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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys
GSX-R1000
SERVICE MANUAL
9 9 5 0 0 — 3 9 3 8 0 — 0 1 E
email: info@motomatrix.co.uk / www.motomatrix.co.uk
Related Manuals for Suzuki GSX-R1000
Summary of Contents for Suzuki GSX-R1000
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys GSX-R1000 SERVICE MANUAL 9 9 5 0 0 — 3 9 3 8 0 — 0 1 E email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys FOREWORD This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys TABLE OF CONTENTS Precautions…………… 00-i Precautions …………00-1 General Information ……….. 0-i General Information ……….0A-1 Maintenance and Lubrication ……… 0B-1 Service Data…………0C-1 Engine …………….. 1-i Precautions ………….. 1-1 Engine General Information and Diagnosis … -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ……….00-1 General Precautions ……….. 00-1 Precautions for Electrical Circuit Service …. 00-2 Precautions…………00-1 Warning / Caution / Note……..00-1 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Precautions: 00-2 • Never reuse a circlip. When installing a • Inspect each terminal for corrosion and new circlip, take care not to expand the contamination. The terminals must be clean and free end gap larger than required to slip the of any foreign material which could impede proper circlip over the shaft. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse is blown, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 00-5 Precautions: 2) Check each connector/coupler at both ends of the Continuity check circuit being checked for loose connection. Also 1) Measure resistance across coupler “B” (between “A” check for condition of the coupler lock if equipped. and “C”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Precautions: 00-6 3) Also, if measured values are as listed following, a Short circuit check (Wire harness to ground) resistance (abnormality) exists which causes the 1) Disconnect the negative (–) cable from the battery. voltage drop in the circuit between terminals “A”… -
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: 09900–25008 (Multi circuit tester set) I705H1000009-02 “D”: To other parts Using The Multi-Circuit Testers • Use the Suzuki multi-circuit tester set. • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi circuit tester set) -
Page 13: General Information
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 0- i Section 0 General Information CONTENTS General Information …….. 0A-1 Valve Clearance Inspection and Adjustment ..0B-5 Spark Plug Replacement ……..0B-9 General Description ……….0A-1 Spark Plug Inspection and Cleaning ….0B-9 Symbols …………..
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Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent. -
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ECM: Engine Control Module Engine Control Unit SAE: Society of Automotive Engineers (ECU) (FI Control Unit) SDS: Suzuki Diagnosis System ECT Sensor: Engine Coolant Temperature Sensor SRAD: Suzuki Ram Air Direct (ECTS) STC System: Secondary Throttle Control System Water Temp. Sensor (WTS) (STCS) -
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Use of SF/SG or SH/SJ in API with MA in JASO. spare parts. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart. -
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2) Upon reaching an odometer reading of 1 600 km (1 Suzuki recommends the use of SUZUKI COOLANT anti- 000 miles) you can subject the motorcycle to full freeze/engine coolant. If this is not available, use an throttle operation. -
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0A-5 General Information: Country and Area Codes B947H10101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX-R1000 K9 (E-02) U.K. JS1CY111100100001 – GSX-R1000 K9 (E-14) Thailand JS1CY121400100001 – GSX-R1000 K9 (E-19) E.U. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-6 Warning, Caution and Information Labels Location B947H10101011 6, 7, 8, 9 6 (E-28) 1 (E-24), 2 1 (E-03, 33) 3, 21, 23 10, 11, 12 16, 17, 18, 19, 20 13, 14, 15 22, 24 I947H1010008-04… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0A-7 General Information: Component Location Electrical Components Location B947H10103001 I947H1010006-06 1. Steering damper solenoid valve 9. Fuel level gauge 17. TO sensor 2. PAIR control solenoid valve 10. Fuel pump 18. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-8 I947H1010007-02 23. Ignition switch/Immobilizer antenna (E-02, 19, 24, 51) 30. Turn signal/Side-stand relay 37. Horn 24. IAT sensor 31. Cooling fan relay 38. EXCV actuator 25. Secondary fuel injector 32. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0A-9 General Information: Specifications Specifications B947H10107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 045 mm (80.5 in) Overall width 720 mm (28.3 in) Overall height… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-10 Chassis Item Specification Remark Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 125 mm (4.9 in) Rear wheel travel 130 mm (5.1 in) Caster… -
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Small bore gauge (18 0.076 mm) 0.152 mm) – 18 mm) – 35 mm) 09900–25008 09900–25009 09904–41010 09913–50121 09913–70210 Multi circuit tester set Needle-point probe SUZUKI Diagnostic Oil seal remover Bearing installing set (10 – 75 Φ) system set email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-12 09915–17410 09915–40610 09915–63311 09915–64512 09915–74521 Oil pressure gauge Oil filter wrench Compression gauge Compression gauge Adapter hose adapter attachment 09915–77331 09916–10911 09916–14510 09916–14522 09916–33210 Oil pressure gauge Valve lapper set Valve lifter Valve lifter attachment… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0A-13 General Information: 09925–18011 09930–10121 09930–11920 09930–11940 09930–11950 Bearing installer Spark plug wrench set Torx bit (JT40H) Torx bit holder Torx wrench (5 mm) 09930–11960 09930–30104 09930–30460 09930–34970 09930–40113 Torx wrench (4 mm) Rotor remover sliding Rotor remover bolt… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys General Information: 0A-14 09943–74111 09943–88211 09944–28321 99565–01010–020 Front fork oil level Pinion bearing installer Hexagon socket (19 CD-ROM Ver.20 gauge email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 28: Maintenance And Lubrication
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B947H10200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy.
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Page 29: Scheduled Maintenance
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-2 Scheduled Maintenance Periodic Maintenance Schedule Chart B947H10205001 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace. T = Tighten. Interval 1 000 6 000…
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-3 Maintenance and Lubrication: Lubrication Points B947H10205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. NOTE •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-4 3) Drain water from the air cleaner box by removing the Exhaust Control Valve Inspection B947H10206004 drain plug (1). Inspect exhaust control valve Initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter Inspect exhaust control valve as follows: 1) Remove the left side cowling. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-5 Maintenance and Lubrication: Valve Clearance Inspection and Adjustment B947H10206005 “A” “A” Inspect valve clearance “B” “B” Initially every 24 000 km (14 500 miles, 48 months) Inspection Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-6 7) In this condition, read the valve clearance at the Adjustment valves “F” (IN and EX of No. 4 cylinder, EX of No. 3 The clearance is adjusted by replacing the existing and IN of No. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-7 Maintenance and Lubrication: (INTAKE SIDE) I837H1020015-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-8 (EXHAUST SIDE) I837H1020016-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-9 Maintenance and Lubrication: 6) Install the camshafts and cam chain tension adjuster. 2) Measure the spark plug gap using a wire gauge. If it Refer to “Engine Top Side Assembly” in Section 1D is not within the specification, replace the spark plug. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-10 Fuel Line Inspection Engine Oil Replacement B947H10206008 1) Place the motorcycle on the side-stand. Inspect fuel line 2) Place an oil pan below the engine, and drain engine Every 6 000 km (4 000 miles, 12 months) oil by removing the oil drain plug (1) and filler cap (2). -
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(thread diameter and pitch), filtering performance and durability I815H1020023-01 which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki Oil Level Inspection automobile oil filter on this motorcycle. 1) Place the motorcycle on the side-stand. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-12 Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization B947H10206011 B947H10206013 Inspect throttle cable play Inspect throttle valve synchronization Initially at 1 000 km (600 miles, 2 months) and every Initially at 1 000 km (600 miles, 2 months) (E-33 only) 6 000 km (4 000 miles, 12 months) thereafter and every 12 000 km (7 500 miles, 24 months) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-13 Maintenance and Lubrication: Engine Coolant Change Air Bleeding From the Cooling Circuit Refer to “Engine Coolant Description” in Section 1F 1) Remove the side cowlings. Refer to “Exterior Parts (Page 1F-1). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-14 Clutch Cable Play Inspection and Adjustment 7) From this position, turn out the clutch release B947H10206015 adjusting screw (6) 1 rotation, and tighten the lock- nut (5) while holding the screw (6). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-15 Maintenance and Lubrication: 2) Visually check the drive chain for the possible defects listed as follows. If any defects are found, the 1 2 3 19 20 21 drive chain must be replaced. -
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“drive chain oil”. Such oil can damage the meets the following specification. O-rings. BF: Brake fluid (DOT 4) • The standard drive chain is a DID 50VAZ. SUZUKI recommends to use this standard drive chain as a replacement. “A” I947H1020023-01 I947H1020022-01… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-17 Maintenance and Lubrication: Brake Pads Check The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-18 Air Bleeding from Brake Fluid Circuit CAUTION Refer to “Air Bleeding from Brake Fluid Circuit” in The standard tire fitted on this motorcycle is Section 4A (Page 4A-4). 120/70 ZR17 M/C (58W) for front and 190/50 ZR17 M/C (73W) for rear. -
Page 46: Front Fork Inspection
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-19 Maintenance and Lubrication: Front Fork Inspection Chassis Bolt and Nut Inspection B947H10206021 B947H10206023 Inspect front fork Tighten chassis bolt and nut Every 12 000 km (7 500 miles, 24 months) Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect the front forks for oil leakage, scoring or…
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-20 I947H1020043-02 I947H1020046-02 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Rear shock absorber bracket nut 115 N⋅m (11.5 kgf-m, 83.0 lbf-ft) Front axle bolt 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) Front axle pinch bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Front brake disc bolt 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) Front brake caliper mounting bolt 39 N⋅m (3.9 kgf-m, 28.0 lbf-ft) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0B-21 Maintenance and Lubrication: Compression Pressure Check B947H10206024 Refer to “Compression Pressure Check” in Section 1D (Page 1D-3). Oil Pressure Check B947H10206025 Refer to “Oil Pressure Check” in Section 1E (Page 1E- SDS Check B947H10206026 Refer to “SDS Check”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Maintenance and Lubrication: 0B-22 Special Tools and Equipment Recommended Service Material B947H10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-16) NOTE Required service material is also described in the following. -
Page 50: Service Data
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-1 Service Data: Service Data General Information Specifications Service Data B947H10307001 Valve + Guide Unit: mm (in) Item Standard Limit 31.0 (1.22) — Valve diam. 25.0 (0.98) — 0.08 – 0.18 (0.003 – 0.007) —…
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-2 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 –… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-3 Service Data: Balancer Unit: mm (in) Item Standard Limit Balancer shaft journal oil clearance 0.028 – 0.052 (0.0011 – 0.0020) 0.080 (0.0031) Balancer shaft journal O.D. 19.992 – 20.000 (0.7871 – 0.7874) —… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-4 Thermostat + Radiator + Cooling Fan + Coolant Item Standard/Specification Note Thermostat valve opening Approx. 82 °C (180 °F) — temperature Over 8 mm (0.31 in) and at 95 °C (203 °F) Thermostat valve lift —… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-5 Service Data: FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage 4.5 –… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-6 Throttle Body Item Specification Bore size 44 mm (1.73 in) I.D. No. 47H1 (For E-33), 47H0 (For others) 1 150 ± 100 r/min Idle r/min Throttle cable play 2.0 –… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-7 Service Data: Wattage Unit: W Specification Item E-02, 19, 24, 51 E-03, 14, 28, 33 ← Headlight ← ← Position light 5 x 2 ← Brake light/Taillight ← Turn signal light 21 x 4 ←… -
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75 (2.95) — outer tube fully compressed) 70 (2.76) 10 min. after adjustment Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 476 ml (16.1/16.8 US/lmp oz) — Front fork inner tube O.D. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-9 Service Data: Tightening Torque List B947H10307002 Engine Item N⋅m kgf-m lbf-ft Exhaust pipe bolt 16.5 Muffler chamber connecting bolt 21.5 Muffler chamber bracket bolt 18.0 Muffler chamber mounting bolt 16.5 Muffler connecting bolt 16.5… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-10 Item N⋅m kgf-m lbf-ft 37 N⋅m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/6 Conrod cap bolt (60°) turn Breather cover bolt Oil pan bolt Oil cooler mounting bolt Driveshaft bearing case bolt (LH and RH) Driveshaft oil seal retainer screw Gearshift arm stopper… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-11 Service Data: Chassis Item N⋅m kgf-m lbf-ft Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt 16.5 Steering damper nut 16.5 Front fork clamp bolt (Upper and Lower) 16.5 Front fork cap 25.5… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Service Data: 0C-12 Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 0C-13 Service Data: email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 1- i Section 1 Engine CONTENTS Precautions ……….1-1 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Precautions…………. 1-1 Malfunction…………1A-75 Precautions for Engine………. 1-1 DTC “C28”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1-ii Table of Contents Emission Control Devices …… 1B-1 ECT Sensor Inspection ……..1C-4 IAT Sensor Removal and Installation….1C-5 Precautions…………1B-1 IAT Sensor Inspection………1C-5 Precautions for Emission Control Devices ..1B-1 AP Sensor Inspection……….1C-5 General Description ……….1B-1 AP Sensor Removal and Installation….1C-5… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 1-iii Camshaft Inspection ………1D-36 Oil Pressure Switch Inspection ……1E-10 Camshaft Sprocket ………..1D-38 Oil Jet Removal and Installation……1E-10 Cam Chain Tension Adjuster Inspection…1D-38 Oil Jet Inspection……….1E-12 Cam Chain Guide / Cam Chain Tensioner Oil Pump Removal and Installation ….1E-12 Removal and Installation………1D-39 Oil Pump Inspection ……….1E-14… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1-iv Table of Contents Schematic and Routing Diagram……. 1G-3 Component Location ……….1I-1 Fuel Tank Drain Hose and Breather Hose Starting System Components Location ….1I-1 Routing Diagram ……….1G-3 Diagnostic Information and Procedures ….. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 1-v Exhaust System……..1K-1 EXCVA Pulley Inspection……..1K-9 EXCVA Adjustment ……….1K-9 Precautions…………1K-1 Muffler / Muffler Chamber / Exhaust Pipe Precautions for Exhaust System ……1K-1 Removal and Installation………1K-11 General Description ……….1K-1 Exhaust System Inspection…….1K-13 Exhaust Control System Description…. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1-1 Precautions: Precautions Engine Precautions Precautions for Engine B947H11000001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2). email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 69: Engine General Information And Diagnosis
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine General Description Injection Timing Description B947H11101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-2 Engine General Information and Diagnosis: Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions When atmospheric pressure is low, the sensor sends the signal to… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-3 Self-Diagnosis Function B947H11101002 The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-4 Engine General Information and Diagnosis: Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-5 Combination meter Cooling fan Cooling fan relay motor 15 A Br/Y Y/Bl R/Bl *1 Immobilizer *2 Ignition switch 23 11 42 Fuel 64*1 Lg/W pump 64*2… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-6 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B947H11102002 I837H1110004-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT EXCVA power (MO+) ISC valve signal (ISC, 2A) Speed sensor signal ISC valve signal (ISC, 1B) STVA signal (STVA, 2A) ISC valve signal (ISC, 1A) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-7 Component Location FI System Parts Location B947H11103001 “I” “C” “J” “A” “D” “F” “B” “K” “H” “G” I947H1110005-01 “A”: ECM “E”: Intake air pressure sensor (IAPS) “I”: Fuel pump relay (FP relay) “B”: Throttle position sensor (TPS) “F”: EVAP system purge control solenoid valve (E-33 only) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-8 Engine General Information and Diagnosis: “Y” “M” “O” “S” “P” “A” “T” “Q” “R” “W” “U” “N” “L” “X” “V” I947H1110006-01 “A”: ECM “Q”: Camshaft position sensor (CMPS) “W”: Atmospheric pressure sensor (APS) “L”: Exhaust control valve actuator (EXCVA) “R”: Ignition coil (IG coil) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-9 Condition Possible cause Correction / Reference Item Engine will not start or is TP sensor out of adjustment. Adjust. hard to start (Incorrect Defective fuel pump. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-10 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Noisy engine (Noise Worn down piston or cylinder. Replace. seems to come from Combustion chamber fouled with Clean. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-11 Condition Possible cause Correction / Reference Item Engine runs poorly in Low fuel pressure. Repair or replace. high speed range Defective TP sensor. Replace. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-12 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Dirty or heavy exhaust Too much engine oil. Check with inspection window, drain out smoke excess oil. Worn piston ring or cylinder. -
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Removal and Installation” in Section 9D (Page 9D- 2) Set up the SDS tools. (Refer to the SDS operation manual for further details.) Special tool (A): 09904–41010 (SUZUKI Diagnostic I705H1110116-03 system set) 3) Click the DTC inspection button (1). (B): 99565–01010–020 (CD-ROM Ver.20) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-14 Engine General Information and Diagnosis: 4) Start the engine or crank the engine for more than 4 3) Check the DTC. seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-15 Show Data When Trouble (Displaying Data at the Time of DTC) B947H11104004 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. -
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1) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6). 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) Special tool : 09904–41010 (SUZUKI Diagnostic system set) : 99565–01010–020 (CD-ROM Ver.20) NOTE •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-17 Sample Data sampled from cold starting through warm-up Check the engine r/min. XXX r/min Check the engine coolant temperature. XX ˚C Check the manifold absolute pressure. XXX kPa I947H1110146-01 Data at 3 000 r/min under no load… -
Page 86
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-18 Engine General Information and Diagnosis: Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens closes in according with the throttle valve opening PAIR control solenoid valve OFF in according with the throttle valve opens… -
Page 87
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-19 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XXX kPa I947H1110150-01 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 88
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-20 Engine General Information and Diagnosis: Example of Trouble Three data; value 3 (current data 3), value 1 (past data 1) and value 2 (past data 2); can be made in comparison by showing them in the graph. -
Page 89
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-21 Code Malfunction Part Remarks C25 (P0352) Ignition signal #2 (IG coil #2) For #2 cylinder (Page 1A-75) C26 (P0353) Ignition signal #3 (IG coil #3) For #3 cylinder (Page 1A-75) C27 (P0354) -
Page 90
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-22 Engine General Information and Diagnosis: Fail-Safe Function Table B947H11104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. -
Page 91
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-23 Item Fail-Safe Mode Starting Ability Running Ability EVAP system purge control ECM stops controlling EVAP system purge “YES” “YES” solenoid valve (E-33 only) control solenoid valve. -
Page 92
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-24 Engine General Information and Diagnosis: MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair / Cloudy / Rain / Snow / Always / Other Cold ( °C / °F) / Temperature Hot / Warm /… -
Page 93
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-25 Malfunction Code and Defective Condition Table B947H11104009 Malfunction Detected Item Detected Failure Condition Check For Code NO FAULT — — CMP sensor wiring and The signal does not reach ECM for 3 sec. -
Page 94
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-26 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned TO sensor, lead wire/coupler 0.2 V ≤… -
Page 95
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-27 Malfunction Detected Item Detected Failure Condition Check For Code No voltage is applied to the fuel pump, Fuel pump relay, lead wire/ although fuel pump relay is turned ON, or coupler connection, power voltage is applied to fuel pump although fuel source to fuel pump relay and… -
Page 96
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-28 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code Speedometer does not receive signal from the vehicle speed sensor for more than 6 sec. when the motorcycle is running. -
Page 97
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-29 DTC “C11” (P0340): CMP Sensor Circuit Malfunction B947H11104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after •… -
Page 98
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-30 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Y, R or B/Br wire • Inspect that metal open or shorted to particles or foreign 2) Lift and support the fuel tank. -
Page 99
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-31 Step Action 6) Under this condition, if a suitable screwdriver touching • B/Y, R or B/Br wire • Inspect that metal the pick-up surface of the CMP sensor is moved, the open or shorted to particles or foreign tester reading voltage changes (0.8 V and less ↔… -
Page 100
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-32 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B947H11104011 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after •… -
Page 101
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-33 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation”… -
Page 102
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-34 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi circuit tester set) CKP sensor continuity… -
Page 103
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-35 DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B947H11104012 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the •… -
Page 104
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-36 Engine General Information and Diagnosis: C13 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. -
Page 105
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-37 P0105-H for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open. -
Page 106
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-38 Engine General Information and Diagnosis: Step Action
Check the continuity between the G/B wire and terminal Go to Step 3. G/B wire shorted to “19”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire and terminal “35”. -
Page 107
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-39 P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/B wire open, G/ B wire shorted to 2) Lift and support the fuel tank. -
Page 108
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-40 Engine General Information and Diagnosis: Step Action Check the continuity between the R wire and terminal Go to Step 2. R and G/B wire open, G/ “7”. Also, check the continuity between the G/B wire and B wire shorted to terminal “19”. -
Page 109
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-41 Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum hose for crack or 2) Connect the ECM couplers and IAP sensor coupler. damage. -
Page 110
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-42 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor. -
Page 111
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-43 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B947H11104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following •… -
Page 112
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-44 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. -
Page 113
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-45 P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. P/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. -
Page 114
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-46 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 3. P/B wire shorted to “6”. Also, check the continuity between the B/Br wire and VCC, or B/Br wire open. -
Page 115
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-47 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or P/B wire open, or Y/W wire shorted to 2) Lift and support the fuel tank. -
Page 116
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-48 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 2. R or P/B wire open, or “6”. Also, check the continuity between the R wire and Y/W wire shorted to terminal “7”. -
Page 117
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-49 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the ECM couplers and TP sensor couplers. -
Page 118
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-50 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B947H11104014 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following •… -
Page 119
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-51 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the left side cowling. -
Page 120
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-52 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation”… -
Page 121
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-53 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation”… -
Page 122
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-54 Engine General Information and Diagnosis: Step Action 9) Measure the output voltage between the B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. ground. •… -
Page 123
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-55 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B947H11104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following •… -
Page 124
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-56 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. -
Page 125
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-57 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Lift and support the fuel tank. -
Page 126
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-58 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation”… -
Page 127
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-59 Step Action 10) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. ground. •… -
Page 128
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-60 Engine General Information and Diagnosis: DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction B947H11104016 Detected Condition and Possible Cause Detected Condition Possible Cause AP sensor voltage is not within the •… -
Page 129
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-61 C22 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the front seat. -
Page 130
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-62 Engine General Information and Diagnosis: P1450-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/Y wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. -
Page 131
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-63 Step Action 9) Check the continuity between the G/Y wire and terminal Go to Step 3. G/Y wire shorted to “20”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire and terminal “35”. -
Page 132
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-64 Engine General Information and Diagnosis: P1450-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/Y wire open, G/ Y wire shorted to 2) Remove the front seat. -
Page 133
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-65 Step Action 9) Check the continuity between the R wire and terminal Go to Step 2. R and G/Y wire open, G/ “7”. Also, check the continuity between the G/Y wire and Y wire shorted to terminal “20”. -
Page 134
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-66 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum port for crack or 2) Connect the ECM couplers and AP sensor coupler. damage. -
Page 135
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-67 Step Action 1) Turn the ignition switch OFF. • G/Y, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the AP sensor. -
Page 136
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-68 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B947H11104017 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the •… -
Page 137
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-69 C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the front seat. -
Page 138
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-70 Engine General Information and Diagnosis: P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. -
Page 139
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-71 Step Action Check the continuity between the B wire and terminal Go to Step 2. B wire shorted to VCC, “31”. Also, check the continuity between B/Br wire and or B/Br wire open. -
Page 140
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-72 Engine General Information and Diagnosis: P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or B wire open, or B wire shorted to ground. -
Page 141
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-73 Step Action Check the continuity between the R wire and terminal Go to Step 2. R or B wire open, or B “7”. -
Page 142
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-74 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Insert the needle pointed probes to the lead wire coupler. -
Page 143
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-75 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B947H11104018 NOTE Refer to “No Spark or Poor Spark” in Section 1H (Page 1H-5) for details. DTC “C28”… -
Page 144
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-76 Engine General Information and Diagnosis: Step Action 1) Lift and support the fuel tank. Refer to “Fuel Tank Go to Step 2. • Loose or poor Removal and Installation” in Section 1G (Page 1G-9). contacts on the STVA coupler. -
Page 145
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-77 Step Action 1) Turn the ignition switch OFF. • B/Lg, P/W, G and W/ • Loose or poor B wire open or contacts on the ECM 2) Disconnect the STVA lead wire coupler. -
Page 146
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-78 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control”… -
Page 147
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-79 DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B947H11104020 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following •… -
Page 148
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-80 Engine General Information and Diagnosis: C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. -
Page 149
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-81 P1654-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. Y/W wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. -
Page 150
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-82 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 3. Y/W wire shorted to “18”. Also, check the continuity between the B/Br wire VCC, or B/Br wire open. -
Page 151
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-83 P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Y/W wire open, or Y/W wire shorted to 2) Lift and support the fuel tank. -
Page 152
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-84 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 2. R or Y/W wire open, or “18”. Also, check the continuity between the R wire and Y/W wire shorted to terminal “7”. -
Page 153
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-85 Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM couplers and STP sensor couplers. -
Page 154
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-86 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B947H11104021 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range. -
Page 155
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-87 Step Action 1) Turn the ignition switch OFF. • P wire open or • P or B/W wire open, shorted to ground. or P wire shorted to 2) Lift and support the fuel tank. -
Page 156
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-88 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction B947H11104022 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is •… -
Page 157
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-89 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation”… -
Page 158
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-90 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and… -
Page 159
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-91 DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction B947H11104023 Detected Condition and Possible Cause Detected Condition Possible Cause Some failure exists in the fuel injector signal in a high •… -
Page 160
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-92 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation”… -
Page 161
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-93 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and… -
Page 162
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-94 Engine General Information and Diagnosis: DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B947H11104024 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is •… -
Page 163
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-95 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Bl, Y, G or Br wire open. 2) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation”… -
Page 164
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-96 Engine General Information and Diagnosis: Step Action 1) Check the continuity between each ISC valve terminal If wire is OK, Replace the ISC valve and ground. intermittent trouble or with a new one. -
Page 165
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-97 ACTIVE CONTROL INSPECTION (ISC RPM Check 2 CONTROL) 1) Click the button (4) and decrease the “Spec” (2) to 1 Check 1 050 rpm slowly. 1) Set up the SDS tool. -
Page 166
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-98 Engine General Information and Diagnosis: Check 4 1) Click the button (6) and increase the “Spec” (2) to 1 900 rpm. 2) Check that the “Desired idle speed” (3) is approx. 1 900 rpm. -
Page 167
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-99 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. -
Page 168
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-100 Engine General Information and Diagnosis: P0230-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. • Y/B wire shorted to Replace the FP relay power source. with a new one. -
Page 169
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-101 DTC “C41” (P2505): ECM Power Input Signal Malfunction B947H11104026 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the ECM. •… -
Page 170
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-102 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • Fuel pump relay Open or short circuit in circuit malfunction. the R/Bl wire. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation”… -
Page 171
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-103 DTC “C42” (P1650): IG Switch Circuit Malfunction B947H11104027 Detected Condition and Possible Cause Detected Condition Possible Cause Ignition switch signal is not input to the ECM. •… -
Page 172
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-104 Engine General Information and Diagnosis: Troubleshooting (When Indicating C44/P0130:) CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. -
Page 173
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-105 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. W/G wire shorted to the and Installation” in Section 1C (Page 1C-1). power source, or W/G or B/Br wire open. -
Page 174
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-106 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and HO2 sensor coupler. • W/G or B/Br wire Replace the HO2 open or shorted to sensor with a new one. -
Page 175
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-107 Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures” (Page 1A-14). Step Action 1) Turn the ignition switch OFF. -
Page 176
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-108 Engine General Information and Diagnosis: Step Action 1) Connect the HO2 sensor coupler. • O/W or W/B wire • Open or short circuit open or shorted to in the W/B wire or O/ 2) Insert the needle pointed probes to the lead wire coupler. -
Page 177
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-109 DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction B947H11104029 Detected Condition Possible Cause The operation signal does not reach the • EXCVA maladjusted. EXCV actuator. -
Page 178
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-110 Engine General Information and Diagnosis: C46 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Go to Step 6. 2) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation”… -
Page 179
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-111 P1657-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 4. Y wire shorted to VCC, or B/Br wire open. 2) Remove the left side cowling. -
Page 180
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-112 Engine General Information and Diagnosis: Step Action Also, check the continuity between B/Br wire and Go to Step 4. Y wire shorted to VCC, terminal “35”. or B/Br wire open. Special tool (A): 09900–25008 (Multi circuit tester set) (B): 09900–25009 (Needle-point probe set) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-113 P1657-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2 and go to R or Y wire open, or Y Step 4. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-114 Engine General Information and Diagnosis: Step Action 9) Also, check the continuity between R wire and terminal Go to Step 2 and go to R or Y wire open, or Y “7”. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-115 Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Check the installation of EXCV cables. If it is necessary, coupler (terminal “7”… -
Page 184
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-116 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 4. Replace the EXCVA with a new one. 2) Check the continuity between Y wire and ground. Special tool (A): 09900–25008 (Multi circuit tester set) EXCVA position sensor continuity… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-117 Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Go to Step 5. known good one, and 2) Connect the EXCVA coupler. inspect it again. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-118 Engine General Information and Diagnosis: Step Action 9) Click “Full opened” (4). Replace the ECM with a Go to Step 5. known good one, and inspect it again. I947H1110098-02 10) Measure the EXCVA position sensor output voltage at EXCV fully opened position. -
Page 187
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-119 Step Action 1) If the EXCVA position sensor output voltage is 0.45 V Replace the ECM with a Replace the EXCVA and less at EXCV fully closed position, adjust the output known good one, and with a new one. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-120 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • Loose or poor • Replace the EXCVA contacts on the with a new one. 2) Disconnect the EXCVA coupler (1). -
Page 189
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-121 DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B947H11104030 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve voltage is not input to ECM. •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-122 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the PAIR control solenoid valve 2) Remove the air cleaner box. Refer to “Air Cleaner Box with a new one. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-123 Step Action 1) Turn the ignition switch ON. • W/G wire open or Open or short circuit in shorted to ground, or the O/W wire. 2) Measure the voltage between the O/W wire and ground. -
Page 192
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-124 Engine General Information and Diagnosis: DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B947H11104031 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-125 Step Action 1) Turn the ignition switch OFF. • O/W and G/R wire Replace the cooling fan open or shorted to relay with a new one. 2) Remove the frame covers. -
Page 194
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-126 Engine General Information and Diagnosis: 4) Click the “Operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. -
Page 195
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-127 DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) B947H11104032 Detected Condition and Possible Cause Detected Condition Possible Cause EVAP system purge control valve voltage is not input to •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-128 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the EVAP system purge control 2) Lift and support the fuel tank. Refer to “Fuel Tank with a new one. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-129 Step Action 1) Turn the ignition switch ON. • Dbr wire open or Open or short circuit in shorted to ground, or the O/W wire. 2) Measure the voltage between the O/W wire and ground. -
Page 198
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-130 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “EVAP purge valve operating control”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-131 DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction B947H11104033 Detected Condition and Possible Cause Detected Condition Possible Cause Speedometer does not receive signal from the vehicle •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-132 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • P wire open or • Inspect that metal shorted to ground. particles or foreign 2) Lift and support the fuel tank. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-133 Step Action 5) Under this condition, if a suitable screwdriver touching • P wire open or • Inspect that metal the pick-up surface of the speed sensor is moved, the shorted to ground. -
Page 202
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-134 Engine General Information and Diagnosis: DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction B947H11104034 Detected Condition and Possible Cause Detected Condition Possible Cause Steering damper control current does not flow to •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-135 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the steering damper with a new one. 2) Check the steering damper solenoid valve coupler (1) for loose or poor contacts. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-136 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • B/Bl (W) wire shorted • Low battery voltage to VCC, or poor “26” or fuse is blown. 2) Measure the voltage between B/Bl wire and ground. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine General Information and Diagnosis: 1A-137 Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Raise the front wheel off the ground. 3) Turn the ignition switch ON. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-138 Engine General Information and Diagnosis: Specifications Service Data B947H11107001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance FI Sensors Item… -
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(Page 1A-54) / (Page 1A-104) / (Page 1A-56) / (Page 1A-105) / (Page 1A-57) / (Page 1A-106) (Page 1A-58) 09904–41010 09917–47011 SUZUKI Diagnostic system Vacuum pump gauge set (Page 1A-13) / (Page 1A-42) / (Page 1A-16) (Page 1A-67) email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1A-140 Engine General Information and Diagnosis: 09930–82720 99565–01010–020 Mode selection switch CD-ROM Ver.20 (Page 1A-4) / (Page 1A- (Page 1A-13) / 12) / (Page 1A-12) (Page 1A-16) email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
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Fuel Injection System Description B947H11201001 GSX-R1000 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1B-2 Emission Control Devices: Crankcase Emission Control System Description B947H11201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Emission Control Devices: 1B-3 Exhaust Emission Control System Description B947H11201003 The exhaust emission control system is composed of the PAIR system, exhaust control system, HO2 sensor, three- way catalyst system and ISC system. The fresh air is drawn into the exhaust ports through the PAIR control solenoid valve and PAIR reed valves. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1B-4 Emission Control Devices: PAIR System Diagram B947H11201006 “A” “B” I947H1120004-01 1. PAIR control solenoid valve 2. PAIR reed valve “A”: Fresh air “B”: Exhaust gas Noise Emission Control System Description B947H11201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof:… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Emission Control Devices: 1B-5 Among Those Acts Presumed to Constitute Tampering are the Acts Listed Below: • Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1B-6 Emission Control Devices: Schematic and Routing Diagram PAIR System Hose Routing Diagram B947H11202001 “F” “ b ” “C” “ a ” “B” “E” “D” “ b ” “A” “… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Emission Control Devices: 1B-7 EVAP Canister Hose Routing Diagram (Only for E-33) B947H11202002 “A” “C” “D” “G” “F” “E” “B” “H” “J” “I” “L” “A” “K” I947H1120007-03 1. EVAP system purge control solenoid valve “A”: White marking “H”: Stick the clamp firmly in this area. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1B-8 Emission Control Devices: Repair Instructions Heated Oxygen Sensor (HO2S) Removal and Installation Install the HO2 sensor in the reverse order of removal. Installation B947H11206001 Pay attention to the following points: Removal CAUTION WARNING… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Emission Control Devices: 1B-9 4) Remove the PAIR reed valves (3). 3) Remove the PAIR control solenoid valve (1) along with the PAIR reed valve covers (2). I947H1120013-01 I947H1120015-02 Installation 4) Disconnect the PAIR control solenoid valve coupler Install the PAIR reed valve in the reverse order of… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1B-10 Emission Control Devices: 3) Inspect the PAIR hoses for wear or damage. If it is 2) Check that air flows through the air inlet port to the worn or damaged, replace the PAIR hose with a new air outlet ports. -
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Installation is in the reverse order of removal. Pay attention to the following points: • Apply bond to the hatching part of crankcase breather (PCV) cover. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I947H1120022-01 4) Install the removed parts. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1B-12 Emission Control Devices: Crankcase Breather (PCV) Cover Inspection 3) Remove the EVAP canister (3) from the bracket. B947H11206008 Inspect the crankcase breather (PCV) cover in the following procedures: 1) Remove the crankcase breather (PCV) cover. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Emission Control Devices: 1B-13 Installation 6) Disconnect the license plate light coupler (2). Install the EVAP system purge control solenoid valve in the reverse order of removal. Pay attention to the following point: •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1B-14 Emission Control Devices: 11) Disconnect the surge hose (9). EVAP Canister Inspect the EVAP canister for damage to the body. If any defect is found, replace the EVAP canister with a new one. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Emission Control Devices: 1B-15 3) Check the resistance between the terminals of the Fuel Shut-off Valve EVAP system purge control solenoid valve. If the WARNING resistance is not within the standard range, replace the EVAP system purge control solenoid valve with a Gasoline and gasoline vapor is toxic. -
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For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-9). Special Tools and Equipment Recommended Service Material B947H11208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1B-11) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Electrical Devices: 1C-1 Engine Electrical Devices 8Engine Precautions Precautions for Engine Electrical Device B947H11300001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1C-2 Engine Electrical Devices: CMP Sensor Inspection CKP Sensor Removal and Installation B947H11306002 B947H11306005 Refer to “DTC “C11” (P0340): CMP Sensor Circuit Removal Malfunction” in Section 1A (Page 1A-29). 1) Remove the clutch cover. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Electrical Devices: 1C-3 TP Sensor Removal and Installation 4) Check the position of the bar in the left of C code B947H11306009 displayed on the LCD panel. Refer to “Throttle Body Disassembly and Assembly” in Section 1D (Page 1D-11). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1C-4 Engine Electrical Devices: ECT Sensor Removal and Installation ECT Sensor Inspection B947H11306011 B947H11306012 Removal Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction” in Section 1A (Page 1A-50). 1) Remove the left side cowling. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Electrical Devices: 1C-5 IAT Sensor Removal and Installation CAUTION B947H11306013 Removal • The IAT sensor operative temperature range is –30 – 120 °C (–22 – 248 °F). 1) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1C-6 Engine Electrical Devices: TO Sensor Removal and Installation 2) Disconnect the STVA lead wire coupler (1). B947H11306018 Removal 1) Remove the AP sensor. Refer to “AP Sensor Removal and Installation” (Page 1C-5). 2) Disconnect the coupler (1) and remove the TO sensor (2). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Electrical Devices: 1C-7 Tighten the STP sensor mounting screw to the STV Actuator Inspection B947H11306022 specified torque. Refer to “DTC “C28” (P1655): Secondary Throttle Valve Tightening torque Actuator (STVA) Malfunction”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1C-8 Engine Electrical Devices: NOTE ISC Valve Preset and Opening Initialization B947H11306026 The leaned value of the ISC valve is set at When removing or replacing the ISC valve, set the ISC Preset position. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Electrical Devices: 1C-9 Specifications Service Data B947H11307001 FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage 4.5 –… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1C-10 Engine Electrical Devices: Special Tools and Equipment Special Tool B947H11308001 09900–25008 09900–25009 Multi circuit tester set Needle-point probe set (Page 1C-4) / (Page 1C- (Page 1C-6) 09930–11950 09930–82720 Torx wrench (5 mm) Mode selection switch (Page 1C-3) /… -
Page 235: Engine Mechanical
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B947H11402001 I947H1140249-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk…
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-2 Engine Mechanical: Throttle Cable Routing Diagram B947H11402002 “A” “ a ” “ a ” “ a ” “B” “C” “D” I947H1140250-02 1. Throttle cable No. 1 “B”: Pass the clutch cable above the right air intake pipe. 2. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-3 Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B947H11404001 Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-8). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-4 Engine Mechanical: Repair Instructions Engine Components Removable with the Engine in Place B947H11406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-5 Engine Right Side Item Removal Inspection Installation Refer to “Cam Chain Tension Refer to “Engine Top Side Refer to “Engine Top Side Cam chain tension adjuster Adjuster Inspection”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-6 Engine Mechanical: Engine Left Side Item Removal Inspection Installation Refer to “Speed Sensor Refer to “Speed Sensor Refer to “Speed Sensor Speed sensor Removal and Installation” in Inspection” in Section 9C Removal and Installation”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-7 Air Cleaner Box Removal and Installation 7) Remove the air cleaner box. B947H11406003 Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G- 2) Remove the air cleaner box cover. -
Page 242
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-8 Engine Mechanical: Throttle Body Components B947H11406008 I947H1140252-03 1. Fuel delivery pipe 6. Secondary fuel injector 11. Vacuum hose : 6.5 Nm (0.65 kgf-m, 4.5 lbf-ft) 2. Fuel delivery pipe T-joint 7. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-9 Throttle Body Construction B947H11406009 “D” “A” “K” “G” “C” “B” “H” “7” “6” “2” “1” “5” “4” “3” “H” “3” “J” “5” “1” “6” “2” “4” “I”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-10 Engine Mechanical: Throttle Body Removal and Installation 10) Place a rag under the fuel feed hose (9) and B947H11406010 disconnect the fuel feed hose from the fuel pump. Removal 1) Remove the side cowlings. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-11 14) Disconnect the throttle cables. • Connect the throttle cable No. 1 (3) and throttle cable No. 2 (4) to the throttle cable drum. CAUTION After disconnecting the throttle cables, do not snap the throttle valve from full open to “… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-12 Engine Mechanical: 2) Disconnect the purge hose (4). (E-33 only) 5) Remove the fuel pipe (9) from the primary fuel injectors (7). I947H1140299-01 3) Remove the fuel delivery pipe assembly (5). I947H1140010-01 6) Remove the T-joint (6) from the fuel delivery pipes. -
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“A” with the groove “B” of the STP sensor. • Apply grease to the secondary throttle valve shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool I947H1140014-01 : 09930–11950 (Torx wrench (5 mm)) -
Page 248
“D” of the TP sensor. 1.5 lbf-ft) • Apply grease to the throttle valve shaft end “C” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool : 09930–11950 (Torx wrench (5 mm)) Tightening torque TP sensor mounting screw: 3.5 N·m (0.35 kgf-m,… -
Page 249
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-15 • Apply thin coat of engine oil to the new O-rings (1) and • Install each fuel injector by pushing it straight to the cushion seals (2). delivery pipe. -
Page 250
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-16 Engine Mechanical: Throttle Body Inspection and Cleaning ISC Valve Visual Inspection B947H11406012 B947H11406013 Refer to “Throttle Body Disassembly and Assembly” Visually inspect the ISC valve if necessary. (Page 1D-11). •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-17 5) Disconnect the respective vacuum hoses (2) from 9) Start the engine. vacuum nipples on the throttle body. 10) Click “Data monitor”. 6) Disconnect the IAP sensor coupler (3). 11) Warm up the engine (Engine coolant temp. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-18 Engine Mechanical: 15) Check for the synchronization of vacuum from #1 to ISC Valve Reset B947H11406015 #4 cylinders. When removing or replacing the throttle body assembly, reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-19 NOTE 5) Click the “Reset” button (2) to clear the TP learned value. The learned value of the ISC valve is set at RESET position. I947H1140303-01 6) Close the SDS tool. -
Page 254
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-20 Engine Mechanical: Engine Assembly Removal 11) Remove the radiator assembly. Refer to “Radiator / B947H11406017 Cooling Fan Motor Removal and Installation” in Before taking the engine out of the frame, wash the Section 1F (Page 1F-6). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-21 15) Remove the exhaust system components. Refer to 21) Remove the crankcase breather (PCV) hose (15). “Muffler / Muffler Chamber / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K-11). 16) Remove the clamp (7). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-22 Engine Mechanical: 25) Remove the engine sprocket cover (19). Refer to 28) Support the engine using an engine jack. “Engine Sprocket Removal and Installation” in Section 3A (Page 3A-2). I947H1140274-01 29) Loosen the engine mounting pinch bolts (22) (RH). -
Page 257
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-23 34) Loosen the engine mounting thrust adjuster (27) 37) Loosen the engine mounting thrust adjuster (30) fully. fully. Special tool Special tool (A): 09940–14990 (Engine mounting adjust (A): 09940–14990 (Engine mounting adjust wrench) wrench) -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-24 Engine Mechanical: Engine Assembly Installation B947H11406018 Install the engine in the reverse order of engine removal. Pay attention to the following points: • Before installing the engine, install the collars (1). I947H1140285-02 I947H1140282-01 •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-25 • Tighten all engine mounting bolts and nuts to the • Tighten the engine mounting pinch bolt to the specified torque, as shown in the following illustration. specified torque, as shown in the following illustration. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-26 Engine Mechanical: • Install the engine sprocket. Refer to “Engine Sprocket Engine Top Side Disassembly B947H11406019 Removal and Installation” in Section 3A (Page 3A-2). It is unnecessary to remove the engine assembly from •… -
Page 261
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-27 Camshafts 3) Remove the cam chain tension adjuster (2). 1) Remove the valve timing inspection cap (1). I947H1140034-02 4) Remove the gasket (3). I947H1140030-01 2) Turn the crankshaft to bring the line “A” on the CKP sensor rotor to the slit “B”… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-28 Engine Mechanical: Remove the intake camshaft (6) and exhaust 4) Remove the cylinder head. camshaft (7). I947H1140040-01 5) Remove the dowel pins and cylinder head gasket I947H1140037-01 (3). -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-29 • Place the cylinder head on the gasket. • After firmly tightening the cylinder head bolts (M10), tighten the cylinder head bolts (M6) (2). NOTE Tightening torque •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-30 Engine Mechanical: • Turn the crankshaft clockwise and align the line “A” on • Bind the cam chain and the sprocket with a proper the CKP sensor rotor to the slit “B” of cap hole thread clamp (1) to prevent the cam chain disengagement while keeping the cam chain pulled upward. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-31 I947H1140051-01 • Install the dowel pins. “F” I947H1140053-02 • Tighten the camshaft journal holder bolts in ascending I947H1140052-01 • Install the camshaft journal holders and cam chain order of numbers to the specified torque. -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-32 Engine Mechanical: (3) 11 (1) 7 (2) 8 (4) 12 (2) 6 (1) 5 I947H1140054-03 • Remove the clamps. “C” “A” “B” I823H1140365-01 I947H1140055-01 Cam Chain Tension Adjuster •… -
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Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-33 • Hook the outer circlip “A” into the groove “B”, then turn • Rotate the crankshaft (some turns) and recheck the the plunger head clockwise more than 90° to make a valve timing. -
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• Install new gaskets to the cylinder head cover. to the specified torque. • Apply bond to the cam end cap points of the gasket as shown. CAUTION : Sealant 99000–31140 (SUZUKI BOND Use a new gasket to prevent oil leakage. No.1207B or equivalent) Tightening torque CAUTION Cam chain tension adjuster service cap (b): 23 Use new gaskets to prevent oil leakage. -
Page 269
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-35 • Tighten the cylinder head cover bolts to the specified 4) Remove the PAIR reed valves (5) and CMP sensor torque in two steps. (6). Tightening torque Cylinder head cover bolt (Initial): 10 N·m (1.0 kgf- m, 7.0 lbf-ft) Cylinder head cover bolt (Final): 14 N·m (1.4 kgf-… -
Page 270
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-36 Engine Mechanical: • Apply thread lock to the PAIR reed valve cover bolts PAIR Reed Valve (2) and tighten them to the specified torque. Inspect the PAIR reed valves for carbon deposit. If the carbon deposit is found, replace the reed valve with a : Thread lock cement 99000–32110 new one. -
Page 271
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-37 Camshaft Runout 3) Install each camshaft journal holder to its original Measure the runout using the dial gauge. Replace the position. Refer to “Engine Top Side Assembly” camshaft if the runout exceeds the limit. -
Page 272
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-38 Engine Mechanical: 7) If the camshaft journal oil clearance exceeds the Camshaft Sprocket B947H11406022 limit, measure the inside diameter of the camshaft Inspect the camshaft sprocket in the following journal holder and the outside diameter of the procedures: camshaft journal. -
Page 273
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-39 3) Hook the outer circlip “A” into the groove “B”, then 4) Check that the plunger goes out automatically when turn the plunger head clockwise more than 90° to its head “D”… -
Page 274
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-40 Engine Mechanical: Installation Cylinder Head Disassembly and Assembly B947H11406027 Install the cam chain guides/cam chain tensioner in the Refer to “Engine Top Side Disassembly” (Page 1D-26). reverse order of removal. Refer to “Engine Top Side Assembly”… -
Page 275
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-41 5) Pull out the valve (6) from the combustion chamber 11) Remove the bypass hose union (12). side. I947H1140076-01 12) Remove the oil jet (13). I947H1140073-01 6) Remove the oil seal (7) and spring seat (8). -
Page 276
Replace the O-rings with new ones. I947H1140083-01 • Apply bond to the thread part of bypass hose union (4) and tighten it to the specified torque. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Bypass hose union (d): 12 N·m (1.2 kgf-m, 8.5 lbf-… -
Page 277
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-43 • Tighten the thermostat cover bolts (6) to the specified torque. Tightening torque Thermostat cover bolt (e): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) “B” I947H1140087-01 • Insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break. -
Page 278
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-44 Engine Mechanical: • Put on the valve spring retainer (10), and using the • Install the tappet shims and the tappets to their special tools, press down the springs, fit the cotter original positions. -
Page 279
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-45 Valve Stem Runout Valve Stem and Valve Face Wear Condition Support the valve using V-blocks, as shown in the figure, Visually inspect each valve stem and valve face for wear and check its runout using the dial gauge. -
Page 280
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-46 Engine Mechanical: Valve Stem Wear Measure the valve stem O.D. using the micrometer. If it is out of specification, replace the valve with a new one. If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide. -
Page 281
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-47 4) Check that the transferred red lead (blue) on the Valve Guide Replacement B947H11406029 valve face is uniform all around and in center of the 1) Remove the cylinder head. Refer to “Engine Top valve face. -
Page 282
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-48 Engine Mechanical: 5) Cool down the new valve guides in a freezer for After installing the valve guides, refinish their guiding about one hour and heat the cylinder head to 100 – bores using the reamer. -
Page 283
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-49 Valve Seat Repair Engine Bottom Side Disassembly B947H11406030 B947H11406031 The valve seats (1) for both the intake and exhaust NOTE valves are machined to three different angles. The seat The crankcase must be separated to service contact surface is cut at 45°. -
Page 284
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-50 Engine Mechanical: Gearshift System 2) Remove the cam chain tensioner (2) and cam chain Remove the gearshift shaft (1) and gearshift cam plate guide No. 1 (3). (2). Refer to “Gearshift Shaft / Gearshift Cam Plate 3) Remove the cam chain drive sprocket (4) and cam Removal and Installation”… -
Page 285
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-51 2) Remove the water pump (2). I947H1140119-01 I947H1140116-01 Oil Pan Gear Position Switch 1) Remove the plate (1). Remove the gear position switch (1). 2) Remove the oil pan (2) and gasket. I947H1140117-01 I947H1140297-01 Oil Pressure Switch… -
Page 286
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-52 Engine Mechanical: Oil Pump Crankcase 1) Remove the spacer (1) and bearing (2). 1) Remove the clutch push rod oil seal retainer (1). I947H1140126-01 I947H1140123-01 2) Remove the oil pump drive sprocket (3) and chain 2) Remove the cap (2). -
Page 287
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-53 5) Remove the crankshaft journal bolts (M9). Transmission Remove the transmission component. Refer to “Transmission Removal” in Section 5B (Page 5B-3). I947H1140130-01 6) Make sure that all of the bolts are removed. Then, tap the sides of the lower crankcase using a plastic I947H1140133-01 hammer to separate the upper and lower crankcase… -
Page 288
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-54 Engine Mechanical: 3) Remove the crankshaft (1) and thrust bearings (2). I947H1140140-01 2) Remove the piston pin circlip (1). I947H1140137-01 Piston Cooling Oil Jet Remove the piston cooling oil jet (1) from the upper crankcase. -
Page 289
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-55 Crankshaft Journal Bearing Oil Jet Remove the crankshaft journal bearings, upper and Remove the oil jet (1) (for transmission) from the lower lower. crankcase. CAUTION • When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings. -
Page 290
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-56 Engine Mechanical: 2) Remove the oil gallery plug (4) from the upper Breather Oil Return Plate crankcase. Remove the breather oil return plate (1) from the upper crankcase. I947H1140149-01 I947H1140153-01 Water Jacket Plug… -
Page 291
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-57 • Tighten each plug to the specified torque. CAUTION Replace the O-rings with new ones. Tightening torque Water jacket plug (a): 9.5 N·m (0.95 kgf-m, 6.9 lbf- I947H1140157-01 •… -
Page 292
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-58 Engine Mechanical: Crankshaft Journal Bearing • Install the piston pin circlips (1). When fitting the crankshaft journal bearings to the upper CAUTION and lower crankcases, be sure to fix the stopper part “A” first and press the other end. -
Page 293
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-59 • Install the pistons with conrods into the cylinders from topside using the special tool. NOTE When installing the pistons, the indent “D” of each piston head must be brought to the exhaust side. -
Page 294
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-60 Engine Mechanical: 2) Position the No. 2 and No. 3 conrod big ends on the 6) Apply engine oil to the conrod cap bolts. same side, and the No. 1 and No. 4 conrod big ends on the opposite side of No. -
Page 295
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-61 10) Check the conrod movement for smooth turning. I947H1140179-01 I947H1140176-01 Balancer Shaft 11) Insert the right and left thrust bearings with the oil • Apply a molybdenum oil solution to each balancer grooves “B”… -
Page 296
• Take extreme care not to apply sealant to any oil hole, oil groove and bearing. • Apply sealant to distorted surfaces as it forms a comparatively thick film. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I947H1140182-02 I947H1140183-02 : Apply bond. -
Page 297
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-63 • Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in the following two steps. CAUTION Fit new gasket washers to the bolts “A” to prevent oil leakage. -
Page 298
The chamfer side “A” of thrust washer should face the crankcase side. “A” I947H1140191-01 • Apply grease to new O-ring (2). : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1140194-01 • Install the oil pump drive sprocket (5) to the CAUTION countershaft. -
Page 299
Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) • Apply grease to new O-ring (1). CAUTION Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) • Install the oil strainer (2). “A”… -
Page 300
Gear position switch mounting bolt (a): 6.5 N·m ( NOTE 0.65 kgf-m, 4.7 lbf-ft) Be careful not to apply bond to the hole of thread end. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lbf-ft) I947H1140203-01 Water Pump •… -
Page 301
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-67 • Tighten the water pump mounting bolts (2) to the Cam Chain / Cam Chain Tensioner / Cam Chain specified torque. Guide No. 1 • Install the cam chain drive sprocket (1) to the Tightening torque crankshaft. -
Page 302
• Apply bond to the hatching part of crankcase breather Install the gearshift cam plate (1) and gearshift shaft (2). (PCV) cover. Refer to “Gearshift Shaft / Gearshift Cam Plate Removal : Sealant 99000–31140 (SUZUKI BOND and Installation” in Section 5B (Page 5B-17). No.1207B or equivalent) I947H1140212-01 I947H1140293-01 •… -
Page 303
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-69 • Tighten the crankcase breather (PCV) cover bolts. “A” I947H1140217-02 I947H1140215-03 Engine Top Side Assemble the engine top side. Refer to “Engine Top Side Disassembly” (Page 1D-26). Cylinder Inspection B947H11406033 Refer to “Engine Top Side Disassembly”… -
Page 304
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-70 Engine Mechanical: Installation b) Install the 2nd ring (3) and 1st ring (4) to piston. NOTE NOTE 1st ring (4) and 2nd ring (3) differ in shape. • When installing the piston ring, be careful not to damage the piston. -
Page 305
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-71 Piston and Piston Ring Inspection Piston Ring-to-groove Clearance B947H11406035 Measure the side clearances of the 1st and 2nd piston Refer to “Piston Ring Removal and Installation” rings using the thickness gauge. -
Page 306
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-72 Engine Mechanical: Piston Ring Free End Gap and Piston Ring End Gap Piston Pin and Pin Bore Measure the piston ring free end gap using vernier Measure the piston pin bore inside diameter using the calipers. -
Page 307
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-73 Balancer Shaft Disassembly and Assembly • Set the dampers and install the balancer shaft to B947H11406036 balancer gear. Refer to “Engine Bottom Side Disassembly” (Page 1D- 49). -
Page 308
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-74 Engine Mechanical: Balancer Shaft Journal Bearing Removal and Installation When installing the bearings to the crankcases, be sure Installation B947H11406038 to install the tab “A” first, and then press in the other Refer to “Engine Bottom Side Disassembly”… -
Page 309
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-75 Balancer Shaft Journal Bearing Inspection and Selection B947H11406039 Refer to “Engine Bottom Side Disassembly” (Page 1D- 49). Refer to “Engine Bottom Side Assembly” (Page 1D-56). Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. -
Page 310
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-76 Engine Mechanical: 4) Check the corresponding crankcase journal I.D. Conrod Crank Pin Bearing Removal and code number “A”, [A], [B] or [C] which is stamped on Installation the rear of upper crankcase. B947H11406040 Refer to “Engine Bottom Side Disassembly”… -
Page 311
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-77 Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B947H11406041 and measure the conrod big end width and crank pin Refer to “Engine Bottom Side Disassembly” (Page 1D- width. -
Page 312
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-78 Engine Mechanical: Conrod Crank Pin Bearing Inspection and 4) Remove the conrod cap bolts and measure the width of the compressed plastigauge using the envelope Selection B947H11406042 scale. This measurement should be taken at the Refer to “Engine Bottom Side Disassembly”… -
Page 313
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-79 Bearing thickness specification 2) Check the corresponding crank pin O.D. code numbers ([1], [2] or [3]) “B”. Color “C” (Part No.) Thickness Yellow 1.488 – 1.492 mm (12164-47H00-0D0) (0.0586 –… -
Page 314
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-80 Engine Mechanical: 2) Set the crankshaft onto the upper crank case. 6) Remove the lower crankcase and measure the width of compressed plastigauge using the envelope 3) Install the plastigauge onto each crankshaft journal. scale. -
Page 315
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-81 2) Check the corresponding crankshaft journal O.D. 4) Select the specified bearings from the bearing codes “B” ([A], [B] or [C]), which are stamped on the selection table. -
Page 316
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-82 Engine Mechanical: Crankshaft Thrust Clearance Inspection and Selection Selection 1) Remove the right-side thrust bearing and measure B947H11406044 its thickness using the micrometer. If the thickness of Refer to “Engine Bottom Side Disassembly” (Page 1D- the right-side thrust bearing is below standard, 49). -
Page 317
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-83 4) Select a left-side thrust bearing from the selection table. NOTE Right-side thrust bearing has the same specification as the GREEN (12228-48B00-0E0) of left-side thrust bearing. Thrust bearing selection table Clearance before inserting Color “A”… -
Page 318
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-84 Engine Mechanical: Specifications Service Data B947H11407001 Valve + Guide Unit: mm (in) Item Standard Limit 31.0 (1.22) — Valve diam. 25.0 (0.98) — 0.08 – 0.18 (0.003 – 0.007) —… -
Page 319
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-85 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 –… -
Page 320
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-86 Engine Mechanical: Tightening Torque Specifications B947H11407002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Throttle cable lock-nut 0.45 (Page 1D-11) STP sensor mounting screw 0.35 (Page 1D-13) TP sensor mounting screw 0.35 (Page 1D-14) ISC valve mounting screw… -
Page 321
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-9). Special Tools and Equipment Recommended Service Material B947H11408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1D-13) /… -
Page 322
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-88 Engine Mechanical: Special Tool B947H11408002 09900–20102 09900–20202 Vernier calipers (200 mm) Micrometer (25 – 50 mm) (Page 1D-46) / (Page 1D-36) / (Page 1D-72) (Page 1D-79) / (Page 1D-81) 09900–20203 09900–20205 Micrometer (50 –… -
Page 323
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Mechanical: 1D-89 09900–22403 09915–40610 Small bore gauge (18 – 35 Oil filter wrench (Page 1D-38) (Page 1D-51) / (Page 1D-65) 09915–63311 09915–64512 Compression gauge Compression gauge attachment (Page 1D-3) (Page 1D-3) 09916–10911 09916–14510… -
Page 324
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1D-90 Engine Mechanical: 09930–11960 09940–14990 Torx wrench (4 mm) Engine mounting adjust wrench (Page 1D-14) (Page 1D-23) / (Page 1D-23) / (Page 1D-24) email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 325: Engine Lubrication System
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B947H11500001 Refer to “Fuel and Oil Recommendation” in Section 0A (Page 0A-3). email: info@motomatrix.co.uk / www.motomatrix.co.uk…
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Page 326: Oil Pan
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1E-2 Engine Lubrication System: Schematic and Routing Diagram Engine Lubrication System Chart Diagram B947H11502001 OIL JET (#16) CAM CHAIN TENSION ADJUSTER INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER INTAKE CAMSHAFT JOURNALS, CAMFACES AND TAPPETS EXHAUST CAMSHAFT EXHAUST CAMSHAFT…
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Page 327
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Lubrication System: 1E-3 Engine Lubrication Circuit Diagram B947H11502002 I947H1150002-03 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 328
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1E-4 Engine Lubrication System: I947H1150003-01 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 329
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Lubrication System: 1E-5 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B947H11504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. -
Page 330
“Engine Assembly Removal” in Section 1D (Page 1D-20). Use a new O-ring to prevent oil leakage. 2) Remove the plate (1). : Grease 99000–25010 (SUZUKI SUPER 3) Remove the oil pan (2). GREASE “A” or equivalent) • Install the oil strainer (2). -
Page 331
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Lubrication System: 1E-7 • Push in the oil pressure regulator (4) to the oil pump Oil Pressure Regulator as shown. Inspect the operation of the oil pressure regulator by pushing the piston with a proper bar. -
Page 332
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1E-8 Engine Lubrication System: Oil Cooler Inspection CAUTION 1) Remove the oil cooler guard (1). • Make sure not to bend the fins when using compressed air. • If compressed air is applied from the front side, dirt will be forced into the pores of oil cooler. -
Page 333
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Lubrication System: 1E-9 5) Remove the oil cooler guard (4). I947H1150019-01 • Apply thread lock to the oil cooler hose bolts and I947H1150017-01 tighten them securely. Installation : Thread lock cement 99000–32110 Install the oil cooler and oil cooler hoses in the reverse (THREAD LOCK CEMENT SUPER “1322”… -
Page 334
3) Remove the piston cooling oil jets (1) from the upper NOTE crankcase. Be careful not to apply bond to the hole of thread end. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lbf- I947H1150022-01 Installation Installation is in the reverse order of removal. -
Page 335
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Lubrication System: 1E-11 • Apply a small quantity of thread lock to the bolts and 4) Remove the oil jet (2) (for cam chain tension tighten them to the specified torque. adjuster). -
Page 336
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1E-12 Engine Lubrication System: Oil Jet (For Transmission) Oil Pump Removal and Installation B947H11506011 Removal NOTE 1) Remove the engine assembly. Refer to “Engine Be careful not to drop any parts into the Assembly Removal”… -
Page 337
Oil pump mounting bolt (a): 10 N·m (1.0 kgf-m, CAUTION 7.0 lbf-ft) Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1150033-01 5) Install the washer (1). 6) Install the oil pump driven sprocket (2) with the chain (3). -
Page 338
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1E-14 Engine Lubrication System: Oil Pump Inspection B947H11506012 Inspect the oil pump in the following procedures: 1) Remove the oil pump. Refer to “Oil Pump Removal and Installation” (Page 1E-12). 2) Rotate the oil pump by hand and check that it moves smoothly. -
Page 339
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Lubrication System: 1E-15 Special Tools and Equipment Recommended Service Material B947H11508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1E-6) / (Page 1E-… -
Page 340: Engine Cooling System
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-1 Engine Cooling System: Engine Cooling System Engine Precautions Precautions for Engine Cooling System B947H11600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
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Page 341
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-2 Schematic and Routing Diagram Cooling Circuit Diagram B947H11602001 RESERVOIR THERMOSTAT CYLINDER HEAD ECT SENSOR TANK CYLINDER RADIATOR WATER PUMP I947H1160001-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 342
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-3 Engine Cooling System: Water Hose Routing Diagram B947H11602002 “a” “ b ” “A” “C” “E” “D” “F” “B” “H” “G” “I” “A” “A” “B” “A” “J” “B” “K” I947H1160053-03 1. -
Page 343
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B947H11604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. -
Page 344
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-5 Engine Cooling System: Radiator Cap Inspection Radiator Cleaning B947H11606002 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. -
Page 345
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-6 4) Remove the radiator mounting bolts. 9) Apply thread lock to the oil cooler bolts and tighten them securely. : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER “1322” or equivalent) I947H1160007-01 I947H1160057-01… -
Page 346
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-7 Engine Cooling System: 7) Remove the oil cooler (6) from the bracket. Installation Install the radiator in the reverse order of removal. Pay attention to the following points: •… -
Page 347
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-8 3) Any leakage from the connecting section should be Installation corrected by proper tightening. Refer to “Water Hose 1) Install the water hose as shown in the water hose Routing Diagram”… -
Page 348
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-9 Engine Cooling System: 4) Disconnect the reservoir tank overflow hose (3). 2) Test the cooling fan motor for load current with an ammeter connected as shown in the figure. If the fan motor does not turn, replace the cooling fan assembly with a new one. -
Page 349
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-10 3) First check the insulation between “A” and “B” 4) Remove the thermostat (2). terminals with tester. Then apply 12 volts to “C” and “D” terminals, (+) to “C” and (–) to “D”, and check the continuity between “A”… -
Page 350
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-11 Engine Cooling System: Thermostat Inspection 6) Read the thermometer just when opening the B947H11606014 thermostat. If this reading, which is the temperature Inspect the thermostat in the following procedures: level at which the thermostat valve begins to open, is 1) Remove the thermostat. -
Page 351
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-12 Water Pump Components B947H11606015 I947H1160055-02 1. Impeller : 8 N⋅m (0.8 kgf-n, 6.0 Ib-ft) : Apply engine coolant. 2. Mechanical seal : 10 N⋅m (1.0 kgf-n, 7.0 Ib-ft) : Apply molybdenum oil solution. -
Page 352
Filter Replacement” in Section 0B (Page 0B-10) CAUTION and “Cooling System Inspection” in Section 0B (Page 0B-12). Replace the O-ring with the a new one. 3) Disconnect the water bypass hose (1). : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 353
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-14 • Install the water pump assembly with the slot of the Water Pump Disassembly and Assembly B947H11606018 pump shaft end “A” securely engaged with the flat “B” Refer to “Water Pump Removal and Installation”… -
Page 354
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-15 Engine Cooling System: 5) Remove the impeller (3). I947H1160034-01 9) Remove the oil seal (11). I947H1160031-01 6) Remove the mechanical seal ring (5) and rubber NOTE seal (6) from the impeller. If there is no abnormal condition, the oil seal removal is not necessary. -
Page 355
2) Apply a small quantity of the grease to the oil seal 5) Install the impeller shaft (1) and washer (2) to the lip. holder. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1160040-01 6) Install the rubber seal (3) into the impeller. -
Page 356
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1F-17 Engine Cooling System: 10) Hold the impeller with water pump pliers and tighten the impeller securing bolt to the specified torque. Tightening torque Impeller securing bolt (a): 8 N·m (0.8 kgf-m, 6.0 lbf-ft) I947H1160045-01 Water Pump Related Parts Inspection… -
Page 357
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Engine Cooling System: 1F-18 Seal Washer Impeller / Shaft Visually inspect the seal washer for damage, with Visually inspect the impeller and its shaft for damage. particular attention given to the sealing face. Replace the impeller or shaft if necessary. -
Page 358
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-9). Special Tools and Equipment Recommended Service Material B947H11608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1F-13) /… -
Page 359: Fuel System
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B947H11700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. •…
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Page 360
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1G-2 Fuel System: General Description Fuel Injection System Description B947H11701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipes (5) including fuel injectors (6) and (7), fuel pressure regulator (8). -
Page 361
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-3 Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B947H11702001 “E” “D” “B” “I” “F” “G” “H” “C” “ c ” “A” “… -
Page 362
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B947H11704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. -
Page 363
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B947H11706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43 psi) •… -
Page 364
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1G-6 Fuel System: Fuel Pump Inspection 3) Connect a proper fuel hose (2) to the fuel pump. B947H11706002 4) Place the measuring cylinder and insert the fuel Turn the ignition switch ON and check that the fuel pump hose end into the measuring cylinder. -
Page 365
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-7 Fuel Pump Relay Inspection Fuel Hose Inspection B947H11706004 B947H11706005 Refer to “Electrical Components Location” in Section 0A Refer to “Fuel Line Inspection” in Section 0B (Page 0B- (Page 0A-7). -
Page 366
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1G-8 Fuel System: Fuel Tank Construction B947H11706007 “A” “B” “B” “B” I947H1170025-02 1. Fuel tank heat shield 3. Fuel tank front bracket “A”: Insert to the bracket. : Aluminum film side should face the engine side. 2. -
Page 367
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-9 Fuel Tank Removal and Installation 5) Disconnect the fuel pump lead wire coupler (2). B947H11706008 6) Place a rag under the fuel feed hose (3) and disconnect the fuel feed hose from the fuel tank. -
Page 368
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1G-10 Fuel System: Fuel Pump Components B947H11706009 I947H1170030-02 1. Fuel level gauge 4. Joint 7. Fuel mesh filter : Apply grease. 2. Fuel pressure regulator assembly 5. Fuel pump : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Do not reuse. -
Page 369
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-11 Fuel Pump Disassembly and Assembly 5) Remove the fuel pressure regulator assembly (4). B947H11706010 Disassembly CAUTION 1) Remove the fuel tank. Refer to “Fuel Tank Removal Never remove the fuel pressure regulator (5) and Installation”… -
Page 370
2. Fuel level gauge (+) lead wire (R/B) 3. Fuel pump (–) lead wire (B/W) 4. Fuel level gauge (–) lead wire (B/W) • Install a new O-ring and apply grease to it. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1170012-01 WARNING The O-ring must be replaced with a new one to prevent fuel leakage. -
Page 371
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-13 • When installing the fuel pump assembly, first tighten Fuel Injector / Fuel Delivery Pipe / T-joint all the fuel pump mounting bolts lightly and then to the Removal and Installation specified torque in the ascending of numbers. -
Page 372
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1G-14 Fuel System: Specifications Service Data B947H11707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 222 ml (7.5/7.8 US/lmp oz) and more/10 sec. -
Page 373
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Fuel System: 1G-15 Special Tools and Equipment Recommended Service Material B947H11708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1G-12) equivalent NOTE Required service material is also described in the following. -
Page 374: Ignition System
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1H-1 Ignition System: Ignition System Engine General Description Immobilizer Description (For E-02, 19, 24, 51) Operation B947H11801001 When the ignition switch is turned ON with the engine The immobilizer, an anti-theft system, is installed as a stop switch in ON, the immobi-antenna and ECM are standard equipment.
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Page 375
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Ignition System: 1H-2 NOTE Operation Drive mode is preset at A-mode when the ignition switch If the indicator light flashes fast, turn the and engine stop switch are turned on. Follow the ignition switch OFF then ON to make procedure below to operate drive mode selector. -
Page 376
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1H-3 Ignition System: Schematic and Routing Diagram Ignition System Diagram B947H11802001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery… -
Page 377
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Ignition System: 1H-4 Diagnostic Information and Procedures Ignition System Symptom Diagnosis B947H11804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Fouled spark plugs. Clean or replace. -
Page 378
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1H-5 Ignition System: No Spark or Poor Spark B947H11804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. -
Page 379
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Ignition System: 1H-6 Repair Instructions Ignition Coil and Spark Plug Removal and 5) Remove the spark plugs with the spark plug wrench. Installation Special tool B947H11806001 (A): 09930–10121 (Spark plug wrench set) Removal WARNING The hot engine can burn you. -
Page 380
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1H-7 Ignition System: • Install the ignition coil and connect their lead wire 2) Disconnect all ignition coil. Refer to “Ignition Coil and couplers. Spark Plug Removal and Installation” (Page 1H-6). CAUTION Do not hit the ignition coil with a plastic hammer when installing it. -
Page 381
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Ignition System: 1H-8 5) Insert the needle pointed probe to the lead wire coupler. CAUTION “C” Use the special tool to prevent the rubber of “B” the water proof coupler from damage. “D”… -
Page 382
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1H-9 Ignition System: Ignition Coil Resistance 2) Disconnect the CKP sensor coupler (1). 1) Remove the ignition coil. Refer to “Ignition Coil and NOTE Spark Plug Removal and Installation” (Page 1H-6). Be sure that all of the couplers are connected 2) Measure the ignition coil for resistance in both properly and the battery is fully-charged. -
Page 383
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Ignition System: 1H-10 6) If the peak voltage is within the specification, check CKP Sensor Removal and Installation B947H11806005 the continuity between the CKP sensor coupler and Refer to “Generator Removal and Installation” in Section ECM coupler. -
Page 384
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1H-11 Ignition System: Ignition Switch Removal and Installation Installation B947H11806008 Install the ignition switch in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the air cleaner box. Refer to “Air Cleaner •… -
Page 385
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Ignition System: 1H-12 Drive Mode Selector Inspection B947H11806009 Inspect the drive mode selector in the following procedures: 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. -
Page 386
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1H-13 Ignition System: Specifications Service Data B947H11807001 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 ⋅ 4 ⋅ 3 Firing order NGK: CR9EIA-9 Type Spark plug DENSO: IU27D 0.8 –… -
Page 387
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Ignition System: 1H-14 Special Tools and Equipment Recommended Service Material B947H11808001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1H-11) “1322” or equivalent… -
Page 388: Starting System
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B947H11902001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). Ignition Engine stop switch switch Fuse (30 A) ignition coil Gear…
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Page 389
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Starting System: 1I-2 Starter Motor Will Not Run B947H11904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to Step 2. -
Page 390
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1I-3 Starting System: Repair Instructions Starter Motor Components B947H11906001 I947H1190032-02 1. O-ring 5. Armature : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) 2. Housing end (Inside) 6. Housing end (Outside) : Apply grease to sliding surface. -
Page 391
• Apply a small quantity of moly paste to the armature Installation shaft. Install the starter motor in the reverse order of removal. : Moly paste 99000–25140 (SUZUKI MOLY Pay attention to the following points: PASTE or equivalent) • Apply grease to the O-ring. -
Page 392
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1I-5 Starting System: • Tighten the starter motor housing bolts (1) to the Commutator specified torque. Inspect the commutator for discoloration, abnormal wear or undercut “A”. Tightening torque If the commutator is abnormally worn, replace the Starter motor housing bolt (a): 5 N·m (0.5 kgf-m, armature assembly. -
Page 393
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Starting System: 1I-6 Oil Seal Starter Relay Inspection B947H11906006 Check the seal lip for damage. Inspect the starter relay in the following procedures: If any damage is found, replace the housing end. 1) Remove the starter relay. -
Page 394
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1I-7 Starting System: 3) Measure the relay coil resistance between the Side-stand / Ignition Interlock System Parts terminals using the multi-circuit tester. If the Inspection resistance is not within the specified value, replace B947H11906008 Check the interlock system for proper operation. -
Page 395
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Starting System: 1I-8 5) Connect the side-stand switch coupler. Diode inspection 6) Install the removed parts. 1) Remove the turn signal/side-stand relay. Refer to “Turn Signal / Side-stand Relay Removal and Turn Signal / Side-stand Relay Installation”… -
Page 396
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1I-9 Starting System: 2) Disconnect the gear position switch coupler (1). CAUTION When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. -
Page 397
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Starting System: 1I-10 Starter Torque Limiter Inspection 3) Remove the starter idle gear No. 2 bearing (4), shaft B947H11906013 (5) and washer (6). Refer to “Starter Torque Limiter Removal and Installation”… -
Page 398
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1I-11 Starting System: • When installing the starter clutch and CKP sensor Starter Clutch Inspection B947H11906010 rotor, align the wide spline tooth of them with that of Refer to “Starter Clutch Removal and Installation” crankshaft. -
Page 399
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Starting System: 1I-12 Starter Button Inspection 3) Inspect the starter button for continuity with the B947H11906011 tester. Inspect the starter button in the following procedures: If any abnormality is found, replace the right handle 1) Remove the air cleaner box. -
Page 400
Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-4) equivalent Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1I-4) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1I-9) / (Page 1I- NOTE Required service material is also described in the following. -
Page 401: Charging System
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B947H11A02001 Regulator/Rectifier Ignition switch Generator I947H11A0021-01 Component Location Charging System Components Location B947H11A03001 Refer to “Electrical Components Location” in Section 0A (Page 0A-7). Diagnostic Information and Procedures Charging System Symptom Diagnosis B947H11A04001…
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Page 402
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging… -
Page 403
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection 3) Measure the DC voltage between the battery (+) and B947H11A06001 (–) terminals using the multi-circuit tester. If the Inspect the battery current leakage in the following voltage is not within the specified value, inspect the procedures: generator and regulator/rectifier. -
Page 404
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1J-4 Charging System: 3) Measure the resistance between the three lead Special tool wires. : 09900–25008 (Multi circuit tester set) If the resistance is out of specified value, replace the Tester knob indication stator with a new one. -
Page 405
Generator lead wire set bolt (b): 5.5 N·m (0.55 kgf- (C): 09930–34970 (Rotor remover) m, 4.0 lbf-ft) • Apply bond lightly to the generator lead wire grommet (1). : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I947H11A0009-03 I947H11A0011-03 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 406
Harness Routing Diagram” in Section 9A (Page 9A-7). • Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I947H11A0013-01 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 407
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Charging System: 1J-7 Regulator / Rectifier Construction B947H11A06005 “A” I947H11A0020-03 1. Regulator/rectifier 4. Spacer : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Regulator/rectifier bracket 5. Wiring harness 3. Air intake pipe (RH) “A”: Connect the regulator/rectifier couplers under the wiring harness. -
Page 408
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1J-8 Charging System: 5) Disconnect the regulator/rectifier couplers (1). 6) Remove the regulator/rectifier as shown in the regulator/rectifier construction. Refer to “Regulator / Rectifier Construction” (Page 1J-7). Installation 1) Install the regulator/rectifier as shown in the regulator/rectifier construction. -
Page 409
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Charging System: 1J-9 Battery Components 2) Remove the caps (2) from the electrolyte container. B947H11A06008 NOTE • Do not remove or pierce the sealed areas “B” of the electrolyte container. •… -
Page 410
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1J-10 Charging System: 5) Make sure that air bubbles (4) rise to the top of each electrolyte container, and leave in this position for about more than 20 minutes. I718H11A0027-01 Correct I649G11A0042-03… -
Page 411
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Charging System: 1J-11 Battery Recharging 4) Install the battery to the motorcycle. Refer to “Battery Removal and Installation” (Page 1J-11). CAUTION Do not remove the caps on the battery top while recharging. -
Page 412
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1J-12 Charging System: Installation Battery Visual Inspection B947H11A06011 Install the battery in the reverse order of removal. Inspect the battery in the following procedures: Pay attention to following points: 1) Remove the front seat. -
Page 413
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Charging System: 1J-13 Special Tools and Equipment Recommended Service Material B947H11A08001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1J-5) / (Page 1J-… -
Page 414: Exhaust System
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B947H11B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool.
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Page 415
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exhaust System: 1K-2 Exhaust Control System Operation B947H11B01002 The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then the ECM determines the EXCV opening angle based on the engine rpm and gear positions. -
Page 416
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-3 Exhaust System: FULL OPEN I947H11B0003-01 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 417
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exhaust System: 1K-4 Repair Instructions Exhaust Control System Construction B947H11B06001 “ a ” “ b ” “A” “ c ” I947H11B0004-02 1. EXCV cable No. 1 (CL) : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) “c”: 11 –… -
Page 418
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-5 Exhaust System: Exhaust System Components B947H11B06002 “A” I947H11B0005-03 1. Exhaust pipe gasket 7. EXCV cable No. 1 : 5.5 N⋅m (0.55 kgf-m, 4.0 lbf-ft) 2. Exhaust pipe assembly 8. -
Page 419
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exhaust System: 1K-6 EXCV Cable Removal and Installation Loosen the lock-nut (1) on the No. 2 cable (2) and B947H11B06003 turn in the cable adjuster (3) fully. Removal 9) Loosen the lock-nut (4) on the No. -
Page 420
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-7 Exhaust System: Installation 6) Connect the other end of EXCV cable No. 1 (1) and No. 2 (2) to the EXCVA pulley (9). CAUTION The cable slots of EXCVA pulley must be located adjustment position. -
Page 421
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exhaust System: 1K-8 4) After turning the mode select switch ON, turn the 9) Remove the EXCVA (3) with the bracket. ignition switch ON. Special tool (A): 09930–82720 (Mode selection switch) I947H11B0017-01 10) Remove the bracket from the EXCVA. -
Page 422
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-9 Exhaust System: Installation EXCVA Pulley Inspection B947H11B06006 Install the EXCVA in the reverse order of removal. Pay Inspect the EXCVA pulley in the following procedures: attention to the following points: 1) Remove the EXCVA pulley. -
Page 423
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exhaust System: 1K-10 4) Turn the mode select switch ON. If DTC “C46” is not 7) Measure the EXCVA position sensor output voltage indicated on the LCD display, the adjustment is at EXCV fully closed position. -
Page 424
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-11 Exhaust System: Step 4 b) Turn out the No. 2 cable adjuster (2) in or out to set the output voltage within the specified value. 1) Click “Full opened” (1). I947H11B0023-02 2) Measure the EXCVA position sensor output voltage I947H11B0025-02… -
Page 425
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exhaust System: 1K-12 3) Remove the side cowlings. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D- 4) Lift and support the fuel tank with the prop stay. Refer to “Fuel Tank Removal and Installation”… -
Page 426
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-13 Exhaust System: 12) Remove the exhaust pipe assembly by removing the exhaust pipe bolts. CAUTION Take care not to bend the radiator/oil cooler fins. NOTE Support the exhaust pipe assembly to prevent it from falling. -
Page 427
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exhaust System: 1K-14 Specifications Service Data B947H11B07001 FI Sensors Item Standard/Specification Note 0.3 V and less at idle speed HO2 sensor output voltage 0.6 V and more at 5 000 r/min EXCVA position sensor input 4.5 –… -
Page 428
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 1K-15 Exhaust System: Special Tools and Equipment Recommended Service Material B947H11B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-13) (commercially available) or… -
Page 429
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ……….2-1 Swingarm Removal and Installation….2C-9 Swingarm Pivot Boss Removal and Precautions…………. 2-1 Installation …………2C-12 Precautions for Suspension ……..2-1 Swingarm Related Parts Inspection ….2C-12 Suspension General Diagnosis…. -
Page 430
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B947H12000001 Refer to “General Precautions” in Section 00 (Page 00-1). WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. -
Page 431: Suspension General Diagnosis
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B947H12104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace.
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Page 432: Front Suspension
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B947H12206001 I947H1220001-03 1. Front fork cap 8. Rod guide case 15. Outer tube 22. Front axle pinch bolt 2.
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Page 433
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Suspension: 2B-2 Front Fork Removal and Installation 6) Loosen the handlebar clamp bolt (4). B947H12206002 NOTE NOTE The right and left front forks are installed Slightly loosen the front fork cap (5) to symmetrically and therefore the removal facilitate later disassembly. -
Page 434
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2B-3 Front Suspension: 2) Tighten the front fork cap (2) to the specified torque. 7) Tighten the handlebar clamp bolt (4). Tightening torque Tightening torque Front fork cap (a): 35 N·m (3.5 kgf-m, 25.5 lbf-ft) Handlebar clamp bolt (d): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) 3) Loosen the lower clamp bolts. -
Page 435
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Suspension: 2B-4 Front Suspension Adjustment Compression damping force B947H12206003 Fully turn the compression damping force adjuster (1) After installing the front fork, adjust the spring pre-load clockwise. From that position (stiffest), turn it out to and two kinds of damping force as follows: standard setting position. -
Page 436
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2B-5 Front Suspension: 2) Loosen the front fork cap using the special tool and 5) Remove the spring collar B (3) and spring (4). vise. CAUTION Do not clamp the outer tube too tight. Special tool (A): 09941–53670 (Front fork cap socket wrench (45 mm)) -
Page 437
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Suspension: 2B-6 9) Pull out the inner tube from the outer tube. I947H1220023-01 I947H1220020-01 Assembly 10) Remove the slide bushing (8) from the inner tube. 11) Remove the following parts from the inner tube. CAUTION a) Guide bushing (9) •… -
Page 438
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2B-7 Front Suspension: 3) Remove the plastic film and install the oil seal spacer 7) Install the stopper ring (2). (4), guide bushing (5) and slide bushing (6) keep CAUTION them free from dust. -
Page 439
CAUTION side holes of inner tube. Insert the piston rod assembly into the inner : Fork Oil 99000–99001–SS5 (SUZUKI tube with the outer tube lifted up. Be sure not FORK OIL SS-05 or equivalent) to damage the piston ring (12) of the rod guide case. -
Page 440
17) Pour specified fork oil up to the top of the rod guide CAUTION case. Use new O-ring to prevent oil leakage. : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) 21) Tighten the front fork cap to the specified torque. CAUTION Do not clamp the outer tube too tight. -
Page 441
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Suspension: 2B-10 Front Fork Parts Inspection Piston Rod / Piston Ring B947H12206005 Inspect the piston rod and piston ring (1) for wear or Refer to “Front Fork Disassembly and Assembly” damage. -
Page 442
75 (2.95) — outer tube fully compressed) 70 (2.76) 10 min. after adjustment Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 476 ml (16.1/16.8 US/lmp oz) — Front fork inner tube O.D 43 (1.7) -
Page 443
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Suspension: 2B-12 Special Tools and Equipment Recommended Service Material B947H12208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL SS-05 or P/No.: 99000–99001– (Page 2B-8) / (Page 2B-… -
Page 444: Rear Suspension
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B947H12306001 I947H1230001-02 1. Rear shock absorber 10. Swingarm : 115 N⋅m (11.5 kgf-m, 83.0 lbf-ft) 2. Rear shock absorber mounting nut 11.
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Page 445
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Suspension: 2C-2 Rear Suspension Assembly Construction B947H12306002 “ a ” “ a ” “ c ” “ c ” “ b ” “ b ” “ a ” “… -
Page 446
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2C-3 Rear Suspension: Rear Shock Absorber Removal and Installation Installation B947H12306003 Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: Removal •… -
Page 447
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Suspension: 2C-4 Rear Shock Absorber Inspection Rear Shock Absorber Bearing B947H12306005 1) Insert the spacer into bearing. Refer to “Rear Shock Absorber Removal and 2) Check the play by moving the spacer up and down. If Installation”… -
Page 448
STD position NOTE 184.3 mm (7.26 in) Apply a small quantity of the grease to housing when installing the bearing. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool (A): 09924–84521 (Bearing installer set) I947H1230014-01 Damping Force Adjustment NOTE “… -
Page 449
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Suspension: 2C-6 Compression side (Low speed) Gas Pressure Release Fully turn the compression damping force (Low speed) Make sure to observe the following precautions: adjuster (1) clockwise. From that position (stiffest), turn it WARNING out to standard setting position. -
Page 450
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2C-7 Rear Suspension: Cushion Lever Removal and Installation • Install the rear shock absorber. Refer to “Rear Shock B947H12306008 Absorber Removal and Installation” (Page 2C-3). • Install the muffler chamber heat guard No. 2 and left Removal muffler. -
Page 451
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Suspension: 2C-8 Installation Cushion Rod Inspection B947H12306012 Install the cushion rod in the reverse order of removal. Refer to “Cushion Rod Removal and Installation” Pay attention to the following points: (Page 2C-7). -
Page 452
2C-9 Rear Suspension: Cushion Rod Bearing Removal and Installation 2) Apply grease to the bearings. B947H12306013 : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Removal 1) Remove the cushion rod. Refer to “Cushion Rod Removal and Installation” (Page 2C-7). -
Page 453
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Suspension: 2C-10 6) Remove the left muffler and muffler chamber heat 10) Remove the swingarm pivot shaft. guard No. 2. Refer to “Muffler / Muffler Chamber / 11) Remove the swingarm assembly. Exhaust Pipe Removal and Installation”… -
Page 454
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2C-11 Rear Suspension: • Adjust swingarm pivot thrust clearance in the following – Tighten the swingarm pivot lock-nut (4) to the procedures: specified torque with the special tool. – Insert the swingarm pivot shaft (2) and tighten it to Special tool the specified torque with the special tool. -
Page 455
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Suspension: 2C-12 Swingarm Pivot Boss Removal and Installation • Tighten the swingarm boss nut (2) to the specified B947H12306018 torque. Tightening torque Removal Swingarm pivot boss nut (a): 65 N·m (6.5 kgf-m, 1) Remove the swingarm. -
Page 456
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2C-13 Rear Suspension: Plate Swingarm Pivot Shaft Inspect the plate for damage and excessive bend. If any Measure the swingarm pivot shaft runout using the dial defect is found, replace the plate with a new one. gauge. -
Page 457
Special tool (A): 09921–20240 (Bearing remover set) NOTE Apply a small quantity of the grease to housing when installing the bearing. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool (B): 09924–84521 (Bearing installer set) I947H1230053-01 Installation CAUTION “… -
Page 458
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2C-15 Rear Suspension: Specifications Service Data B947H12307001 Suspension Unit: mm (in) Item Standard Limit Rear shock absorber spring pre-set 184.3 (7.26) — length Rebound 2-3/4 turns from stiffed position —… -
Page 459
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Suspension: 2C-16 Special Tools and Equipment Recommended Service Material B947H12308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 2C-5) / (Page 2C-… -
Page 460: Wheels And Tires
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B947H12400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control.
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Page 461
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wheels and Tires: 2D-2 Repair Instructions Front Wheel Components B947H12406001 I947H1240030-01 1. Front axle 6. Spacer 11. Collar : Apply thread lock to the thread part. 2. Brake disc bolt 7. -
Page 462
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-3 Wheels and Tires: Front Wheel Assembly Construction B947H12406002 “ a ” I947H1240031-02 1. Brake disc bolt “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake caliper mounting bolt : 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) : Apply grease. -
Page 463
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wheels and Tires: 2D-4 Front Wheel Assembly Removal and Installation 7) Remove the collar (5) (RH only). B947H12406003 NOTE Removal After removing the front wheel, fit the 1) Remove the brake calipers, left and right. calipers temporarily to the original positions. -
Page 464
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-5 Wheels and Tires: 2) Insert the front axle from the left side and tighten the 5) Tighten two axle pinch bolts (4) on the right fork leg front axle bolt temporarily. to the specified torque. -
Page 465
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wheels and Tires: 2D-6 Front Wheel Related Parts Inspection Wheel B947H12406004 1) Remove the brake pads. Refer to “Front Brake Pad Refer to “Front Wheel Assembly Removal and Replacement” in Section 4B (Page 4B-2). Installation”… -
Page 466
CAUTION The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1240009-01 3) Remove the wheel bearings using the special tool. Special tool (B): 09921–20240 (Bearing remover set) -
Page 467
CAUTION The sealed cover of the bearing must face outside. I947H1240012-01 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I837H1240014-01 I947H1240013-01 5) Install the front wheel assembly. Refer to“Front Wheel Assembly Removal and Installation”… -
Page 468
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-9 Wheels and Tires: Rear Wheel Components B947H12406006 I947H1240033-01 1. Rear axel nut 9. Bearing 17. Rear brake disc 2. Collar 10. Spacer 18. Rear axle 3. Dust seal 11. -
Page 469
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wheels and Tires: 2D-10 Rear Wheel Assembly Construction B947H12406007 “a” I947H1240034-02 1. Rear sprocket nut “a”: Clearance : 35 N⋅m (3.5 kgf-m, 25.5 lbf-ft) 2. Rear axle nut : 60 N⋅m (6.0 kgf-m, 43.0 lbf-ft) : Apply grease. -
Page 470
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-11 Wheels and Tires: Rear Wheel Assembly Removal and Installation 7) Remove the collars (5) and (6). B947H12406008 Removal 1) Loosen the axle nut (1). 2) Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block. -
Page 471
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wheels and Tires: 2D-12 Rear Wheel Related Parts Inspection B947H12406009 Refer to “Rear Wheel Assembly Removal and Installation” (Page 2D-11). Tire Refer to “Tire Inspection” in Section 0B (Page 0B-18). Rear Brake Disc Refer to “Rear Brake Disc Inspection”… -
Page 472
The removed dust seal and bearings must be I947H1240020-02 replaced with new ones. 4) Remove the dust seal. 1) Apply grease to the wheel bearings. Special tool (A): 09913–50121 (Oil seal remover) : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1240021-01 I649G1240019-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 473
I947H1240024-01 4) Install the rear sprocket mounting drum assembly (2). 5) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER I649G1240030-02 GREASE “A” or equivalent) I947H1240025-03 6) Install the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation”… -
Page 474
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-15 Wheels and Tires: 4) Remove the tire using the tire changer. 2) Install the tire onto the wheel. CAUTION CAUTION For operating procedures, refer to the For installation procedure of tire onto the instructions supplied by the tire changer wheel, follow the instructions given by the manufacturer. -
Page 475
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wheels and Tires: 2D-16 7) When the bead has been fitted properly, adjust the pressure to specification. As necessary, adjust the tire balance. Refer to “Wheel Balance Check and Adjustment” (Page 2D- 17). -
Page 476
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-17 Wheels and Tires: 3) Remove the air valve (1) from the wheel. Wheel Balance Check and Adjustment B947H12406014 Check and adjust the wheel balance in the following procedures: 1) Removal the wheel assembly. -
Page 477
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wheels and Tires: 2D-18 Specifications Service Data B947H12407001 Wheel Unit: mm (in) Item Standard Limit Axial Wheel rim runout — 2.0 (0.08) Radial Front 17 M/C x MT 3.50 —… -
Page 478
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 2D-19 Wheels and Tires: Special Tools and Equipment Recommended Service Material B947H12408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 2D-7) /… -
Page 479
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ……….3-1 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation ……3A-3 Precautions…………. 3-1 Drive Chain Related Parts Inspection ….3A-5 Precautions for Driveline / Axle …… -
Page 480
• Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is DID 50VAZ. Suzuki recommends to use this standard drive chain as a replacement. -
Page 481
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B947H13104001 Condition Possible cause… -
Page 482
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 7) Remove the speed sensor rotor (7) by removing its B947H13106002 bolt while depressing the rear brake pedal. Removal 1) Remove the gearshift link arm (1) from the gearshift shaft. -
Page 483
• Before installing the engine sprocket cover, apply a B947H13106003 small quantity of grease to the clutch push rod. Removal : Grease 99000–25010 (SUZUKI SUPER 1) Remove the rear wheel assembly. Refer to “Rear GREASE “A” or equivalent) Wheel Assembly Removal and Installation” in Section 2D (Page 2D-11). -
Page 484
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 3A-4 Drive Chain / Drive Train / Drive Shaft: 5) Remove the retainer (3). • Apply grease to the retainer. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1310003-01 6) Remove the wheel dampers (4). -
Page 485
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Drive Chain / Drive Train / Drive Shaft: 3A-5 Drive Chain Related Parts Inspection Wheel Damper B947H13106004 Inspect the dampers for wear and damage. Replace the Refer to “Rear Sprocket / Rear Sprocket Mounting Drum dampers if there is anything unusual. -
Page 486
5) Remove the sprocket mounting drum bearing with the special tool. Special tool (B): 09921–20240 (Bearing remover set) I947H1310016-01 3) Apply grease to the retainer. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1310015-01 Installation CAUTION The removed dust seal and bearing must be replaced with new ones. -
Page 487
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Drive Chain / Drive Train / Drive Shaft: 3A-7 Drive Chain Replacement NOTE B947H13106006 The tip of pin remover (7) should be Use the special tool in the following procedures, to cut positioned inside “a”… -
Page 488
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 3A-8 Drive Chain / Drive Train / Drive Shaft: 6) Remove the joint pin (9) of the other side of joint 2) Apply grease to the joint pins (8), O-rings (9) and plate. -
Page 489
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Drive Chain / Drive Train / Drive Shaft: 3A-9 7) Turn in the pressure bolt [A] (6) further using the bar 2) Stake the joint pin by turning (approximately 7/8 turn) (7) to press the joint plate over the joint pins. -
Page 490
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 3A-10 Drive Chain / Drive Train / Drive Shaft: Specifications Service Data B947H13107001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Final reduction ratio 2.470 (42/17) — Type DID 50VAZ —… -
Page 491
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Drive Chain / Drive Train / Drive Shaft: 3A-11 Special Tools and Equipment Recommended Service Material B947H13108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 3A-3) / (Page 3A-… -
Page 492
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 3A-12 Drive Chain / Drive Train / Drive Shaft: email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 493
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 4- i Section 4 Brake CONTENTS Precautions ……….4-1 Tightening Torque Specifications……4A-19 Special Tools and Equipment ……4A-20 Precautions…………. 4-1 Recommended Service Material …….4A-20 Precautions for Brake System ……4-1 Special Tool …………4A-20 Brake Fluid Information ……… -
Page 494
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B947H14000001 Refer to “General Precautions” in Section 00 (Page 00-1). Brake Fluid Information B947H14000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based. -
Page 495: Brake Control System And Diagnosis
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B947H14102001 “C” “B” “A” “B” I947H1410046-02 1. Hose clamp “A”: White marking : Clamp end should face downward.
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Page 496
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B947H14102002 “B” “A” “C” I947H1410047-04 1. Hose clamp “A”: White marking : 12 N⋅m (1.2 kgf-m, 8.5 lbf-ft) : Face the clamp end backward. -
Page 497
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B947H14104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. -
Page 498
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-4 Brake Control System and Diagnosis: Rear Brake Light Switch Inspection Rear Brake Light Switch Inspection and B947H14106003 Adjustment Inspect the rear brake light switch in the following B947H14106004 procedures: Check the rear brake light switch so that the brake light will come on just before pressure is felt when the brake… -
Page 499
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-5 Front Brake Close the air bleeder valve and disconnect the hose. Tightening torque NOTE Air bleeder valve (Front caliper): 7.5 N·m (0.75 If air is trapped in the master cylinder, bleed kgf-m, 5.5 lbf-ft) air from the master cylinder first in the same… -
Page 500
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-6 Brake Control System and Diagnosis: 4) Fill the reservoir with brake fluid to the upper line of 5) Fill the reservoir with brake fluid to the upper line of the reservoir. -
Page 501
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-7 6) Loosen the air bleeder valve and pump the brake Rear Brake lever until the old brake fluid flows out of the brake 1) Place the motorcycle on a level surface. -
Page 502
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-8 Brake Control System and Diagnosis: Loosen the air bleeder valve and pump the brake Front Brake Hose Removal and Installation B947H14106009 pedal until the old brake fluid flows out of the brake Removal system. -
Page 503
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Components B947H14106011 I947H1410051-02 1. Reservoir cap 8. Brake lever : 1 N⋅m (0.1 kgf-m, 0.5 lbf-ft) 2. PLATE 9. Brake lever pivot bolt : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) 3. -
Page 504
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal Installation Install the front brake master cylinder in the reverse and Installation B947H14106012 order of removal. Pay attention to the following points: •… -
Page 505
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-11 • After setting the brake hose union to the stopper, Front Brake Master Cylinder / Brake Lever tighten the union bolt (2) to the specified torque. Disassembly and Assembly B947H14106013 Refer to “Front Brake Master Cylinder Assembly… -
Page 506
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-12 Brake Control System and Diagnosis: 5) Remove the following parts from the master cylinder. Assembly Assemble the master cylinder in the reverse order of • Piston (10) disassembly. Pay attention to the following points: •… -
Page 507
4A-13 • Apply grease to the push rod. • When installing the brake light switch, align the projection “C” on the switch with the hole “D” in the : Grease 99000–25100 (SUZUKI SILICONE master cylinder. GREASE or equivalent) “C” “D”… -
Page 508
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-14 Brake Control System and Diagnosis: Rear Brake Master Cylinder Components B947H14106015 I947H1410052-02 1. Reservoir cap 6. Brake hose 11. Piston/Cup set : 17 N⋅m (1.7 kgf-m, 12.5 lbf-ft) 2. -
Page 509
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-15 Rear Brake Master Cylinder Assembly Removal Installation Install the rear brake master cylinder in the reverse order and Installation B947H14106016 of removal. Pay attention to the following points: Refer to “Rear Brake Hose Routing Diagram”… -
Page 510
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-16 Brake Control System and Diagnosis: Rear Brake Master Cylinder Disassembly and 4) Pull out the dust boot (5) and remove the snap ring (6). Assembly B947H14106017 Special tool Refer to “Rear Brake Master Cylinder Assembly : 09900–06108 (Snap ring remover (Close Removal and Installation”… -
Page 511
Inspect the master cylinder bore for any scratches or other damage. I947H1410038-01 • Apply grease to the push rod end. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) I947H1410040-02 Piston / Rubber Parts Inspect the piston surface for any scratches or other damage. -
Page 512
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-18 Brake Control System and Diagnosis: Rear Brake Pedal Construction B947H14106019 I947H1410056-02 1. Footrest bracket No. 2 5. Footrest : Apply grease. 2. Footrest bracket No. 1 : 35 N⋅m (3.5 kgf-m, 25.5 lbf-ft) : Apply thread lock to the thread part. -
Page 513
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Brake Control System and Diagnosis: 4A-19 Specifications Service Data B947H14107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 65 – 75 (2.6 – 3.0) — Front 17.460 –… -
Page 514
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4A-20 Brake Control System and Diagnosis: Special Tools and Equipment Recommended Service Material B947H14108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) /… -
Page 515: Front Brakes
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Brakes: 4B-1 Front Brakes Brake Repair Instructions Front Brake Components B947H14206001 I947H1420020-01 1. Seal set 5. Front brake disc : 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) 2. Piston and seal set : 7.5 N⋅m (0.75 kgf-m, 5.5 lbf-ft) : Apply thread lock to the thread part.
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Page 516
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4B-2 Front Brakes: Front Brake Pad Inspection 4) Clean up the caliper especially around the caliper B947H14206002 pistons. The extent of brake pads wear can be checked by 5) When installing the spring to caliper, bring its wider observing the grooved limit line “A”… -
Page 517
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Brakes: 4B-3 Front Brake Caliper Removal and Installation Installation B947H14206004 Install the brake caliper in the reverse order of removal. Pay attention to the following points: NOTE • Tighten each bolt to the specified torque. The right and left calipers are installed symmetrically and therefore the removal Tightening torque… -
Page 518
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4B-4 Front Brakes: Disassembly Assembly Assemble the caliper in the reverse order of 1) Remove the brake pads (1) and spring from the disassembly. Pay attention to the following points: caliper by removing the pad mounting pins. -
Page 519
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Brakes: 4B-5 • When installing the spring to the caliper, bring its Brake Caliper Piston wider pawl “A” facing top side. Inspect the surface of brake caliper pistons for any scratches or other damage. -
Page 520
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4B-6 Front Brakes: Front Brake Disc Removal and Installation Front Brake Disc Inspection B947H14206007 B947H14206008 Brake Disc Thickness Removal Check the brake disc for damage or cracks and measure the thickness using the micrometer. -
Page 521
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Front Brakes: 4B-7 Specifications Service Data B947H14207001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Front 5.3 – 5.7 (0.21 – 0.22) 5.0 (0.20) Brake disc runout —… -
Page 522
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4B-8 Front Brakes: Special Tools and Equipment Recommended Service Material B947H14208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-4) / (Page 4B- Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32130… -
Page 523: Rear Brakes
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Brakes: 4C-1 Rear Brakes .Brake Repair Instructions Rear Brake Components B947H14306001 I947H1430026-02 1. Rear brake caliper 8. Brake pad spring : Apply silicone grease to sliding surface. 2. Piston seal : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) : Apply thread lock to the thread part.
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Page 524
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4C-2 Rear Brakes: Rear Brake Pad Inspection 2) Remove the brake pads (3). B947H14306002 The extent of brake pads wear can be checked by CAUTION observing the grooved limit line “A” on the pads. When Do not operate the brake pedal while the the wear exceeds the grooved limit line, replace the pads are removed. -
Page 525
• Apply grease to the sliding pins. 1) Remove the rear wheel. Refer to “Rear Wheel Assembly Removal and Installation” in Section 2D : Grease 99000–25100 (SUZUKI SILICONE (Page 2D-11). GREASE or equivalent) 2) Drain brake fluid. Refer to “Brake Fluid Replacement”… -
Page 526
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4C-4 Rear Brakes: • Tighten the caliper sliding pin A (1) to the specified • Bleed air from the brake system after installing the torque. caliper. Refer to “Air Bleeding from Brake Fluid Circuit”… -
Page 527
4) Remove the rubber boot (5), pad spring (6) and sliding pin B (7) from the bracket. • Apply grease to the piston seal (2). : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) • Install the piston seal (2) as shown in the figure. -
Page 528
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 4C-6 Rear Brakes: • Install the rear brake caliper. Refer to “Rear Brake Boot Caliper Removal and Installation” (Page 4C-3). Inspect the boots for damage and wear. If any defects are found, replace it with a new one. -
Page 529
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Rear Brakes: 4C-7 Installation Install the rear brake disc in the reverse order of removal. Pay attention to the following points: • Make sure that the brake disc is clean and free of any grease. -
Page 530
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-9). Special Tools and Equipment Recommended Service Material B947H14308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-5) /… -
Page 531
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ……….5-1 Specifications ………….5B-21 Service Data…………5B-21 Precautions…………. 5-1 Tightening Torque Specifications……5B-22 Precautions for Transmission / Transaxle….. 5-1 Special Tools and Equipment ……5B-22 Manual Transmission…… -
Page 532
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B947H15000001 Refer to “General Precautions” in Section 00 (Page 00-1). email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 533
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B947H15204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. -
Page 534
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-2 Manual Transmission: Repair Instructions Transmission Components B947H15206001 I947H1520072-02 1. 2nd drive gear 11. 5th driven gear : 145 N⋅m (14.5 kgf-m, 105.0 lbf-ft) 2. 6th drive gear 12. 1st driven gear : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 3. -
Page 535
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-3 Transmission Removal Gearshift Fork and Gearshift Cam B947H15206002 1) Remove the gearshift cam bearing retainer screws. 1) Remove the engine assembly from the frame. Refer 2) Remove the gearshift fork shaft (1). to “Engine Assembly Removal”… -
Page 536
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-4 Manual Transmission: 4) Using suitable size bolts (3), remove the driveshaft Bearing and Oil Seal left bearing case (4). NOTE 5) Remove the dowel pin. If there is no abnormal condition, the oil seal and bearing removal is not necessary. -
Page 537
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-5 3) Remove the gearshift shaft bearings (3) and (4) with Transmission Installation B947H15206003 the special tool. Install the transmission in the reverse order of removal. Special tool Pay attention to the following points: (C): 09921–20240 (Bearing remover set) Bearing and Oil Seal… -
Page 538
– 75 Φ)) equivalent) • Apply grease to the oil seal lip. Tightening torque Driveshaft right bearing case bolt (a): 12 N·m (1.2 : Grease 99000–25010 (SUZUKI SUPER kgf-m, 8.7 lbf-ft) GREASE “A” or equivalent) I947H1520041-01 I947H1520039-01 • Install the dowel pin. -
Page 539
CAUTION (THREAD LOCK CEMENT SUPER “1322” or Replace the O-ring with a new one. equivalent) Tightening torque : Grease 99000–25010 (SUZUKI SUPER Driveshaft oil seal retainer screw (c): 12 N·m (1.2 GREASE “A” or equivalent) kgf-m, 8.7 lbf-ft) I947H1520042-01 I947H1520044-01 •… -
Page 540
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-8 Manual Transmission: • Install the gearshift cam (2) with the bearing fitted. • Install the countershaft assembly to the upper crankcase. NOTE Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. -
Page 541
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-9 Transmission Construction B947H15206004 I947H1520060-02 1. Countershaft 2. Driveshaft email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 542
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-10 Manual Transmission: Countershaft Gear / Driveshaft Gear • Slide the 6th (3) and 2nd (4) drive gears toward the 3rd/4th drive gears (2), then remove the 2nd drive Disassembly and Assembly B947H15206005 gear circlip (5). -
Page 543
• Before installing the oil seal, apply grease to the oil seal lip. Special tool (A): 09913–70210 (Bearing installing set (10 : Grease 99000–25010 (SUZUKI SUPER – 75 Φ)) GREASE “A” or equivalent) • When installing a new snap ring (1), pay attention to its direction. -
Page 544
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-12 Manual Transmission: • When installing the gear bushing onto the Gearshift Fork Groove Width countershaft, align the shaft oil hole “A” with the Measure the gearshift fork groove width using the bushing oil hole “B”. -
Page 545
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-13 Gearshift Cam Inspect the driveshaft right bearing for abnormal noise Inspect the gearshift cam groove for abnormal wear and and smooth rotation. damage. If any defects are found, replace the gearshift If there is anything unusual, replace the bearing cam with a new one. -
Page 546
3) Disconnect the gear position switch lead wire NOTE coupler (1). Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) “B” I947H1520068-01 “A” 4) Remove the engine sprocket cover. Refer to “Engine Sprocket Removal and Installation”… -
Page 547
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-15 Gearshift Lever Construction B947H15206009 “A” “ a ” I947H1520058-02 1. Gearshift lever bracket 4. Snap ring “a”: 65 – 75 mm (2.6 – 3.0 in) : Apply grease. 2. -
Page 548
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-16 Manual Transmission: Gearshift Lever Height Inspection and 2) Loosen the lock-nuts (1). Adjustment 3) Turn the gearshift link rod (2) until the gearshift lever B947H15206011 is 65 – 75 mm (2.6 – 3.0 in) below the top of the Inspect and adjust the gearshift lever height in the footrest. -
Page 549
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-17 Gearshift Shaft Construction B947H15206013 I947H1520059-03 1. Gearshift shaft 6. Gearshift plate return spring : Apply thread lock to the thread part. 2. Washer : 8.5 N⋅m (0.85 kgf-m, 6.0 lbf-ft) : Apply thread lock to the thread part. -
Page 550
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-18 Manual Transmission: 5) Remove the following parts from the gearshift shaft. • Apply a small quantity of thread lock to the gearshift arm stopper and tighten it to the specified torque. Special tool : 09900–06107 (Snap ring remover (Open : Thread lock cement 99000–32030… -
Page 551
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-19 • Check the gearshift cam stopper moves smoothly. • Apply a small quantity of thread lock to the gearshift shaft end screw and tighten it to the specified torque. •… -
Page 552
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5B-20 Manual Transmission: • Install a new snap ring (9). Gearshift Shaft Bearing Inspect the gearshift shaft bearings for abnormal noise Special tool and smooth rotation. Replace the bearing if there is : 09900–06107 (Snap ring remover (Open anything unusual. -
Page 553
The stamped mark side of gearshift shaft bearing faces outside. Special tool (A): 09913–70210 (Bearing installing set (10 – 75 Φ)) I947H1520021-01 • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1520020-01 I947H1520022-01 Specifications Service Data B947H15207001… -
Page 554
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-9). Special Tools and Equipment Recommended Service Material B947H15208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 5B-6) /… -
Page 555
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Manual Transmission: 5B-23 Special Tool B947H15208002 09900–06104 09900–06107 Snap ring remover (Open Snap ring remover (Open type) type) (Page 5B-10) (Page 5B-17) / (Page 5B-18) / (Page 5B-20) 09900–20102 09900–20803 Vernier calipers (200 mm) Thickness gauge… -
Page 556
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B947H15300001 Refer to “General Precautions” in Section 00 (Page 00-1). Schematic and Routing Diagram Clutch Cable Routing Diagram B947H15302001 Refer to “Throttle Cable Routing Diagram”… -
Page 557
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Clutch: 5C-2 Repair Instructions Clutch Lever Position Switch Inspection Clutch Cable Inspection B947H15306001 B947H15306002 Inspect the clutch lever position switch in the following Refer to “Clutch Cable Play Inspection and Adjustment” procedures: in Section 0B (Page 0B-14). -
Page 558
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-3 Clutch: Clutch Control System Components B947H15306004 I947H1530043-02 1. Push rod 4. Clutch cable : 10 N⋅m (1.0 kgf-m, 0.7 lbf-ft) 2. Clutch release camshaft : 1 N⋅m (0.1 kgf-m, 0.7 lbf-ft) : Apply grease. -
Page 559
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Clutch: 5C-4 Clutch Components B947H15306005 I947H1530044-03 1. Clutch pressure plate 8. Spring washer 15. Primary driven gear assembly 2. Clutch push piece 9. Spring washer seat 16. Push rod 3. -
Page 560
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-5 Clutch: Clutch Removal 6) Remove the clutch springs and pressure plate (4). B947H15306006 NOTE 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement” in Section 0B (Page 0B-10). Loosen the clutch spring set bolts little by little and diagonally. -
Page 561
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Clutch: 5C-6 9) Remove the thrust washer (9), bearing (10) and 13) Remove the clutch sleeve hub nut. clutch push piece (11). I947H1530010-01 14) Remove the spring washer (13), washer (14) and I947H1530007-01 10) Remove the clutch push rod (12). -
Page 562
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-7 Clutch: 17) Remove the clutch lifter drive cam (19) and thrust 2) Install the spacer (2) and bearing (3), and apply washer (20). engine oil to them. I947H1530014-01 I947H1530017-01 18) Remove the spacer (21) and bearing (22). -
Page 563
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Clutch: 5C-8 7) Install the clutch lifter drive cam (9). I947H1530022-01 11) Lock the clutch sleeve hub nut with a center punch. I947H1530020-02 Install the clutch sleeve hub, washer (10) and spring washer (11). -
Page 564
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-9 Clutch: NOTE 14) Install the spring washer seat (16) and spring washer (17) onto the clutch sleeve hub correctly. Two kinds of drive plate (No. 1 and No. 2) are equipped in the clutch system, they can be distinguished by inside diameter. -
Page 565
Tightening torque Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lbf- : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) NOTE Tighten the clutch spring set bolt little by little and diagonally. -
Page 566
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-11 Clutch: 26) Install the clutch cover and tighten the clutch cover Measure the claw width of drive plates with a vernier bolts. calipers. Replace the drive plates found to have worn down to the limit. -
Page 567
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Clutch: 5C-12 Clutch Release Bearing Wave Spring Washer Inspect the clutch release bearing for any abnormality, Measure the free height “A” of each wave spring washer especially cracks. When removing the bearing from the with a vernier calipers. -
Page 568
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-13 Clutch: Clutch Lifter Pin Inspection and Adjustment 3) Inspect the height “A” of clutch lifter pin at three B947H15306009 positions using the thickness gauge. If the Refer to “Clutch Removal” (Page 5C-5) and “Clutch measurement is out of the specification, adjust the Installation”… -
Page 569
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Clutch: 5C-14 Tighten the lock-nut (1). Tightening torque Clutch lifter pin lock-nut (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) I947H1530041-02 I837H1530046-02 Specifications Service Data B947H15307001 Clutch Unit: mm (in) Item Standard Limit… -
Page 570
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 5C-15 Clutch: Special Tools and Equipment Recommended Service Material B947H15308001 Material SUZUKI recommended product or Specification Note Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 5C-10) Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140… -
Page 571
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 6- i Section 6 Steering CONTENTS Precautions ……….6-1 Steering Damper Construction……6B-6 Steering / Steering Damper Removal and Precautions…………. 6-1 Installation …………6B-6 Precautions for Steering ……..6-1 Steering / Steering Damper Related Parts Steering General Diagnosis…. -
Page 572
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 6-1 Precautions: Precautions Steering Precautions Precautions for Steering B947H16000001 Refer to “General Precautions” in Section 00 (Page 00-1). email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 573: Steering General Diagnosis
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B947H16104001 Condition Possible cause Correction / Reference Item Heavy steering Over tightened steering stem nut. Adjust.
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Page 574
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Components B947H16206001 “A” I947H1620001-05 1. Throttle grip 5. Right handlebar “A”: Apply handle grip bond. 2. Grip rubber 6. -
Page 575
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Steering / Handlebar: 6B-2 Handlebar Removal and Installation 3) Loosen the handlebar clamp bolts (9) and front fork B947H16206002 upper clamp bolts (10). Removal 1) Remove the following parts from the left handlebar. a) Left handlebar switch box (1) b) Handlebar balancer (2) c) Grip rubber (3) -
Page 576
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 6B-3 Steering / Handlebar: 7) Remove the clutch lever assembly (15) from the left • Insert the protrusion “B” of the handlebar into the hole handlebar. “C” of the steering stem upper bracket. “C”… -
Page 577
– Clutch cable routing (Refer to “Throttle Cable Routing Diagram” in Section 1D (Page 1D-2)) : Grease 99000–25010 (SUZUKI SUPER – Throttle cable play (Refer to “Throttle Cable Play GREASE “A” or equivalent) Inspection and Adjustment” in Section 1D •… -
Page 578
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 6B-5 Steering / Handlebar: Steering Components B947H16206004 I947H1620017-04 1. Steering stem head nut 7. Dust seal : 90 N⋅m (9.0 kgf-m, 65.0 lbf-ft) 2. Steering stem upper bracket 8. Steering stem upper bearing : 80 N⋅m (8.0 kgf-m, 58.0 lbf-ft) 3. -
Page 579
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Steering / Handlebar: 6B-6 Steering Damper Construction B947H16206005 I837H1620040-01 1. Steering damper 2. Dust seal 3. Bearing : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply grease. Steering / Steering Damper Removal and 5) Remove the steering damper mounting bolt (5). -
Page 580
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 6B-7 Steering / Handlebar: 6) Remove the air cleaner box. Refer to “Air Cleaner 11) Remove the steering stem lock-nut (7), washer and Box Removal and Installation” in Section 1D steering stem nut (8) with the special tools. -
Page 581
NOTE • Apply grease to the bearings, bearing races and dust seals before remounting the steering stem. This adjustment will vary from motorcycle to motorcycle. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) “ a” I947H1620028-01 I947H1620025-01 • When installing the washer (2), align the lug of the washer to the groove of the steering stem. -
Page 582
• Tighten the front fork upper and lower clamp bolts. Refer to “Front Fork Removal and Installation” in Section 2B (Page 2B-2). Steering damper • Apply grease to the bearings and dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1620034-01 I823H1620019-02 email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 583
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Steering / Handlebar: 6B-10 Bearing Steering System Inspection B947H16206008 • Bearing wear or damage Refer to “Steering System Inspection” in Section 0B • Abnormal bearing noise (Page 0B-18). • Race wear or damage Steering Stem Bearing Removal and Installation •… -
Page 584
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 6B-11 Steering / Handlebar: Outer race 4) With the front wheel in the straight ahead state, hitch the spring scale (special tool) on one handlebar grip • Press in the upper and lower outer races using the end as shown in the figure and read the graduation special tool. -
Page 585
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Steering / Handlebar: 6B-12 Specifications Tightening Torque Specifications B947H16207001 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Front fork upper clamp bolt 16.5 (Page 6B-3) Handlebar clamp bolt 16.5 (Page 6B-3) Steering stem head nut (Page 6B-3) /… -
Page 586
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 6B-13 Steering / Handlebar: Special Tools and Equipment Recommended Service Material B947H16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 6B-4) /… -
Page 587
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ……….9-1 Specifications ………….9B-13 Service Data…………9B-13 Precautions…………. 9-1 Tightening Torque Specifications……9B-13 Precautions for Electrical System ……9-1 Special Tools and Equipment ……9B-13 Component Location ………. -
Page 588
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9-ii Table of Contents Specifications………….9D-12 Pillion Footrest Construction …….9E-4 Tightening Torque Specifications……9D-12 Side-stand Removal and Installation….9E-4 Specifications …………9E-5 Body Structure ………9E-1 Tightening Torque Specifications……9E-5 Repair Instructions ……….9E-1 Special Tools and Equipment ……9E-5 Body Frame Construction …….. -
Page 589
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B947H19000001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2). -
Page 590: Wiring Systems
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B947H19102001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). For E-02, 19, 24, 51 HANDLEBAR SWITCH (RH) STARTER BUTTON…
-
Page 591
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wiring Systems: 9A-2 LICENSE PLTE LIGHT REAR TURN SIGNAL LIGHT (RH) B/Bl REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (LH) COOLING SENSOR FAN RELAY TO SENSOR COOLING HO2 SENSOR SENSOR SENSOR FAN MOTOR… -
Page 592
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9A-3 Wiring Systems: For E-03, 28 HANDLEBAR SWITCH (RH) STARTER BUTTON FREE FREE DOWN PUSH ENGINE FRONT BRAKE STOP IGNITION IGNITION SWITCH SIDE-STAND SWITCH COIL #4 COIL #2 SWITCH PUSH FREE PAIR… -
Page 593
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wiring Systems: 9A-4 LICENSE PLTE LIGHT REAR TURN SIGNAL LIGHT (RH) B/Bl REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (LH) COOLING SENSOR FAN RELAY TO SENSOR COOLING HO2 SENSOR SENSOR FAN MOTOR SENSOR… -
Page 594
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9A-5 Wiring Systems: For E-14, 33 HANDLEBAR SWITCH (RH) STARTER BUTTON FREE FREE DOWN PUSH ENGINE FRONT BRAKE STOP IGNITION IGNITION SWITCH SIDE-STAND SWITCH COIL #4 COIL #2 SWITCH PUSH FREE PAIR… -
Page 595
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wiring Systems: 9A-6 EVAP SYSTEM PURGE CONTROL SOLENOID VALVE LICENSE PLTE LIGHT REAR TURN SIGNAL LIGHT (RH) B/Bl REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (LH) COOLING SENSOR FAN RELAY TO SENSOR COOLING HO2 SENSOR… -
Page 596
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9A-7 Wiring Systems: Wiring Harness Routing Diagram B947H19102002 “A”, “B” “A” “C” “D” “E” “F” I947H1910907-03 1. Wiring harness No. 2 “B”: Pass the left position light lead wires under the wiring harness No. 2. 2. -
Page 597
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wiring Systems: 9A-8 “C” “B” Upside “A” “D” “E” “ a ” I947H1910908-03 1. Clamp 13. Battery negative lead wire : Pass the side-stand switch lead wire left side of the water by- : Pass the battery negative lead wire in front of the PCV hose. -
Page 598
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9A-9 Wiring Systems: “B” Upside “A” “D” “C” “E” I947H1910909-03 1. Steel clamp 8. Clamp : Set the clamp facing downward and bend it to outside. : Put the coupler in the frame rib and face the clamp end inside. 2. -
Page 599
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Wiring Systems: 9A-10 “ a” “ a” “ a ” “A” “ b ” “ d ” “ c ” I947H1910910-02 1. Cylinder head cover “A”: Pass the oil pressure switch lead wire between cylinder and : 14 N⋅m (1.4 kgf-m, 10.0 lbf-ft) generator lead wires. -
Page 600
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9A-11 Wiring Systems: Specifications Service Data B947H1910S001 Electrical Item Specification Note 10 A Headlight 10 A Ignition 15 A Fuse size Signal 10 A Fuel 10 A 15 A Main 30 A Tightening Torque Specifications… -
Page 601
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B947H19206001 I947H1920001-02 1. Headlight Low beam bulb (12 V 55 W, H11) 2. Headlight High beam bulb (12 V 65 W, H9) 3. -
Page 602
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9B-2 Lighting Systems: 4) Remove the intake pipe covers (3). Headlight Bulb and Position Light Bulb Replacement B947H19206003 CAUTION When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure. -
Page 603
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Lighting Systems: 9B-3 Position Light Bulb Headlight Beam Adjustment B947H19206004 1) Disconnect the position light socket (1). Adjust the headlight beam, both horizontally and vertically. NOTE • To adjust the headlight beam, adjust the beam horizontally first, then vertically. -
Page 604
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9B-4 Lighting Systems: Front Turn Signal Light Removal and Front Turn Signal Light Bulb Replacement B947H19206007 Installation B947H19206006 CAUTION Removal When you touch the bulb with your bare 1) Remove the screw. hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure. -
Page 605
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Lighting Systems: 9B-5 Rear Lighting System Construction B947H19206008 I947H1920017-01 1. License plate light assembly 4. Rear combination light : 1.8 N⋅m (0.18 kgf-m, 1.5 lbf-ft) 2. Reflex reflector (E-03, 28, 33 only) 5. -
Page 606
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9B-6 Lighting Systems: Rear Combination Light Removal and Installation Install the rear combination light in the reverse order of Installation B947H19206009 removal. Pay attention to the following point: Removal •… -
Page 607
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Lighting Systems: 9B-7 License Plate Light Components B947H19206011 I947H1920021-01 1. License plate light bulb (12 V 5 W) 3. Lens 2. Lens cover : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) License Plate Light Removal and Installation 3) Remove the nuts. -
Page 608
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9B-8 Lighting Systems: Installation 2) Remove the lens cover (1) by removing the screws. Install the license plate light in the reverse order of removal. Pay attention to the following point: •… -
Page 609
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Lighting Systems: 9B-9 Rear Turn Signal Light Components B947H19206014 I947H1920030-01 1. Rear turn signal light lens 2. Rear turn signal light bulb (12 V 21 W) 3. Socket Rear Turn Signal Light Removal and Installation 5) Remove the side frame cover (3) from the center B947H19206015 frame cover (4). -
Page 610
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9B-10 Lighting Systems: 6) Remove the rear turn signal light (5). 1) Remove the rear turn signal light lens (1). I947H1920033-02 I947H1920034-01 2) Replace the bulb (2). Installation Install the rear turn signal light in the reverse order of removal. -
Page 611
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Lighting Systems: 9B-11 Turn Signal / Side-Stand Relay Inspection Hazard Switch Inspection B947H19206019 B947H19206021 Refer to “Electrical Components Location” in Section 0A Inspect the hazard switch in the following procedures: (Page 0A-7). -
Page 612
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9B-12 Lighting Systems: Turn Signal Switch Inspection Dimmer / Passing Light Switch Inspection B947H19206022 B947H19206023 Inspect the turn signal switch in the following Inspect the dimmer/passing light switch in the following procedures: procedures: 1) Remove the air cleaner box. -
Page 613
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-9). Special Tools and Equipment Recommended Service Material B947H19208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9B-6) “1322”… -
Page 614
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B947H19301001 This combination meter mainly consists of a stepping motor, LCD (Liquid Crystal Display) and LEDs (Light Emitting Diode). -
Page 615
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Combination Meter / Fuel Meter / Horn: 9C-2 Repair Instructions Combination Meter Components B947H19306001 I947H1930002-01 1. Combination meter unit 2. Combination meter case 3. Combination meter cover Combination Meter Removal and Installation 2) Disconnect the coupler (2) and remove the B947H19306002 combination meter assembly (3). -
Page 616
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9C-3 Combination Meter / Fuel Meter / Horn: NOTE Combination Meter Disassembly and Assembly B947H19306003 Refer to “Combination Meter Removal and Installation” • The pointers may not return to the proper (Page 9C-2). -
Page 617
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Combination Meter / Fuel Meter / Horn: 9C-4 Engine Coolant Temperature Indicator Light Inspection B947H19306005 Inspect the engine coolant temperature meter and indicator light (LED) in the following procedures: 1) Remove the left side cowling. -
Page 618
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9C-5 Combination Meter / Fuel Meter / Horn: Fuel Level Indicator Inspection 3) Install the fuel pump. Refer to “Fuel Pump B947H19306007 Disassembly and Assembly” in Section 1G If the fuel level indicator light (1) does not function (Page 1G-11). -
Page 619
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Combination Meter / Fuel Meter / Horn: 9C-6 Installation 3) Move a screwdriver back and forth across the pick- Install the speed sensor in the reverse order of removal. up surface of the speed sensor. -
Page 620
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9C-7 Combination Meter / Fuel Meter / Horn: 4) Check if the oil pressure indicator (LED) (2) will light Ignition Switch Inspection B947H19306015 up and LCD (3) will flicker when grounding the lead Inspect the ignition switch in the following procedures: wire (1). -
Page 621
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Combination Meter / Fuel Meter / Horn: 9C-8 Horn Inspection Horn Inspection B947H19306017 1) Disconnect the horn coupler (1). NOTE If the horn sound condition is normal, it is not necessary to inspect the horn button continuity. -
Page 622
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9C-9 Combination Meter / Fuel Meter / Horn: Specifications Service Data B947H19307001 Wattage Unit: W Specification Item E-02, 19, 24, 51 E-03, 14, 28, 33 ← Combination meter light ←… -
Page 623: Exterior Parts
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B947H19406001 “B” “A” “C” “A” “A” “A” “D” I947H1940001-01 1. Upper cowling bracket “A”: To frame “C”: To sprocket cover : Set the punch mark to the front and upper side.
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Page 624
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9D-2 Exterior Parts: Rear Fender Construction B947H19406004 I947H1940002-02 1. Electric parts holder bracket 3. Rear fender (Rear) 5. Rear fender guard (E-24 only) 2. Rear fender (Front) 4. Rear fender (Lower) email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 625
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exterior Parts: 9D-3 Frame Cover Construction B947H19406005 I947H1940003-01 1. Frame cover (Center) 2. Frame cover (Rear), LH/RH 3. Frame cover (LH/RH) email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 626
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9D-4 Exterior Parts: Rear View Mirror Construction B947H19406008 I947H1940004-01 1. Body cowling 4. Turn signal lead wire 7. Mirror body 2. Cowling brace 5. Turn signal lead wire coupler : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Locate the turn signal lead wire coupler (5) between the mirror cover (6) and mirror body (7). -
Page 627
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exterior Parts: 9D-5 Fastener Removal and Installation Type B B947H19406010 Removal Type A 1) Pry up the head of fastener center piece (1) with a Removal screw driver. 1) Depress the head of fastener center piece (1). 2) Pull out the fastener “A”. -
Page 628
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9D-6 Exterior Parts: Exterior Parts Removal and Installation Installation B947H19406011 1) Slide the seat hooks into the seat hook retainers on Side Frame Cover the frame and tighten the bolts. Removal NOTE The left and right side frame covers are… -
Page 629
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exterior Parts: 9D-7 Installation Installation Slide the hook into the hook retainer and push down Install the windscreen in the reverse order of removal. firmly until the rear seat/seat tail cover snaps into the Pay attention to the following point: locked position. -
Page 630
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9D-8 Exterior Parts: • Tighten the rear view mirror mounting nuts to the Side Cowling specified torque. Removal 1) Remove the fasteners and cowling bracket (1). Tightening torque Rear view mirror mounting nut (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) I947H1940019-01 I947H1940017-01… -
Page 631
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exterior Parts: 9D-9 Installation 6) Remove the combination meter. Refer to Install side cowling in the reverse order of removal. “Combination Meter Removal and Installation” in Pay attention to the following points: Section 9C (Page 9C-2). -
Page 632
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9D-10 Exterior Parts: 12) Remove the body cowling assembly (4) forward. Cowling Brace Removal 1) Remove the body cowling. 2) Remove the cowling brace (1). I947H1940026-01 13) Disassemble the body cowling assembly. Refer to “Headlight Removal and Installation”… -
Page 633
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Exterior Parts: 9D-11 Frame Cover 4) Disconnect the rear combination light coupler (2). Removal 5) Remove the frame cover assembly from the frame. 1) Remove the front and rear seats. 2) Remove the bolts and fasteners. -
Page 634
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9D-12 Exterior Parts: Specifications Tightening Torque Specifications B947H19407001 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Rear view mirror mounting nut (Page 9D-8) Cowling brace mounting bolt 16.5 (Page 9D-10) NOTE The specified tightening torque is described in the following. -
Page 635: Body Structure
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B947H19506001 I947H1950001-01 1. Frame 5. Engine mounting thrust adjuster : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2.
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Page 636
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9E-2 Body Structure: Front Footrest Bracket Construction B947H19506002 “A” “ a ” I947H1950002-02 1. Footrest bracket bolt 8. Rear brake pedal : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Rear brake master cylinder mounting bolt 9. -
Page 637
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Body Structure: 9E-3 Side-stand Construction B947H19506003 I947H1950003-03 1. Frame 3. Washer : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) : Apply grease to sliding surface. 2. Side-stand bracket 4. Side-stand : 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft) email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 638
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys 9E-4 Body Structure: Pillion Footrest Construction B947H19506004 I947H1950004-02 1. Pillion footrest 3. Ball 5. Washer 7. Footrest pin : Do not reuse. 2. Spring 4. E-ring 6. O-ring : Apply grease. Side-stand Removal and Installation B947H19506005 Removal… -
Page 639
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Body Structure: 9E-5 Specifications Tightening Torque Specifications B947H19507001 NOTE The specified tightening torque is described in the following. “Body Frame Construction” (Page 9E-1) “Front Footrest Bracket Construction” (Page 9E-2) “Side-stand Construction”… -
Page 640
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Prepared by March, 2009 Part No. 99500-39380-01E Printed in Japan email: info@motomatrix.co.uk / www.motomatrix.co.uk… -
Page 641
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys Printed in Japan email: info@motomatrix.co.uk / www.motomatrix.co.uk…
Check the continuity between the G/B wire and terminal Go to Step 3. G/B wire shorted to “19”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire and terminal “35”. 
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GSX-R1000
Service
Manual
*99500-39271-03E*
* 9 9 5 0 0 — 3 9 2 7 1 — 0 3 E *
Related Manuals for Suzuki GSX-R1000
Summary of Contents for Suzuki GSX-R1000
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Page 1
GSX-R1000 Service Manual *99500-39271-03E* * 9 9 5 0 0 — 3 9 2 7 1 — 0 3 E *… -
Page 2
System and Fuel System be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLETIN. -
Page 4
SUPPLEMENTS GSX-R1000K6 WIRING DIAGRAM… -
Page 51
2-30 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N•m… -
Page 373: Reassembly And Installation
8-44 CHASSIS REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 100 N·m (10.0 kgf-m, 72.5 lb-ft) 35 N·m 60 N·m (3.5 kgf-m, 25.5 lb-ft) (6.0 kgf-m, 43.5 lb-ft) E-02, 19, 24 25 N·m…
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Page 376
CHASSIS 8-47 • Tighten the sprocket mounting nuts to the specified torque. Rear sprocket nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) NOTE: Stamped mark A on the sprocket should face outside. • Install the collar 2. BRAKE DISC • Apply THREAD LOCK to the disc bolts and tighten them to the specified torque. -
Page 455
9-36 ELECTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. NOTE: * Use a screw driver + for adjuster A, B and C. * To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. A: Horizontal adjuster (Low beam) B: Vertical adjuster (Low beam) C: Horizontal adjuster (High beam) D: Vertical adjuster (High beam) -
Page 508
SERVICING INFORMATION 10-47 CHASSIS N·m kgf-m lb-ft ITEM Steering stem head nut 65.0 Steering stem lock-nut 65.0 Steering damper bolt and nut 16.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork inner rod lock-nut 21.0 Front fork damper rod bolt… -
Page 532
GSX-R1000K6… -
Page 533: Specifications
SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ………………2 030 mm (79.9 in) Overall width………………710 mm (28.0 in) Overall height ………………1 130 mm (44.5 in) Wheelbase ………………1 405 mm (55.3 in) Ground clearance…………….130 mm (5.1 in) Seat height ………………
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Page 534: Service Data
SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (0.94) Valve clearance (when cold) 0.10 – 0.20 — (0.004 – 0.008) 0.20 – 0.30 — (0.008 – 0.012) Valve guide to valve stem 0.010 –…
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Page 535
ITEM STANDARD LIMIT Camshaft runout 0.10 — (0.004) Cam chain pin (at arrow “3”) 14th pin — Cylinder head distortion 0.20 — (0.008) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 000 kPa (13 –… -
Page 536: Oil Pump
CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5909 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 – 20.00 —…
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Page 537
CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/2 turn back — Drive plate thickness 2.72 – 2.88 2.42 No. 1, 2 and 3 (0.107 – 0.113) (0.095) Drive plate claw width 13.85 –… -
Page 538
THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 82 °C (180 °F) — ature Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) — ECT sensor resistance 20 °C Approx. -
Page 539
FI SENSORS ITEM SPECIFICATION NOTE CMP sensor resistance 0.9 – 1.7 kΩ CMP sensor peak voltage 0.5 V and more When cranking 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage 4.5 –… -
Page 540: Throttle Body
THROTTLE BODY ITEM SPECIFICATION Bore size 44 mm I.D. No. 41G1 (For E-33), 41G0 (For the others) Idle r/min 1 150 ± 100 r/min Fast idle r/min 1 400 – 2 000 r/min (When cold engine) Throttle cable play 2.0 – 4.0 mm (0.08 –…
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Page 541
WATTAGE Unit: W STANDARD/SPECIFICATION ITEM E-03, 28, 33 Others ← Headlight ← ← Position/Parking light 5 × 2 ← Brake light/Taillight ← Turn signal light 21 × 4 ← License plate light ← Combination meter light ← Turn signal indicator light ←… -
Page 542
ITEM STANDARD LIMIT Wheel rim runout Axial — (0.08) Radial — (0.08) Wheel rim size Front 17 M/C × MT 3.50 — Rear 17 M/C × MT 6.00 — Wheel axle runout 0.25 Front — (0.010) 0.25 Rear — (0.010) TIRE ITEM STANDARD… -
Page 543
(8.86) Front fork oil level (without spring, — outer tube fully compressed) (3.98) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (each leg) 510 ml — (17.2/17.9 US/Imp oz) Front fork spring adjuster 4 th groove from top —… -
Page 544
BATTERY HOLDER CUSHION RUBBER INSTALLATION Forward – 13 –… -
Page 547
Prepared by 2005 Part No. 99500-39271-03E Printed in U.S.A. -
Page 548
Printed in USA K5 K6…
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Page 1
GSX-R1000 9 9 5 0 0 — 3 9 3 1 0 — 0 1 E PDF processed with CutePDF evaluation edition www.CutePDF.com… -
Page 2: Table Of Contents
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.
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Page 3
GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE……………. 1- 2 GENERAL PRECAUTIONS …………….. 1- 2 SUZUKI GSX-R1000K7 (’07-MODEL)…………1- 4 SERIAL NUMBER LOCATION …………..1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION…… 1- 5 FUEL (FOR USA AND CANADA)…………1- 5 FUEL (FOR OTHER COUNTRIES) …………1- 5 ENGINE OIL (FOR USA)…………… -
Page 4: Warning/Caution/Note
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
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Page 5
GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. -
Page 6: Suzuki Gsx-R1000K7 (’07-Model)
1-4 GENERAL INFORMATION SUZUKI GSX-R1000K7 (’07-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head pipe.
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Page 7: Fuel, Oil And Engine Coolant Recommendation
Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.
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Page 8: Front Fork Oil
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
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Page 9: Break-In Procedures
GENERAL INFORMATION 1-7 BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
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Page 10: Information Labels
1-8 GENERAL INFORMATION INFORMATION LABELS GSX-R1000 GSX-R1000UF Noise label A (For E-03, 24, 33) Information label A (For E-03, 28, 33) Vacuum hose routing label A (For E-33) Fuel caution label A (For E-02, 24) Fuel information label Manual notice label A (For E-03, 33) Screen label Warning steering label…
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Page 11: Specifications
GENERAL INFORMATION 1-9 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………….2 045 mm (80.5 in) Overall width …………….720 mm (28.3 in) Overall height …………….1 130 mm (44.5 in) Wheelbase …………….1 415 mm (55.7 in) Ground clearance…………..130 mm (5.1 in) Seat height …………….
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Page 12: Chassis
1-10 GENERAL INFORMATION CHASSIS Front suspension …………..Inverted telescopic, coil spring, oil damped Rear suspension …………..Link type, coil spring, oil damped Front fork stroke…………..125 mm (4.9 in) Rear wheel travel …………..135 mm (5.3 in) Steering angle…………….. 27° Caster ………………
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Page 13: Periodic Maintenance
PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ………… 2- 2 PERIODIC MAINTENANCE CHART…………. 2- 2 LUBRICATION POINTS ……………. 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ……………….. 2- 4 AIR CLEANER………………2- 4 SPARK PLUG………………2- 5 VALVE CLEARANCE…………….2- 7 ENGINE OIL AND OIL FILTER ………….
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Page 14: Periodic Maintenance Schedule
2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions.
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Page 15: Lubrication Points
PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Brake pedal pivot and footrest pivot Clutch lever holder Side-stand pivot Footrest pivot and and spring hook…
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Page 16: Maintenance And Tune-Up Procedures
2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months). Replace every 18 000 km (11 000 miles, 36 months). •…
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Page 17: Spark Plug
PERIODIC MAINTENANCE 2-5 SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). Replace every 12 000 km (7 500 miles, 24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Lift and support the fuel tank. (5-3) •…
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Page 18
2-6 PERIODIC MAINTENANCE SPARK PLUG GAP • Measure the spark plug gap » with a wire gauge. • If it is not within the specification, replace the spark plug. * To prevent the damage of iridium center electrode, use a wire gauge to check the gap. * Never adjust the spark plug gap. -
Page 19: Valve Clearance
PERIODIC MAINTENANCE 2-7 VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-14) • Disconnect the CMP sensor coupler •…
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Page 20
2-8 PERIODIC MAINTENANCE • Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches $ on the left ends of both camshafts (Ex. and In.) to the positions as shown. -
Page 21
PERIODIC MAINTENANCE 2-9 VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (3-16) • Remove the tappet and shim by fingers or magnetic hand. •… -
Page 22
2-10 PERIODIC MAINTENANCE (INTAKE SIDE) -
Page 23
PERIODIC MAINTENANCE 2-11 (EXHAUST SIDE) -
Page 24: Engine Oil And Oil Filter
2-12 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.
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Page 25: Exhaust Control Valve
Oil and filter change : 3.3 L (3.5/2.9 US/Imp qt) Engine overhaul : 3.6 L (3.8/3.2 US/Imp qt) ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
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Page 26: Fuel Line
2-14 PERIODIC MAINTENANCE • Remove the right under cowling. (8-5) • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play (6-9) and tighten them. FUEL LINE Inspect every 6 000 km (4 000 miles, 12 months). •…
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Page 27: Throttle Cable Play
PERIODIC MAINTENANCE 2-15 THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. • Adjust the throttle cable play » as follows. • Loosen the lock-nut of the throttle pulling cable •…
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Page 28: Clutch
2-16 PERIODIC MAINTENANCE CLUTCH (CLUTCH HOSE AND CLUTCH FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hose every 4 years. Replace fluid every 2 years. CLUTCH FLUID LEVEL • Keep the motorcycle upright and place the handlebars straight.
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Page 29
PERIODIC MAINTENANCE 2-17 BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT The clutch fluid circuit may be purged of air in the following man- ner. • Keep the motorcycle upright and place the handlebars straight. • Fill up the clutch master cylinder reservoir to the upper line. Place the reservoir cap to prevent entry of dirt. -
Page 30: Cooling System
2-18 PERIODIC MAINTENANCE COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the upper and lower lines on the engine coolant reservoir.
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Page 31
PERIODIC MAINTENANCE 2-19 AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •… -
Page 32
2-20 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the under cowlings. (8-5) • Lift and support the fuel tank. (5-3) • Remove the sprocket cover bolts. • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one. -
Page 33: Drive Chain
PERIODIC MAINTENANCE 2-21 DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below.
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Page 34
* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is DID530 V9. Suzuki rec- ommends to use this standard drive chain as a replacement. -
Page 35: Brake
PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years.
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Page 36
2-24 PERIODIC MAINTENANCE BRAKE PADS Front brake The extent of brake pad wear can be checked by observing the grooved limit line » on the pads. When the wear exceeds the grooved limit line, replace the pads with the new ones. (8-66) Replace the brake pads as a set, otherwise braking performance will be adversely affected. -
Page 37: Brake Pedal Height
PERIODIC MAINTENANCE 2-25 BRAKE PEDAL HEIGHT • Loosen the lock-nut • Turn the push rod until the brake pedal height becomes 65 – 75 mm (2.6 – 3.0 in) » below the top of the footrest. • Tighten the lock-nut securely.
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Page 38
2-26 PERIODIC MAINTENANCE FRONT BRAKE (Caliper side) • Fill the master cylinder reservoir to the upper level. Place the reservoir cap to prevent dirt from entering. • Attach a hose to the brake caliper air bleeder valve and insert the free end of the hose into a receptacle. •… -
Page 39: Tires
PERIODIC MAINTENANCE 2-27 TIRES Inspect every 6 000 km (4 000 miles, 12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.
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Page 40: Steering
2-28 PERIODIC MAINTENANCE STEERING Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtighten steering pre- vents smooth turning of the handlebars and too loose steering will cause poor stability.
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Page 41: Exhaust Pipe Bolt And Muffler Bolt
PERIODIC MAINTENANCE 2-29 EXHAUST PIPE BOLT AND MUFFLER BOLT Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolts and muffler connecting bolts to the specified torque.
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Page 42: Chassis Bolts And Nuts
2-30 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m…
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Page 43
PERIODIC MAINTENANCE 2-31… -
Page 44: Compression Pressure Check
2-32 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit…
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Page 45: Oil Pressure Check
PERIODIC MAINTENANCE 2-33 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 100 – 400 kPa (1.0 – 4.0 kgf/cm , 14 – 57 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) If the oil pressure is lower or higher than the specification, the following causes may be considered.
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Page 46: Sds Check
2-34 PERIODIC MAINTENANCE SDS CHECK Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
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Page 47: Data At The Time Of Racing
PERIODIC MAINTENANCE 2-35 Data at 3 000 r/min under no load Approx. 3 000 r/min Check the engine coolant temperature. XX ˚C Check the manifold absolute pressure. XX kPa Data at the time of racing Secondary throttle valve opens closes in accordance with the throttle valve opening PAIR control solenoid valve OFF in accordance with…
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Page 48
2-36 PERIODIC MAINTENANCE Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. Approx. 100 ˚C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XX kPa… -
Page 49
PERIODIC MAINTENANCE 2-37 Example of trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring. -
Page 50
ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION……….3- 3 ENGINE REMOVAL …………….3- 3 ENGINE INSTALLATION …………..3-10 ENGINE DISASSEMBLY …………….3-15 ENGINE COMPONENTS INSPECTION AND SERVICE ………………… 3-29 CYLINDER HEAD COVER………….. -
Page 51: Engine Components Removable With Engine In Place
3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION…
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Page 52: Engine Removal And Installation
ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. •…
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Page 53
3-4 ENGINE OIL COOLER • Remove the oil cooler hose bolts. • Remove the oil cooler Be careful not to bend the oil cooler fins. RADIATOR • Remove the regulator/rectifier bracket. • Disconnect the water/air bleed hose and radiator inlet hose •… -
Page 54
ENGINE 3-5 • Remove the radiator mounting bolts. • Remove the radiator Be careful not to bend the radiator fins. • Remove the horn • Remove the front engine cover MUFFLER, CHAMBER AND EXHAUST PIPE • Remove the EXCV cables along with the bracket •… -
Page 55
3-6 ENGINE ELECTRIC PARTS AND PAIR HOSE • Disconnect the oil pressure switch lead wire • Disconnect the starter motor lead wire • Disconnect the ground lead wire • Disconnect the CKP sensor lead wire coupler • Disconnect the ECT sensor lead wire coupler •… -
Page 56
ENGINE 3-7 • Remove the ignition coils/plug caps. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage. * Be careful not to drop the ignition coil/plug cap to prevent its short or open circuit. •… -
Page 57
3-8 ENGINE • Loosen the rear axle nut • Loosen the chain adjuster lock-nuts (LH and RH). • Loosen the chain adjusters . (LH and RH) • Push the rear wheel forward and make sure that the drive chain has enough slack. •… -
Page 58
ENGINE 3-9 • Loosen the engine mounting pinch bolts • Remove the engine mounting bolts # and %. • Remove the engine mounting nut • Remove the engine mounting thrust adjuster lock-nut with the special tool. • Loosen the engine mounting thrust adjuster fully. -
Page 59: Engine Installation
3-10 ENGINE • Remove the engine mounting nut • Loosen the engine mounting thrust adjuster lock-nut with the special tool. • Loosen the engine mounting thrust adjuster 09940-14980: Engine mounting thrust adjuster socket wrench NOTE: Do not remove the engine mounting bolts at this stage. •…
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Page 60
ENGINE 3-11 • Gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft. • Install all engine mounting bolts, spacers and tighten them temporarily. (3-12) Be careful not to catch the wiring harness between the frame and the engine. -
Page 61
3-12 ENGINE » LENGTH ITEM N·m kgf-m lb-ft ITEM «#$% «$ 40.0 1.77 54.0 Bolt 2.17 &( 16.5 8.46 16.5 Spacer 30.5 1.20 32.5 Adjuster 1.57 B LH C RH… -
Page 62
» Speed sensor rotor bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Apply grease to the clutch push rod end. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the engine sprocket cover • Install the gearshift lever . -
Page 63
3-14 ENGINE • Install the exhaust pipes, muffler chamber and mufflers. (6-16) Replace the gaskets and connectors with new ones. • Connect the EXCV cables and install the bracket » EXCV cable bracket nut: 11 N·m (1.1 kgf-m, 8.0 lb-ft) •… -
Page 64: Engine Disassembly
ENGINE 3-15 ENGINE DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove all the spark plugs. (2-5) • Remove the engine coolant reservoir bracket. STARTER MOTOR •…
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Page 65
3-16 ENGINE CAMSHAFT • Remove the valve timing inspection cap • Turn the crankshaft to bring the line » on the starter clutch to the index mark # of the valve timing inspection hole and also to bring the cams to the position as shown below. •… -
Page 66
ENGINE 3-17 • Remove the cam chain guide No.2 • Remove the intake camshaft journal holder • Remove the exhaust camshaft journal holder Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers. -
Page 67
3-18 ENGINE • Remove the cylinder head gasket and dowel pins. CLUTCH • Remove the clutch cover • Remove the gasket and dowel pins. • Hold the clutch housing with the special tool. Do not damage the clutch plates by the special tool. 09920-53740: Clutch sleeve hub holder •… -
Page 68
ENGINE 3-19 • Remove the pressure plate • Remove the clutch drive plates and driven plates • Remove the clutch push piece , bearing and the thrust washer • Remove the spring washer and its seat • Remove the clutch push rod NOTE: If it is difficult to pull out the push rod , use a magnetic hand or… -
Page 69
3-20 ENGINE • Hold the clutch sleeve hub with the special tool. 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub • Remove the conical spring washer , washer and spring washer seat from the clutch sleeve hub. •… -
Page 70
3-20 ENGINE • Hold the clutch sleeve hub with the special tool. 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub #. • Remove the conical spring washer , washer and spring washer seat from the clutch sleeve hub. •… -
Page 71
ENGINE 3-21 • Remove the thrust washer • Remove the oil pump drive gear from the primary driven gear assembly OIL PUMP • Remove the snap ring . • Remove the oil pump driven gear . NOTE: Do not drop the snap ring into the crankcase. •… -
Page 72
3-22 ENGINE STARTER IDLE GEAR • Remove the starter idle gear cover . • Remove the dowel pins and gasket . • Remove the spring washer , washer and starter idle gear No.1 . • Remove the shaft , bearing and thrust washer . •… -
Page 73
ENGINE 3-23 • Remove the dowel pins and gasket . • Remove the spring washer «, starter idle gear No.2 # and shaft STARTER CLUTCH • Hold the starter clutch with the special tool. 09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. •… -
Page 74
3-24 ENGINE GENERATOR COVER • Remove the generator cover . • Remove the dowel pins and gasket . GENERATOR ROTOR • Hold the generator rotor with the special tool. 09930-44520: Rotor holder • Remove the generator rotor bolt. • Install a bolt » of suitable size to the left end of crankshaft. SUITABLE BOLT «… -
Page 75
ENGINE 3-25 WATER PUMP • Remove the water inlet cover . • Remove the water pump . Water pump servicing ( 7-13) GEAR POSITION SWITCH • Remove the gear position switch . CRANKCASE BREATHER (PCV) COVER • Remove the crankcase breather cover . •… -
Page 76
3-26 ENGINE OIL FILTER • Remove the oil filter with the special tool. 09915-40610: Oil filter wrench OIL PAN • Remove the oil pan . • Remove the gasket . • Remove the oil pipe . OIL PRESSURE SWITCH • Remove the oil pressure switch . OIL STRAINER •… -
Page 77
ENGINE 3-27 TRANSMISSION • Remove the countershaft assembly and driveshaft assem- bly . • Remove the O-rings and dowel pins. • Remove the C-rings and bearing pins . MIDDLE CRANKCASE • Remove the crankcase bolts (M6). • Remove the crankcase bolts (M6). •… -
Page 78
3-28 ENGINE CRANKSHAFT • Remove the O-ring . • Loosen the bearing cap bolts by using 10 mm, 12 point socket wrench, and tap the bearing cap bolts lightly with plastic ham- mer to remove the bearing cap. • Remove the crankshaft and thrust washers . PISTON AND CONROD •… -
Page 79: Engine Components Inspection And Service
ENGINE 3-29 ENGINE COMPONENTS INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER •…
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Page 80: Camshaft
3-30 ENGINE INSPECTION • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. INSTALLATION • Install the PAIR reed valves and PAIR reed valve covers. •…
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Page 81
ENGINE 3-31 CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge to read the clearance at the widest portion, which is specified as follows: Camshaft journal oil clearance: Service Limit (IN &… -
Page 82: Cam Chain Tension Adjuster
3-32 ENGINE • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. Camshaft journal holder I.D.: Standard (IN &…
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Page 83: Cam Chain Tensioner
ENGINE 3-33 CAM CHAIN TENSIONER INSPECTION • Check the contacting surface of the cam chain tensioner. • If it is worn or damaged, replace it with a new one. CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guides No.1 and No.2.
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Page 84
3-34 ENGINE • Remove the oil seal and spring seat . Do not reuse the removed oil seal. • Remove the other valves in the same manner as described previously. CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. -
Page 85
ENGINE 3-35 VALVE HEAD RADIAL RUNOUT • Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. • If it measures more than the service limit, replace the valve. Valve head radial runout: Service Limit: 0.03 mm (0.001 in) 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand… -
Page 86
3-36 ENGINE VALVE STEM WEAR • If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. • If the stem is within the limit, then replace the guide. • After replacing valve or guide, be sure to recheck the deflec- tion. -
Page 87
ENGINE 3-37 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. Do not use a burner to heat the valve guide hole to prevent cylinder head distortion. -
Page 88
3-38 ENGINE • If the seat width measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter. Valve seat width Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) If the valve seat is out of specification, re-cut the seat. VALVE SEAT SERVICING •… -
Page 89
ENGINE 3-39 VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • Check the valve spring for proper strength by measuring its free length and also by the force required to compress it. -
Page 90
3-40 ENGINE • Put on the valve spring retainer , and using the special tools, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem. 09916-14510: Valve lifter 09916-14530: Valve lifter attachment 09916-84511: Tweezers… -
Page 91: Clutch
• Remove the water bypass union . • Apply bond to the thread part of water bypass union and tighten it to the specified torque. 99000-31140: SUZUKI BOND “1207B” or equivalent » Water bypass union: 12 N·m (1.2 kgf-m, 8.5 lb-ft) CLUTCH…
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Page 92
3-42 ENGINE • Measure the claw width of drive plates with a vernier calipers. • Replace the drive plates found to have worn down to the limit. Drive plate claw width: Service Limit: 13.05 mm (0.5138 in) 09900-20102: Vernier calipers CLUTCH DRIVEN PLATE INSPECTION NOTE: Wipe off engine oil from the clutch driven plates with a clean rag. -
Page 93: Clutch Lifter
ENGINE 3-43 CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY • Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one. CLUTCH LIFTER CLUTCH LIFTER DRIVE CAM AND DRIVEN CAM INSPEC- TION •…
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Page 94: Oil Pump
3-44 ENGINE • Check the height of clutch lifter adjusting pin screws at three positions using the thickness gauges. • If the measurement is out of the specification, adjust the height in the following procedures. NOTE: Each clutch lifter adjusting pin screw height should be as close as possible.
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Page 95: Starter Clutch
ENGINE 3-45 STARTER CLUTCH INSPECTION • Install the starter driven gear onto the starter clutch . • Turn the starter driven gear by hand. • Inspect the starter clutch for a smooth movement. • Check that the gear turns only in one direction. •…
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Page 96: Water Pump
3-46 ENGINE WATER PUMP 7-13 GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. Washer Gearshift cam drive plate Snap ring Plate return spring Gearshift shaft return spring GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION •…
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Page 97: Oil Pressure Regulator
• If the piston does not operate, replace the oil pressure regula- tor with a new one. INSTALLATION • Apply grease to the O-ring. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent Use new O-ring to prevent oil leakage. • Press in the oil pressure regulator to the oil pan.
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Page 98: Transmission
3-48 ENGINE TRANSMISSION DISASSEMBLY Disassemble the countershaft and driveshaft. Pay attention to the following points: • Remove the 6th drive gear snap ring from its groove and slide it towards the 3rd/4th drive gears . • Slide the 6th and 2nd drive gears toward the 3rd/4th drive gears , then remove the 2nd drive gear circlip .
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Page 99
* Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply grease to it. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent * Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed. -
Page 100
3-50 ENGINE TRANSMISSION PARTS LOCATION Countershaft Driveshaft… -
Page 101: Cylinder
ENGINE 3-51 CYLINDER CRANKCASE SERVICING (3-55) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set.
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Page 102: Piston And Piston Ring
3-52 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) » from the piston skirt end. • If the measurement is less than the limit, replace the piston. Piston diameter: Service Limit: 73.280 mm (2.8850 in) at 10 mm (0.39 in) from the skirt end…
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Page 103: Piston Ring Thickness
ENGINE 3-53 PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0 –…
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Page 104: Piston Ring End Gap
3-54 ENGINE PISTON RING FREE END GAP AND PISTON RING END GAP • Measure the piston ring free end gap using the vernier cali- pers. • Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. •…
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Page 105: Crankcase
ENGINE 3-55 CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer screws gearshift fork shaft retainer from the lower crankcase. • Remove the gearshift fork shafts and gearshift forks from the lower crankcase. • Remove the gearshift cam and its bearing GEARSHIFT FORK-TO-GROOVE CLEARANCE •…
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Page 106
3-56 ENGINE GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers. Shift fork thickness: Standard: 4.8 – 4.9 mm (0.189 – 0.193 in) 09900-20102: Vernier calipers GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT BEARING Bearing inspection •… -
Page 107
• Install the oil seal with the special tool. 09913-70210: Bearing installer set (¬22) • Apply grease to the oil seal lip. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the gearshift cam with the bearing… -
Page 108
3-58 ENGINE • Install the gearshift forks and their shafts as shown. For 3rd/4th drive gears For 5th driven gear For 6th driven gear • Apply a small quantity of thread lock to the bearing retainer screws • Tighten the bearing retainer screws and gearshift fork shaft retainer bolt to the specified torque. -
Page 109
ENGINE 3-59 OIL JET Removal • Remove the piston cooling oil jets from the upper crank- case. • Remove the oil jet (for transmission) from the lower crank- case. • Remove the oil jet (for cam chain tension adjuster) from the cylinder head. -
Page 110
3-60 ENGINE Installation • Fit new O-ring to each piston cooling oil jet and apply engine oil to them. Use new O-rings to prevent oil pressure leakage. • Install each piston cooling oil jet with the bolt. NOTE: Apply a small quantity of thread lock to the bolts and tighten them to the specified torque. -
Page 111
ENGINE 3-61 • Remove the water jacket plugs • Remove the oil gallery plugs (for lower crankcase side). Installation • Apply engine coolant to the O-rings of the water jacket plugs • Apply thread lock to the oil gallery plug H 99000-32110: THREAD LOCK SUPER “1322”… -
Page 112: Balancer Shaft
3-62 ENGINE BALANCER SHAFT DISASSEMBLY • Remove the balancer gear along with the dampers from the balancer shaft. INSPECTION • Inspect the damper for wear and damage, replace it if any defects are found. REASSEMBLY • Apply MOLYBDENUM OIL SOLUTION to each part. P MOLYBDENUM OIL SOLUTION •…
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Page 113
ENGINE 3-63 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. Balancer shaft journal oil clearance: Standard: 0.028 –… -
Page 114: Crankshaft And Conrod
3-64 ENGINE INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part » first and press the other end. Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.
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Page 115
ENGINE 3-65 CONROD BIG END SIDE CLEARANCE • Inspect the conrod side clearance by using a thickness gauge. • If the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width. •… -
Page 116
3-66 ENGINE *1: The number faces the intake side. • Remove the bearing caps and measure the width of the com- pressed plastigauge using the envelope scale. This measure- ment should be taken at the widest part of the compressed plastigauge. -
Page 117
ENGINE 3-67 Crank pin O.D. Code O.D. specification 34.992 – 35.000 mm (1.3776 – 1.3780 in) 34.984 – 34.992 mm (1.3773 – 1.3776 in) 34.976 – 34.984 mm (1.3770 – 1.3773 in) 09900-20202: Micrometer (25 – 50 mm) Bearing thickness Color (Part No.) Thickness… -
Page 118: Crankshaft Journal Bearing
3-68 ENGINE CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and middle crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown. 09900-22301: Plastigauge Never rotate the crankshaft when a piece of plasti- gauge is installed.
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Page 119
ENGINE 3-69 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. Crankshaft journal oil clearance: Standard: 0.010 – 0.028 mm (0.0004 – 0.0011 in) Service Limit: 0.080 mm (0.0031 in) •… -
Page 120
3-70 ENGINE Crankshaft journal O.D. specification Code O.D. specification 34.994 – 35.000 mm (1.3777 – 1.3780 in) 34.988 – 34.994 mm (1.3775 – 1.3777 in) 34.982 – 34.988 mm (1.3772 – 1.3775 in) 09900-20202: Micrometer (25 – 50 mm) Bearing thickness specification Color (Part No.) Thickness… -
Page 121: Crankshaft Thrust Bearing
ENGINE 3-71 CRANKSHAFT THRUST BEARING • With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. -: Left-side thrust bearing 3: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.
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Page 122
3-72 ENGINE Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.570 – 2.590 mm Brown 2.480 – 2.500 mm 0.070 – 0.110 mm (0.1012 – 0.1020 in) (12228-48B00-0B0) (0.0976 – 0.0984 in) (0.0028 –… -
Page 123: Engine Reassembly
ENGINE 3-73 ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. •…
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Page 124
3-74 ENGINE • Be sure to bring the concave side of 1st ring to the top when fitting it to the piston. • 2nd ring has letters “T” marked on the side. Be sure to bring the marked side ring to the top when fitting it to the piston. •… -
Page 125
ENGINE 3-75 • Apply a small quantity of MOLYBDENUM OIL SOLUTION to the sliding surface of the pistons and cylinder walls. P MOLYBDENUM OIL SOLUTION NOTE: Be sure to install the pistons in the cylinders from which they were removed in disassembly, referring to the cylinder numbers, “1”… -
Page 126
3-76 ENGINE CRANKSHAFT • Position the No.2 and No.3 conrod big ends on the same side, and the No.1 and No.4 conrod big ends on the opposite side of No.2 and No.3. • Set the crankshaft to the conrods and upper crankcase. •… -
Page 127
ENGINE 3-77 • Apply a MOLYBDENUM OIL SOLUTION to each crankshaft journal and bearing lightly. P MOLYBDENUM OIL SOLUTION • Insert the right and left-thrust bearings with oil groove # fac- ing the crank web. NOTE: Right-thrust bearing has green painting. BALANCER SHAFT •… -
Page 128
3-78 ENGINE • Apply bond to the mating surface of the middle crankcase. D 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: Use of bond is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes. -
Page 129
ENGINE 3-79 • Tighten the other crankcase bolts a little at a time to equalize the pressure. » Crankcase bolt: (M6) Initial: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Final : 11 N·m (1.1 kgf-m, 8.0 lb-ft) (M8) Initial : 15 N·m (1.5 kgf-m, 11.0 lb-ft) Final : 26 N·m (2.6 kgf-m, 19.0 lb-ft) NOTE: Fit a new gasket washer to the crankcase bolt «. -
Page 130
3-80 ENGINE TRANSMISSION • Install the bearing pins and the C-rings on the middle crankcase. • Install the countershaft assembly to the middle crankcase. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. •… -
Page 131
ENGINE 3-81 • Apply bond to the mating surface of the lower crankcase. D 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: Use of bond is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Apply to both mating surfaces of crankcases at hatched parts. -
Page 132
• Check that the countershaft and driveshaft rotate smoothly. OIL STRAINER • Install the O-ring. • Apply grease to the O-ring. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent Use a new O-ring to prevent oil leakage. • Install the oil strainer and tighten the oil strainer bolts to the specified torque. -
Page 133
OIL PRESSURE SWITCH • Apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. D 99000-31140: SUZUKI BOND “1207B” or equivalent » Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft) NOTE: Be careful not to apply bond to the hole of thread end. -
Page 134
• Apply grease to the O-ring. NOTE: Align the gear position switch pin » with the gearshift cam hole X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the gear position switch. • Apply thread lock to the gear position switch bolts. -
Page 135
ENGINE 3-85 WATER PUMP • Apply grease to the O-ring. Use a new O-ring to prevent oil leakage. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the water pump mounting bolts to the specified torque. » Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) -
Page 136
• Apply bond lightly to the mating surfaces at the parting line between the upper and middle crankcases as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent • Install the dowel pins and new gasket Use a new gasket to prevent oil leakage. -
Page 137
• Install the CKP sensor • Apply bond lightly to the groove of signal generator lead wire grommet. D 99000-31140: SUZUKI BOND “1207B” or equivalent CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft. NOTE: When installing the cam chain drive sprocket, align the wide spline teeth «… -
Page 138
• Apply bond lightly to the mating surfaces » at the parting line between the upper and middle crankcases and surface of grommet # as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent • Install a new gasket and dowel pins. -
Page 139
ENGINE 3-89 • Install the starter clutch cover and tighten the bolts. NOTE: * Fit a new gasket washer to the bolt $. Use a new gasket washer to prevent oil leakage. » Starter clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •… -
Page 140
3-90 ENGINE GEARSHIFT SYSTEM • Install the gearshift cam stopper , its bolt , washer return spring NOTE: Apply a small quantity of thread lock to the gearshift cam stop- per bolt and tighten it to the specified torque. H 99000-32110: THREAD LOCK SUPER “1322” or equivalent «… -
Page 141
Use a new O-ring to prevent oil leakage. NOTE: Set the oil pump shaft end » to the water pump shaft. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the oil pump with the oil pump mounting bolts and then tighten them to the specified torque. -
Page 142
3-92 ENGINE • Install the oil pump drive gear to the primary driven gear assembly • Install the primary driven gear assembly NOTE: * If it is difficult to install the primary driven gear, rotate the crankshaft. * Be sure to engage the oil pump driven gear with the drive gear and the primary driven gear with the drive gear. -
Page 143
ENGINE 3-93 • Install the clutch sleeve hub assembly onto the countershaft. • Install the washer and spring washer NOTE: * Before installing the washer , visually inspect the washer surface for wear and damage. If necessary, replace it with a new one. -
Page 144
3-94 ENGINE • Install the clutch push rod into the countershaft. • Install the clutch push piece , bearing and thrust washer to the countershaft. NOTE: Thrust washer is located between the pressure plate and bearing • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. -
Page 145
ENGINE 3-95 *1: Direction of outside *2: Paint DRIVE PLATE: B No. 2 Drive plate..1 pc. [No paint/Friction Piece: 48 pcs/I.D. 111 mm (4.4 in)] C No. 1 Drive plate..8 pcs. [Purple paint/Friction Piece: 36 pcs/I.D. 111 mm (4.4 in)] D No. -
Page 146
CLUTCH COVER • Apply bond lightly to the mating surfaces at the parting line between the upper, middle and lower crankcases as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent • Install gasket and dowel pins. Use a new gasket to prevent oil leakage. -
Page 147
ENGINE 3-97 • Install the clutch cover and tighten its bolts to the specified torque. » Clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: * Fit the clamp to the bolt «. * Fit new gasket washers to the bolts #. Use new gasket washers to prevent oil leakage. -
Page 148
3-98 ENGINE • Tighten the cylinder head bolts to the specified torque. » Cylinder head bolt (M6): 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Fit the gasket and tighten the ECT sensor. » ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •… -
Page 149
ENGINE 3-99 CAMSHAFT • Turn the crankshaft clockwise with the box wrench and align the line » on the starter clutch with the index mark # of valve timing inspection hole while keeping the cam chain pulled upward. Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. -
Page 150
3-100 ENGINE • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked “1” $. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. •… -
Page 151
ENGINE 3-101 • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust, and cam chain guide. • Have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers. -
Page 152
3-102 ENGINE CAM CHAIN TENSION ADJUSTER • Retract the push rod by pushing the stopper • Fit a new gasket “UP” “UP” Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster with “UP” mark faced to the top side. -
Page 153
ENGINE 3-103 23 N·m (2.3 kgf-m, 16.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) -
Page 154
• Install new gaskets to the cylinder head cover. • Apply bond to the cam end caps of the gaskets as shown. D 99000-31140: SUZUKI BOND “1207B” or equivalent Use new gaskets to prevent oil leakage. • Place the cylinder head cover on the cylinder head. -
Page 155
ENGINE 3-105 STARTER MOTOR • Apply grease to the O-ring. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the starter motor » Starter motor mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) ENGINE COOLANT RESERVOIR BRACKET • Install the engine coolant reservoir bracket… -
Page 156: Fi System Diagnosis
FI SYSTEM DIAGNOSIS 4-1 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING …………..4- 3 ELECTRICAL PARTS …………….4- 3 FUSE…………………. 4- 4 SWITCH ………………..4- 4 ECM/VARIOUS SENSORS …………..4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE……4- 6 USING THE MULTI-CIRCUIT TESTER……….4- 9 FI SYSTEM TECHNICAL FEATURES…………
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Page 157
4-2 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION………………4-79 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION ….4-83 “C41” (P2505) ECM/PCM POWER INPUT SIGNAL MALFUNCTION………………4-86 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION …… 4-87 “C44”… -
Page 158: Precautions In Servicing
FI SYSTEM DIAGNOSIS 4-3 PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.
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Page 159: Fuse
4-4 FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
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Page 160
FI SYSTEM DIAGNOSIS 4-5 • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch , or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied. -
Page 161: Electrical Circuit Inspection Procedure
4-6 FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
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Page 162
FI SYSTEM DIAGNOSIS 4-7 Continuity check • Measure resistance across coupler (between the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals • Disconnect the coupler and measure resistance between couplers If no continuity is indicated, the circuit is open between cou- plers . -
Page 163
4-8 FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts. -
Page 164: Using The Multi-Circuit Tester
FI SYSTEM DIAGNOSIS 4-9 USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the probes may cause the inside of the tester to burnout.
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Page 165: Fi System Technical Features
4-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
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Page 166: Compensation Of Injection Time (Volume)
FI SYSTEM DIAGNOSIS 4-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (volume).
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Page 167: Fi System Parts Location
4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION Intake air temperature sensor (IATS) Throttle position sensor (TPS) Secondary throttle position sensor (STPS) Secondary throttle valve actuator (STVA) Exhaust control valve actuator (EXCVA) Fuel pump relay (FP relay) Fuel pump (FP) Crankshaft position sensor (CKPS) Heated oxygen sensor (HO2S) Driving mode selection switch (DMSS)
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Page 168
FI SYSTEM DIAGNOSIS 4-13 — Tip-over sensor (TOS) . Atmospheric pressure sensor (APS) / Engine coolant temperature sensor (ECTS) 0 Camshaft position sensor (CMPS) 1 Gear position switch (GP switch) 2 Speed sensor 3 Cooling fan relay 4 Cooling fan 5 Primary fuel injector 6 Secondary fuel injector 7 Idle speed control valve (ISC valve) -
Page 169: Fi System Wiring Diagram
4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM Speedometer Cooling fan motor Cooling fan relay 15 A Y/BI R/BI Br/Y *1 Immobilizer signal Fuel pump *2 Ignition switch signal Lg/W Lg/G Speed sensor Lg/BI O/BI Gr/W Camshaft position Gr/B sensor (CMPS) Gr/Y Gr/R Secondary…
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Page 170: Ecm Terminal
FI SYSTEM DIAGNOSIS 4-15 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT EXCVA power (MO+) IAP sensor signal (IAPS) Speed sensor signal AP sensor signal (APS) STVA signal (STVA 2A) CKP sensor signal (CKPS–) STVA signal (STVA 1A) Gear position switch signal (GP) —…
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Page 171
4-16 FI SYSTEM DIAGNOSIS TERMINAL TERMINAL CIRCUIT CIRCUIT ISC valve signal (ISC 2A) PAIR control solenoid (PAIR) ISC valve signal (ISC 1B) Secondary injector #4 (#42) ISC valve signal (ISC 1A) Secondary injector #3 (#32) Fuel pump relay (FP relay) Secondary injector #2 (#22) HO2 sensor heater (HO2H) Secondary injector #1 (#12) -
Page 172: Self-Diagnosis Function
FI SYSTEM DIAGNOSIS 4-17 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.
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Page 173: Dealer Mode
4-18 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.
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Page 174
FI SYSTEM DIAGNOSIS 4-19 CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air temperature sensor (IATS) Atmospheric pressure sensor (APS) Tip-over sensor (TOS) Ignition signal #1 (IG coil #1) -
Page 175
4-18 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form. -
Page 176: Tps Adjustment
FI SYSTEM DIAGNOSIS 4-21 TPS ADJUSTMENT 1. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 2. If the throttle position sensor adjustment is necessary, loosen the screw and turn the throttle position sensor and bring the line to the middle.
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Page 177: Fail-Safe Function
4-22 FI SYSTEM DIAGNOSIS FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY CMP sensor When camshaft position signal has…
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Page 178
FI SYSTEM DIAGNOSIS 4-23 STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY Secondary injection signal — “YES” — #2, #3 & #4 cylinders can run. — “YES” — #1, #3 & #4 cylinders can run. — “YES” — #1, #2 & #4 cylinders can run. —… -
Page 179: Fi System Troubleshooting
4-24 FI SYSTEM DIAGNOSIS FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.
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Page 180: Visual Inspection
FI SYSTEM DIAGNOSIS 4-25 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (…
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Page 181: Self-Diagnostic Procedures
4-26 FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory. Such disconnection will erase the memorized information in ECM memory.
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Page 182: Use Of Sds Diagnostic Procedures
FI SYSTEM DIAGNOSIS 4-27 USE OF SDS DIAGNOSTIC PROCEDURES * Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory.
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Page 183: Use Of Sds Diagnosis Reset Procedure
4-28 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
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Page 184: Show Data When Trouble (Displaing Data At The Time Of Dtc)
FI SYSTEM DIAGNOSIS 4-29 SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.
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Page 185: Malfunction Code And Defective Condition
4-30 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.
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Page 186
FI SYSTEM DIAGNOSIS 4-31 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated. -
Page 187
4-32 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated. -
Page 188
FI SYSTEM DIAGNOSIS 4-33 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM FP relay No voltage is applied to the fuel pump, Fuel pump relay, lead wire/cou- although fuel pump relay is turned ON, pler connection, power source to C41 (P0230) or voltage is applied to fuel pump fuel pump relay and fuel injec-… -
Page 189
4-34 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM EXCV EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- actuator lowing voltage. pler 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1675) is indicated. -
Page 190
FI SYSTEM DIAGNOSIS 4-35 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Steering Steering damper control current does Steering damper solenoid valve damper not flow to the solenoid valve. circuit interrupter element solenoid With IG turned ON, ECM detects a fail- shorted, feedback current con- valve ure of internal circuit element. -
Page 191: C11″ (P0340) Cmp Sensor Circuit Malfunction
4-36 FI SYSTEM DIAGNOSIS “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • CMP sensor circuit open or short after receiving the starter signal. • CMP sensor malfunction •…
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Page 192
FI SYSTEM DIAGNOSIS 4-37 6) Under this condition, if a suitable screwdriver touching the pick-up surface of the CMP sensor is moved, the tester read- ing voltage changes (0.8 V and less ↔ 4.3 V and more). Is the voltage OK? ECM coupler (Harness side) (Black) (Gray) -
Page 193: C12″ (P0335) Ckp Sensor Circuit Malfunction
4-38 FI SYSTEM DIAGNOSIS “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip •…
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Page 194
FI SYSTEM DIAGNOSIS 4-39 5) If OK, then check the continuity between each terminal and ground. CKP sensor continuity: ∞ Ω (Infinity) (B – Ground) (G – Ground) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. -
Page 195: C13″ (P0105-H/L) Iap Sensor Circuit Malfunction
4-40 FI SYSTEM DIAGNOSIS “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage < 4.85 V •…
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Page 196
FI SYSTEM DIAGNOSIS 4-41 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Insert the needle pointed probes to the lead wire coupler. 7) Measure the voltage at the R wire and ground.If OK, then measure the voltage at the R wire and B/Br wire. IAP sensor input voltage: 4.5 –…
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Page 197
4-42 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between G/B wire and terminalIf OK, then check the continuity between B/Br wire and ter- minal IAPS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
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Page 198
FI SYSTEM DIAGNOSIS 4-43 7) Disconnect the ECM coupler.Check the continuity between R wire and terminal 9) Also, check the continuity between G/B wire and terminal IAPS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
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Page 199
4-44 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series (check that total — voltage is 4.5 –… -
Page 200: C14″ (P0120-H/L) Tp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-45 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •…
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Page 201
4-46 FI SYSTEM DIAGNOSIS TP sensor input voltage: 4.5 – 5.5 V R – Ground) R – B/Br) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal •… -
Page 202
FI SYSTEM DIAGNOSIS 4-47 Step 1 (When indicating P0120-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler. -
Page 203
4-48 FI SYSTEM DIAGNOSIS Step 2 1) Connect the special tool between TP sensor and its coupler. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the terminals (between P/B and B/Br) by turning the throttle grip. TP sensor output voltage Throttle valve is closed: Approx. -
Page 204: C15″ (P0115-H/L) Ect Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-49 “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction 0.15 V Sensor voltage < 4.85 V •…
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Page 205
4-50 FI SYSTEM DIAGNOSIS ECT sensor voltage: 4.5 – 5.5 V B/Bl – Ground) B/Bl – B/Br) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal •… -
Page 206
FI SYSTEM DIAGNOSIS 4-51 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 4) Disconnect the ECT sensor coupler. -
Page 207
4-52 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance. ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Refer to page 7-7 for details. -
Page 208: C21″ (P0110-H/L) Iat Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-53 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction 0.15 V Sensor voltage < 4.85 V •…
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Page 209
4-54 FI SYSTEM DIAGNOSIS 5) Measure the voltage between Dg wire terminal ground. 6) If OK, then measure the voltage between Dg wire terminal and B/Br wire terminal IAT sensor input voltage: 4.5 – 5.5 V Dg – Ground) Dg –… -
Page 210
FI SYSTEM DIAGNOSIS 4-55 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler. -
Page 211
4-56 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. IAT sensor resistance: Approx. 2.58 kΩ at 20 °C (68 °F) (Terminal – Terminal) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Is the resistance OK? ECM coupler (Harness side) •… -
Page 212: C22″ (P1450-H/L) Ap Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-57 “C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE AP sensor voltage is not within the fol- • Clogged air passage with dust lowing range. • AP sensor circuit open or shorted to ground • AP sensor malfunction 0.5 V Sensor voltage <…
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Page 213
4-58 FI SYSTEM DIAGNOSIS 4) Disconnect the AP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the R wire and B/Br wire AP sensor input voltage: 4.5 –… -
Page 214
FI SYSTEM DIAGNOSIS 4-59 6) Disconnect the ECM coupler. 7) Check the continuity between G/Y wire and terminalIf OK, then check the continuity between B/Br wire and ter- minal APS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
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Page 215
4-60 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler.Check the continuity between R wire and terminal 9) If OK, then check the continuity between G/Y wire and ter- minal APS lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
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Page 216
FI SYSTEM DIAGNOSIS 4-61 Step 3 1) Remove the AP sensor. 2) Connect the vacuum pump gauge to the vacuum port of the AP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect terminal to the ground terminal terminal to the VCC terminal… -
Page 217: C23″ (P1651-H/L) To Sensor Circuit Malfunction
4-62 FI SYSTEM DIAGNOSIS “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON.
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Page 218
FI SYSTEM DIAGNOSIS 4-63 5) Measure the resistance between terminal and terminal TO sensor resistance: 16.5 – 22.3 kΩ (Terminal – Terminal 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Is the resistance OK? Go to Step 2. Replace the TO sensor with a new one. -
Page 219
4-64 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler. -
Page 220: C24″ (P0351), «C25» (P0352), «C26» (P0353) Or «C27» (P0354) Ignition System Malfunction
FI SYSTEM DIAGNOSIS 4-65 Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between B and B/Br wires.
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Page 221: C28″ (P1655) Stv Actuator Circuit Malfunction
4-66 FI SYSTEM DIAGNOSIS “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. •…
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Page 222
FI SYSTEM DIAGNOSIS 4-67 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground. STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between B wire and P wire ) and (between G wire and W/BI wire… -
Page 223
4-68 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 4) Click each button At this time, if an operation sound is heard from the STVA, the function is normal. -
Page 224: C29″ (P1654-H/L) Stp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-69 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short • STP sensor malfunction Difference between actual throttle open- ing and opening calculated by ECM is •…
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Page 225
4-70 FI SYSTEM DIAGNOSIS STP sensor input voltage: 4.5 – 5.5 V R – Ground) R – B/Br) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal •… -
Page 226
FI SYSTEM DIAGNOSIS 4-71 Step 1 (When indicating P1654-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler. -
Page 227
4-72 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between Y wire and… -
Page 228: C31″ (P0705) Gp Switch Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-73 “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No GP switch voltage • GP switch circuit open or short GP switch voltage is not within the following range. • GP switch malfunction • ECM malfunction GP switch voltage 0.6 V Side-stand relay…
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Page 229
4-74 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM coupler (Harness side) • P wire open or shorted to ground (Black) (Gray) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. -
Page 230: C32″ (P0201), «C33» (P0202), «C34» (P0203) Or «C35» (P0204) Primary Fuel Injector Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-75 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short interrupted by 4 times or more continuously. •…
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Page 231
4-76 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground. Primary injector continuity: ∞ Ω (Infinity) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. -
Page 232: C36″ (P1764), «C37» (P1765), «C38» (P1766) Or «C39» (P1767) Secondary Fuel Injector Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-77 “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Some failure exists in the fuel injector signal in a • Injector circuit open or short high load, high revolution condition. •…
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Page 233
4-78 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground. Secondary injector continuity: ∞ Ω (Infinity) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. -
Page 234: C40″ (P0505 Or P0506 And P0507) Isc Valve Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-79 “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground (P0505) unusual. • Power source circuit open Idle speed is lower than the desired idle •…
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Page 235
4-80 FI SYSTEM DIAGNOSIS 4) Disconnect the ISC valve coupler and ECM couplers. 5) Check the continuity between terminals (Y) and , termi- nals (Bl) and , terminals (Br) and , terminals ISC valve continuity: Continuity (?) 09900-25008: Multi-circuit tester set ECM coupler (Harness side) (Black) (Gray) -
Page 236
FI SYSTEM DIAGNOSIS 4-81 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control” 5) Check that the “Spec”… -
Page 237
4-82 FI SYSTEM DIAGNOSIS Check 3 1) Click the button and increase the “Spec” to 1 500 rpm slowly. 2) Check that the “Desired idle speed” is nearly equal to the “Spec” . Also, check that the number of steps in the ISC valve position increases Check 4… -
Page 238: C41″ (P0230-H/L) Fp Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-83 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump • FP relay circuit open or short although FP relay is turned ON, or volt- • FP relay malfunction age is applied to fuel pump, although FP •…
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Page 239
4-84 FI SYSTEM DIAGNOSIS Is the FP relay OK? ECM coupler (Harness side) • Y/B or O/W wire open or short or poor con- (Black) (Gray) nection • Y/R or R/Bl wire open, shorted or poor con- nection • If wire and connection are OK, intermittent trou- ble or faulty ECM. -
Page 240
FI SYSTEM DIAGNOSIS 4-85 Step 1 (When indicating P0230-L:) 1) Turn the ignition switch OFF. 2) Remove the front seat. (8-8) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (5-7) Is the FP relay OK? ECM coupler (Harness side) •… -
Page 241: C41″ (P2505) Ecm/Pcm Power Input Signal Malfunction
4-86 FI SYSTEM DIAGNOSIS “C41” (P2505) ECM/PCM POWER INPUT SIGNAL MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the ECM, • Lead wire/coupler connection of ECM terminal to although the ignition switch is turned (P2505) fuel fuse • Fuel fuse No voltage is applied to the speedome- •…
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Page 242: C42″ (P01650) Ig Switch Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-87 4) Disconnect the ECM couplers. 5) Measure the voltage between terminal and ground. ECM coupler (Harness side) ECM input voltage: Battery voltage (Black) (Gray) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set W Tester knob indication: Voltage () Is the voltage OK? •…
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Page 243: C44″ (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction
4-88 FI SYSTEM DIAGNOSIS “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open to ECM during engine operation and (P0130) running condition. (Sensor voltage < 1.0 V) In other than the above value, C44 (P0130) is indicated.
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Page 244
FI SYSTEM DIAGNOSIS 4-89 7) Disconnect the ECM coupler.Check the continuity between W/G wire and terminal 9) Also, check the continuity between B/Br wire and terminal HO2S lead wire continuity: Continuity (?) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Black) (Gray)
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Page 245
4-90 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM coupler (Harness side) • W/G wire or B/Br wire open or shorted to (Black) (Gray) ground, or poor connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •… -
Page 246
FI SYSTEM DIAGNOSIS 4-91 Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probe to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W (O/W) wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition. -
Page 247: C46″ (P1657-H/L Or P1658) Excv Actuator Circuit Malfunction
4-92 FI SYSTEM DIAGNOSIS “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the • EXCVA maladjusted EXCV actuator. • EXCVA circuit open or short EXCVA position sensor voltage low or •…
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Page 248
FI SYSTEM DIAGNOSIS 4-93 4) Turn the ignition switch ON. 5) Check the operation of the EXCVA (EXCVA operating order: Full close → Full open → 30% open) Is the operation OK? Go to Step 2. Go to Step 6. Step 1 (When indicating P1657-H:) 1) Turn the ignition switch OFF. -
Page 249
4-94 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity. -
Page 250
FI SYSTEM DIAGNOSIS 4-95 Step 1 (When indicating P1658:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA motor coupler for loose or poor con- tacts. Is the contacting OK? Go to Step 6. Loose or poor contacts on the EXCV motor cou- pler 4) After repairing the trouble, clear the DTC using SDS tool. -
Page 251
4-96 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Y wire and ground. EXCVA position sensor continuity: ∞ Ω (Infinity) 3) If OK, then measure the EXCVA position sensor resistance. 4) Connect the EXCVA position sensor coupler. 5) Set the EXCVA to adjustment position. -
Page 252
FI SYSTEM DIAGNOSIS 4-97 Step 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler 3) Measure the EXCVA position sensor output voltage at EXCV fully closed position and fully opened position. 4) Insert the needle pointed probes to the back side of the EXCVA position sensor coupler. -
Page 253
4-98 FI SYSTEM DIAGNOSIS Step 5 1) If the EXCVA position sensor output voltage is 0.5 V and less at EXCV fully closed position, adjust the output voltage to the specified value by turning out the No.1 cable adjuster 2) Repeat the above procedure (Step 4) until the output voltage becomes specified value. -
Page 254
FI SYSTEM DIAGNOSIS 4-99 Step 6 1) Turn the ignition switch OFF. 2) Disconnect the EXCVA motor coupler 3) Apply 12 V to the terminals and check the operation of EXCVA. 12 V 4) Then, switch the wires supplied 12 V and check the operation of EXCVA. -
Page 255
4-100 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Exhaust valve operating control” 4) Click each button At this time, if an operation sound is heard from the EXCVA, the function is normal. -
Page 256: C49″ (P1656) Pair Control Solenoid Valve Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-101 “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction •…
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Page 257
4-102 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground. PAIR valve voltage: Battery voltage O/W – Ground) 09900-25008: Multi-circuit tester set W Tester knob indication: Voltage () Is the voltage OK? ECM coupler (Harness side) •… -
Page 258: C60″ (P0480) Cooling Fan Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-103 “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short • ECM malfunction Engine stop Side-stand Ignition Cooling fan switch relay switch…
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Page 259
4-104 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 4) Click the “Operate” At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal. -
Page 260
FI SYSTEM DIAGNOSIS 4-105 6) Click the “Off” to check the cooling fan relay and cooling fan motor operation. NOTE: This inspection should be begun from when the engine coolant temperature is below 50 °C (122 °F). Check that the cooling fan relay operates for a few seconds as the engine coolant temperature arrives each at 50 °C (122 °F), 70 °C (158 °F) and 90 °C (194 °F)/above 4 000 r/min. -
Page 261: C91″ (P0500) Vehicle Speed Sensor Circuit Malfunction
4-106 FI SYSTEM DIAGNOSIS “C91” (P0500) VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Speedometer does not recieve signal from the vehi- • Speed sensor circuit open or short cle speed sensor for more than 6 sec. when the •…
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Page 262
FI SYSTEM DIAGNOSIS 4-107 5) Under this condition, if a suitable screwdriver touching the pick-up surface of the speed sensor is moved, the tester reading voltage changes (0 V → 12 V or 12 V → 0 V). If the tester reading voltage does not change, replace the speed- ometer sensor with a new one. -
Page 263: C93″ (P1769) Steering Damper Solenoid Valve Circuit Malfunction
4-108 FI SYSTEM DIAGNOSIS “C93” (P1769) STEERING DAMPER SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Steering damper control current does • Steering damper solenoid valve circuit interrupter not flow to the solenoid valve. element shorted With IG turned ON, ECM detects a fail- •…
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Page 264
FI SYSTEM DIAGNOSIS 4-109 3) Disconnect the steering damper solenoid valve coupler. 4) Measure the steering damper solenoid valve resistance. Steering damper solenoid valve resistance: Approx 12.5 Ω at 20 °C (68 °F) 09900-25008: Multi-circuit tester set V Tester knob indication: Resistance (Ω) Is the resistance OK? Go to Step 2. -
Page 265
4-110 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Raise the front wheel off the ground. 3) Turn the ignition switch ON. 4) Click “Steering damper solenoid operating control” 5) Click each button ON/OFF while turning the handlebars left and right. -
Page 266: Sensors
FI SYSTEM DIAGNOSIS 4-111 SENSORS CMP SENSOR INSPECTION The camshaft position sensor is installed on the cylinder head cover. (4-36) CMP SENSOR REMOVAL AND INSTALLATION • Remove the CMP sensor. (3-29) • Install the CMP sensor in the reverse order of removal. CKP SENSOR INSPECTION The crankshaft position sensor is installed on the right side of middle crankcase cover.
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Page 267: Ect Sensor Inspection
4-112 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the cylin- der head. (4-49) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor. (7-7) • Install the ECT sensor in the reverse order of removal. «…
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Page 268: Stp Sensor Inspection
FI SYSTEM DIAGNOSIS 4-113 STP SENSOR INSPECTION The secondary throttle position sensor is installed at the right side of the No.4 throttle body. (4-69) STP SENSOR REMOVAL AND INSTALLATION • Remove the STP sensor. (5-17) • Install the STP sensor in the reverse order of removal. STP SENSOR ADJUSTMENT •…
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Page 269: Fuel System And Throttle
FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM…………….5- 2 FUEL SYSTEM………………… 5- 3 FUEL TANK LIFT-UP …………….5- 3 FUEL TANK REMOVAL……………. 5- 4 FUEL TANK INSTALLATION …………… 5- 4 FUEL PRESSURE INSPECTION …………5- 5 FUEL PUMP INSPECTION …………..
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Page 270: Fuel Delivery System
5-2 FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injectors installed in the fuel delivery pipe.
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Page 271: Fuel System
FUEL SYSTEM AND THROTTLE BODY 5-3 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seats. (8-8 and -9) • Remove the fuel tank side covers. (8-8) • Take out the fuel tank prop stay • Remove the fuel tank bolt. •…
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Page 272: Fuel Tank Removal
5-4 FUEL SYSTEM AND THROTTLE BODY FUEL TANK REMOVAL • Lift and support the fuel tank. (5-3) • Disconnect the fuel pump lead wire coupler • Disconnect the fuel tank drain hose and fuel tank breather hose (Except for E-33). •…
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Page 273: Fuel Pressure Inspection
FUEL SYSTEM AND THROTTLE BODY 5-5 FUEL PRESSURE INSPECTION • Lift and support the fuel tank. (5-3) • Place a rag under the fuel feed hose • Remove the fuel feed hose. • Install the special tools between the fuel tank and fuel delivery pipe.
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Page 274: Fuel Pump Inspection
5-6 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor.
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Page 275: Fuel Pump Relay Inspection
FUEL SYSTEM AND THROTTLE BODY 5-7 • Connect proper lead wires to the fuel pump lead wire coupler (fuel pump side) and apply 12 V to the fuel pump (between Y/R wire and B/W wire) for 10 seconds and measure the amount of fuel discharged.
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Page 276: Fuel Pump And Fuel Filter Removal
5-8 FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION » Fuel level gauge Fuel pump case Fuel filter cartridge Fuel mesh filter ITEM N·m kgf-m lb-ft » Fuel outlet joint O-ring O-ring O-ring » Fuel pump mounting bolt Fuel pump…
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Page 277
FUEL SYSTEM AND THROTTLE BODY 5-9 REMOVAL • Remove the fuel tank. (5-4) • Remove the fuel pump assembly by removing its mounting bolts diagonally. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Disconnect the lead wires (R and B). •… -
Page 278: Fuel Mesh Filter Inspection And Cleaning
5-10 FUEL SYSTEM AND THROTTLE BODY • Remove the O-ring • Remove the nut • Remove the fuel pump plate • Remove the fuel mesh filter • Remove the fuel pump from the case. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.
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Page 279: Fuel Pump And Fuel Mesh Filter Installation
FUEL SYSTEM AND THROTTLE BODY 5-11 FUEL PUMP AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh filter in the reverse order of removal. Pay attention to the following points: • Replace the O-rings with new ones. Use new O-rings to prevent fuel leakage.
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Page 280
5-12 FUEL SYSTEM AND THROTTLE BODY • Install a new O-ring and apply grease to it. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The O-ring must be replaced with a new one to prevent fuel leakage. • Install the clamp to the bolt •… -
Page 281: Throttle Body
FUEL SYSTEM AND THROTTLE BODY 5-13 THROTTLE BODY CONSTRUCTION Only for E-33 TP sensor Cushion seal STP sensor ISC valve » STVA EVAP purge control solenoid valve Fuel delivery pipe Vacuum hose ITEM N·m kgf-m lb-ft » Fuel delivery pipe mounting screw «…
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Page 282: Air Cleaner Box Removal
5-14 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX REMOVAL • Lift and support the fuel tank. (5-3) • Disconnect the PAIR hose , IAT sensor lead wire coupler and IAP sensor • Loosen the throttle body clamp screw (RH). •…
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Page 283: Throttle Body Removal
FUEL SYSTEM AND THROTTLE BODY 5-15 THROTTLE BODY REMOVAL • Remove the air cleaner box. (5-14) • Disconnect the throttle cables from their drum. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body.
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Page 284: Throttle Body Disassembly
5-16 FUEL SYSTEM AND THROTTLE BODY • Remove the fasteners on the main frame. (LH and RH) • Loosen the throttle body clamp screws at the intake pipe side. • Remove the throttle body assembly. THROTTLE BODY DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.
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Page 285
FUEL SYSTEM AND THROTTLE BODY 5-17 • Remove the fuel pipe from the primary injectors. • Disassemble the fuel delivery pipe assembly. • Remove the ISC valve hoses • Remove the ISC valve • Remove the TP sensor and STP sensor with the special tool. -
Page 286
5-18 FUEL SYSTEM AND THROTTLE BODY Never remove the secondary throttle valves throttle valves * These adjusting screws ( , ) are fac- tory-adjusted at the time of delivery and do not turn or remove them. * Do not separate the throttle body. -
Page 287: Throttle Body Cleaning
FUEL SYSTEM AND THROTTLE BODY 5-19 THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean passageways (except for main bore) with a spray-type carburetor cleaner and blow dry with compressed air.
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Page 288: Throttle Body Reassembly
* Align the secondary throttle shaft end » with the groove # of STP sensor. * Apply grease to the secondary throttle shaft end » if neces- sary. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent 09930-11950: Torx wrench » STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5lb-ft)
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Page 289
FUEL SYSTEM AND THROTTLE BODY 5-21 • Apply thin coat of engine oil to the new O-rings and cush- ion seals Replace the O-rings and cushion seals with new ones. • Assemble the fuel delivery pipes as shown. Be careful not to twist the fuel delivery pipe T-joint when installing the fuel delivery pipes, or joint part &… -
Page 290: Throttle Body Installation
5-22 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector.
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Page 291: Stp Sensor Adjustment
FUEL SYSTEM AND THROTTLE BODY 5-23 STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor output voltage and adjust the STP sensor position as follows: • Disconnect the STVA lead wire coupler. • Remove the air cleaner box cover. (2-4) •…
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Page 292: Fuel Injector Removal
5-24 FUEL SYSTEM AND THROTTLE BODY FUEL INJECTOR REMOVAL • Remove the air cleaner box. (5-14) • With battery negative cable disconnected, disconnect the injector couplers. • Remove the fuel delivery pipe assemblies. (5-16) • Remove the primary and secondary fuel injectors #1, #2, #3 and #4.
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Page 293: Isc Valve Removal
FUEL SYSTEM AND THROTTLE BODY 5-25 ISC VALVE REMOVAL • Remove the air cleaner box. (5-14) • Disconnect the ISC valve coupler Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned OFF. If the ECM coupler or ISC valve coupler is discon- nected within 5 seconds after ignition switch is turned OFF, there is a possibility of an unusual valve position…
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Page 294: Isc Valve Pre-Set
5-26 FUEL SYSTEM AND THROTTLE BODY ISC VALVE PRE-SET When removing or replacing the ISC valve, set the ISC valve in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tool. (4-27) 3) Click “Active control”. 4) Click “ISC learned value reset”…
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Page 295: Throttle Valve Synchronization
FUEL SYSTEM AND THROTTLE BODY 5-27 THROTTLE VALVE SYNCHRONIZATION USE OF SDS TOOL Check and adjust the throttle valve synchronization among four cylinders. Step 1 • Lift and support the fuel tank. (5-3) • Disconnect the respective vacuum hoses from each vac- uum nipple.
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Page 296
5-28 FUEL SYSTEM AND THROTTLE BODY • Click “Active control”. • Click “ISC air volume control” • Click “ON” to fix the ISC air volume of four cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 70 – 100 °C (158 – 212 °F). «… -
Page 297
FUEL SYSTEM AND THROTTLE BODY 5-29 • Repeat the procedures of Step 2. • Disconnect the vacuum tester and install the removed parts. • After completing the throttle valve synchronization, clear the DTC and reset the ISC learned value using SDS tool. (4-28 and 5-26) USE OF MODE SELECT SWITCH The following procedure discribes only defference between use… -
Page 298
EXHAUST SYSTEM 6-1 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM………………6- 2 EXHAUST CONTROL SYSTEM …………6- 2 OPERATION………………6- 3 EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)…………6- 4 EXCVA REMOVAL…………….6- 4 EXCVA PULLEY INSPECTION…………. 6- 5 EXCVA INSTALLATION …………… -
Page 299: Exhaust System
6-2 EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exhaust control system (EXCS) consists of the exhaust control valve (EXCV), exhaust control valve actuator (EXCVA) and exhaust control valve cables (EXCV cables). EXCV is installed in the exhaust pipe. EXCVA is mounted inside of the right frame. The EXCV is operated by the EXCVA via the cables.
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Page 300: Operation
EXHAUST SYSTEM 6-3 OPERATION The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then the ECM determines the EXCV opening angle based on the engine rpm and gear positions.
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Page 301: Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)
6-4 EXHAUST SYSTEM EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA REMOVAL • Turn the ignition switch OFF. • Lift and support the fuel tank. (5-3) • Remove the right under cowling. (8-5) • Connect the special tool (Mode select switch) to the dealer mode coupler.
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Page 302: Excva Pulley Inspection
EXHAUST SYSTEM 6-5 • Disconnect the No.2 cable and then No.1 cable from the pulley. • Remove the EXCVA. • Hold the EXCVA pulley with an adjustable wrench, and loosen the pulley mounting bolt. * When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.
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Page 303: Excva Installation
6-6 EXHAUST SYSTEM EXCVA INSTALLATION • Install the EXCVA pulley to the shaft. NOTE: Align the shaft’s line » and cable slots # as shown. • Hold the EXCVA pulley with an adjustable wrench, and then tighten the EXCVA pulley mounting bolt to the specified torque.
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Page 304: Excva Inspection
EXHAUST SYSTEM 6-7 in or out until the thread length $ • Turn the adjuster becomes the measured value before disconnecting the No.1 cable • Tighten the lock-nut in or out until the thread length % • Turn the adjuster becomes the measured value before disconnecting the No.2 cable •…
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Page 305
6-8 EXHAUST SYSTEM • Connect the EXCV cables (No.1 and No.2) temporarily to the EXCV pulley. • Make the No. 1 cable (21H0CL) straight and turn the No. 1 in or out until the inner cable length » cable adjuster becomes 44 –… -
Page 306
EXHAUST SYSTEM 6-9 44 – 45 mm (1.73 – 1.77 in) 60 – 61 mm (2.36 – 2.40 in) No.1 No.2 * When adjusting the No.1 and No.2 cables, the cable slots of EXCVA pulley must be located to adjustment position. * Do not use the adjustable wrench to turn EXCVA pulley so as not to cause damage to the internal gear of EXCVA. -
Page 307: Excva Adjustment
6-10 EXHAUST SYSTEM EXCVA ADJUSTMENT 1st step: • Set the EXCVA to adjustment position. (6-4) 2nd step: • Turn the mode select switch OFF. • Turn the ignition switch ON to check the EXCVA operation. • Turn the mode select switch ON. •…
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Page 308
EXHAUST SYSTEM 6-11 • Turn the ignition switch ON. • Measure the EXCVA position sensor output voltage at fully closed position. Position sensor output voltage: EXCV is fully closed: 0.45 output voltage 1.4 V ( Y – B/Br) 09900-25008: Multi circuit tester set 09900-25009: Needle pointed probe set W Tester knob indication: Voltage () -
Page 309: Muffler, Muffler Chamber And Excv/Exhaust Pipe Removal
6-12 EXHAUST SYSTEM If the measured voltage is more than specification, adjust the No.2 cable adjuster as follows: • Set the EXCVA to adjustment position. (6-4) Adjusting the No.2 cable with the EXCV fully opened can damage the EXCVA. Be sure to adjust the No.2 cable with the EXCV set in adjustment position.
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Page 310
EXHAUST SYSTEM 6-13 • Remove the No.1 muffler joint cover • Separate the muffler and muffler joint • Remove the gasket and O-rings from the muffler. • Remove the under cowlings. (8-5) • Disconnect the HO2 sensor lead wire coupler •… -
Page 311
6-14 EXHAUST SYSTEM • Remove the EXCV cable bracket nut. • Disconnect the EXCV cables from the EXCV pulley. • Remove the side cowlings. (8-6) • Move the radiator and oil cooler forward. • Disconnect one of the oil cooler hose from the oil cooler. -
Page 312: Excv Inspection
EXHAUST SYSTEM 6-15 EXCV INSPECTION • Turn the EXCV by hand and check that it moves smoothly. • If it does not move smoothly, replace the EXCV together with the exhaust pipe assembly. • Decarbonize the EXCV if necessary. * Do not attempt to disassemble the EXCV. * The EXCV is available only as the exhaust pipe assembly.
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Page 313: Muffler, Muffler Chamber And Excv/Exhaust Pipe Installation
6-16 EXHAUST SYSTEM MUFFLER, MUFFLER CHAMBER AND EXCV/EXHAUST PIPE INSTALLATION Install the EXCV/exhaust pipe, muffler chamber and mufflers in the reverse order of removal. Pay attention to the following points: Replace the gaskets, connectors and O-rings with new ones. • Tighten each bolt/nut to the specified torque. 25 N·m (2.5 kgf-m, 18.0 lb-ft) Clamp 25 N·m…
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Page 314: Cooling And Lubrication System
COOLING AND LUBRICATION SYSTEM 7-1 COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ………………7- 2 COOLING CIRCUIT ………………7- 3 COOLING CIRCUIT INSPECTION…………7- 3 RADIATOR AND WATER HOSES ………….. 7- 4 RADIATOR REMOVAL …………….. 7- 4 RADIATOR CAP INSPECTION…………. 7- 4 RADIATOR INSPECTION AND CLEANING………
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Page 315: Engine Coolant
7-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).
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Page 316: Cooling Circuit
COOLING AND LUBRICATION SYSTEM 7-3 COOLING CIRCUIT RESERVOIR ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER RADIATOR WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the right under cowling. (8-5) •…
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Page 317: Radiator And Water Hoses
7-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowlings. (8-5) • Drain the engine coolant. (2-18) • Remove the radiator assembly. (3-4) • Remove the cooling fan from the radiator. RADIATOR CAP INSPECTION •…
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Page 318: Radiator Installation
COOLING AND LUBRICATION SYSTEM 7-5 RADIATOR INSTALLATION • Install the cooling fan. » Cooling fan mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) • Install the radiator. • Route the radiator hoses properly. (10-20) • Pour engine coolant. (2-18) • Bleed air from the cooling circuit. (2-19) •…
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Page 319: Cooling Fan
7-6 COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the cooling fan. (7-4) INSPECTION • Remove the right under cowling. (8-5) • Disconnect the cooling fan coupler • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration.
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Page 320: Cooling Fan Relay Inspection
COOLING AND LUBRICATION SYSTEM 7-7 COOLING FAN RELAY INSPECTION Cooling fan relay is located under the front seat. • Remove the front seat. (8-8) • Remove the cooling fan relay First check the insulation between » and # terminals with tester.
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Page 321: Installation
7-8 COOLING AND LUBRICATION SYSTEM • If the ECT sensor ohmic value does not change in the propor- tion indicated, replace it with a new one. Temperature sensor specification Temperature Standard resistance 20 °C (68 °F) Approx. 2.45 kΩ 50 °C (122 °F) Approx.
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Page 322: Thermostat
COOLING AND LUBRICATION SYSTEM 7-9 THERMOSTAT REMOVAL • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Place a rag under the thermostat cover. • Remove the thermostat cover • Remove the thermostat INSPECTION Inspect the thermostat pellet for signs of cracking.
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Page 323: Installation
7-10 COOLING AND LUBRICATION SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in). Thermostat valve lift «: Standard: 8.0 mm and over at 95 °C (0.31 in and over at 203 °F) •…
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Page 324: Water Pump
COOLING AND LUBRICATION SYSTEM 7-11 WATER PUMP REMOVAL AND DISASSEMBLY NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer.
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Page 325
7-12 COOLING AND LUBRICATION SYSTEM • Remove the water pump cover and clamp • Holding the impeller with water pump pliers, remove the impeller securing bolt. • Remove the mechanical seal ring and rubber seal from the impeller. • Remove the impeller shaft and washer •… -
Page 326: Inspection
COOLING AND LUBRICATION SYSTEM 7-13 • Remove the oil seal NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. The removed oil seal must be replaced with a new one. INSPECTION MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face.
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Page 327: Reassembly And Installation
The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the grease to the oil seal lip. X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the new mechanical seal using a suitable size socket wrench.
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Page 328
NOTE: * Apply engine coolant to the O-ring * Apply grease to the O-ring X 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the water pump cover screws to the specified torque. » Water pump cover screw: 5 N·m (0.5 kgf-m, 3.5 lb-ft) NOTE: Fit the clamp &… -
Page 329
7-16 COOLING AND LUBRICATION SYSTEM • Install the water pump. NOTE: Set the water pump shaft end ‘ to the oil pump shaft ( as shown. 8 N·m (0.8 kgf-m, 6.0 lb-ft) • Tighten the water pump mounting bolts to the specified torque. -
Page 330: Lubrication System
COOLING AND LUBRICATION SYSTEM 7-17 LUBRICATION SYSTEM OIL PRESSURE 2-33 OIL FILTER 2-13 OIL PRESSURE REGULATOR 3-47 OIL STRAINER 3-47 OIL JET 3-59 OIL PUMP 3-44 OIL PRESSURE SWITCH 9-34 OIL COOLER REMOVAL • Remove the under cowlings. (8-5) • Drain the engine oil. (2-12) •…
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Page 331
7-18 COOLING AND LUBRICATION SYSTEM INSPECTION AND CLEANING • Road dirt or trash stuck to the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. -
Page 332: Engine Lubrication System Chart
COOLING AND LUBRICATION SYSTEM 7-19 ENGINE LUBRICATION SYSTEM CHART INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER CAM CHAIN OIL JET CAMSHAFT JOURNALS, TENSION ADJUSTER CAMFACES AND TAPPETS EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER CAMSHAFT JOURNALS, CAM DRIVE CHAIN CAMFACES AND TAPPETS STARTER CLUTCH BALANCER SHAFT BEARING…
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Page 333: Engine Lubrication System
7-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM To sub- To sub- gallery gallery MAIN GALLERY…
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Page 334
COOLING AND LUBRICATION SYSTEM 7-21 SUB-GALLERY VIEW OF A MAIN GALLERY To transmission… -
Page 335
CHASSIS 8-1 CHASSIS CONTENTS EXTERIOR PARTS ………………8- 3 FASTENER REMOVAL AND INSTALLATION……..8- 3 LOWER BRACKET COVER …………..8- 5 UNDER COWLING …………….8- 5 SIDE COWLING ………………8- 6 BODY COWLING COVER…………..8- 6 SCREEN ………………..8- 7 BODY COWLING ……………… -
Page 336
8-2 CHASSIS CHASSIS CONTENTS REAR SUSPENSION ………………. 8-55 CONSTRUCTION ……………… 8-55 REMOVAL ………………… 8-56 INSPECTION AND DISASSEMBLY …………. 8-58 REASSEMBLY ………………8-61 INSTALLATION………………8-63 FINAL INSPECTION AND ADJUSTMENT ……….. 8-64 FRONT BRAKE……………….. 8-65 CONSTRUCTION ……………… 8-65 BRAKE PAD REPLACEMENT …………. 8-66 BRAKE FLUID REPLACEMENT ………… -
Page 337: Exterior Parts
CHASSIS 8-3 EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece . • Pull out the fastener Installation • Let the center piece stick out toward the head so that the pawls close.
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Page 338
8-4 CHASSIS Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl from damage, insert the fastener all the way into the installation hole. • Push in the head of center piece. -
Page 339: Lower Bracket Cover
CHASSIS 8-5 LOWER BRACKET COVER REMOVAL • Remove the lower bracket cover by removing the bolts. INSTALLATION • Install the lower bracket cover in the reverse order of removal. UNDER COWLING REMOVAL • Remove the fasteners and bolts. • Remove the under cowlings . (LH/RH) •…
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Page 340: Side Cowling
8-6 CHASSIS SIDE COWLING REMOVAL NOTE: The left and right side cowlings are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. • Remove the under cowling. ( 8-5) • Remove the body cowling cover fasteners and . •…
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Page 341: Screen
CHASSIS 8-7 SCREEN REMOVAL • Remove the screws. • Remove the combination meter . ( 9-29) • Disconnect the turnsignal lead wire couplers. • Remove the rear view mirrors/turn signals . • Remove the screen . INSTALLATION • Install the screen in the reverse order of removal. •…
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Page 342: Air Intake Pipe
8-8 CHASSIS AIR INTAKE PIPE REMOVAL • Remove the body cowling. ( 8-7) • Remove the side cowling (-s) . ( 8-6) • Remove the air intake pipe (-s) . (LH/RH) INSTALLATION • Install the air intake pipe (-s) in the reverse order of removal. COWLING BRACE REMOVAL •…
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Page 343: Rear Seat/Seat Tail Cover
CHASSIS 8-9 REAR SEAT/SEAT TAIL COVER REMOVAL • Remove the rear seat (seat tail cover) using the ignition key. INSTALLATION • Insert the seat hook to the guide and push down the seat (seat tail cover) firmly until the seat (seat tail cover) snaps into the locked position.
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Page 344: Front Wheel
8-10 CHASSIS FRONT WHEEL CONSTRUCTION Brake disc Front axle » Collar Front wheel ITEM N·m kgf-m lb-ft Dust seal » Front axle bolt » 10.0 72.5 Bearing # Brake disc bolt 23.0 16.5 Spacer…
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Page 345: Removal
CHASSIS 8-11 REMOVAL • Remove the brake calipers. (LH and RH) Do not operate the brake lever with the caliper removed. • Loosen two axle pinch bolts on the right front fork leg. • Remove the front axle bolt . •…
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Page 346: Inspection And Disassembly
8-12 CHASSIS INSPECTION AND DISASSEMBLY • Remove the brake discs. (LH and RH) TIRE INSPECTION ( 2-27 and 8-93) BRAKE DISC INSPECTION ( 8-71) • Remove the dust seals on both sides with the special tool. 09913-50121: Oil seal remover The removed dust seals must be replaced with new ones.
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Page 347
CHASSIS 8-13 • Remove the wheel bearings with the special tool. 09921-20240: Bearing remover set The removed bearings must be replaced with new ones. • Remove the spacer . -
Page 348: Reassembly And Installation
100 N·m (10.0 kgf-m, 72.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 39 N·m (3.9 kgf-m, 28.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) WHEEL BEARING • Apply grease to the wheel bearings. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…
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Page 349
• Install the dust seal with the special tool. 09913-70210: Bearing installer set • Apply grease to the dust seal lip. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent BRAKE DISC • Make sure that the brake disc is clean and free of any greasy matter. -
Page 350
8-16 CHASSIS • Install the collar to the right side of wheel. WHEEL • Install the front wheel with the front axle and hand-tighten the front axle bolt temporarily. The directional arrow mark on the tire should point to the wheel rotation, when remounting the wheel. -
Page 351
CHASSIS 8-17 • Move the front fork up and down 4 or 5 times. • Tighten two axle pinch bolts on the left front fork leg to the specified torque. » Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) -
Page 352: Front Fork
8-18 CHASSIS FRONT FORK CONSTRUCTION O-ring Oil seal Spring retainer Oil seal stopper ring Spacer Dust seal Washer » Inner tube Spring » Front fork cap bolt ITEM N·m kgf-m lb-ft Adjuster rod # Lock-nut «…
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Page 353: Removal And Disassembly
CHASSIS 8-19 REMOVAL AND DISASSEMBLY NOTE: * The left and right front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. * When the brake caliper is removed, care must be used so as not to cause stress to the brake hose.
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Page 354
8-20 CHASSIS • Remove the front fork cap bolt from the inner rod by loosening the lock-nut. • Compress the fork spring with the special tool » and remove the special tools » and #. • Remove the front fork cap bolt , adjuster rod , spring retainer , spacer , washer and spring . -
Page 355
CHASSIS 8-21 • Remove the inner rod/damper rod (cartridge) Do not disassemble the inner rod/damper rod (car- tridge). • Slide the outer tube to remove it from the inner tube. NOTE: Be careful not to damage the “ANTI-FRICTION” metals. • Remove the dust seal and oil seal stopper ring •… -
Page 356: Inspection
8-22 CHASSIS INSPECTION INNER AND OUTER TUBES • Inspect the inner tube outer surface and outer tube inner sur- face for scratches. • Inspect the “ANTI-FRICTION” metal surfaces for scratches. • If any defects are found, replace them with the new ones. Do not remove the “ANTI-FRICTION”…
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Page 357: Reassembly
CHASSIS 8-23 REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. Dust seal Oil seal stopper ring Oil seal…
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Page 358
• Pour specified front fork oil up to the top level of the outer tube. Capacity (each leg): 512 ml (17.3/18.0 US/lmp oz) 99000-99044-L01: SUZUKI FORK OIL L01 or equivalent • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil. -
Page 359
CHASSIS 8-25 • Refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until no more bubbles come out from the oil. • Keep the front fork vertically and wait 5 – 6 minutes. NOTE: * Always keep oil level over the cartridge top end, or air may enter the cartridge during this procedure. -
Page 360
8-26 CHASSIS FRONT FORK CAP BOLT • Pull up the inner rod with the special tool «. • Compress the spring with the special tool # and then insert the special tool $ between the lock-nut and the spacer. 09940-52841: Inner rod holder » 09940-94930: Front fork spacer holder # 09940-94922: Stopper plate $ •… -
Page 361: Installation
CHASSIS 8-27 INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Set the upper surface of the outer tube height » at 7.0 mm (0.276 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts to the specified torque.
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Page 362: Front Suspension Setting
8-28 CHASSIS FRONT SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and three kinds of damping force as follows. SPRING PRE-LOAD ADJUSTMENT There are five grooved lines on the side of the spring adjuster. Position 0 provides the maximum spring pre-load and position 5 provides the minimum spring pre-load.
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Page 363: Steering Damper
CHASSIS 8-29 STEERING DAMPER CONSTRUCTION Steering damper » Convex curve side of the washer Dust seal faces down side. ITEM N·m kgf-m lb-ft Steering stem head nut » Damper rod bolt «# 16.5 # Damper rod nut 65.0…
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Page 364: Removal
8-30 CHASSIS REMOVAL • Turn the ignition switch OFF. • Disconnect the steering damper solenoid coupler . • Remove the lower bracket cover. ( 8-5) • Remove the nut by holding the nut . • Remove the bolt . •…
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Page 365: Installation
Install the steering damper in the reverse order of removal. Pay attention to the following points: • Apply grease to the bearings and dust seals. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the steering damper and tighten the bolt and nut .
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Page 366: Steering
8-32 CHASSIS STEERING CONSTRUCTION Steering stem upper bracket Steering stem lower bracket » handlebars » Steering stem head nut ITEM N·m kgf-m lb-ft Steering stem nut # Steering stem lock-nut » 65.0 Dust seal cover $ Front fork upper clamp bolt 65.0 Dust seal…
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Page 367: Removal
CHASSIS 8-33 REMOVAL • Remove the under cowlings. ( 8-5) • Support the motorcycle with a jack or a wooden block. * Do not work by using side-stand. * Do not support the motorcycle with the exhaust pipes. * Make sure that the motorcycle is supported securely. •…
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Page 368: Inspection And Disassembly
8-34 CHASSIS • Remove the dust seal cover , dust seal , steering stem upper bearing inner race and bearing . INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebar distortion * Race wear and brinelling * Bearing wear or damage * Abnormal noise of bearing If any abnormal points are found, replace defective parts with…
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Page 369: Reassembly
BEARING • Apply grease to the bearings and bearing races. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race.
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Page 370
8-36 CHASSIS • Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will be 1/4 – 1/2 turn seated properly. • Loosen the stem nut by 1/4 – 1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle. -
Page 371: Steering Tension Adjustment
CHASSIS 8-37 STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). •…
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Page 372: Handlebars
8-38 CHASSIS HANDLEBARS CONSTRUCTION Left handle grip Handlebar (RH) Throttle grip Handlebar (LH) » Left handle switch » Handlebar clamp bolt ITEM N·m kgf-m lb-ft Right handle switch » 16.5 REMOVAL • Remove the front brake master cylinder . •…
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Page 373
CHASSIS 8-39 • Remove the clutch master cylinder . ( 8-89) • Remove the left handle switch . • Remove the handle balancer . • Loosen the handlebar clamp bolts and front fork upper clamp bolts. (LH and RH) • Remove the steering stem head nut . •… -
Page 374: Installation
8-40 CHASSIS INSTALLATION Install the handlebars in the reverse order of removal. Pay atten- tion to the following points: • Install the handlebars temporarily. • Install the steering stem upper bracket, washer and head nut. 8-36) • Insert the protrusion » of the handlebars into the hole # of the steering stem upper bracket.
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Page 375
CHASSIS 8-41 • Apply grease onto the right handlebar before installing the throttle grip. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply grease to the throttle cables and cable drum. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • When remounting the right and left handle switches, engage the stopper with the handlebar hole. -
Page 376: Rear Wheel
8-42 CHASSIS REAR WHEEL CONSTRUCTION Rear axle Wheel damper Brake disc Sprocket mounting drum Collar Sprocket » Dust seal » Brake disc bolt ITEM N·m kgf-m lb-ft Rear wheel # Rear sprocket nut «…
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Page 377: Removal
CHASSIS 8-43 REMOVAL • Loosen the axle nut . • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. • Remove the rear wheel by disengaging the drive chain. Do not operate the brake pedal with the rear wheel removed.
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Page 378: Inspection And Disassembly
8-44 CHASSIS • Remove the dust seal with the special tool. 09913-50121: Oil seal remover The removed dust seal must be replaced with a new one. • Remove the dust seal with the special tool. 09913-50121: Oil seal remover The removed dust seal must be replaced with a new one.
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Page 379
CHASSIS 8-45 SPROCKET • Inspect the sprocket teeth for wear. • If they are worn as shown, replace the two sprockets and drive chain as a set. » Normal wear # Excessive wear BEARINGS • Inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place. -
Page 380: Reassembly And Installation
8-46 CHASSIS REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: 100 N·m (10.0 kgf-m, 72.5 lb-ft) 33 N·m (3.3 kgf-m, 24.0 lb-ft) 60 N·m (6.0 kgf-m, 43.5 lb-ft) 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) 35 N·m (3.5 kgf-m, 25.5 lb-ft)
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Page 381
CHASSIS 8-47 BEARINGS • Apply grease to the bearings before installing them. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install a new bearing to the sprocket mounting drum with the special tool. 09924-84510: Bearing installer set • First install the right wheel bearing, then install the left one with the special tools. -
Page 382
• Install new dust seal with the special tool. 09913-70210: Bearing installer set • Apply grease to the dust seal lip before assembling rear wheel. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent REAR SPROCKET AND SPROCKET MOUNTING DRUM • Install the rear sprocket mounting drum spacer . -
Page 383
CHASSIS 8-49 • Tighten the sprocket mounting nuts to the specified torque. » Rear sprocket nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) NOTE: Stamped mark » on the sprocket should face outside. • Install the collar . BRAKE DISC • Apply THREAD LOCK to the disc bolts and tighten them to the specified torque. -
Page 384: Rear Shock Absorber
8-50 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION Right Left » Rear shock absorber mount- Rear shock absorber » ing bolt/nut ITEM N·m kgf-m lb-ft » Rear shock absorber bracket 36.0 Rear shock absorber bracket 11.5 83.0…
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Page 385: Removal
CHASSIS 8-51 REMOVAL • Remove the mufflers and muffler chamber. ( 6-12) • Support the motorcycle with a jack to relieve load on the rear shock absorber. • Remove the muffler chamber brackets . • Remove the rear shock absorber upper and lower mounting bolts and nuts.
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Page 386: Rear Shock Absorber Disposal
8-52 CHASSIS REAR SHOCK ABSORBER DISPOSAL * The rear shock absorber unit contains high-pressure nitrogen gas. * Mishandling can cause explosion. * Keep away from fire and heat. High gas pressure caused by heat can cause an explosion. * Release gas pressure before disposing. GAS PRESSURE RELEASE The rear cushion damper unit contains high-pressure nitrogen gas.
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Page 387: Installation
CHASSIS 8-53 INSTALLATION Remount the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber upper/lower mounting bolts and nuts. » Rear shock absorber mounting nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •…
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Page 388
8-54 CHASSIS Compression damping force (High speed) Fully turn the compression damping force (High speed) adjuster clockwise. From that position (stiffest), turn it out to the stan- dard setting position. STD position: 3 turns out from stiffest position Compression damping force (Low speed) Fully turn the compression damping force (Low speed) adjuster clockwise. -
Page 389: Rear Suspension
CHASSIS 8-55 REAR SUSPENSION CONSTRUCTION Rear shock absorber » Swingarm pivot boss (LH) Rear cushion rod » Rear shock absorber mounting » Rear cushion lever bolt/nut ITEM N·m kgf-m lb-ft Spacer # Rear cushion lever bolt/nut «…
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Page 390: Removal
8-56 CHASSIS REMOVAL • Cut the drive chain. ( 8-97) NOTE: It is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • Remove the rear wheel. ( 8-43) • Remove the brake hose guide . •…
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Page 391
CHASSIS 8-57 • Remove the rear fender (lower) . • Remove the chain case . • Remove the chain buffer . SWINGARM PIVOT BOSS REMOVAL AND INSTALLATION • Remove the swingarm. ( 8-56) • Remove the swingarm pivot boss nut . NOTE: Remove the swingarm pivot boss when only replacing it. -
Page 392: Inspection And Disassembly
8-58 CHASSIS INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm. • Remove the spacers from the cushion lever and cushion rod. • Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones. SWINGARM BEARING •…
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Page 393
CHASSIS 8-59 CUSHION LEVER BEARING • Insert the spacer into bearing and check the play when mov- ing the spacer up and down. • If excessive play is noted, replace the bearing with a new one. • Remove the cushion lever bearings with the special tool. 09921-20240: Bearing remover set ( 20 mm) ( 17 mm) The removed bearings must be replaced with new… -
Page 394
8-60 CHASSIS CHAIN BUFFER • Inspect the chain buffer for wear and damage. • If any defects are found, replace the chain buffer with a new one. PLATE • Inspect the plate for damage and excessive bend. -
Page 395: Reassembly
(0.02 in) 1 mm 1 mm (0.04 in) (0.04 in) Apply SUZUKI SUPER 115 N·m (11.5 kgf-m, 83.0 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) GREASE “A” or equiva- 50 N·m (5.0 kgf-m, 36.0 lb-ft) 65 N·m (6.5 kgf-m, 47.0 lb-ft) lent one to the bearings, 50 N·m (5.0 kgf-m, 36.0 lb-ft)
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Page 396
$ from the cushion rod surface with the special tool and suitable size socket wrench. ( 8-61) 09924-84521: Bearing installer set NOTE: When installing the bearing, stamped mark on the bearing must face outside. • Apply grease to the bearings, spacers. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent… -
Page 397: Installation
CHASSIS 8-63 • Install the chain case chain buffer and rear fender . INSTALLATION Install the swingarm in the reverse order of disassembly and removal, and pay attention to the following points: SWINGARM PIVOT THRUST CLEARANCE ADJUSTMENT Adjust swingarm pivot thrust clearance in the following procedure. •…
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Page 398: Final Inspection And Adjustment
8-64 CHASSIS CUSHION LEVER, CUSHION ROD AND REAR SHOCK ABSORBER • Install the cushion lever and washers. • Install the cushion rod and washers. • Tighten each nut to the specified torque. » Cushion lever mounting nut : 98 N·m (9.8 kgf-m, 71.0 lb-ft) Cushion rod mounting nut (Front side): 98 N·m (9.8 kgf-m, 71.0 lb-ft) (Rear side):…
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Page 399: Front Brake
CHASSIS 8-65 FRONT BRAKE CONSTRUCTION Front brake lever Front brake hose » Dust boot » Master cylinder mounting bolt ITEM N·m kgf-m lb-ft Piston set # Brake hose union bolt » Piston seal $ Caliper mounting bolt 16.5 Dust seal % Caliper air bleeder valve…
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Page 400: Brake Pad Replacement
8-66 CHASSIS * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
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Page 401: Brake Fluid Replacement
CHASSIS 8-67 • Install the spring to the caliper, bring its wider side of pawl » facing top. • Install the new brake pads. • Install the brake caliper. • Tighten each bolt to the specified torque. » Pad mounting pin : 16 N·m (1.6 kgf-m, 11.5 lb-ft) Front brake caliper mounting bolt : 39 N·m (3.9 kgf-m, 28.0 lb-ft) NOTE:…
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Page 402: Caliper Removal
8-68 CHASSIS CALIPER REMOVAL NOTE: * The left and right front brake calipers are installed symmetri- cally and therefore the removal procedure for one side is the same as that for the other side. * Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid.
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Page 403: Caliper Inspection
CHASSIS 8-69 • Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air. Avoid using high pressure air to prevent piston dam- age. • Remove the dust seals and piston seals . Avoid reusing the dust seals and piston seals to pre- vent fluid leakage.
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Page 404: Caliper Reassembly
8-70 CHASSIS CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves. Specification and classification: DOT 4 * Clean the caliper components with fresh brake fluid before reassembly.
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Page 405: Caliper Installation
CHASSIS 8-71 • Temporarily tighten the air bleeder valve . • Tighten each bolt to the specified torque. » Front brake caliper housing bolt : 22 N·m (2.2 kgf-m, 16.0 lb-ft) 09930-11920: Torx bit JT40H 09930-11940: Bit holder CALIPER INSTALLATION Install the caliper in the reverse order of removal.
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Page 406: Master Cylinder Removal And Disassembly
8-72 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain the brake fluid. ( 8-67) • Disconnect the front brake light switch lead wires . • Place a rag underneath the union bolt on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose.
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Page 407: Master Cylinder Inspection
CHASSIS 8-73 • Remove the dust boot push rod and snap ring «. • Remove the following parts. Secondary cup Piston Primary cup Return spring Return spring guide Air bleeder valve • Remove the dust rubber and snap ring •…
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Page 408: Master Cylinder Reassembly
Specification and classification: DOT 4 • Install the O-ring to the brake hose connector. Use a new O-ring to prevent the fluid leakage. • Apply SUZUKI SILICONE GREASE to the push rod. 99500-25100: SUZUKI SILICONE GREASE or equivalent…
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Page 409: Master Cylinder Installation
CHASSIS 8-75 • Apply SUZUKI SILICONE GREASE to the brake lever pivot bolt. 99000-25100: SUZUKI SILICONE GREASE or equivalent » Brake lever pivot bolt: 1.0 N·m (0.1 kgf-m, 0.7 lb-ft) Brake lever lock-nut: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft) • Align the convex part » of brake light switch with the hole # of master cylinder when installing the brake light switch.
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Page 410: Rear Brake
8-76 CHASSIS REAR BRAKE CONSTRUCTION Brake pedal » Caliper air bleeder valve » Piston/Cup set # Brake hose union bolt ITEM N·m kgf-m lb-ft Reservoir hose $ Brake caliper mounting bolt » 0.75 Brake hose % Brake master cylinder mounting bolt 16.5 Brake pad &…
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Page 411: Brake Pad Replacement
CHASSIS 8-77 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
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Page 412: Brake Fluid Replacement
8-78 CHASSIS BRAKE FLUID REPLACEMENT • Remove the brake fluid reservoir mounting bolt . • Place a rag underneath the brake fluid reservoir to catch any split brake fluid. Remove the brake fluid reservoir cap . • Replace the brake fluid in the same manner as the front brake.
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Page 413
CHASSIS 8-79 • Remove the brake pad spring. • Remove the caliper air bleeder valve . • Remove the spacer and rubber boot from the caliper. • Place a rag over the piston to prevent it from popping out and then force out the pistons using compressed air. -
Page 414: Caliper Inspection
8-80 CHASSIS CALIPER INSPECTION BRAKE CALIPER AND BRAKE CALIPER PISTON • Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. • Inspect the brake caliper piston surface for any scratches and other damage.
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Page 415: Caliper Reassembly
Caliper body Piston seal SLIDING PIN • Install the rubber boot . • Apply SUZUKI SILICONE GREASE to the inside of the boot. 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the spacer . • Install the caliper air bleeder valve.
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Page 416: Caliper Installation
8-82 CHASSIS CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Tighten each bolt to the specified torque. » Brake hose union bolt : 23 N·m (2.3 kgf-m, 16.5 lb-ft) Brake caliper mounting bolt : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Brake caliper sliding pin : 33 N·m (3.3 kgf-m, 24.0 lb-ft) •…
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Page 417: Master Cylinder Disassembly
CHASSIS 8-83 MASTER CYLINDER DISASSEMBLY • Remove the reservoir cap, insulator , diaphragm and reservoir tank . • Remove the connector by removing the screw. • Remove the O-ring . Replace the O-ring with a new one. • Pull out the dust boot , then remove the snap ring . 09900-06108: Snap ring pliers •…
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Page 418: Master Cylinder Reassembly
* Apply brake fluid to the cylinder bore and all the component to be inserted into the bore. Specification and classification: DOT 4 • Apply SUZUKI SILICONE GREASE to the push rod end. 99000-25100: SUZUKI SILICONE GREASE or equivalent MASTER CYLINDER INSTALLATION Install the master cylinder in the reverse order of removal.
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Page 419: Clutch Release Cylinder And Master Cylinder
CHASSIS 8-85 CLUTCH RELEASE CYLINDER AND MASTER CYLINDER CONSTRUCTION Diaphragm Spring » Push rod Clutch release cylinder ITEM N·m kgf-m lb-ft Dust boot » Clutch master cylinder mounting bolt » Piston/cup set # Clutch hose union bolt 16.5 Clutch hose $ Air bleeder valve…
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Page 420: Clutch Fluid Replacement
8-86 CHASSIS * This clutch system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
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Page 421: Clutch Release Cylinder Removal And Disassembly
CHASSIS 8-87 CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY • Drain the clutch fluid. ( 8-86) • Disconnect the clutch hose by removing the union bolt . NOTE: Place a rag underneath the union bolt on the release cylinder to catch any spilled brake fluid. •…
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Page 422: Clutch Release Cylinder Reassembly And Remounting
Air bleeder valve Bleeder cap Clutch release cylinder body • Apply grease to the clutch push rod end. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Remove the clutch release cylinder. • Tighten each bolt to the specified torque.
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Page 423: Clutch Master Cylinder Removal And Disassembly
CHASSIS 8-89 CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain clutch fluid. ( 8-86) • Disconnect the clutch lever position switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt and disconnect the clutch hose from the master cylinder.
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Page 424: Clutch Master Cylinder Inspection
8-90 CHASSIS • Remove the dust boot and push rod . • Remove the snap ring . 09900-06108: Snap ring pliers • Remove the piston/cup set. » Secondary cup Piston Primary cup Spring CLUTCH MASTER CYLINDER INSPECTION • Inspect the piston surface for any scratches or other damage. •…
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Page 425: Clutch Master Cylinder Reassembly And Remounting
• Install O-rings to the master cylinder and reservoir tank . • Install the reservoir tank . Use new O-rings to prevent fluid leakage. • Apply SUZUKI SILICONE GREASE to the push rod. • Install the push rod and dust boot. 99500-25100: SUZUKI SILICONE GREASE…
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Page 426
8-92 CHASSIS • Apply SUZUKI SILICONE GREASE to the bushing and clutch lever pivot bolt. 99000-25100: SUZUKI SILICONE GREASE or equivalent » Clutch lever pivot bolt: 1.0 N·m (0.1 kgf-m, 0.7 lb-ft) Clutch lever lock-nut: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft) •… -
Page 427: Tire And Wheel
CHASSIS 8-93 TIRE AND WHEEL TIRE REMOVAL The most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
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Page 428: Valve Inspection
8-94 CHASSIS VALVE INSPECTION • Inspect the valve after the tire is removed from the rim. • Replace the valve with a new one if the seal » rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.
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Page 429: Tire Installation
CHASSIS 8-95 TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points. * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant.
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Page 430: Balancer Weight Installation
8-96 CHASSIS • In this condition, check the “rim line” # cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.
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Page 431: Drive Chain
CHASSIS 8-97 DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain. 09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.
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Page 432: Drive Chain Connecting
8-98 CHASSIS • Place the drive chain link being disjointed on the holder part of the tool. • Turn in both the adjuster bolt and pressure bolt “A” so that each of their end hole fits over the chain joint pin properly. •…
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Page 433
CHASSIS 8-99 • Apply grease on the recessed portion of the joint plate holder and set the joint plate . NOTE: When positioning the joint plate on the tool, its stamp mark must face the joint plate holder side. •… -
Page 434
8-100 CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “A” with the bar until the pin end diameter becomes the specified dimension. Pin end diameter specification % 5.50 – 5.80 mm (0.217 – 0.228 in) * After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found. -
Page 435
ELECTRICAL SYSTEM 9-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING …………….. 9- 3 CONNECTOR ………………9- 3 COUPLER………………..9- 3 CLAMP ………………..9- 3 FUSE…………………. 9- 3 SWITCH ………………..9- 3 SEMI-CONDUCTOR EQUIPPED PART ……….9- 4 BATTERY ………………..9- 4 CONNECTING THE BATTERY…………. -
Page 436
9-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS RELAYS …………………. 9-37 TURN SIGNAL/SIDE-STAND RELAY ……….9-37 STARTER RELAY …………….. 9-37 FUEL PUMP RELAY …………….9-37 COOLING FAN RELAY…………….. 9-37 SWITCH ………………….. 9-38 IGNITION SWITCH REMOVAL …………. 9-38 IGNITION SWITCH INSTALLATION…………. 9-38 DRIVING MODE SWITCH …………..9-39 SWITCH INSPECTION ……………. -
Page 437: Cautions In Servicing
ELECTRICAL SYSTEM 9-3 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.
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Page 438: Semi-Conductor Equipped Part
9-4 ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •…
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Page 439: Using The Multi-Circuit Tester
ELECTRICAL SYSTEM 9-5 USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester and probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •…
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Page 440: Location Of Electrical Components
9-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS EXCVA ( 6-10) CMP sensor ( 4-36) IAP sensor ( 4-40) Ignition coil STV actuator ( 4-66) ISC valve ( 4-79) STP sensor ( 4-69) EVAP system purge control solenoid valve TP sensor ( 4-45) (E-33 only)
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Page 441
ELECTRICAL SYSTEM 9-7 Steering damper solenoid valve ( 4-108) Mode select switch coupler Secondary fuel injector ( 4-77) Primary fuel injector ( 4-75) Starter relay/Main fuse Fuel pump Generator Fuel level gauge Fuse box Regulator/Rectifier Turn signal/Side-stand relay Horn Speed sensor… -
Page 442: Charging System
9-8 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier IG. switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. ( 9-9) Is the battery for current leaks OK? Go to Step 3.
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Page 443: Inspection
ELECTRICAL SYSTEM 9-9 Step 5 1) Measure the generator no-load performance. ( 9-11) Is the generator no-load performance OK? Go to Step 6. Faulty generator Step 6 1) Inspect the regulator/rectifier. ( 9-11) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier Step 7 1) Inspect wirings.
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Page 444
9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. ( 8-8) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the and battery termi- nals using the multi-circuit tester. -
Page 445
ELECTRICAL SYSTEM 9-11 GENERATOR NO-LOAD PERFORMANCE • Lift and support the fuel tank. ( 5-3) • Disconnect the generator coupler. • Start the engine and keep it running at 5 000 r/min. • Using the multi-circuit tester, measure the voltage between three lead wires. -
Page 446: Starter System And Side-Stand/Ignition Interlock System
9-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To Ignition coil Starter motor Fuse GP switch (Neutral) (10 A) Battery Starter relay Starter Turn signal/ button side-stand relay Clutch switch side-stand switch TROUBLESHOOTING Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.
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Page 447: Starter Motor Removal
ELECTRICAL SYSTEM 9-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G and B/Y ) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch •…
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Page 448: Starter Motor Disassembly
9-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. O-ring Armature Housing end (inside) Housing end (outside) ITEM N·m kgf-m lb-ft Starter motor case » Lead wire mounting bolt «…
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Page 449: Starter Motor Reassembly
• Apply grease to the lip of the oil seal. 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. 99000-25140: SUZUKI MOLY PASTE or equivalent • Fit the projection of the starter motor case to the depression of the housing end.
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Page 450: Starter Relay Inspection
9-16 ELECTRICAL SYSTEM • Install the starter motor to the engine. • Tighten the starter motor mounting bolts and lead wire bolt. 10-16) Starter motor mounting bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Starter motor lead wire bolt: 5 N·m (0.5 kgf-m, 3.5 lb-ft) STARTER RELAY INSPECTION •…
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Page 451: Side Stand/Ignition Interlock System Parts Inspection
ELECTRICAL SYSTEM 9-17 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH The side-stand switch coupler is located above the crankcase.
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Page 452
9-18 ELECTRICAL SYSTEM GEAR POSITION SENSOR • Lift and support the fuel tank. ( 5-3) • Disconnect the gear position switch coupler and check the continuity between Bl and B/W with the transmission in “NEU- TRAL”. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test ( ON (Neutral) OFF (Except neutral) -
Page 453
ELECTRICAL SYSTEM 9-19 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the turn signal/side-stand relay . SIDE-STAND RELAY INSPECTION First check the insulation between % and & terminals with the tester. -
Page 454: Ignition System
9-20 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Side- stand Power source relay circuit Fuse sensor Waveform arrangement Ignition circuit switch Fuse Waveform arrangement circuit Battery sensor sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 13 500 r/min, this circuit cuts off fuel at the fuel injector.
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Page 455: Immobilizer (Except For E-03, 28, 33)
ELECTRICAL SYSTEM 9-21 IMMOBILIZER (Except for E-03, 28, 33) DESCRIPTION The immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start. Immobilizer antenna Indicator light Transponder…
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Page 456
9-22 ELECTRICAL SYSTEM Operation When the ignition switch is turned ON with the engine stop switch in ON, the immobi-antenna and ECM are powered ON. The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID. -
Page 457: Troubleshooting
ELECTRICAL SYSTEM 9-23 TROUBLESHOOTING No spark or poor spark NOTE: * Check that the transmission is in neutral and the engine stop switch is in the RUN position. Grasp the clutch lever. * Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.
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Page 458
9-24 ELECTRICAL SYSTEM Step 5 1) Inspect the ignition coil/plug caps. ( 9-25) Is the ignition coil/plug cap OK? Go to Step 6. • Poor connection of the ignition coil/plug cap(-s). • Faulty ignition coil/plug cap(-s). Step 6 1) Measure the crankshaft position sensor peak voltage and its resistance. ( 9-27) NOTE: The crankshaft position sensor peak voltage inspection is applicable only with the multi circuit tester and… -
Page 459: Inspection
ELECTRICAL SYSTEM 9-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. ( 5-14) • Disconnect all the ignition coil/plug cap lead wire couplers before removing the ignition coil/plug caps. • Remove all of the ignition coil/plug caps. * Do not remove the ignition coil/plug cap before dis- connecting the lead wire coupler, or the lead wire will be damaged.
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Page 460
9-26 ELECTRICAL SYSTEM NOTE: Use the special tool, to prevent the rubber of the water proof coupler from damage. • Shift the transmission into neutral and turn the ignition switch • Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage. -
Page 461
ELECTRICAL SYSTEM 9-27 CKP SENSOR PEAK VOLTAGE NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Lift and support the fuel tank. ( 5-3) • Disconnect the CKP sensor lead wire coupler and connect the multi-circuit tester with the peak volt adaptor as follows. -
Page 462: Combination Meter
9-28 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition. The rpm pointer is driven by the stepping motor.
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Page 463: Removal And Disassembly
ELECTRICAL SYSTEM 9-29 REMOVAL AND DISASSEMBLY • Remove the screw . • With the hooked parts behind the combination meter pulled from the cowling brace, disconnect the combination meter lead wire coupler. • Remove the combination meter. When disconnecting and reconnecting the combina- tion meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
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Page 464: Inspection
9-30 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights [FI light, Fuel level indicator light, Engine revolution indicator lamp and immobilizer indicator light (For E-02, 19, 24)] immediately after turning the ignition switch ON. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depend- ing on each switch position.
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Page 465
ELECTRICAL SYSTEM 9-31 ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection ( 7-7 to -8) • Lift and support the fuel tank. ( 5-3) • Disconnect the ECT sensor coupler . When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. -
Page 466
9-32 ELECTRICAL SYSTEM FUEL LEVEL GAUGE INSPECTION • Remove the fuel pump assembly. ( 5-9) • Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. Float position Resistance 245.4 mm… -
Page 467
ELECTRICAL SYSTEM 9-33 SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. SPEED SENSOR •… -
Page 468
9-34 ELECTRICAL SYSTEM OIL PRESSURE INDICATOR NOTE: Before inspecting the oil pressure switch, check if the engine oil level is correct. ( 2-12) • Remove the right under cowling. ( 8-5) • Disconnect the oil pressure switch lead wire from the oil pres- sure switch. -
Page 469: Lamps
ELECTRICAL SYSTEM 9-35 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 55 W H7 12 V 65 W H9 POSITION LIGHT 12 V 5 W BRAKE LIGHT/TAILLIGHT LICENCE PLATE LIGHT 12 V 5 W TURN SIGNAL LIGHT 12 V 21 W ×…
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Page 470
9-36 ELECTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. NOTE: * Use a screw driver for adjuster » and #. * To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. «: Horizontal adjuster #: Vertical adjuster… -
Page 471: Relays
ELECTRICAL SYSTEM 9-37 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
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Page 472: Switch
9-38 ELECTRICAL SYSTEM SWITCH IGNITION SWITCH REMOVAL • Remove the air cleaner box. ( 5-14) • Disconnect the ignition switch lead wire coupler (Green) . • Disconnect the immobilizer lead wire coupler (Black) . (For E-02, 19, 24) • Remove the cable guide . •…
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Page 473: Driving Mode Switch
ELECTRICAL SYSTEM 9-39 DRIVING MODE SWITCH DESCRIPTION Engine power characteristics can be changed in 3 modes by operating the driving mode switch to meet various riding condi- tions and rider’s preference. MODE OPERATION Driving mode is preset at A-mode when the ignition switch and engine stop switch are turned ON.
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Page 474
9-40 ELECTRICAL SYSTEM INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Data monitor”. 4) Make sure each of “Driving mode selection” on the monitor is indicated “Open”. -
Page 475: Switch Inspection
ELECTRICAL SYSTEM 9-41 SWITCH INSPECTION Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. PUSH HAZARD SWITCH HORN BUTTON Color Position Color B/Bl (OFF) Position (ON) PUSH…
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Page 476: Battery
9-42 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation FT12A-BS Capacity 12 V, 36 kC (10 Ah)/10 HR Upper cover breather Terminal Cathode plates Safety valve Stopper Anode plates Filter Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •…
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Page 477
ELECTRICAL SYSTEM 9-43 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery. -
Page 478: Servicing
9-44 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
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Page 479: Servicing Information
SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING …………….10- 3 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION…………..10- 3 ENGINE ………………..10- 3 RADIATOR (COOLING SYSTEM) …………10- 9 CHASSIS ………………..10-10 BRAKES ………………..10-11 ELECTRICAL ………………10-12 BATTERY ………………… 10-13 WIRING HARNESS, CABLE AND HOSE ROUTING………
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Page 480
10-2 SERVICING INFORMATION SERVICING INFORMATION CONTENTS REAR VIEW MIRROR INSTALLATION……….10-37 REAR COMBINATION LIGHT INSTALLATION ……..10-38 REAR COMBINATION LIGHT CUSHION/FASTENER INSTALLATION………………10-39 REGULATOR/RECTIFIER INSTALLATION ……..10-40 SPECIAL TOOLS …………….. 10-41 TIGHTENING TORQUE …………….10-45 ENGINE ………………..10-45 FI SYSTEM AND INTAKE AIR SYSTEM ……….10-46 COOLING SYSTEM……………. -
Page 481: Troubleshooting
SERVICING INFORMATION 10-3 TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION (4-30 to -35) ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of adjustment Adjust. 2.
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Page 482
10-4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace. -
Page 483
SERVICING INFORMATION 10-5 Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace. -
Page 484
10-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust. -
Page 485
SERVICING INFORMATION 10-7 Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinders Replace. -
Page 486
10-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts 1. Heavy carbon deposit on piston crowns Clean. 2. Not enough oil in the engine Add oil. 3. Defective oil pump or clogged oil circuit Replace or clean. -
Page 487: Radiator (Cooling System)
SERVICING INFORMATION 10-9 Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn shifting gears on driveshaft or Replace. out of gear. countershaft 2. Distorted or worn gearshift forks Replace. 3. Weakened stopper spring on gearshift stopper Replace. 4. Worn gearshift cam plate Replace.
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Page 488: Chassis
10-10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering 1. Overtightened steering stem nut Adjust. 2. Broken bearing in steering stem Replace. 3. Distorted steering stem Replace. 4. Not enough pressure in tires Adjust. 5. Defective steering damper solenoid Replace.
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Page 489: Brakes
SERVICING INFORMATION 10-11 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system Repair or replace. power 2. Worn pads Replace. 3. Oil adhesion of engaging surface of pads/shoe Clean disc and pads. 4.
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Page 490: Electrical
10-12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective spark plugs Replace. 3. Defective CKP sensor Replace. 4. Defective ECM Replace. 5. Defective TO sensor Replace. 6. Open-circuited wiring connections Check and repair.
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Page 491: Battery
SERVICING INFORMATION 10-13 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates Battery runs down…
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Page 492: Wiring Harness, Cable And Hose Routing
10-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING PAIR control solenoid valve Clamp Fixed clamp Fixed clamp Clamp Fixed clamp Clamp Clamp Fixed clamp Fixed clamp Secondary fuel injector White tape 5 – 10 mm (0.2 – 0.4 in) Immobilizer label Primary fuel injector (For E-02, 19, 24)
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Page 493
SERVICING INFORMATION 10-15 ECM cushion Clamp Clamp Backside of the headlight Fixed clamp Guide Clamp Guide Clutch hose Side-stand switch HO2 sensor lead wire… -
Page 494
10-16 SERVICING INFORMATION Grommet 120 N . m 12.0 kgf-m 87 lb-ft Make slack to the gear position switch lead wire at this point. Gear position sensor Oil pressure switch 14 N . m 1.4 kgf-m 6.5 N . m 10.0 lb-ft (0.65 kgf-m, 4.7 lb-ft) 1.5 N . -
Page 495: Throttle Cable Routing
SERVICING INFORMATION 10-17 THROTTLE CABLE ROUTING 0 mm (0 in) 0 mm (0 in) Throttle cable No.1 Brake hose Pass the throttle cables along the air cleaner Throttle cable No.2 box.
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Page 496: Throttle Body Hose Routing
10-18 SERVICING INFORMATION THROTTLE BODY HOSE ROUTING Fuel feed hose EVAP purge hose (E-33 only) EVAP system purge control solenoid valve PCV (breather) hose (E-33 only) ISC valve hose EVAP system purge control solenoid valve hose » To IAP sensor EVAP surge hose (E-33 only) # To EVAP system purge control solenoid valve EVAP canister (E-33 only)
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Page 497: Fuel Tank Drain Hose Routing
SERVICING INFORMATION 10-19 FUEL TANK DRAIN HOSE ROUTING Pass the breather hose and drain hose Fuel feed hose through over the wiring harness. Bend the hose clamp at the white painted mark Breather hose (Except for E-33) on the breather hose .
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Page 498: Cooling System Hose Routing
10-20 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING “A” : Backward. Marking (White) “A” : Top side. “B” : Backward. “A” : Right side. “B” : Right side. “A” “B” : Backward. Left side. Marking (Green) “B” : Left side. “A” : Left side.
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Page 499: Front Brake Hose Routing
SERVICING INFORMATION 10-21 FRONT BRAKE HOSE ROUTING 1 – 2 mm (0.04 – 0.08 in) 14˚ 42˚ 42˚ Clamp ends should face downward. The green paint is right side and face upside. Clamp ends should face backward. Brake hose guide. After the brake hose union has contacted the 23 N·m (2.3 kgf-m, 16.5 lb-ft) stopper, tighten the union bolt.
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Page 500: Rear Brake Hose Routing
10-22 SERVICING INFORMATION REAR BRAKE HOSE ROUTING 21˚ 28˚ Clamp ends should face backward. 23 N·m (2.3 kgf-m, 16.5 lb-ft) Clamp ends should face inside. 33 N·m (3.3 kgf-m, 24.0 lb-ft) White paint faces outside. 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) After the brake hose union has contacted the 18 N·m (1.8 kgf-m, 13.0 lb-ft) stopper, tighten the union bolt.
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Page 501: Clutch Hose Routing
SERVICING INFORMATION 10-23 CLUTCH HOSE ROUTING 14˚ 28˚ Clutch hose guide. 6 N·m (0.6 kgf-m, 4.3 lb-ft) Stopper: After the clutch hose union has con- 23 N·m (2.3 kgf-m, 16.5 lb-ft) tacted the stopper, tighten the union bolt. Grommet: Install the grommet of the clutch 10 N·m (1.0 kgf-m, 7.0 lb-ft) hose to the clutch.
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Page 502: Pair (Air Supply) System Hose Routing
10-24 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 0˚ Approx. 45˚ Approx. 25˚ 0˚ PAIR control solenoid valve Air cleaner box PAIR reed valve *1 To air cleaner box…
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Page 503: Fuel Tank Installation
SERVICING INFORMATION 10-25 FUEL TANK INSTALLATION “A” “A” “A” “A” “A” “B” “C” Fuel tank cover Apply adhesive agent. “A” Velcro fastening View from bottom. “B” Frame cover cushion Align the fuel tank cushion with the dent mark “C”…
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Page 504: Fuel Tank Lower Side Cover Cushion Rubber/ Fastener Installation
10-26 SERVICING INFORMATION FUEL TANK LOWER SIDE COVER CUSHION RUBBER/ FASTENER INSTALLATION 3 mm (0.12 in) Cushion Protective tape Cushion Align the velcro fastening to the aligned mark. Clean an adhesive surface before adhering the cushion and Velcro fastening velcro fastening.
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Page 505: Body Cowling Cushion Rubber Installation
SERVICING INFORMATION 10-27 BODY COWLING CUSHION RUBBER INSTALLATION Align the cushion rubber to the aligning mark. NOTE: Clean the adhesive surface before adhering the cushion rubber. UNDER COWLING HEAT SHIELD INSTALLATION Heat shield (RH) Clean the adhesive surface before adhering the heat shield. NOTE: Clean an adhesive surface before adhering the heat shield.
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Page 506: Fuel Tank Heat Shield And Fuel Tank Bracket Cushion Installation
10-28 SERVICING INFORMATION FUEL TANK HEAT SHIELD AND FUEL TANK BRACKET CUSHION INSTALLATION The ends of the clamp should face forward. FUEL TANK COVER CUSHION/VELCRO FASTENING INSTALLATION Fuel tank cover cushion Velcro fastening…
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Page 507: Cowling Installation
SERVICING INFORMATION 10-29 COWLING INSTALLATION “A1” “B” To “A” To Radiator heat shield “A” To “B” To “A1”…
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Page 508: Frame Cover Installation
10-30 SERVICING INFORMATION FRAME COVER INSTALLATION SEAT LOCK CABLE ROUTING…
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Page 509: Front Fender Installation
SERVICING INFORMATION 10-31 FRONT FENDER INSTALLATION (For E-03, 24, 28, 33) 1 Reflex reflector 1.8 N·m (0.18 kgf-m, 1.3 lb-ft) 4.5 N·m (0.45 kgf-m, 3.25 lb-ft)
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Page 510: Rear Fender Installation
10-32 SERVICING INFORMATION REAR FENDER INSTALLATION Rear fender (front) Rear fender (lower) Rear fender cover (front) Swingarm Rear fender (rear)
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Page 511: Side-Stand Installation
SERVICING INFORMATION 10-33 SIDE-STAND INSTALLATION 50 N·m (5.0 kgf-m, 36.0 lb-ft) 95 N·m (9.5 kgf-m, 68.5 lb-ft) X Apply grease to sliding surface. 40 N·m (4.0 kgf-m, 29.0 lb-ft)
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Page 512: Gearshift Pedal Installation
10-34 SERVICING INFORMATION GEARSHIFT PEDAL INSTALLATION “A” “C” 2˚ “B” * When adjusting the footrest position to the backside, the optional gearshift rod must be used. Adjust the thread of each rod end b to “A” “STD” footrest top position A: 195.65 mm (7.70 in) equal length.
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Page 513: Front Footrest Installation
SERVICING INFORMATION 10-35 FRONT FOOTREST INSTALLATION “A” 39 N·m (3.9 kgf-m, 28.0 lb-ft) 18 N·m (1.8 kgf-m, 13.0 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) Align the cutaway when installing. “A” 10 N·m (1.0 kgf-m, 9.0 lb-ft)
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Page 514: Pillion Footrest Installation
10-36 SERVICING INFORMATION PILLION FOOTREST INSTALLATION Footrest X Apply grease to sliding surface.
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Page 515: Rear View Mirror Installation
SERVICING INFORMATION 10-37 REAR VIEW MIRROR INSTALLATION “A” Body cowling Mirror cover Cowling brace Mirror body Cushion 10 N·m (1.0 kgf-m, 7.0 lb-ft) Turn signal lead wire Locate the turn signal lead wire coupler between “A” the mirror cover and mirror body Turn signal lead wire coupler…
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Page 516: Rear Combination Light Installation
10-38 SERVICING INFORMATION REAR COMBINATION LIGHT INSTALLATION 5 N·m (0.5 kgf-m, 3.5 lb-ft) 2.75 N·m (0.275 kgf-m, 2.0 lb-ft) 2.75 N·m (0.275 kgf-m, 2.0 lb-ft)
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Page 517: Rear Combination Light Cushion/Fastener Installation
SERVICING INFORMATION 10-39 REAR COMBINATION LIGHT CUSHION/FASTENER INSTALLATION Rear combination light Align the corner of cushions and fasteners with the root of the rib. Fastener 25 mm (0.98 in) 30 mm (1.18 in) Cushion 33 mm (1.30 in) 40 mm (1.58 in) 4 mm (0.16 in) or more…
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Page 518: Regulator/Rectifier Installation
10-40 SERVICING INFORMATION REGULATOR/RECTIFIER INSTALLATION 1 Regulator/Rectifier 3 Clamp 2 Bracket 4 Radiator NOTE: To remove or install the regulator/rectifier easily, hold its bolt head with an open-end wrench.
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Page 519: Special Tools
SERVICING INFORMATION 10-41 SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-20203 09900-06108 Hexagon socket 09900-20102 Micrometer Micrometer Snap ring pliers (24 mm) Vernier calipers (25 – 50 mm) (50 – 75 mm) 09900-20205 09900-20602 09900-20605 09900-20607 Micrometer 09900-20530 Dial gauge Dial calipers Dial gauge (0 –…
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Page 520
10-42 SERVICING INFORMATION 09915-64512 09915-74521 09913-50121 09913-70210 09915-40610 Compression gauge Oil pressure gauge Oil seal remover Bearing installer set Oil filter wrench hose 09915-74540 09915-77331 09916-14530 Oil pressure gauge Meter 09916-10911 09916-14510 Valve lifter attach- attachment (for high pressure) Valve lapper set Valve lifter ment 09916-33210… -
Page 521
SERVICING INFORMATION 10-43 09920-53740 09922-22711 Clutch sleeve hub 09921-20210 09921-20240 Drive chain cutting 09923-74511 holder Bearing remover Bearing remover set and joining tool Bearing remover 09925-18011 09924-84510 09924-84521 Steering bearing 09930-11920 09930-11940 Bearing installer set Bearing installer set installer Torx bit JT40H Bit holder 09930-82720 09930-11950… -
Page 522
10-44 SERVICING INFORMATION 09940-40211 09940-40220 09940-52841 09940-52861 Fuel pressure Fuel pressure gauge Front fork inner Front fork oil seal 09940-92720 gauge adaptor hose attachment rod holder installer Spring scale 09940-94922 09940-94930 09941-34513 09944-28320 Front fork spring Front fork spacer Steering race 09943-74111 Hexagon socket stopper plate… -
Page 523: Tightening Torque
SERVICING INFORMATION 10-45 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Exhaust pipe bolt 16.5 Muffler connecting bolt 16.5 Muffler mounting bolt 18.0 Muffler chamber bracket bolt 18.0 Muffler chamber mounting bolt 16.5 Muffler joint nut 18.0 Speed sensor rotor bolt 18.0 Speed sensor bolt 0.65…
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Page 524: Fi System And Intake Air System
10-46 SERVICING INFORMATION ITEM N·m kgf-m lb-ft Crankcase bolt (Initial) (M: 6) (Final) (Initial) 11.0 (M:
(Final) 19.0 Crankshaft journal bolt (Initial) 13.0 (M: 9) 50° (Final) Oil gallery plug (M: 6) (M:
13.0 (M: 10) 13.0 (M: 16) 25.5 Oil drain plug 16.5…
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Page 525: Chassis
SERVICING INFORMATION 10-47 CHASSIS N·m kgf-m lb-ft ITEM Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt and nut 16.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork inner rod lock-nut 11.0 Front fork damper rod bolt…
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Page 526: Tightening Torque Chart
10-48 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt » (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15 0.23 0.45 0.55…
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Page 527: Service Data
SERVICING INFORMATION 10-49 SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (0.94) Valve clearance (when cold) 0.08 – 0.18 — (0.003 – 0.007) 0.18 – 0.28 — (0.007 – 0.011) Valve guide to valve stem 0.010 –…
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Page 528
10-50 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 000 kPa (13 – 17 kgf/cm², 185 – 242 psi) (10 kgf/cm , 142 psi) Compression pressure difference 200 kPa —… -
Page 529
SERVICING INFORMATION 10-51 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5909 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –… -
Page 530
10-52 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.72 – 2.88 2.42 No. 1, 2 and 3 (0.107 – 0.113) (0.095) Drive plate claw width 13.85 – 13.96 13.05 No. 1, 2 and 3 (0.5453 – 0.5496) (0.5138) Driven plate distortion 0.10… -
Page 531
SERVICING INFORMATION 10-53 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 82 °C (180 °F) — ature Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) — ECT sensor resistance 20 °C Approx. -
Page 532
10-54 SERVICING INFORMATION FI SENSORS ITEM SPECIFICATION NOTE 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.6 V at idle speed TP sensor input voltage 4.5 –… -
Page 533
SERVICING INFORMATION 10-55 THROTTLE BODY ITEM SPECIFICATION Bore size 44 mm (1.73 in) I.D. No. 21G1 (For E-33), 21G0 (For the others) Idle r/min 1 150 ± 100 r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) ELECTRICAL Unit: mm (in) ITEM… -
Page 534
10-56 SERVICING INFORMATION WATTAGE Unit: W STANDARD/SPECIFICATION ITEM E-03, 28, 33 Others ← Headlight ← ← Position/Parking light ← Brake light/Taillight ← Turn signal light 21 × 4 ← License plate light ← Combination meter light ← Turn signal indicator light ←… -
Page 535
SERVICING INFORMATION 10-57 ITEM STANDARD LIMIT Wheel rim runout Axial — (0.08) Radial — (0.08) Wheel rim size Front 17 M/C × MT 3.50 — Rear 17 M/C × MT 6.00 — Wheel axle runout 0.25 Front — (0.010) 0.25 Rear —… -
Page 536
Front fork oil level (without spring, 124 (4.88) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (each leg) 512 ml (17.3/18.0 US/Imp oz) — Front fork inner tube O.D. -
Page 537
SERVICING INFORMATION 10-59 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible. -
Page 538: Emission Control Information
EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ………….. 11- 2 FUEL INJECTION SYSTEM…………..11- 2 CRANKCASE EMISSION CONTROL SYSTEM……..11- 3 EXHAUST EMISSION CONTROL SYSTEM……..11- 4 HO2 SENSOR INSPECTION …………… 11- 5 HO2 SENSOR REMOVAL AND INSTALLATION ……. 11- 5 NOISE EMISSION CONTROL SYSTEM……….
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Page 539: Emission Control Systems
11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM GSX-R1000 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.
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Page 540: Crankcase Emission Control System
EMISSION CONTROL INFORMATION 11-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atomo- sphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combus- tion chamber through the PCV (breather) hose, air cleaner and throttle body.
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Page 541: Exhaust Emission Control System
11-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of the PAIR system, exhaust control system, three-way catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control sole- noid valve and PAIR reed valve.
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Page 542: Ho2 Sensor Inspection
EMISSION CONTROL INFORMATION 11-5 HO2 SENSOR INSPECTION (4-88) HO2 SENSOR REMOVAL AND INSTALLATION (4-113) NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.
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Page 543: Pair (Air Supply) System And Emission Control System Inspection
11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses for secure connection. PAIR REED VALVE • Lift and support the fuel tank. (5-3) •…
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Page 544
EMISSION CONTROL INFORMATION 11-7 • Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow. • If air does not flow out, the solenoid valve is in normal condi- tion. • Check the resistance between the terminals of the PAIR con- trol solenoid valve. -
Page 545: Pair (Air Supply) System Diagram
11-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM DIAGRAM PAIR control solenoid valve *1 From air cleaner PAIR reed valve *2 To #1 and #2 cylinders » FRESH AIR *3 To #3 and #4 cylinders # EXHAUST GAS PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (10-24)
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Page 546: Wiring Diagram
WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. PAIR ISC VALVE HANDLEBAR SWITCH (RH) IGNITION IGNITION IGNITION IGNITION CONTROL COIL #1 COIL #2 COIL #3 COIL #4 DRIVING SOLENOID MODE ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH BUTTON…
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Page 547
E-03, 28, 33 PURGE CONTROL SOLENOID (E33 only) PAIR ISC VALVE HANDLEBAR SWITCH (RH) IGNITION IGNITION IGNITION IGNITION CONTROL COIL #1 COIL #2 COIL #3 COIL #4 DRIVING SOLENOID MODE ENGINE STOP FRONT BRAKE STARTER SWITCH SWITCH BUTTON SWITCH DOWN PUSH SIDE-STAND SWITCH… -
Page 548
Prepared by January, 2007 Part No. 99500-39310-01E Printed in Japan… -
Page 549
Printed in Japan…