Y/R wire open or shorted to ground or poor

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.

Replace the FP relay with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(



4-26)

ECM couplers (Harness side)

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GSR600

Manuals and User Guides for Suzuki GSR600. We have 1 Suzuki GSR600 manual available for free PDF download: Service Manual

Источник

Detail Specifications:

764/764296-gsr600.pdf file (24 Oct 2022)

Accompanying Data:

Suzuki GSR600 Motorcycle PDF Service Manual (Updated: Monday 24th of October 2022 01:04:21 AM)

Rating: 4.9 (rated by 91 users)

Compatible devices: GSF600Y 2000, 2001 GSX-R600, 1994 RF600R, DL650, GSX-R1000/A, A50, 700, GT 380.

Text Version of Service Manual

(Ocr-Read Summary of Contents, UPD: 24 October 2022)

85, ENGINE 3-33 VALVE STEM RUNOUT • Support the valve using V-blocks and check its runout using the dial gauge as shown. • If the runout exceeds the service limit, replace the valve.  Valve stem runout: Service Limit: 0.05 mm  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)  VALVE HEAD RADIAL RUNOUT • Place the dial gauge…
73, ENGINE 3-21 • Remove the starter clutch cover 8. • Remove the dowel pins and gasket. • Remove the concaved washer 9, starter idle gear No.2 0 and shaft A. STARTER CLUTCH • Hold the starter clutch with the special tool.  09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. • Remove the starter clutch assembly and washer.…
38, PERIODIC MAINTENANCE 2-21 CLEANING AND LUBRICATING • Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.  • After washing and drying the chain, oil it with a heavyweight motor oil.  Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings. Use only kerosine to cle…
10, GENERAL INFORMATION 1-3  * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * Be sure to use special tools when instructed. * Make sure that all parts u…
224, Suzuki GSR600 FI SYSTEM DIAGNOSIS 4-71 If OK, then measure the STP sensor resistance at the wire terminals (between terminal A and terminal C).  STP sensor resistance: Approx. 4.69 kΩ  09900-25008: Multi-circuit tester set 09900-28630: TPS test wire harness  Tester knob indication: Resistance (Ω) Are the continuity and resistance OK? 9) After repairing the trouble…
58, 3-6 ENGINE • Disconnect the starter motor lead wire 3. • Disconnect the engine ground lead wire 4. • Disconnect the respective lead wire couplers. CKP sensor 5 Generator 6 Side-stand 7 GP switch 8 ECT sensor 9 • Disconnect the ignition coil/plug cap lead wire couplers 0 and CMP sensor lead wire coupler A.  • Remove the ignition coil/plug caps B.  • Disconnect the …
169, 4-16 FI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is provided. In this check, the special tool is …
20, PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. * Lubricate exposed parts which are subject to rust, with a rust preventat…
167, Suzuki GSR600 4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM HO2 sensor 10 A 15 A 15 A 30 A 10 A Speedometer B/Y G/R R/Bl Gr/W Gr/B Gr/Y Gr/R Y/R Y/B O/G W/Bl # 1 # 2 # 3 # 4 # 1 # 2 # 3 # 4 Y G W/G P Y/G B/Y B/W B/W B/W B/W W/B G P/W B/Lg B G/W G/Bl P/B Y/W G/B G/B B G/Y B/Bl B/Br R Br Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Throttle position sensor (TPS) Intake air press…
104, Suzuki GSR600 3-52 ENGINE GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers.  Shift fork thickness: Standard: 4.8 – 4.9 mm  09900-20102: Vernier calipers GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT BEARING Inspection • Inspect the gearshift cam bearing for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Insp…
68, 3-16 ENGINE • Remove the intake camshaft 6. • Remove the exhaust camshaft 7. • Remove the dowel pins. CYLINDER HEAD • Remove the water hose 1. • Remove the thermostat cover 2 and thermostat. THERMOSTAT INSPECTION (7-9) • Remove the ECT sensor 3. ECT SENSOR INSPECTION (7-7) • Remove the cylinder head bolts (M6) 4 and side face bolt 5. • Remove the O-rings 6.…

Recommended Instructions:

W10206413A, IDECT Z1, HI 98129, E422VL, SDE515DAZW, CP30W

READ THIS MANUAL CAREFULLY!Provincial / Municipal governments have different regulations pertaining to owning and operating an off-road vehicle, learn the regulations in your area.Model: 125DXAlways wear a helmet it could save your life!Never allow any child under the age of 16 to operate this Dirt Bike without continual adult supervision.READ THIS MANUAL CAREFULLY!POWERSPORTS …

DB70 41
MOTO GUZZI WOULD LIKE TO THANK YOUfor choosing one of its products. We have drawn up this manual to show you all the features of your motorcycle. Please read it carefully before ridingthe motorcycle for the first time. It contains information, tips and precautions for using your vehicle. You will also discover features, details and deviceswhich will reassure you that you have made the rig …

NORGE 1200 GT 8v 225
OWNER’S SERVICE MANUALMANUEL D’ATELIER DU PROPRIETAIREFAHRER-UND WARTUNGS-HANDBUCHMANUALE DI SEVIZIO DELPROPRIETARIOYZ125(S)/LC5XE-28199-30PRINTED IN JAPAN2003.5—2.2 × 1 !(E, F, G, H)YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED ON RECYCLED PAPERYZ125(S)/LC5XE-9-30 hyoshi 5/13/03 2:34 PM Page 1 …

YZ125(S)/LC 568