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• Page 1
  GSX-R750 99500-37112-03E SUZUKI MOTOR CORPORATION PRINTED IN JAPAN FEBRUARY, 2000…

• Page 2: Table Of Contents

  FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX-R750 and procedures for its inspection/service and overhaul of its main com- ponents. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa- miliarize yourself with the motorcycle and its mainte- nance.

• Page 3: How To Use This Manual

  HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

• Page 4
  99000-99001-SS8 (99000-99044-10G) Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25030 (For USA) 99000-25010 (For the other countries) Apply SUZUKI MOLY PASTE.
• Page 5
  ABBREVIATIONS MAY BE USED IN THIS MANUAL ABDC : After Bottom Dead Center : Hydrocarbons : Alternating Current : Air Cleaner, Air Cleaner Box : American Petroleum Institute IAP Sensor : Intake Air Pressure ATDC : After Top Dead Center Sensor (IAPS) ATM Pressure : Atmospheric Pressure IAT Sensor…
• Page 6
  SAE-TO-FORMER SUZUKI TERM (ONLY FOR U.S.A.) This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM…
• Page 7
  SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION Idle Speed Control ––– Ignition Control Electronic Spark Advance(ESA) Ignition Control Module ––– Intake Air Temperature Intake Air Temperature(IAT), Air Temperature Malfunction Indicator Lamp LED Lamp Malfunction Indicator Lamp(MIL) Manifold Absolute Pressure…

• Page 8: General Information

  GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE …………. 1- 2 GENERAL PRECAUTIONS ………….. 1- 2 SUZUKI GSX-R750Y (2000-MODEL) ……….1- 4 SERIAL NUMBER LOCATION …………1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION … 1- 5 FUEL………………..1- 5 ENGINE OIL ……………… 1- 5 BRAKE FLUID …………….

• Page 9: 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.

• Page 10
  GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.

• Page 11: Suzuki Gsx-R750Y (2000-Model)

  1-4 GENERAL INFORMATION SUZUKI GSX-R750Y (2000-MODEL) RIGHT SIDE LEFT SIDE * Difference between photograph and actual motorcycle depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) A is stamped on the right side of the steering head pipe. The engine serial number B is located on the rear side of the crank- case.

• Page 12: Fuel, Oil And Engine Coolant Recommendation

  Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom- mended. ENGINE OIL (For U.S.A. model) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recom- MULTIGRADE mended viscosity is SAE 10W/40.

• Page 13: Engine Coolant

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

• Page 14: Information Labels

  GENERAL INFORMATION 1-7 INFORMATION LABELS GSX-R750 GSX-R750UD GSX-R750UF 1 Noise label For E-03, 24, 33 2 Information label For E-03, 24, 33 3 Vacuum hose routing label For E-33 4 Fuel caution label For E-02, 24 5 Manual notice label…

• Page 15: Specifications

  1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………..2 040 mm (80.3 in) Overall width …………..715 mm (28.1 in) Overall height …………..1 135 mm (44.7 in) Wheelbase …………..1 410 mm (55.5 in) Ground clearnce …………130 mm (5.1 in) Seat height …………..

• Page 16
  GENERAL INFORMATION 1-9 CHASSIS Front suspension …………Inverted telescopic, coil spring, spring pre-load fully adjustable, rebound and compression damping force fully adjustable. Rear suspension …………Link type system, gas/oil damped, coil spring, spring pre-road fully adjustable, rebound and com- pression damping force fully adjustable. Caster …………….

• Page 17: Country And Area Codes

  1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). MODEL CODE COUNTRY or AREA E-02 U.K. E-03 USA (Except for california) E-19 GSX-R750 E-24 Australia E-28 Canada E-33 California (USA) GSX-R750UD E-19 GSX-R750UF E-19…

• Page 18: Periodic Maintenance

  PERIODIC MAINTENANCE 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- 8 ENGINE OIL AND OIL FILTER ………….

• Page 19: Periodic Maintenance Schedule

  PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and months, and are dependant on whichever comes first. IMPORTANT (USA only): The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.

• Page 20: Lubrication Points

  PERIODIC MAINTENANCE 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 Footrest pivot Side-stand pivot and gearshift and spring hook…

• Page 21: Maintenance And Tune-Up Procedures

  PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months). •…

• Page 22: Spark Plug

  PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front and rear seat. ( 6-8) •…

• Page 23
  PERIODIC MAINTENANCE HEAT RANGE • Check to see the heat range of the plug. If the electrode of the plug is wet appearing or dark color, re- place the plug with hotter type one. If it is white or glazed ap- pearing, replace the plug with colder type one.
• Page 24
  PERIODIC MAINTENANCE SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION • Install the spark plugs to the cylinder head by finger tight, and then tighten them to the specified torque. ! Spark plug: 11 N . m (1.1 kgf . m, 8.0 Ib-ft) To avoid damaging the cylinder head threads, first finger tighten the spark plug and then tighten it to the proper torque using the spark plug wrench.

• Page 25: Valve Clearance

  PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (15 000 miles, 24 months). • Remove the right under cowling. ( 6-5) • Remove the front and rear seats. ( 6-8) • Lift and support the fuel tank. ( 4-51) •…

• Page 26
  PERIODIC MAINTENANCE • Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches A on the left ends of both camshafts (Ex and In) to the positions as shown. Front •…
• Page 27
  2-10 PERIODIC MAINTENANCE 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. ( 3-17) • Remove the tappet and shim by fingers or magnetic hand. •…
• Page 28
  PERIODIC MAINTENANCE 2-11 (INTAKE SIDE)
• Page 29
  2-12 PERIODIC MAINTENANCE (EXHAUST SIDE)

• Page 30: Engine Oil And Oil Filter

  PERIODIC MAINTENANCE 2-13 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 1 month) and ev- ery 18 000 km (11 000 miles, 18 months) thereafter.

• Page 31
  Other manufacturer’s oil filters may differ in thread speci- fications (thread diameter and pitch), filtering perfor- mance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automo- bile oil filter on this motorcycle.

• Page 32: Fuel Hose

  PERIODIC MAINTENANCE 2-15 FUEL HOSE Inspect every 6 000 km (4 000 miles,6 months). Replace every 4 years. Inspect the fuel hose 1 for damage and fuel leakage. If any de- fects are found, the hoses must be replaced. ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter.

• Page 33: Throttle Cable Play

  2-16 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. Adjust the throttle cable play A as follows. MINOR ADJUSTMENT 1st step: •…

• Page 34: Clutch

  PERIODIC MAINTENANCE 2-17 MAJOR ADJUSTMENT • Lift and support the fuel tank with its prop stay. ( 4-51) • Loosen the lock nuts 1 of the throttle returning cable 2. • Turn the returning cable adjuster 3 to obtain proper cable play.

• Page 35: Cooling System

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

• Page 36
  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 37: Drive Chain

  2-20 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed be- low.

• Page 38
  * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is a RK 525R0Z4 Suzuki rec- ommends to use this standard drive chain as a re- placement.

• Page 39: Brake

  2-22 PERIODIC MAINTENANCE BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years.

• Page 40
  PERIODIC MAINTENANCE 2-23 REAR BRAKE • The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ( 6-69) Replace the brake pads as a set, otherwise braking per- formance will be adversely affected.
• Page 41
  2-24 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.

• Page 42: Tire

  PERIODIC MAINTENANCE 2-25 REAR BRAKE • Bleed air from the rear brake system as the same manner of front brake. NOTE: The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal. TIRES Inspect every 6 000 km (4 000 miles, 6 months).

• Page 43: Steering

  2-26 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Cold inflation tire pressure , 36 psi) Solo riding: Front: 250 kPa (2.50 kgf/cm…

• Page 44: Front Fork

  PERIODIC MAINTENANCE 2-27 FRONT FORK Inspect every 12 000 km (7 500 miles, 12 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( 6-17) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 12 months).

• Page 45
  2-28 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle.:2-29 N .
• Page 46
  PERIODIC MAINTENANCE 2-29…

• Page 47: Compression Pressure Check

  2-30 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit…

• Page 48: Oil Pressure Check

  PERIODIC MAINTENANCE 2-31 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 200 – 500 kPa (2.0 – 5.0 kgf/cm , 28 – 71 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) If the oil pressure is lower or higher than the specification, the following causes may be considered.

• Page 49
  ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE …………..3- 2 ENGINE REMOVAL AND INSTALLATION ……..3- 3 ENGINE REMOVAL …………… 3- 3 ENGINE INSTALLATION ………….. 3-11 ENGINE DISASSEMBLY…………..3-15 ENGINE COMPONENTS INSPECTION AND SERVICE ….3-29 PAIR VALVE ………………
• Page 50
  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 REINST ALLA TION 1 PAIR valve…

• Page 51: 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 pro- cedure.

• Page 52
  3-4 ENGINE • Remove the air cleaner box. ( 4-61) • Remove the throttle body and STV actuator. ( 4-61) RADIATOR • Disconnect the reserve tank hose. • Disconnect the radiator inlet hoses.
• Page 53
  ENGINE 3-5 • Disconnect the cooling fan thermo-switch coupler 1 and cool- ing fan coupler 2. • Remove the radiator mounting bolt. • Remove the radiator. Be careful not to bent the radiator fin. • Remove the front engine cover 1. EXHAUST PIPE AND MUFFLER •…
• Page 54
  3-6 ENGINE • Remove the radiator mounting bracket 1. ELECTRIC PARTS • Disconnect the oil pressure switch lead wire 1 and remove it from the clamps. • Disconnect the starter motor lead wire 2. • Disconnect the ground lead wire 3. •…
• Page 55
  ENGINE 3-7 • Disconnect the lead wire couplers from each ignition coil/plug cap and camshaft position sensor. Do not remove the ignition coil/plug cap before discon- necting its lead wire coupler. • Remove the ignition coils/plug caps. * Do not pry up the ignition coil/plug cap with a driver or a bar to avoid its damage.
• Page 56
  3-8 ENGINE • Remove the speed sensor rotor 1. • Remove the engine sprocket nut 2 and the washer. • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut 3 and the rear torque link nut 4. •…
• Page 57
  ENGINE 3-9 ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolts 1, 2. • Loosen the engine mounting pinch bolts 3. • Remove the engine mounting bolts 4. • Remove the engine mounting nut 5. •…
• Page 58
  3-10 ENGINE • Remove the engine mounting nut 1. • Loosen the engine mounting thrust adjuster locknut 2. • Loosen the engine mounting thrust adjuster 3. NOTE: Do not remove the engine mounting bolts at this stage. • Remove the engine mounting bolts and gradually lower the front side of the engine.

• Page 59: Engine Installation

  ENGINE 3-11 ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: Be careful not to damage the frame and engine when installing the engine. • Before installing the engine, install the spacer 1. •…

• Page 60
  3-12 ENGINE Left Right LENGTH N . m kgf . m ITEM lb-ft ITEM 39.8 1.77 54.0 Bolt 2.17 16.5 8.46 Spacer 30.5 1.20 32.5 Adjuster 1.57…
• Page 61
  ! Speed sensor rotor bolt: 20 N . m (2.0 kgf . m, 14.4 lb-ft) • Apply grease to the clutch push rod and install it. W 99000-25030: SUZUKI SUPER GREASE “A” • Align the hole of the clutch release cylinder with the end of the clutch push rod when installing the engine sprocket cover.
• Page 62
  3-14 ENGINE • Install the radiator mounting bracket 1. • Install the exhaust pipe/muffler. Replace the gaskets with new ones. 23 N . m (2.3 kgf . m, 16.5 lb-ft) 23 N . m (2.3 kgf . m, 16.5 lb-ft) 23 N .

• Page 63: Engine Disassembly

  ENGINE 3-15 ENGINE DISASSEMBLY ENGINE DISASSEMBLY PROCEDURE FLOW CHART Cylinder head cover Cam chain tensioner adjuster Generator cover Cam shaft (IN. & EX) Starter Idle gear Cylinder head Starter clutch Generator rotor Cam chain guide No.1 and Piston, conrod and Cam chain tensioner upper crankcase (Cylinder) Cam chain and sprocket…

• Page 64
  3-16 ENGINE ENGINE DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original posi- tions. • Remove the spark plugs. ( 2-5) STARTER MOTOR •…
• Page 65
  ENGINE 3-17 CAMSHAFTS • Remove the valve timing inspection cap 1. • Turn the crankshaft to bring the line A on the starter clutch to the index mark B of the valve timing inspection hole and also to bring the cams to the position as shown. •…
• Page 66
  3-18 ENGINE • Remove the intake camshaft 1. • Remove the exhaust camshaft 2. CYLINDER HEAD • Remove the water hose 1. • Remove the thermostat cover 2 and thermostat. THERMOSTAT INSPECTION: 5-9 • Remove the engine coolant temp. gauge 3. ENGINE COOLANT TEMP.
• Page 67
  ENGINE 3-19 CLUTCH • Remove the clutch cover. • Hold the clutch housing with the special tool. Do not damage the clutch plates by the special tool. [ 09920-53740: Clutch sleeve hub holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. •…
• Page 68
  3-20 ENGINE • Unlock the clutch sleeve hub nut. • Hold the clutch sleeve hub with the special tool. [ 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the wave washer 1 washer 2, clutch sleeve hub 3 and washer 4.
• Page 69
  ENGINE 3-21 OIL PUMP • Remove the circlip 1. • Remove the oil pump driven gear 2. NOTE: Do not drop the circlip 1 , the pin 3 and the washer 4 into the crankcase. • Remove the pin 3 and the washer 4. •…
• Page 70
  3-22 ENGINE STARTER IDLE GEAR • Remove the starter idle gear cover. • Remove the shaft 1, wave washer 2 washer 3 starter idle gear No.1 4, bearing 5 and washer 6. • Remove the starter clutch cover. • Remove the wave washer 1, the starter idle gear No.2 2 and its shaft 3.
• Page 71
  ENGINE 3-23 STARTER CLUTCH • Hold the starter clutch with the special tool. [ 09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. • Remove the starter clutch assembly. CAM CHAIN, CAM CHAIN TENSIONER, CAM CHAIN GUIDE •…
• Page 72
  3-24 ENGINE GENERATOR COVER • Remove the generator cover. GENERATOR ROTOR • Hold the generator rotor with the special tool. [ 09930-44530: Rotor holder • Loosen the generator rotor bolt. NOTE: Install the bolt (M 12, length: 28 – 38 mm) to the left end of crankshaft as shown in illustration.
• Page 73
  ENGINE 3-25 GEAR POSITION SWITCH • Remove the gear position switch. • Remove the switch contacts and springs. BREATHER COVER • Remove the breather cover. OIL FILTER • Remove the oil filter with the special tool. ( 2-14) [ 09915-40610: Oil filter wrench OIL COOLER •…
• Page 74
  3-26 ENGINE OIL PAN • Remove the cowling brackets 1. • Remove the oil pan. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL PRESSURE SWITCH • Remove the oil pressure switch 2. OIL STRAINER • Remove the oil strainer 3 and O-ring. LOWER CRANK CASE •…
• Page 75
  ENGINE 3-27 MIDDLE CRANKCASE • Remove the crankcase bolts (6 mm). NOTE: Loosen the crankcase bolts diagonally and the smaller sizes first. • Remove the crankcase bolts (8 mm). CRANKSHAFT • Remove the O-ring 1. • Loosen the bearing cap bolts by using 10 mm, 12 point socket wrench, and tap the bearing cap bolt lightly with plastic ham- mer to remove the bearing cap.
• Page 76
  3-28 ENGINE PISTON AND CONROD • Push the conrod to upward and remove the piston and conrod from the upper crankcase. Be careful not to damage the cylinder wall by the conrod. • Remove the piston pin circlip. • Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the head of the piston.

• Page 77: 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. PAIR VALVE PAIR REED VALVE •…

• Page 78: Cylinder Head Cover

  3-30 ENGINE CYLINDER HEAD COVER CAM POSITION SENSOR • Install the oil seal 1 and cam position sensor 2. NOTE: When installing, clean the cam position sensor’s face. ! Cam position sensor bolt: 8 N . m (0.8 kgf . m, 5.8 lb-ft) CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the…

• Page 79
  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 por- tion, which is specified as follows: Camshaft journal oil clearance: Service Limit: (IN &…

• Page 80: Camshaft Runout

  3-32 ENGINE CAMSHAFT RUNOUT • Measure the runout using the dial gauge. • Replace the camshaft if the runout exceeds the limit. [ 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) Camshaft runout: Service Limit (IN & EX): 0.10 mm (0.004 in) CAM SPROCKET •…

• Page 81: Cylinder Head And Valve

  ENGINE 3-33 CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY • Remove the tappets 1 and shims 2 by fingers or magnetic hand. Identify the position of each removed part. • Using special tools, compress the valve springs and remove the two cotter halves 3 from valve stem.

• Page 82
  3-34 ENGINE • Remove the oil seal 1 and the spring seat 2. 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. •…
• Page 83
  ENGINE 3-35 VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.
• Page 84
  3-36 ENGINE VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out to- ward the intake or exhaust camshaft side. [ 09916-53310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No.
• Page 85
  ENGINE 3-37 VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with Prussian Blue and set the valve in place.
• Page 86
  3-38 ENGINE INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. • If the valve seat is pitted or burned, use the 45° cutter to condi- tion the seat some more.
• Page 87
  ENGINE 3-39 FINAL SEAT CUT Contact area too low and too • If the contact area W is too low or too narrow, use the 45° cutter narrow on face of valve to raise and widen the contact area. NOTE: After cutting the 15°, 30°…
• Page 88
  3-40 ENGINE VALVE STEM END CONDITION • Check the valve stem end face for pitting and wear. VALVE SPRING The force of the coil springs keeps the valve seat tight. Weak- ened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism.
• Page 89
  ENGINE 3-41 VALVE AND VALVE SPRING REASSEMBLY • Install the valve spring seats. • Apply molybdenum oil solution to each oil seal, and press-fit them into position with the valve guide installer. [ 09916-44310: Valve guide remover/installer O MOLYBDENUM OIL SOLUTION Do not reuse the removed oil seals.
• Page 90
  I 99000-32050: THREAD LOCK “1342” WATER BYPASS UNION • Apply SUZUKI BOND “1207B” to the thread part of the water bypass union and tighten it to the specified torque. C 99104-31140: SUZUKI BOND “1207B” ! Water bypass union: 14 N . m (1.4 kgf . m, 10.0 lb-ft)

• Page 91: Clutch

  ENGINE 3-43 CLUTCH CLUTCH DRIVE PLATES INSPECTION NOTE: * Wipe off engine oil from the clutch drive plates with a clean rag. * Clutch drive plate No.1: Purple paint * Clutch drive plate No.2: Green paint • Measure the thickness of drive plates with a vernier calipers. •…

• Page 92: Oil Pump

  3-44 ENGINE OIL PUMP INSPECTION • Rotate the oil pump by hand and check that it moves smoothly. • If it does not move smoothly, replace the oil pump assembly. * Do not attempt to disassemble the oil pump assembly. * The oil pump is available only as an assembly.

• Page 93: Gearshift System

  ENGINE 3-45 GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. 1 Washer 5 Plate return spring 2 Circlip 6 Washer 3 Gearshift shaft return spring 7 Circlip 4 Gearshift cam drive plate [ 09900-06107: Snap ring pliers GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION •…

• Page 94: Oil Pressure Regulator

  3-46 ENGINE OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regula- tor with a new one. OIL STRAINER •…

• Page 95: Transmission

  ENGINE 3-47 TRANSMISSION • Disassemble the countershaft and drive shaft. Pay attention to the following point. [ 09900-06104: Snap ring pliers • Remove the 6th drive gear circlip from its groove and slide it towards the 3rd/4th drive gear. • Slide the 6th 1 and 2nd 2 drive gears toward the 3rd/4th drive gears, then remove the 2nd drive gear circlip 3.

• Page 96
  * Before installing the oil seal, apply grease to oil seal. W 99000-25030: SUZUKI SUPER GREASE “A” * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
• Page 97
  ENGINE 3-49 TRANSMISSION PARTS LOCATION…

• Page 98: Cylinder

  3-50 ENGINE CYLINDER CRANKCASE SERVICING: 3-54 CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. • If the largest reading at any position of the straightedge ex- ceeds the limit, replace the cylinder.

• Page 99: Piston And Piston Ring

  ENGINE 3-51 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: 71.880 mm (2.8230 in) at 15 mm (0.6 in) from the skirt end [ 09900-20204: Micrometer (75 –…

• Page 100: Piston Ring Groove Width

  3-52 ENGINE PISTON RING TO GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston rings. [ 09900-20803: Thickness gauge 09900-20205: Micrometer (0 –…

• Page 101
  ENGINE 3-53 PISTON RING REASSEMBLY • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. NOTE: Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way.

• Page 102: Crankcase

  3-54 ENGINE CRANKCASE LOWER CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer 1 and gearshift fork retainer 2 from the lower crankcase. • Remove the gearshift fork shafts and gearshift forks from the lower crankcase. •…

• Page 103
  ENGINE 3-55 • Inspect the gearshift cam bearing for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Inspect the gearshift cam bearing 1, gearshift fork bearing 2 and gearshift shaft bearing 3 for abnormal noise and smooth rotation while they are in the crankcase.
• Page 104
  3-56 ENGINE Installation • Install the bearings using the special tool. [ 09913-70210: Bearing installer set NOTE: The stamped mark side of the gearshift shaft bearing faces outside. • Install the oil seal. • Install the gearshift cam with the bearing. NOTE: The stamped mark side of the gearshift cam bearing faces out- side.
• Page 105
  ENGINE 3-57 • Install the gearshift forks and their shafts as shown. 1 For 3rd/4th drive gears 2 For 6th driven gear 3 For 5th driven gear • Apply a small quantity of THREAD LOCK “1342” to the bearing retainer screws and the shift fork shaft retainer bolt. •…
• Page 106
  3-58 ENGINE OIL JET Removal • Remove the piston cooling oil jets 1 from the upper crank- case. • Remove the oil jet (for transmission) from the lower crankcase. Inspection and cleaning • Check the oil jets for clogging. • If they are clogged, clean their oil passage with a proper wire and compressed air.
• Page 107
  ENGINE 3-59 Installation • Fit the new O-rings 1 to each piston cooling oil jet as shown and apply engine oil to them. Use the new O-rings to prevent oil pressure down. NOTE: Be sure to face the oil holes A on each piston cooling oil jet to the top when installing them.

• Page 108: Crankshaft And Conrod

  3-60 ENGINE CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with “V” blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. •…

• Page 109
  ENGINE 3-61 CONROD-CRANK PIN BEARING INSPECTION • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. CONROD-CRANK PIN BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown.
• Page 110
  3-62 ENGINE • Check the corresponding conrod I.D. code number (“1” or “2”) • Check the corresponding crank pin O.D. code number (“1” , “2” or “3”) B. Bearing selection table Conrod I.D. Code I.D. specification 36.000 – 36.008 mm (1.4173 –…

• Page 111: Crankshaft Journal Bearing

  ENGINE 3-63 CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and lower crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoid- ing the oil hole, as shown. [ 09900-22301: Plastigauge Never rotate the crankshaft when a piece of plastigauge is installed.

• Page 112
  3-64 ENGINE • Check the corresponding crankcase journal I.D. code number A, “A” or “B” which are stamped on the rear of upper crank- case. • Check the corresponding crankshaft journal O.D. code number B, “A”, “B” or “C” which are stamped on the crankshaft. Bearing selection table Crankcase I.D.

• Page 113: Crankshaft Thrust Bearing

  ENGINE 3-65 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. R: Right-side thrust bearing L: Left-side thrust bearing NOTE: Pull the crankshaft to the left-side, so that there is no clearance on the right-side thrust bearing.

• Page 114
  3-66 ENGINE Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.560 – 2.585 mm White 2.475 – 2.500 mm 0.060 – 0.110 mm (0.1008 – 0.1018 in) (12228-17E00-0F0) (0.0974 – 0.0984 in) (0.0024 –…

• Page 115: Engine Reassembly

  ENGINE 3-67 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 reassem- bling. •…

• Page 116
  3-68 ENGINE der walls. • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent A of the piston head must be faced to each exhaust side. Be carefull not to damage the cylinder wall by the conrod. •…
• Page 117
  ENGINE 3-69 CRANKSHAFT • Position the No.2 and No.3 conrod big ends toward same side, and position the No.1 and No.4 conrod big ends toward oppo- site side of No.2 and No.3. • Set the crankshaft to the conrods and upper crankcase. •…
• Page 118
  NOTE: Right-thrust bearing has green painting. CRANKCASE • Clean the mating surfaces of the crankcases. • Install the dowel pins 1 and O-ring 2 to the upper crankcase. • Apply SUZUKI BOND to the mating surface of the middle crank-…
• Page 119
  ENGINE 3-71 case. C 99104-31140: SUZUKI BOND “1207B” (For USA) D 99000-31110: SUZUKI BOND “1215” (For the others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.
• Page 120
  3-72 ENGINE • Tighten the other crankcase bolts a little at a time to equalize the pressure. ! Crankcase bolt: 6 N . m (0.6 kgf . m, 4.5 lb-ft) (M6) initial: Final: 11 N . m (1.1 kgf . m, 8.0 lb-ft) NOTE: Fit the clamp to the crankcase bolt A .
• Page 121
  ENGINE 3-73 TRANSMISSION • Install the bearing pins 1 and the C-ring 2 on the upper crank- case. • Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove on the bearing and the bearing pin with the indent on the bearing.
• Page 122
  3-74 ENGINE • Apply SUZUKI BOND to the mating surface of the lower crank- case. C 99104-31140: SUZUKI BOND “1207B” (For USA) D 99000-31110: SUZUKI BOND “1215” (For the others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
• Page 123
  ENGINE 3-75 • Tighten the crankcase bolts a little at a time to equalize the pres- sure. ! 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 .
• Page 124
  • Install the O-ring. NOTE: Apply grease to the O-ring. W 99000-25030: SUZUKI SUPER GREASE “A” Use the new O-ring to prevent oil leakage. • Install the oil strainer as shown. ! Oil strainer bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) OIL PRESSURE REGULATOR •…
• Page 125
  ENGINE 3-77 OIL PRESSURE SWITCH • Apply SUZUKI BOND “1207B” to the thread part of the oil pres- sure switch 1 and tighten it to the specified torque. C 99104-31140: SUZUKI BOND “1207B” ! Oil pressure switch: 14 N . m (1.4 kgf . m, 10.0 lb-ft) NOTE: Be careful not to apply SUZUKI BOND “1207B”…
• Page 126
  • Install the gear position switch contacts 1 and the springs 2. • Apply the grease to the O-ring. W 99000-25030: SUZUKI SUPER GREASE “A” • Apply the THREAD LOCK to the gear position switch bolt, in- stall the gear position switch as shown.
• Page 127
  • Apply grease to the O-ring. Use the new O-ring to prevent oil leakage. W 99000-25030: SUZUKI SUPER GREASE “A” • 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 128
  [ 09930-44530: Rotor holder ! Generator rotor bolt: 100 N . m (10.0 kgf . m, 72.3 lb-ft) GENERATOR COVER • Apply SUZUKI BOND “1207B” lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.
• Page 129
  ENGINE 3-81 • Install the CKP sensor. • Apply SUZUKI BOND “1207B” light to the groove of the signal generator lead wire gromet. C 99104-31140: SUZUKI BOND “1207B” CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft.
• Page 130
  • Install the starter idle gear No.2 1, its shaft 2 and the wave washer 3. • Apply SUZUKI BOND “1207B” lightly to the mating surfaces A at the parting line between the upper and lower crankcases and surface B as shown.
• Page 131
  ENGINE 3-83 • Install the new gasket 1 and the dowel pins. Use a new gasket to prevent oil leakage. • Install the starter clutch cover and tighten its bolt as shown. NOTE: * Fit the wire clamp to the starter clutch cover bolt A as shown. * Fit the new gasket washer to the starter clutch cover bolt B as shown.
• Page 132
  3-84 ENGINE GEARSHIFT SYSTEM • Install the gearshift cam stopper 1, its bolt 2, the washer 3 and the return spring 4. NOTE: Apply a small quantity of THREAD LOCK “1342” to the gearshift cam stopper bolt 2 and tighten it to the specified torque. I 99000-32050: THREAD LOCK “1342”…
• Page 133
  OIL PUMP • Install the O-ring to the oil pump and apply grease to it. Use the new O-ring to prevent oil leakage. W 99000-25030: SUZUKI SUPER GREASE “A” NOTE: Set the oil pump shaft end to the water pump shaft.
• Page 134
  3-86 ENGINE CLUTCH • Install the thrust washer onto the countershaft. NOTE: The chamfer side A of the thrust washer faces crankcase side. • Install the oil pump drive gear 1 to the primary driven gear assembly. NOTE: Rotate the crankshaft so as not to contact the primary driven gear and crankshaft balance weight.
• Page 135
  ENGINE 3-87 • Install the clutch sleeve hub 2 onto the countershaft. • Install the washer 3 and spring washer 4. NOTE: The convex side of the washer 4 faces outside. • Install the clutch sleeve hub nut. • Hold the clutch sleeve hub using the special tool. [ 09920-53740: Clutch sleeve hub holder •…
• Page 136
  3-88 ENGINE the clutch sleeve hub in the prescribed order. NOTE: Insert the outermost No.1 drive plate claws A to the other slits B of clutch housing as shown. DRIVE PLATE: Direction of outside A No.1 Drive Plate (Thickness): 3.0 mm (0.12 in) … 8 pcs [Purple paint] B No.2 Drive Plate (Thickness): 3.0 mm (0.12 in) …
• Page 137
  ! Clutch spring set bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) NOTE: Tighten the clutch spring set bolts diagonally. CLUTCH COVER • Apply SUZUKI BOND “1207B” lightly to the mating surfaces at the parting line between the upper, middle and lower crankcases as shown. C 99104-31140: SUZUKI BOND “1207B”…
• Page 138
  3-90 ENGINE cylinder. Use the new gasket to prevent gas leakage. • Place the cylinder head on the cylinder. • Install the cylinder head side bolt 2 and gasket 3 and tighten it to the specified torque. ! Cylinder head side bolt: 14 N . m (1.4 kgf . m, 10.0 lb-ft) NOTE: * The metal side of the gasket A faces out.
• Page 139
  ENGINE 3-91 • Fit the gasket 1 and tighten the water temp. gauge. ! Water temp. gauge: 18 N . m (1.8 kgf . m, 13.0 lb-ft) • Install the thermostat. (5-10) • Install the thermostat cover. ! Thermostat cover bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) NOTE: Fit the clamp to the bolt A .
• Page 140
  3-92 ENGINE CAMSHAFT • Turn the crankshaft clockwise with the box wrench and align the line A on the starter clutch with the index mark B of the valve timing inspection hole while keeping the cam chain pulled up- ward. Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.
• Page 141
  ENGINE 3-93 • Engage the 14 roller pin C on the cam chain with the arrow marked “3” on the intake sprocket. • Bind the cam chain and the sprocket with a proper wire clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders.
• Page 142
  3-94 ENGINE • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust and cam chain guide. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. NOTE: * Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.
• Page 143
  ENGINE 3-95 Cam chain tension adjuster • Retract the push rod by pushing the stopper. • Install the ball 1 to the cam chain tension adjuster. • Install the new gasket 2. Use the new gasket to prevent oil leakage. •…
• Page 144
  3-96 ENGINE…
• Page 145
  • Install the dowel pins. • Install the O-rings. • Install the new gaskets to the cylinder head cover. • Apply SUZUKI BOND “1207B” to the cam end caps of the gas- kets as shown. C 99104-31140: SUZUKI BOND “1207B”…
• Page 146
  ! PAIR reed valve cover bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) STARTER MOTOR • Apply the grease to the O-ring. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the starter motor. ! Starter motor mounting bolt: 10 N . m (1.0 kgf . m, 7 lb-ft)

• Page 147: Fi System And Intake Air

  FI SYSTEM AND INTAKE AIR SYSTEM CONTENTS PRECAUTIONS IN SERVICING …………4- 2 FI SYSTEM TECHNICAL FEATURES ……….4- 8 INJECTION TIME …………….4- 8 COMPENSATION OF INJECTION TIME ……..4- 9 INJECTION STOP CONTROL …………4- 9 FUEL DELIVERY SYSTEM …………4-10 FUEL PUMP ………………

• Page 148
  FI SYSTEM AND INTAKE AIR SYSTEM 4-1 FUEL SYSTEM …………….. 4-51 FUEL TANK LIFT-UP …………..4-51 FUEL TANK REMOVAL …………..4-51 FUEL TANK INSTALLATION …………4-51 FUEL PRESSURE INSPECTION ……….4-52 FUEL PUMP INSPECTION …………4-53 FUEL PUMP RELAY INSPECTION ……….4-55 FUEL PUMP AND FUEL FILTER REMOVAL ……

• Page 149: Precautions In Servicing

  4-2 FI SYSTEM AND INTAKE AIR SYSTEM PRECAUTIONS IN SERVICING When handling the FI component parts or servicing the FI sys- tem, observe the following points for the safety of the system. Click CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.

• Page 150
  FI SYSTEM AND INTAKE AIR SYSTEM 4-3 FUSE • When a fuse blows, always investigate the cause, correct it and then replace the fuse. • Do not use a fuse of a different capacity. • Do not use wire or any other substitute for the fuse. ECM/VARIOUS SENSORS •…

• Page 151: Electrical Circuit Inspection Procedure

  4-4 FI SYSTEM AND INTAKE AIR SYSTEM • Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electro- motive force will be applied to the ECM which may result in serious damage.

• Page 152
  FI SYSTEM AND INTAKE AIR SYSTEM 4-5 • Disconnect the negative cable from the battery. • Check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock if equipped. Sensor Check for loose connection •…
• Page 153
  4-6 FI SYSTEM AND INTAKE AIR SYSTEM VOLTAGE CHECK If voltage is supplied to the circuit being checked, voltage check can be used as circuit check. • With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each ter- minal and body ground.

• Page 154: Using Testers

  If continuity is indicated, the circuit is shorted to the ground between terminals A and B. USING TESTERS • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range.

• Page 155: Fi System Technical Features

  4-8 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations which are determined according to the signals from various sensors that detect the engine and driving conditions.

• Page 156: Compensation Of Injection Time

  FI SYSTEM AND INTAKE AIR SYSTEM 4-9 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR SIG- When atmospheric pressure is low, the sensor sends the signal to the ECM and reduce the injection time (volume).

• Page 157: Fuel Delivery System

  4-10 FI SYSTEM AND INTAKE AIR SYSTEM FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel to flow into the injector installed in the fuel delivery pipe.

• Page 158: Fuel Pump

  FI SYSTEM AND INTAKE AIR SYSTEM 4-11 FUEL PUMP The electric fuel pump is located under the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM.

• Page 159: Fuel Pressure Regulator

  4-12 FI SYSTEM AND INTAKE AIR SYSTEM FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm , 43 psi) applied to the injector at all times. When the fuel pressure rises more than 300 kPa (3.0 kgf/cm , 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank.

• Page 160: Fuel Pump Control System

  FI SYSTEM AND INTAKE AIR SYSTEM 4-13 FUEL PUMP CONTROL SYSTEM When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the side-stand relay and the fuel pump relay causing the motor to turn. Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has been turned on.

• Page 161: Ecm (Fi Control Unit)

  4-14 FI SYSTEM AND INTAKE AIR SYSTEM ECM (FI CONTROL UNIT) The ECM is located under the seat. The ECM consists of CPU (Central Processing Unit), memory (ROM) and I/O (Input/Output) sections. The signal from each sensor is sent to the input section and then sent to CPU. On the basis of signal information received, CPU calculates the volume of fuel necessary for injection using maps programmed for varying engine conditions.

• Page 162: Injection Timing

  FI SYSTEM AND INTAKE AIR SYSTEM 4-15 INJECTION TIMING The system employs a sequential, four-cylinder independent injection type, using the crankshaft position sensor (signal generator) to determine the piston position (injection timing and ignition timing) and the cam- shaft position sensor to identify the cylinder during operation, and these information are sent to the ECM. This makes it possible to inject the optimum volume of fuel in the best timing for the engine operating conditions.

• Page 163: Sensors

  4-16 FI SYSTEM AND INTAKE AIR SYSTEM SENSORS INTAKE AIR PRESSURE SENSOR (IAP SENSOR) The intake air pressure sensor is located at the rear side of the air cleaner box and its vacuum hose is connected to the throttle body. The sensor detects the intake air pressure, which is then con- verted into voltage signal and sent to the ECM.

• Page 164
  FI SYSTEM AND INTAKE AIR SYSTEM 4-17 CRANKSHAFT POSITION SENSOR (CKP SENSOR) The signal rotor is mounted on the right end of the crankshaft, and the crankshaft position sensor (Pick-up coil) is installed on the right side of the middle crankcase. The sensor generates the pick-up signal to be supplied to the ECM.
• Page 165
  4-18 FI SYSTEM AND INTAKE AIR SYSTEM ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) The engine coolant temperature sensor is installed at the rear side of the cylinder head. The sensor detects the engine coolant temperature in thermistor resistance value, which is then converted to voltage signal and sent to the ECM.
• Page 166
  FI SYSTEM AND INTAKE AIR SYSTEM 4-19 TIP OVER SENSOR (TO SENSOR) The tip over sensor is located in ahead of the rear fender. The sensor detects the leaning of the motorcycle. When it leans more than 43°, the mechanical switch turns ON and a signal is sent to the ECM.

• Page 167: Intake Air System

  4-20 FI SYSTEM AND INTAKE AIR SYSTEM INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM The secondary throttle control system (STC system) consists of the secondary throttle valve (ST valve), secondary throttle valve actuator (STV actuator) and ST valve control cables. ST valve is installed in each throttle body.

• Page 168: Operation

  FI SYSTEM AND INTAKE AIR SYSTEM 4-21 OPERATION The secondary throttle control system (STC system) operates on the signal supplied from the ECM. The open/close operation of the secondary throttle valve (ST valve) is performed by the secondary throttle valve actuator (STV actuator) which is controlled by the ECM to change the current direction into the motor of the STV actuator.

• Page 169: Fi System Parts Location

  4-22 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM PARTS LOCATION…

• Page 170
  FI SYSTEM AND INTAKE AIR SYSTEM 4-23…

• Page 171: Fi System Diagram

  4-24 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM DIAGRAM BATTERY RELAY SWITCH FI #1 FI #2 FI #3 FI #4 IATS STVA CMPS ECTS STARTER MOTOR IAPS SPEED SENSOR CKPS…

• Page 172: Fi System Wiring Diagram

  FI SYSTEM AND INTAKE AIR SYSTEM 4-25 FI SYSTEM WIRING DIAGRAM…

• Page 173: Self-Diagnosis Function

  4-26 FI SYSTEM AND INTAKE AIR SYSTEM SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.

• Page 174: Dealer Mode

  FI SYSTEM AND INTAKE AIR SYSTEM 4-27 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.

• Page 175
  4-28 FI SYSTEM AND INTAKE AIR SYSTEM CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMP sensor) Crankshaft position sensor (CKP sensor) Pick-up coil signal, signal generator Intake air pressure sensor (IAP sensor) Throttle position sensor (TP sensor) Engine coolant temp.

• Page 176: Fail-Safe Function

  FI SYSTEM AND INTAKE AIR SYSTEM 4-29 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. ITEM FAIL-SAFE MODE STARTING ABILITY RUNNING ABILITY Camshaft position When camshaft position…

• Page 177: Fi System Troubleshooting

  4-30 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.

• Page 178: Self-Diagnostic Procedures

  FI SYSTEM AND INTAKE AIR SYSTEM 4-31 SELF-DIAGNOSTIC PROCEDURES • Don’t disconnect couplers from ECM, battery cable from bat- tery, ECM ground wire harness from engine or main fuse be- fore confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized information in ECM memory.

• Page 179: Malfunction Code And Defective Condition

  4-32 FI SYSTEM AND INTAKE AIR SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 4 sec. after re- sensor ceiving the starter signal.

• Page 180
  FI SYSTEM AND INTAKE AIR SYSTEM 4-33 Secondary throttle STVA position sensor produces following voltage. valve actuator (0.1 sensor voltage < 4.9) Without the above value, c28 is indicated. STVA motor can not move. STV actuator, STV actuator adjustment, lead wire/coupler. Gear position signal voltage should be higher than the follow- Gear position signal ing for more than 3 seconds.

• Page 181: C11″ Cmp Sensor Circuit Malfunction

  4-34 FI SYSTEM AND INTAKE AIR SYSTEM “C11” CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CMP sensor signal for 4 seconds at engine • Metal particles or foreign material being cranking. attached on the CMP sensor and rotor tip. •…

• Page 182: C12″ Ckp Sensor Circuit Malfunction

  FI SYSTEM AND INTAKE AIR SYSTEM 4-35 “C12” CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for 4 seconds at engine • Metal particles or foreign material being cranking. attached on the CKP sensor and rotor tips. •…

• Page 183: C13″ Iap Sensor Circuit Malfunction

  4-36 FI SYSTEM AND INTAKE AIR SYSTEM “C13” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. • Clogged vacuum passage between throttle High pressure and high voltage. body and IAP sensor. 0.5 V Sensor voltage < 4.85 V •…

• Page 184
  FI SYSTEM AND INTAKE AIR SYSTEM 4-37 Remove the IAP sensor. Ground Connect the vacuum pump gauge to the vacuum port of Vout the IAP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect — terminal to the ground terminal and + terminal to the Vcc terminal.

• Page 185: C14″ Tp Sensor Circuit Malfunction

  4-38 FI SYSTEM AND INTAKE AIR SYSTEM “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. • TP sensor maladjusted. Difference between actual throttle opening and • TP sensor circuit open or short. opening calculated by ECM in larger than specified • TP sensor malfunction. value.

• Page 186
  FI SYSTEM AND INTAKE AIR SYSTEM 4-39 Connect the TP sensor coupler. Insert the copper wires to the lead wire coupler. Turn the ignition switch ON. Measure the TP sensor output voltage at the coupler (be- tween Yellow and Black wires) by turning the throttle grip. Yellow Yellow TP sensor output voltage…

• Page 187: C15″ Ect Sensor Circuit Malfunction

  4-40 FI SYSTEM AND INTAKE AIR SYSTEM “C15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High engine coolant temp. (Low voltage – Low • B/Bl circuit shorted to ground. resistance) • B/Br circuit open. Low engine coolant temp. (High voltage – High •…

• Page 188: C21″ Iat Sensor Circuit Malfunction

  FI SYSTEM AND INTAKE AIR SYSTEM 4-41 “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High intake air temp. (Low voltage – Low • Dg circuit shorted to ground. resistance) • B/Br circuit open. Low intake air temp. (High voltage – High •…

• Page 189: C22″ Ap Sensor Circuit Malfunction

  4-42 FI SYSTEM AND INTAKE AIR SYSTEM “C22” AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. • Clogged air passage with dust. High pressure and high voltage. • Red wire circuit open or shorted to ground. 0.5 V Sensor Voltage <…

• Page 190
  FI SYSTEM AND INTAKE AIR SYSTEM 4-43 Remove the AP sensor. Connect the vacuum pump gauge to the air passage port Vout Ground of the AP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect — terminal to the ground terminal and + terminal to the Vcc terminal.

• Page 191: C23″ To Sensor Circuit Malfunction

  4-44 FI SYSTEM AND INTAKE AIR SYSTEM “C23” TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No TO sensor signal for more than 2 seconds, • TO sensor circuit open or short. after ignition switch turns ON. • TO sensor malfunction. Sensor voltage high.

• Page 192: C24″, «C25», «C26» Or «C27» Ignition System Malfunction

  FI SYSTEM AND INTAKE AIR SYSTEM 4-45 “C24”, “C25”, “C26” or “C27” IGNITION SYSTEM MALFUNCTION *Refer to the IGNITION SYSTEM for details. (7-20) “C28” STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the STV •…

• Page 193
  4-46 FI SYSTEM AND INTAKE AIR SYSTEM Turn the ignition switch OFF. Check the continuity between Yellow wire and ground. Position sensor continuity: ∞Ω ∞Ω ∞Ω ∞Ω ∞Ω (Infinity) If OK, then measure the position sensor resistance. Yellow Yellow Connect the position sensor coupler 1.
• Page 194
  FI SYSTEM AND INTAKE AIR SYSTEM 4-47 If the position sensor output voltage is less than 0.2 V at fully close position, adjust the output voltage to specified by turning out the No.2 cable adjuster 1. Adjusting the cable with the ST valve fully opened or fully closed can damage the STV actuator.

• Page 195: C31″ Gear Position Switch Circuit Malfunction

  4-48 FI SYSTEM AND INTAKE AIR SYSTEM “C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short. Switch voltage low. • Gear Position switch malfunction. Sensor Voltage > 0.6 V •…

• Page 196: C32″, «C33», «C34» Or «C35» Fuel Injection Malfunction

  FI SYSTEM AND INTAKE AIR SYSTEM 4-49 “C32”, “C33”, “C34” or “C35” FUEL INJECTION MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No injector current. • Injector circuit open or short. • Injector malfunction. • ECM malfunction. INSPECTION • Lift and support the fuel tank with its prop stay. ( 4-51) Turn the ignition switch OFF.

• Page 197: C41″ Fp Relay Circuit Malfunction

  4-50 FI SYSTEM AND INTAKE AIR SYSTEM “C41” FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No signal from fuel pump relay. • Fuel pump relay circuit open or short. • Fuel pump relay malfunction. • ECM malfunction. INSPECTION • Remove the front and rear seats. •…

• Page 198: Fuel System

  FI SYSTEM AND INTAKE AIR SYSTEM 4-51 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the front and rear seats. • Remove the fuel tank mounting bolts. • Lift and support the fuel tank with the fuel tank prop stay 1. FUEL TANK REMOVAL •…

• Page 199: Fuel Pressure Inspection

  4-52 FI SYSTEM AND INTAKE AIR SYSTEM FUEL PRESSURE INSPECTION • Lift and support the fuel tank with its prop stay. (4-51) • Place a rag under the fuel pressure check bolt 1 and slowly loosen it and catch the remaining fuel using a suitable con- tainer.

• Page 200: Fuel Pump Inspection

  FI SYSTEM AND INTAKE AIR SYSTEM 4-53 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, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor.

• Page 201
  4-54 FI SYSTEM AND INTAKE AIR SYSTEM • Pull out the power source lead wire 1 (Yellow with red tracer). ECM couplers • Place the measuring cylinder and insert the fuel hose end into the measuring cylinder. • Apply 12 volts to the fuel pump for 30 seconds and measure the amount of fuel discharged.

• Page 202: Fuel Pump Relay Inspection

  FI SYSTEM AND INTAKE AIR SYSTEM 4-55 FUEL PUMP RELAY INSPECTION Fuel pump relay is located in ahead of the rear fender. • Remove the front and rear seats. • Lift and support the fuel tank with its prop stay. (4-51) •…

• Page 203
  4-56 FI SYSTEM AND INTAKE AIR SYSTEM REMOVAL • Remove the fuel tank. (4-51) • Remove the fuel pump assembly by removing its mounting bolts diagonally. » Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the nuts. •…

• Page 204: Fuel Filter Inspection And Cleaning

  FI SYSTEM AND INTAKE AIR SYSTEM 4-57 • Remove the fuel filter. • Remove the fuel pressure regulator holder 1 and the fuel pres- sure regulator 2. FUEL FILTER INSPECTION AND CLEANING If the fuel filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

• Page 205
  4-58 FI SYSTEM AND INTAKE AIR SYSTEM • Pass through the wires behind the thermistors. Thermistor f Thermistor for mistor for high level high level Thermistor f Thermistor for mistor for low le low level w level • Be sure to connect the wires to the proper terminals. A ..
• Page 206
  FI SYSTEM AND INTAKE AIR SYSTEM 4-59 • Install the O-ring and apply grease to it. W 99000-25030: SUZUKI SUPER GREASE “A” » The O-ring must be replaced with a new one to prevent fuel leakage. • When installing the fuel pump assembly, lightly tighten all the…

• Page 207: Throttle Body And Stv Actuator

  4-60 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY AND STV ACTUATOR CONSTRUCTION 1 TP sensor 2 Throttle stop screw 3 Fast idle adjusting screw 4 Fuel delivery pipe 5 O-ring 6 Dust seal 7 Ignitor 8 Cusion seal 9 Vacuum hose 0 STV actuator bracket A STV actuator N .

• Page 208: Throttle Body And Stv Actuator Removal

  FI SYSTEM AND INTAKE AIR SYSTEM 4-61 THROTTLE BODY AND STV ACTUATOR REMOVAL ADJUSTMENT POSITION SETTING PROCEDURE • Turn the ignition switch OFF. • Remove the rear seat. • Connect the special tool to the dealer mode coupler. • After turning the special tool’s switch ON, turn the ignition switch [ 09930-82710: Mode select switch •…

• Page 209
  4-62 FI SYSTEM AND INTAKE AIR SYSTEM • Loosen the throttle body clamp screws. • Remove the air cleaner box mounting bolt. • Remove the air cleaner box. THROTTLE BODY • Disconnect the throttle cables from their drum. • Disconnect the fast idle cable from its cam. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close.
• Page 210
  FI SYSTEM AND INTAKE AIR SYSTEM 4-63 • Disconnect the vacuum hose 1 from the No.4 throttle body. • Disconnect the fuel injector lead wire coupler 2. • Remove the throttle stop screw 3 from the cable guide. • Loosen the throttle body clamp screws at the intake pipe side. •…
• Page 211
  4-64 FI SYSTEM AND INTAKE AIR SYSTEM SECONDARY THROTTLE VALVE ACTUATOR • Disconnect the STV actuator lead wire couplers 1. • Loosen the lock nuts 2. • Hold the actuator pulley 3 with an adjustable wrench, and loosen the pulley mounting bolt 4. When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or STV actuator may get damaged.
• Page 212
  FI SYSTEM AND INTAKE AIR SYSTEM 4-65 • Remove the STV actuator. • Remove the actuator bracket 1. A little portion of the ST valve is visible from the top of the throttle body. Don’t put the secondary valve’s side of the throttle body down, for it may damage the ST valve.

• Page 213: Throttle Body Disassembly

  4-66 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY DISASSEMBLY • Disconnect the TP sensor lead wire coupler 1. • Disconnect the fuel injector lead wire couplers 2. • Remove the fuel delivery pipe assembly 3 by removing its mounting screws. •…

• Page 214: Throttle Body Cleaning

  FI SYSTEM AND INTAKE AIR SYSTEM 4-67 THROTTLE BODY CLEANING » Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.

• Page 215: Throttle Body Reassembly

  4-68 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- bly. Pay attension to the following points: • When installing the TP sensor, align the groove 1 with the lib TP sensor setting procedure 4-28 [ 09930-11960: Torx wrench…

• Page 216
  FI SYSTEM AND INTAKE AIR SYSTEM 4-69 • Apply thin coat of the engine oil to the new fuel injector cushion seals 1, and install them to each fuel injector. Replace the cushion seal with a new one. • Install the seals 2 and O-rings 3 to each fuel injector. •…

• Page 217: Throttle Body And Stv Actuator Installation

  4-70 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY AND STV ACTUATOR INSTALLATION STV ACTUATOR INSTALLATION • Install the STV actuator bracket 1 to the throttle body. • Fit the clamp to the bolt A. • Install the STV actuator to the bracket. ! STV actuator mounting bolt: 5 N .

• Page 218
  FI SYSTEM AND INTAKE AIR SYSTEM 4-71 • Connect the two cables temporarily to the throttle body. No.1 Cable No.1 Cable No.2 Cable No.2 Cable • Connect the cables to the inside slots 1 of the STV actuator pulley. • Install the pulley to the shaft by aligning the groove 2 with the line 3.

• Page 219: Stv Actuator Adjustment

  4-72 FI SYSTEM AND INTAKE AIR SYSTEM STV ACTUATOR ADJUSTMENT 1st step: • Set the STV actuator to adjustment position. (4-61) 2nd step: • Turn out the No.2 cable adjuster 1 until the outer cable play A becomes zero. NOTE: Make sure that outer cable end is fixed into the rubber stopper B .

• Page 220
  FI SYSTEM AND INTAKE AIR SYSTEM 4-73 No.2 cable (2-35 F) 5 N . m (0.5 kgf . m, 3.5 lb-ft) Slack Slack 0 – 1,0 mm 0 – 1.0 mm (0 – 0.04 in) (0 – 0.04 in) Play Play 0 mm 0 mm…
• Page 221
  4-74 FI SYSTEM AND INTAKE AIR SYSTEM 5th step: This procedure is only required when C28 is indicated. • Turn the ignition switch OFF. • Insert the two copper wires into the back side of the position sensor lead wire coupler 1. B/Br B/Br •…

• Page 222: Fuel Injector Inspection

  FI SYSTEM AND INTAKE AIR SYSTEM 4-75 To set the ST valve to fully open position, apply 12 volts to A and B terminals. Positive wire ––– B (Gray wire) terminal Negative wire ––– A (Pink wire) terminal Pink Pink Gray Gray To prevent the motor damage, stop to apply 12V as soon…

• Page 223: Fuel Injector Installation

  4-76 FI SYSTEM AND INTAKE AIR SYSTEM FUEL INJECTOR INSTALLATION • Apply thin coat of the engine oil to new injector cushion seals and O-rings. • Install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. ( 4-68) FAST IDLE ADJUSTMENT The fast idle system is a kind of starter system, which opens throttle valve by the fast idle cam mechanically.

• Page 224: Throttle Valve Synchronization

  FI SYSTEM AND INTAKE AIR SYSTEM 4-77 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH GAUGE • Lift and support the fuel tank. ( 4-51) • Start up the engine and run it in idling condition for warming •…

• Page 225
  4-78 FI SYSTEM AND INTAKE AIR SYSTEM • Connect one of the four rubber hoses of the vacuum balancer gauge to the nipple 1 on the No.1 throttle body. [ 09913-13121: Vacuum balancer gauge • Connect a tachometer. • Start up the engine and keep it running at 1 200 rpm by turning throttle stop screw 2.
• Page 226
  FI SYSTEM AND INTAKE AIR SYSTEM 4-79 THROTTLE VALVE SYNCHRONIZATION • To synchronize throttle valves, remove the rubber caps 1 from each vacuum nipple and connect the vacuum balancer gauge hoses to the vacuum nipples respectively. [ 09913-13121: Vacuum balancer gauge •…

• Page 227: Throttle Position Sensor (Tps) Setting

  4-80 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS set- ting condition. (Refer to page 4-28 for TPS setting procedure.) THROTTLE CABLE ADJUSTMENT NOTE: Minor adjustment can be made by the throttle grip side adjuster. ( 2-16) MAJOR ADJUSTMENT •…

• Page 228: Sensors

  FI SYSTEM AND INTAKE AIR SYSTEM 4-81 SENSORS IAP SENSOR INSPECTION The intake air pressure sensor is located at the rear side of the air cleaner box. ( 4-36) IAP SENSOR REMOVAL/INSTALLATION • Lift and support the fuel tank. ( 4-51) •…

• Page 229: Ect Sensor Inspection

  4-82 FI SYSTEM AND INTAKE AIR SYSTEM ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the rear side of the cylinder head. ( 4-40 and 5-8) ECT SENSOR REMOVAL/INSTALLATION ( 5-8 and -9) AP SENSOR INSPECTION The atmospheric pressure sensor is located beneath the left side of the seat rail.

• Page 230: Cooling And Lubrication

  COOLING AND LUBRICATION SYSTEM 5-1 COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT …………….5- 2 COOLING CIRCUIT …………….5- 3 COOLING CIRCUIT INSPECTION ……….5- 3 RADIATOR AND WATER HOSES ………… 5- 4 RADIATOR REMOVAL …………..5- 4 RADIATOR CAP INSPECTION …………. 5- 4 RADIATOR INSPECTION AND CLEANING ………

• Page 231: Engine Coolant

  5-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a Anti-freeze Freezing point 50:50 mixture of distilled water and ethylene glycol anti-freeze. density This 50:50 mixture will provide the optimum corrosion protection –30°C (–24°F) and excellent heat protection, and will protect the cooling system –40°C (–44°F)

• Page 232: Cooling Circuit

  COOLING AND LUBRICATION SYSTEM 5-3 COOLING CIRCUIT RESERVE ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER COOLING FAN THERMO RADIATOR SWITCH WATER PUMP OIL COOLER COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. •…

• Page 233: Radiator And Water Hoses

  5-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowling. (6-5) • Drain engine coolant. (2-18) • Remove the radiator. (3-4 and -5) RADIATOR CAP INSPECTION • Fit the cap 1 to the radiator cap tester 2. •…

• Page 234: Radiator Remounting

  COOLING AND LUBRICATION SYSTEM 5-5 RADIATOR REMOUNTING • Install the radiator. • Route the radiator hoses. (8-24) • Pour engine coolant. (2-18) • Bleed the air from the cooling circuit. (2-19) • Install the under cowling. (6-5) WATER HOSE INSPECTION •…

• Page 235: Cooling Fan

  5-6 COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the under cowling. (6-5) • Drain engine coolant. (2-18) • Remove the radiator. (3-4 and -5) • Remove the cooling fan. INSPECTION • Remove the under cowling. (6-5) • Disconnect the cooling fan lead wire coupler 1. •…

• Page 236: Inspection

  COOLING AND LUBRICATION SYSTEM 5-7 INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure. Connect the thermo-switch to a circuit tester and place it in the oil contained in a pan, which is placed on a stove. •…

• Page 237: Engine Coolant Temperature Sensor

  5-8 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SENSOR REMOVAL • Remove the under cowling. (6-5) • Drain engine coolant. (2-18) • Remove the front and rear seats. (6-8) • Lift and support the fuel tank. (4-51) • Remove the air cleaner box. (4-60 and -61) •…

• Page 238: Installation

  COOLING AND LUBRICATION SYSTEM 5-9 INSTALLATION • Tighten the engine coolant temperature sensor to the specified torque. ! Engine coolant temperature sensor: 18 N . m (1.8 kgf . m, 13.0 lb-ft) Take special care when handling the temperature sen- sor.

• Page 239: Inspection

  5-10 COOLING AND LUBRICATION SYSTEM INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner. • Pass a string between flange, as shown in the illustration. • Immerse the thermostat in the water contained in a beaker, as shown in the illustration.

• Page 240: Water Pump

  COOLING AND LUBRICATION SYSTEM 5-11 • Install the thermostat case. NOTE: Fit the clamp to the thermostat case bolt A . • Tighten the thermostat case bolt to the specified torque. ! Thermostat case bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) •…

• Page 241
  5-12 COOLING AND LUBRICATION SYSTEM • Remove the engine sprocket cover 1. • Disconnect the water hoses. • Remove the water pump. • Remove the water pump cover. • Remove the impeller securing bolt 2 by holding the impeller shaft with a water pump pliers.
• Page 242
  COOLING AND LUBRICATION SYSTEM 5-13 • Remove the mechanical seal ring 1 and the rubber seal 2 from the impeller. • Remove the impeller shaft 3. • Remove the bearing using the special tool. [ 09921-20220: Bearing remover set ( φ 10) NOTE: If no abnormal noise, bearing removal is not necessary.

• Page 243: Inspection

  5-14 COOLING AND LUBRICATION SYSTEM INSPECTION BEARING • Inspect the play of the bearing by hand while it is in the water pump case. • Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • Replace the bearing if there is anything unusual. MECHANICAL SEAL •…

• Page 244: Reassembly And Installation

  [ 09913-70210: Bearing installer set ( φ 20) NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. W 99000-25030: SUZUKI SUPER GREASE “A”…

• Page 245
  5-16 COOLING AND LUBRICATION SYSTEM • Apply grease to the impeller shaft. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the impeller shaft to the water pump body. • Install the rubber seal 1 into the impeller. • After wiping off the oily or greasy matter from the mechanical seal ring, install it into the impeller.
• Page 246
  * Apply engine coolant to the O-ring 1 . * Apply grease to the O-ring 2 . W 99000-25030: SUZUKI SUPER GREASE “A” • Tighten the water pump cover screws to the specified torque. ! Water pump cover screw: 6 N . m (0.6 kgf . m, 4.5 lb-ft) •…

• Page 247: Lubrication System

  5-18 COOLING AND LUBRICATION SYSTEM WATER PUMP OIL PUMP LUBRICATION SYSTEM OIL PRESSURE 2-31 OIL FILTER 2-13 OIL PRESSURE REGULATOR 3-46 OIL STRAINER 3-46 OIL JET 3-58 OIL PUMP 3-44 OIL PRESSURE SWITCH 7-39…

• Page 248: Engine Lubrication System Chart

  COOLING AND LUBRICATION SYSTEM 5-19 ENGINE LUBRICATION SYSTEM CHART INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER CAMSHAFT JOURNALS, CAMFACES AND TAPPETS EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER CAMSHAFT JOURNALS, CAM DRIVE CHAIN CAMFACES AND TAPPETS STARTER CLUTCH SUB-GALLERY OIL HOSE #1 PISTON COOLING #2 PISTON COOLING #3 PISTON COOLING #4 PISTON COOLING…

• Page 249: Engine Lubrication System

  5-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM To sub-gallery MAIN GALLERY…

• Page 250: System

  COOLING AND LUBRICATION SYSTEM 5-21…

• Page 251
  CHASSIS CONTENTS EXTERIOR PARTS …………….6- 2 CONSTRUCTION…………….6- 2 FASTENER REMOVAL AND REINSTALLATION ……. 6- 4 SCREEN ………………6- 4 BODY COWLING COVER …………. 6- 5 RIGHT AND LEFT UNDER COWLINGS ……..6- 5 BODY COWLING …………….6- 6 RIGHT AND LEFT AIR INTAKE PIPES……..
• Page 252
  CHASSIS 6-1 REAR SUSPENSION …………… 6-50 CONSTRUCTION…………….6-50 REMOVAL ………………6-52 INSPECTION AND DISASSEMBLY ……….6-54 REASSEMBLY …………….6-56 REMOUNTING …………….6-58 FINAL INSPECTION AND ADJUSTMENT ……..6-59 FRONT BRAKE …………….6-60 CONSTRUCTION…………….6-60 BRAKE PAD REPLACEMENT …………. 6-61 BRAKE FLUID REPLACEMENT ……….6-61 CALIPER REMOVAL AND DISASSEMBLY ……..

• Page 253: Exterior Parts

  6-2 CHASSIS EXTERIOR PARTS CONSTRUCTION…

• Page 254: Heat Shield

  CHASSIS 6-3 Front seat 23 N . m (2.3 kgf . m, 16.5 lb-ft) Frame cover HEAT SHIELD Left under cowling Left under cowling heat shield No.1 Right under cowling Left under cowling Left under cowling heat shield No.3 heat shield No.2 Right under cowling heat shield No.1 Center under cowling…

• Page 255: Fastener Removal And Reinstallation

  6-4 CHASSIS FASTENER REMOVAL AND REINSTALLATION FASTENER a REMOVAL • Depress the head of fasteners center piece 1. • Pull out the fastener. INSTALLATION • Let the center piece stick out toward the head so that the pawls 2 close. •…

• Page 256: Body Cowling Cover

  CHASSIS 6-5 BODY COWLING COVER • With all the fasteners removed, remove the body cowling cover RIGHT AND LEFT UNDER COWLINGS • Remove the fastener. • Remove the fastener. • With the bolts removed, remove the right under cowling. • Disconnect the turn signal light coupler. •…

• Page 257: Body Cowling

  6-6 CHASSIS BODY COWLING • Remove the rear view mirrors, right and left, by removing the bolts. • Remove the fasteners. • Remove all the bolts. • Disconnect the headlight coupler. REMOUNTING NOTE: When remounting the body cowling, install the hooks A to the cowling brace holes.

• Page 258: Right And Left Air Intake Pipes

  CHASSIS 6-7 RIGHT AND LEFT AIR INTAKE PIPES • Remove the body cowling. • With the fastener removed, remove the right air intake pipe • With the fastener removed, remove the left air intake pipe 2. COWLING BRACE REMOVAL • Remove the body cowling. ( 6-6) •…

• Page 259: Front Seat

  6-8 CHASSIS FRONT SEAT • With the bolts removed, remove the front seat. REAR SEAT AND SEAT TAIL COVER • Remove the rear seat (seat tail cover) with the ignition key. FRAME COVER • Remove the seats. • Remove the bolts. •…

• Page 260: Front Wheel

  CHASSIS 6-9 FRONT WHEEL CONSTRUCTION 1 Brake disc 2 Dust seal 3 Bearing 4 Spacer 5 Spacer nut 6 Front wheel A Front axle B Brake disc bolt (Front) N . m kgf . m ITEM lb-ft 10.0 72.5 16.5…

• Page 261
  6-10 CHASSIS Left Right 25 N . m (2.5 kgf . m, 18.1 lb-ft) 25 N . m (2.5 kgf . m, 18.1 lb-ft) 23 N . m (2.3 kgf . m, 16.5 lb-ft) 23 N . m (2.3 kgf . m, 16.5 lb-ft) 100 N .

• Page 262: Removal

  CHASSIS 6-11 REMOVAL • Remove the brake calipers, left and right. Do not operate the brake lever while removing the cali- pers. • Loosen two axle pinch bolts 1 on the right front fork leg. • Loosen the front axle 2. •…

• Page 263: Inspection And Disassembly

  6-12 CHASSIS INSPECTION AND DISASSEMBLY TIRE INSPECTION: 6-71 • Remove the brake disc. BRAKE DISC INSPECTION: 6-62 • Remove both side dust seals by using the oil seal remover. [ 09913-50121: Oil seal remover The removed dust seals must be replaced with new ones.

• Page 264
  CHASSIS 6-13 • Remove the wheel bearings by using the special tool A or B. [ 09921-20220: A Bearing remover set or 09944-60210: B Wheel bearing remover The removed bearings should be replaced with new ones.

• Page 265: Reassembly And Remounting

  6-14 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 25 N . m (2.5 kgf . m, 18.1 lb-ft) 25 N . m (2.5 kgf .

• Page 266
  CHASSIS 6-15 WHEEL BEARING • Apply grease to the wheel bearings. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the wheel bearings as follows by using the special tools. [ 09941-34513: Bearing/Steering race installer set First install the left wheel bearing, then install the right wheel bearing.
• Page 267
  6-16 CHASSIS SPACER NUT After touching the flange of spacer nut being contact with the left front fork leg, tighten the two axle pinch bolts on the left front fork leg to the specified torque. ! Front axle pinch bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) WHEEL Install the front wheel with the front axle and hand-tighten the front axle temporarily.

• Page 268: Front Fork

  CHASSIS 6-17 FRONT FORK CONSTRUCTION 1 Spring adjuster bolt 2 O-ring 3 Spring adjuster 4 Rebound damping force adjuster 5 Rubber seat 6 Spacer 7 Spring 8 Oil flow pipe 9 Inner rod/damper rod (cartridge) 0 Outer tube A Anti-friction metal B Oil seal N .

• Page 269: Removal And Disassembly

  6-18 CHASSIS REMOVAL AND DISASSEMBLY • Remove the body cowling. ( 6-6) • Remove the front wheel. ( 6-11) • Disconnect the brake hose from the brake hose guides on the front fender. • Remove the front fender. • Loosen the front fork upper clamp bolts 1, left and right. •…

• Page 270
  CHASSIS 6-19 • Remove the front fork cap bolt from the inner rod by loosening the lock nut. • Compress the fork spring with the special tool A and remove the special tool B. • Remove the rubber seat 1, washer 2, spacer seat 3, spacer 4, oil flow pipe 5 and spring 6.
• Page 271
  6-20 CHASSIS • Remove the inner rod/damper rod (cartridge) 1 and plate 2. Do not disassemble the inner rod/damper rod (cartridge). • Remove the dust seal 3 and the oil seal stopper ring 4. • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the inner tube.

• Page 272: Inspection

  CHASSIS 6-21 FRONT FORK CAP BOLT DISASSEMBLY • Remove the spring adjuster stopper ring. • Remove the spring adjuster bolt 1 and adjuster 2. • Remove the rebound damping force adjuster 3. INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and outer tube inner sur- face for scratches.

• Page 273: Reassembly And Remounting

  • Apply grease to the oil seal lip lightly before installing it. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the dust seal, oil seal stopper ring, oil seal, oil seal re- tainer and anti-friction metal onto the inner tube.

• Page 274
  CHASSIS 6-23 COMPRESSION DAMPING FORCE ADJUSTER • Tighten the compression damping force adjuster to the speci- fied torque. ! Compression damping force adjuster: 18 N . m (1.8 kgf . m, 13.0 lb-ft) The removed O-ring must be replaced with a new one. DAMPER ROD BOLT Insert the inner rod/damper rod (cartridge) and the plate into the inner tube and tighten the damper rod bolt to the specified…
• Page 275
  [ 09943-74111: Front fork oil level gauge Fork oil level: 103 mm (4.06 in) 99000-99001-SS8: SUZUKI FORK OIL SS-08 (#10) or an equivalent fork oil Capacity (each leg): 473 ml (16.0/16.7 US/lmp oz)
• Page 276
  CHASSIS 6-25 FORK SPRING Upper side • Install the fork spring as shown in the illustration. Lower side FRONT FORK CAP BOLT • Adjust the height A of the rebound damping force adjuster at 1.5 mm (0.06 in). • Install the rebound damping force adjuster housing to the cap bolt.
• Page 277
  6-26 CHASSIS • Install the front fork cap bolt to the outer tube temporarily. • Set the upper surface of the outer tube at 4.0 mm (0.16 in) height A from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts to the speci- fied torque.

• Page 278: Suspension Setting

  CHASSIS 6-27 SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damp- ing force as follows. SPRING PRE-LOAD ADJUSTMENT There are seven grooved lines on the side of the spring ad- juster. Position 0 provides the maximum spring pre-load and position 7 provides the minimum spring pre-load.

• Page 279: Steering Damper

  • Install the steering damper and tighten the bolt and nut. ! Steering damper bolt and nut: 23 N . m (2.3 kgf . m, 16.5 lb-ft) • Apply grease to the bearings and dust seals. W 99000-25030: SUZUKI SUPER GREASE “A”…

• Page 280: Steering

  CHASSIS 6-29 STEERING CONSTRUCTION 1 Steering stem upper bracket 2 Handlebar 3 Handlebar balancer 4 Steering stem nut 5 Dust seal 6 Bearing 7 Steering stem lower bracket A Steering stem head nut B Steering stem lock nut C Front fork upper clamp bolt D Handlebar clamp bolt E Handlebar set bolt F Front fork lower clamp bolt…

• Page 281
  6-30 CHASSIS • Remove the left and right handlebars by removing its set bolts. • Remove the left and right handlebar switch lead wires from the guide. NOTE: Place the rags under each handlebar to prevent scratching the upper fairing and the air intake pipes. •…

• Page 282: Inspection And Disassembly

  CHASSIS 6-31 INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal noise of bearing If any abnormal points are found, replace defective parts with the new ones.

• Page 283
  6-32 CHASSIS BEARING • Apply grease to the bearings and bearing races. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race. STEM NUT •…

• Page 284: Steering Tension Adjustment

  CHASSIS 6-33 FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem upper bracket following steps: 1) Install the upper bracket, washer 1 and steering stem head nut 2 temporarily. 2) Set the front forks and tighten the steering stem head nut 2. ! Steering stem head nut: 90 N .

• Page 285: Handlebar

  6-34 CHASSIS HANDLEBAR CONSTRUCTION 1 Left handle grip 2 Right handle grip 3 Right handle switch 4 Left handle switch N . m kgf . m 5 handlebar ITEM lb-ft 6 Handle balancer 16.5 A Handlebar clamp bolt B Handlebar set bolt REMOVAL AND DISASSEMBLY RIGHT HANDLEBAR •…

• Page 286: Reassembly And Remounting

  CHASSIS 6-35 • Remove the handlebar set bolts. • With the handlebar clamp bolts and steering stem head nut loosened, remove the steering stem upper bracket. • With the handlebar clamp bolts loosened, draw out the handle- bars to upward. REASSEMBLY AND REMOUNTING Reassemble and remount the handlebar in the reverse order of removal and disassembly.

• Page 287
  • When remounting the right and left handle switches, engage the stopper with the handlebar hole. • Apply the grease to the throttle cables and their holder. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the front brake master cylinder. ( 6-64)

• Page 288: Rear Wheel

  CHASSIS 6-37 REAR WHEEL CONSTRUCTION 1 Rear axle 2 Caliper bracket 3 Brake disc 4 Collar 5 Bearing 6 Rear wheel 7 Spacer 8 Bearing 9 Cushion 0 Spacer A Sprocket drum B Sprocket C Bearing D Dust seal E Collar A Brake disc bolt B Rear sprocket nut C Rear axle nut…

• Page 289
  6-38 CHASSIS Left Right 35 N . m (3.5 kgf . m, 25.5 lb-ft) 120 N . m (12.0 kgf . m, 86.8 lb-ft) 26 N . m (2.6 kgf . m, 19.0 lb-ft) For the others 110 N . m 7.5 N .

• Page 290: Removal

  CHASSIS 6-39 REMOVAL • Remove the cotter pin. (For Canada and USA) • Loosen the axle nut. • Raise the rear wheel off the ground and support the motor- cycle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. •…

• Page 291: Inspection And Disassembly

  6-40 CHASSIS • Remove the collar 1. • Remove the brake disc. INSPECTION AND DISASSEMBLY TIRE INSPECTION: 2-25 and 6-71 WHEEL INSPECTION: 6-11 and 71 REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. Axle shaft runout: Service Limit: 0.25 mm (0.010 in) [ 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand…

• Page 292
  CHASSIS 6-41 BEARINGS Inspect the play of the wheel and sprocket mounting drum bear- ings by hand while they are in the wheel and drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. •…

• Page 293: Reassembly And Remounting

  6-42 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 35 N . m (3.5 kgf . m, 25.5 lb-ft) 120 N . m (12.0 kgf .

• Page 294
  CHASSIS 6-43 BEARINGS • Apply grease to the bearings before installing. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the new bearing to the sprocket mounting drum using the special tool. [ 09924-84510: Bearing installer set • First install the right wheel bearing, then install the left wheel bearing using the special tool.
• Page 295
  • Install the new dust seal using proper drift. • Apply grease to the dust seal lip before assembling rear wheel. W 99000-25030: SUZUKI SUPER GREASE “A” BRAKE DISC • Apply THREAD LOCK SUPER “1360” to the disc bolts and tighten them to the specified torque.
• Page 296
  CHASSIS 6-45 REAR AXLE • Remount the rear wheel and rear axle shaft, install the washer 1 and rear axle nut 2. • Adjust the chain slack after rear wheel installation. ( 2-20) • Tighten the rear axle nut 2 to the specified torque. ! Rear axle nut: 110 N .

• Page 297: Rear Shock Absorber

  6-46 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION 1 Rear shock absorber 2 Height adjuster A Rear shock absorber mounting bolt/nut B Height adjuster nut N . m kgf . m ITEM lb-ft 36.0 11.5 83.2 Left Right…

• Page 298: Removal

  CHASSIS 6-47 REMOVAL • Support the motorcycle with a jack to be no load for the rear shock absorber. • Remove the rear shock absorber upper mounting bolt and nut. • Remove the rear cushion lever bolt and nut. • Remove the rear shock absorber lower mounting bolt and nut. •…

• Page 299: Rear Shock Absorber Scrapping Procedure

  6-48 CHASSIS REAR SHOCK ABSORBER SCRAPPING PROCEDURE » * Handle the rear shock absorber with caution since a high pressure nitrogen gas is contained. * Avoid incineration, exposure to high pressure or over- hauling. * In the case of scrapping the rear shock absorber, evacuate gas in the following procedures.

• Page 300: Suspension Setting

  CHASSIS 6-49 SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The set length 186.5 mm provides the maximum spring pre- load. The set length 196.5 mm provides the minimum spring pre-load. (STD length: 191.5 mm) DAMPING FORCE ADJUSTMENT (Rebound side)

• Page 301
  6-50 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Rear cushion rod 3 Rear cushion lever 4 Spacer 5 Bearing 6 Dust seal 7 Torque link 8 Chain cover 9 Chain buffer 0 Chain adjuster A Chain adjuster lock nut A Rear shock absorber mount- ing bolt/nut B Rear cushion lever bolt/nut…
• Page 302
  CHASSIS 6-51 Left Right 50 N . m (5.0 kgf . m, 36.0 lb-ft) 78 N . m (7.8 kgf . m, 56.5 lb-ft) 15 N . m 1.5 kgf . m 11.0 lb-ft 90 N . m 100 N . m 9.0 kgf .
• Page 303
  6-52 CHASSIS REMOVAL • Raise the rear wheel off the ground and support the motor- cycle with a jack or a wooden block. • Remove the rear wheel. ( 6-39) • Remove the side-stand. ( 8-26) • Remove the rear brake hose union bolt. •…
• Page 304
  CHASSIS 6-53 • Remove the swingarm pivot shaft lock nut by using the special tool. [ 09940-14970: Swingarm pivot thrust adjuster socket wrench • Hold the swingarm pivot shaft 1 with a 27 mm socket wrench and remove the swingarm pivot nut 2 with a 36 mm socket wrench.
• Page 305
  6-54 CHASSIS INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm. • Remove the spacers from the cushion lever. • Inspect the spacers for any flaws or other damage. If any de- fects are found, replace the spacers with new ones. SWINGARM BEARING Insert the spacer into bearing and check the play when moving the spacer up and down.
• Page 306
  CHASSIS 6-55 CUSHION LEVER BEARING Insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Draw out the cushion lever bearings with the special tool. [ 09921-20220: Bearing remover set The removed bearings must be replaced with new ones.

• Page 307: Reassembly

  6-56 CHASSIS REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: Left Right 50 N . m (5.0 kgf . m, 36.0 lb-ft) 78 N . m (7.8 kgf . m, 56.5 lb-ft) 15 N .

• Page 308
  • Press the bearings into the cushion lever with the special tool. [ 09941-34513: Steering race installer NOTE: When installing the bearing, stamped mark on bearing must face outside. • Apply grease to the bearings, spacers, washers and dust seals. W 99000-25030: SUZUKI SUPER GREASE “A”…

• Page 309: Remounting

  6-58 CHASSIS • Assemble the cushion rod onto the swingarm. ( 6-58) ! Cushion rod mounting nut: 78 N . m (7.8 kgf . m, 56.5 lb-ft) • Install the torque link and tighten the rear torque link nut. ! Torque link nut (Front): 28 N . m (2.8 kgf . m, 20.0 lb-ft) REMOUNTING Remount the swingarm in the reverse order of disassembly and removal, and pay attention to the following points.

• Page 310: Final Inspection And Adjustment

  CHASSIS 6-59 SHOCK ABSORBER AND CUSHION LEVER MOUNTING • Install the washers A and cushion lever. ! Cushion lever mounting nut: 78 N . m (7.8 kgf . m, 56.5 lb-ft) • Assemble the cushion lever, cushion rod and rear shock ab- sorber.

• Page 311: Front Brake

  6-60 CHASSIS FRONT BRAKE CONSTRUCTION 1 Front brake lever 2 Dust boot 3 Piston set 4 Piston set (Trailing) 5 Piston set (Leading) 6 Brake pad 7 Brake pad spring 8 Pad mounting pin 9 Brake hose 0 Brake hose A Front master cylinder mounting bolt B Brake hose union bolt C Caliper mounting bolt…

• Page 312: Brake Pad Replacement

  CHASSIS 6-61 BRAKE PAD REPLACEMENT • Remove the spring 1. • Remove the brake pads by removing the clip 2 and pad mount- ing pin 3. * Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected.

• Page 313: Caliper Removal And Disassembly

  6-62 CHASSIS CALIPER REMOVAL AND DISASSEMBLY • Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.

• Page 314: Caliper Inspection

  CHASSIS 6-63 • Remove the dust seals and piston seals. Do not reuse the dust seals and piston seals to pre- vent fluid leakage. CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches or other damage.

• Page 315: Brake Disc Inspection

  6-64 CHASSIS • Tighten each bolt to the specified torque. ! Front brake caliper housing bolt 1: 21 N . m (2.1 kgf . m, 15.1 lb-ft) Front brake caliper mounting bolt 2: 25 N . m (2.5 kgf . m, 18.1 lb-ft) Front brake hose union bolt 3: 23 N .

• Page 316: Master Cylinder Removal And Disassembly

  CHASSIS 6-65 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Disconnect the front brake light switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid. Remove the union bolt and dis- connect the brake hose.

• Page 317: Master Cylinder Inspection

  6-66 CHASSIS • Pull out the dust boot 1 and remove the circlip 2. [ 09900-06108: Snap ring pliers. • Remove the piston/secondary cup, primary cup and return spring. 3 Secondary cup 4 Piston 5 Primary cup 6 Return spring •…

• Page 318
  CHASSIS 6-67 • When remounting the brake master cylinder onto the handle- bar, align the master cylinder holder’s mating surface with punched mark A on the handlebar and tighten the upper clamp bolt first as shown. ! Front brake master cylinder mounting bolt: 10 N . m (1.0 kgf .

• Page 319: Rear Brake

  6-68 CHASSIS REAR BRAKE CONSTRUCTION N . m kgf . m ITEM lb-ft 1 Brake pedal 2 Piston/cup set 16.5 3 Reservoir tank hose 4 Brake hose A Caliper air bleeder valve 18.1 5 Pad B Brake hose union bolt 6 Inner shim C Rear brake caliper mounting bolt 7 Outer shim…

• Page 320: Brake Pad Replacement

  CHASSIS 6-69 BRAKE PAD REPLACEMENT • Remove the brake pad cover. • Remove the clip 1. • Remove the brake pads along with the shims by removing the brake pad mounting pins 2 and springs 3. * Do not operate the brake pedal while dismounting the pads.

• Page 321: Caliper Removal And Disassembly

  6-70 CHASSIS CALIPER REMOVAL AND DISASSEMBLY • Remove the union bolt 1 and catch the brake fluid in a suitable receptacle. Never reuse the brake fluid left over from previous ser- vicing and stored for long periods. » Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.

• Page 322: Caliper Inspection

  CHASSIS 6-71 CALIPER INSPECTION CALIPER INSPECTION: 6-63 6-63 PISTON: DISC: 6-64 Service Limit: Rear disc thickness: 4.5 mm (0.18 in) Rear disc runout: 0.30 mm (0.012 in) CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of re- moval and disassembly.

• Page 323: Master Cylinder Removal And Disassembly

  6-72 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY • Remove the frame cover. ( 6-8) • Remove the brake fluid reservoir tank mounting bolt 1. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 2 and disconnect the brake hose.

• Page 324: Master Cylinder Inspection

  CHASSIS 6-73 MASTER CYLINDER INSPECTION CYLINDER, PISTON AND CUP SET Inspect the cylinder bore wall for any scratches or other damage. Inspect the cup set and each rubber part for damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse or- der of removal and disassembly.

• Page 325: Tire And Wheel

  6-74 CHASSIS TIRE AND WHEEL TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

• Page 326: Valve Inspection

  CHASSIS 6-75 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 peeling or has dam- age. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.

• Page 327
  6-76 CHASSIS • When installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation. • Align the chalk mark put on the tire at the time of removal with the valve position. •…

• Page 328: Drive Chain

  CHASSIS 6-77 DRIVE CHAIN Use the special tool in the following procedures, to cut and re- join the drive chain. [ 09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.

• Page 329: Drive Chain Connecting

  6-78 CHASSIS • Place the drive chain link being disjointed on the holder part 8 of the tool. • Turn in both the adjuster bolt 6 and pressure bolt “A” 3 so that each of their end hole fits over the chain joint pin properly. •…

• Page 330
  CHASSIS 6-79 • Apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0. NOTE: When positioning the joint plate 0 on the tool, face its stamp mark on the joint plate holder 3 side. •…
• Page 331
  6-80 CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pres- sure bolt “A” 3 with the bar until the pin end diameter becomes the specified dimension. Pin end diameter specification D 5.45 – 5.85 mm (0.215–0.230 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 332: Electrical System

  ELECTRICAL SYSTEM 7-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING …………… 7- 2 LOCATION OF ELECTRICAL COMPONENTS …….. 7- 4 CHARGING SYSTEM …………… 7- 6 DESCRIPTION …………….7- 6 TROUBLESHOOTING …………..7- 8 INSPECTION …………….. 7- 9 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM …………..

• Page 333: Cautions In Servicing

  7-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it.

• Page 334
  • Route the wire harness properly according to “WIRE HARNESS ROUTING”. ( 8-14 – 16) USING MULTI CIRCUIT TESTER • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range.

• Page 335: Location Of Electrical Components

  7-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Battery 0 Handlebar switch (R) 2 ECM (Engine Control Module) A Rear brake switch 3 Tip over sensor ( 4-44) B Starter motor 4 Fuel pump relay C Crankshaft position sensor 5 Secondary valve actuator D Oil pressure switch 6 Throttle position sensor E Horn…

• Page 336
  ELECTRICAL SYSTEM 7-5 1 Clutch lever position switch B Cooling fan thermo-switch ( 5-6) 2 Handlebar switch (L) C Cooling fan ( 5-5) 3 Camshaft position sensor ( 4-34) D Intake air pressure sensor ( 4-36) 4 Ignition coil (No. 1, 2, 3, 4) E Engine coolant temp.

• Page 337: Charging System

  7-6 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in the figure, which is composed of the generator, regulator/ rectifier unit and battery. The AC current generated from the generator is rectified by the rectifier and is turned into DC current, then it charges the battery.

• Page 338
  ELECTRICAL SYSTEM 7-7 When the engine r/min becomes higher, the generated voltage of the generator also becomes higher and the voltage between the battery terminals becomes high accordingly. When it reaches the adjusted voltage of the I.C., (Integrated Circuit) and it is turned “ON”, a signal will be sent to the SCR (Thyristor) gate probe and the SCR will be turned “ON”.

• Page 339: Troubleshooting

  7-8 ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories. are installed amounts of electricity. No accessories Check the battery for current Current leaks • Short circuit of wire harness leaks. ( 7-9) •…

• Page 340: Inspection

  ELECTRICAL SYSTEM 7-9 INSPECTION BATTERY CURRENT LEAK INSPECTION • Remove the front seat. ( 6-8) • Turn the ignition switch to the OFF position. • Disconnect the battery lead wire. • Connect the multi circuit tester between the terminal and lead wire of the battery.

• Page 341
  7-10 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE INSPECTION • Remove the frame cover. ( 6-8) • Disconnect the generator coupler. Measure the resistance between the three lead wires. Also check that the stator core is insulated. If the resistance is not specified value, replace the stator with a new one.

• Page 342: Starter System And Side-Stand/Ignition Interlock System

  ELECTRICAL SYSTEM 7-11 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, turn signal/side-stand relay, side-stand switch, gear position switch, starter button, engine stop switch, ignition switch and battery.

• Page 343
  7-12 ELECTRICAL SYSTEM The circuit consists of the turn signal/side-stand relay, neutral indicator light, gear position switch and side- stand switch. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side-stand is either up or down. The gear position and side-stand switches work to- gether in this system.

• Page 344: Troubleshooting

  ELECTRICAL SYSTEM 7-13 TROUBLE SHOOTING Starter motor will not run. The transmission is in neutral. Grasp the Check if the starter motor runs clutch lever, turn on the ignition switch when its terminal is connected with the engine stop switch in the “RUN” Clicks to the battery terminal (Do…

• Page 345: Starter Motor Removal And Disassembly

  7-14 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND DISASSEMBLY • Disconnect the starter motor lead wire. ( 3-6) • Remove the starter motor. ( 3-16) • Disassemble the starter motor as shown in the illustration. 10 N . m (1.0 kgf . m, 7.0 lb-ft) 1 O-ring 2 Housing end (inside) 3 Starter motor case…

• Page 346: Starter Motor Reassembly

  Replace the O-ring with a new one to prevent oil leak- age and moisture. • Apply grease to the lip of the oil seal. W 99000-25030: SUZUKI SUPER GREASE “A” • Apply grease to the O-ring, and remount the starter motor. (3-98)

• Page 347: Starter Relay Inspection

  7-16 ELECTRICAL SYSTEM STARTER RELAY INSPECTION • Remove the front seat and frame cover. ( 6-8) • Disconnect the battery lead wire, and starter relay cover • Disconnect the starter motor lead wire 2, and battery lead wire 3 and starter relay coupler 4 from the starter relay. •…

• Page 348: Side-Stand/Ignition Interlock System Part Inspection

  ELECTRICAL SYSTEM 7-17 SIDE-STAND/IGNITION INTERLOCK SYSTEM PART INSPECTION If the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH The side-stand switch coupler is located behind the left upper fairing.

• Page 349
  7-18 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Lift the fuel tank. ( 4-51) • Disconnect the gear position switch lead wire and check the continuity between Blue and Black/White with the transmission in “NEUTRAL”. [ 09900-25008: Multi circuit tester set <…
• Page 350
  ELECTRICAL SYSTEM 7-19 TURN SIGNAL/SIDE-STAND RELAY REMOVAL The turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode. • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.

• Page 351: Ignition System

  7-20 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION The ignition system is controlled by the ECM. The system is called fully transistorized ignition system which decides accurate ignition timing according to the engine rpm, gear position and throttle position. The ignition system has four ignition coils called DIRECT IGNITION. In this system, the plug cap and ignition coil for each cylinder are unified.

• Page 352
  ELECTRICAL SYSTEM 7-21 Engine stop switch Side- stand Power source relay circuit Fuse sensor Wave form arrangement Ignition circuit switch Battery Wave form arrangement circuit Cam position sensor Throttle Engine Gear position coolant position sensor temp. switch sensor NOTE: The ignition cut-off circuit is incorporated in this ECM to prevent over-running of engine. If engine rpm reaches 13 700 r/min., this circuit cuts off the ignition primary current for all spark plugs.

• Page 353: Troubleshooting

  7-22 ELECTRICAL SYSTEM TROUBLESHOOTING * Check that the transmission is in neutral and the No spark or poor spark 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. Check the ignition system couplers for Looseness •…

• Page 354: Inspection

  ELECTRICAL SYSTEM 7-23 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. ( 4-61) • Disconnect all the ignition coil/plug cap lead wire couplers be- fore removing the ignition coil/plug caps. • Remove all of the ignition coil/plug caps. * Do not remove the ignition coil/plug cap before dis- connecting the lead wire coupler, or the lead wire will be damaged.

• Page 355
  7-24 ELECTRICAL SYSTEM Inspect each ignition coil primary peak voltage at the ignition coil/plug cap coupler. • Connect the multi circuit tester with peak voltage adaptor as follows. No.1 ignition coil/plug cap: W/Bl terminal (+ Probe) – Ground (- Probe) terminal No.2 ignition coil/plug cap: B terminal (+ Probe) –…
• Page 356
  ELECTRICAL SYSTEM 7-25 IGNITION COIL/PLUG CAP RESISTANCE • Check the ignition coil/plug cap for resistance in both primary and secondary windings. If the resistance is not within the stan- dard range, replace the ignition coil/plug cap with a new one. [ 09900-25008: Multi circuit tester set U Tester knob indication: Resistance (Ω…
• Page 357
  7-26 ELECTRICAL SYSTEM CKP SENSOR PEAK VOLTAGE • Remove the front seat. ( 6-8) NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Connect the multi circuit tester with peak volt adaptor as fol- lows.
• Page 358
  ELECTRICAL SYSTEM 7-27 • Lift up the fuel tank. ( 4-51) • Disconnect the CKP sensor lead wire coupler and connect the multi circuit tester with the peak volt adaptor. Green (+ Probe) – Blue (- Probe) • Measure the CKP sensor peak voltage at the CKP sensor lead wire coupler.

• Page 359: Combination Meter

  7-28 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 high response on those currently in use because of this composition.

• Page 360
  ELECTRICAL SYSTEM 7-29 STEPPING MOTOR The following contents and illustration shows the explanation of stepping motor’s basic principle by using a simple structure. Tachometer is driven by stepping motor. Its pointer moves to the full-scale immediately after the ignition switch is turned on to enable self-calibration. The stepping motor consists of the stator, coils, rotor, angle position sensor, exciter circuit and distribution circuit.
• Page 361
  7-30 ELECTRICAL SYSTEM STEPPING MOTOR OPERATION Step.1) When current is sent only through circuit B, the magnetic force is equilibrated and causes the rotor to stay at position b. Step.2) When the same amount of current as circuit B is sent also through circuit A, the rotor turns 15° counterclockwise by the same amount of magnetic force both from a and b.

• Page 362: Removal

  ELECTRICAL SYSTEM 7-31 REMOVAL • Remove the screw 1. • Draw out the hook 2 from the body cowling. • Disconnect the lead wire coupler. • Remove the combination meter. When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

• Page 363: Inspection

  7-32 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights immediately after turning the ignition switch on. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire harness/coupler. STEPPING MOTOR Check that the pointer calibrates itself immediately after turning the ignition switch on and stops at starting point.

• Page 364
  ELECTRICAL SYSTEM 7-33 ENGINE COOLANT TEMPERATURE METER AND INDICATOR Engine coolant temp. sensor inspection: 5-8 • Lift up the fuel tank. ( 4-51) • Disconnect the engine coolant temp. sensor coupler 1. When connecting and disconnecting the engine cool- ant temp.
• Page 365
  7-34 ELECTRICAL SYSTEM FUEL LEVEL INDICATOR SWITCH INSPECTION • Remove and disassemble the fuel pump assembly. (4- • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel level indicator switch as shown in the right illustlations. The Battery Test Battery…
• Page 366
  ELECTRICAL SYSTEM 7-35 SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of cou- plers. If the speedometer sensor and connection are all right, replace the meter with a new one. SPEEDOMETER SENSOR •…

• Page 367: Lamps

  7-36 ELECTRICAL SYSTEM LAMPS HEADLIGHT BULB REPLACEMENT • Disconnect the socket 1 and the rubber cap 2. • Remove the bulb by removing the bulb holder spring. • Reassemble the headlight bulb in the reverse order of removal. Headlight bulb 1: 55W (H7) 2: 55W (H7) Lo: 1 Hi: 1 + 2…

• Page 368
  ELECTRICAL SYSTEM 7-37 BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT BULB REPLACEMENT • Remove the lens. • Remove the brake light/taillight bulb by turning it counterclock- wise. • Reassemble the brake light/taillight bulb in the reverse order of removal. • Remove the screw and take off the lens. •…

• Page 369: Switches

  7-38 ELECTRICAL SYSTEM TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the op- eration of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

• Page 370
  ELECTRICAL SYSTEM 7-39 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. IGNITION SWITCH PUSH (For E-24) HORN BUTTON Color Color Position B/Bl Position PUSH LOCK FRONT BRAKE SWITCH…

• Page 371: Battery

  7-40 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YT12A-BS Capacity 12V, 36 kC (10 Ah)/10HR INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes. • Remove the caps 2. NOTE: * After filling the electrolyte completely, use the removed cap 2 as the sealed caps of battery-filler holes.

• Page 372: Servicing

  ELECTRICAL SYSTEM 7-41 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the 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 battery.

• Page 373: Recharging Operation

  7-42 ELECTRICAL SYSTEM RECHARGING OPERATION • Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0V (DC), recharge the bat- tery with a battery charger. * When recharging the battery, remove the battery from the motorcycle.

• Page 374
  SERVICING INFORMATION 8-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING …………..8- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ………….. 8- 2 ENGINE ………………8- 4 RADIATOR (COOLING SYSTEM) ……….8- 9 CHASSIS ………………8-10 BRAKES ………………8-11 ELECTRICAL …………….8-12 BATTERY ………………8-13 WIRE HARNESS, CABLE AND HOSE ROUTING ……

• Page 375: Troubleshooting

  8-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 4 sec. after re- sensor ceiving the starter signal. The camshaft position sensor wiring and mechanical parts.

• Page 376
  SERVICING INFORMATION 8-3 Secondary throttle The position sensor of the STV actuator produces following valve actuator voltage. (0.1 sensor voltage 4.9) Without the above value, c28 is indicated. STVA motor can not move. STV actuator, STV actuator adjustment, lead wire/coupler. Gear position signal voltage should be higher than the follow- Gear position signal ing for more than 3 seconds.

• Page 377: Engine

  8-4 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start, Compression too low or is hard to start. 1. Out of adjustment valve clearance. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.

• Page 378
  SERVICING INFORMATION 8-5 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Out of adjustment valve clearance. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn down camshaft. Replace. 5. Too wide spark plug gaps. Adjust or replace.
• Page 379
  8-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter 1. Too large valve clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace.
• Page 380
  SERVICING INFORMATION 8-7 Complaint Symptom and possible causes Remedy Engine runs poorly Defective air flow system in high speed range. 1. Clogged air cleaner element. Clean or replace. 2. Defective throttle valve. Adjust or replace. 3. Defective secondary throttle valve. Adjust or replace.
• Page 381
  8-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. Defective engine internal parts 1. Heavy carbon deposit on piston crowns. Clean. 2. Not enough oil in the engine. Add oil. 3. Defective oil pump or clogged oil circuit. Replace or clean.

• Page 382: Radiator (Cooling System)

  SERVICING INFORMATION 8-9 RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats. 1. Not enough engine coolant. Add coolant. 2. Clogged with dirt or trashes radiator core. Clean. 3. Faulty cooling fan. Repair or replace. 4. Defective cooling fan thermo-switch. Replace.

• Page 383: Chassis

  8-10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. Adjust.

• Page 384: Brakes

  SERVICING INFORMATION 8-11 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace. power. 2. Worn pads. Replace. 3. Oil adhesion of engaging surface of pads/shoe. Clean disc and pads. 4.

• Page 385: Electrical

  8-12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil/plug cap or camshaft Replace. sparking. position sensor. 2. Defective spark plugs. Replace. 3. Defective crankshaft position sensor. Replace. 4. Defective ECM. Replace. 5.

• Page 386: Battery

  SERVICING INFORMATION 8-13 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case. Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates.

• Page 387: Wiring Harness Routing

  8-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Install the wiring harness to left side of headlight, and not to be loosely. Wiring harness Clamp INSIDE OF THE BODY COWLING Clamp Wiring harness Handle switch (L, R) Ignition switch Clamp to the frame.

• Page 388
  SERVICING INFORMATION 8-15 Pass through the side-stand switch Clamp lead wire over the starter motor lead wire and engine ground lead wire. Handle switch (L, R) Clamp Clamp Clamp Clamp Handle switch Ignition switch Wiring harness Do not put the tip (L, R) Starter motor Battery…
• Page 389
  8-16 SERVICING INFORMATION…

• Page 390: Cable Routing

  SERVICING INFORMATION 8-17 CABLE ROUTING…

• Page 391: Fuel Tank Drain Hose Routing

  8-18 SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING…

• Page 392: Cooling System Hose Routing

  SERVICING INFORMATION 8-19 COOLING SYSTEM HOSE ROUTING…

• Page 393: Front Brake Hose Routing

  8-20 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING…

• Page 394: Rear Brake Hose Routing

  SERVICING INFORMATION 8-21 REAR BRAKE HOSE ROUTING…

• Page 395: Pair (Air Supply) System Hose Routing

  8-22 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR valve vacuum hose (530 mm) To throttle body (No.4 cylinder) PAIR valve hose R (50 mm) PAIR cleaner hose PAIR valve 10 N . m (1.0 kgf . m, 7.5 lb-ft) Matching mark PAIR valve hose L (30 mm) PAIR reed valve…

• Page 396: Fuel Tank Set-Up

  SERVICING INFORMATION 8-23 FUEL TANK SET-UP…

• Page 397: Cowling Set-Up

  8-24 SERVICING INFORMATION COWLING SET-UP…

• Page 398: Frame Cover Set-Up

  SERVICING INFORMATION 8-25 FRAME COVER SET-UP Front seat 23 N . m (2.3 kgf . m, 16.5 lb-ft) Frame cover HEAT SHIELD SET-UP Left under cowling Left under cowling heat shield No.1 Right under cowling Left under cowling Left under cowling heat shield No.3 heat shield No.2 Right under cowling…

• Page 399: Side-Stand Set-Up

  8-26 SERVICING INFORMATION SIDE-STAND SET-UP 50 N . m (5.0 kgf . m, 36.2 lb-ft) 40 N . m (4.0 kgf . m, 28.9 lb-ft) GEARSHIFT PEDAL SET-UP Footrest 52 – 62 mm (2.05 – 2.44 in)

• Page 400: Special Tools

  SERVICING INFORMATION 8-27 SPECIAL TOOLS 09900-20101 09900-20202 09900-06104 09900-06107 09900-06108 09900-20102 Micrometer Snap ring pliers Snap ring pliers Snap ring pliers Vernier calipers (25–50 mm) 09900-20204 09900-20205 09900-20602 09900-20605 Micrometer Micrometer 09900-20508 Dial gauge Dial calipers (75–100 mm) (0–25 mm) Cylinder gauge set (1/1000 mm, 1 mm) (1/100 mm, 10–34 mm)

• Page 401
  8-28 SERVICING INFORMATION 09915-74520 09915-74540 09916-14510 09915-77330 09916-10911 Oil pressure gauge Oil pressure gauge Valve spring Meter Valve lapper set hose adaptor compressor (for high pressure) 09916-14521 09916-20630 09916-20650 Valve spring compressor 09916-21111 Valve seat cutter head Solid pilot 09916-34542 attachment Valve seat cutter set (N-126)
• Page 402
  SERVICING INFORMATION 8-29 09940-14911 09930-30450 09930-11960 09930-44520 09930-82710 Steering stem nut Rotor remover Torx wrench Rotor holder Mode selection switch wrench 09940-30221 09940-14960 09940-14990 09940-40211 09940-14970 Front fork assembling Steering nut wrench Engine mounting thrust Fuel pressure gauge Swingarm pivot shaft tool adjuster socket wrench adaptor…

• Page 403: Tightening Torque

  8-30 SERVICING INFORMATION TIGHTENING TORQUE ENGINE N . m kgf . m ITEM lb-ft Exhaust pipe bolt 16.5 Muffler mounting nut 16.5 Speed sensor rotor bolt 14.4 Engine sprocket nut 11.5 83.2 Engine mounting bolt and nut (M:12) 54.0 (M:10) 39.8 Engine mounting thrust adjuster Engine mounting thrust adjuster lock nut…

• Page 404
  SERVICING INFORMATION 8-31 N . m kgf . m lb-ft ITEM Piston cooling oil jet bolt Oil pump mounting bolt Conrod bearing cap bolt (Initial) 11.0 (Final) 90° (µ turn) Bearing retainer screw Breather cover bolt Oil strainer bolt Oil pan bolt Oil cooler bolt FI SYSTEM AND INTAKE AIR SYSTEM N .
• Page 405
  8-32 SERVICING INFORMATION CHASSIS N . m kgf . m ITEM lb-ft Steering stem head nut 65.0 Steering stem lock nut 58.0 Steering damper bolt and nut 16.6 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 25.5 Front fork inner rod lock nut…
• Page 406
  SERVICING INFORMATION 8-33 TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt N . m kgf . m N . m kgf . m A (mm) lb-ft lb-ft 0.15…

• Page 407: Service Data

  8-34 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STD/SPEC. LIMIT ——— Valve diam. (1.14) ——— (0.94) 0.10 – 0.20 Valve clearance ——— (0.004 – 0.008) (when cold) 0.20 – 0.30 ——— (0.008 – 0.012) Valve guide to valve stem 0.010 –…

• Page 408
  SERVICING INFORMATION 8-35 ITEM STD/SPEC. LIMIT Camshaft journal O.D. 23.959 – 23.980 IN. & EX. ——— (0.9433 – 0.9441) 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 STD/SPEC.
• Page 409
  8-36 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STD/SPEC. LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5921) (0.5910 – 0.5913) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –…
• Page 410
  SERVICING INFORMATION 8-37 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STD/SPEC. LIMIT 1.857 (78/42) ——— Primary reduction ratio 2.470 (42/17) ——— Final reduction ratio 2.785 (39/14) ——— Gear ratios 2.052 (39/19) ——— 1.681 (37/22) ——— 1.450 (29/20) ———…
• Page 411
  8-38 SERVICING INFORMATION ITEM STD/SPEC. LIMIT Use an antifreeze/coolant compatible with alumi- Engine coolant type num radiator, mixed with distilled water only, at ——— the ratio of 50:50. Reserve Approx. 250 ml Engine coolant ——— tank side (0.3/0.2 US/Imp qt) Engine Approx.
• Page 412
  SERVICING INFORMATION 8-39 THROTTLE BODY ITEM STD/SPEC. Bore size 42 mm I.D. No. 35 F1 (For E-33), 35 F0 (For the others) Idle r/min. 1 200 ± 100 r/min. Fast idle r/min. 3 500 r/min. (After warming up) Throttle cable play 2.0 –…
• Page 413
  8-40 SERVICING INFORMATION WATTAGE STD/SPEC. ITEM E-03, -24, -28, -33 E-02, -19 ← 55 + 55 W Headlight ← 55 W ——— Parking or position light ← 21/5 W × 2 Brake light / Taillight ← 21 W × 4 Turn signal light ←…
• Page 414
  (9.831) Front fork oil level (without spring, ——— outer tube fully compressed) (4.06) Front fork oil type SUZUKI Fork oil SS-08 (#10) or an equivalent fork oil ——— Front fork oil capacity (each leg) 473 ml ——— (16.0/16.7 US/Imp oz) ———…
• Page 415
  8-42 SERVICING INFORMATION ITEM STD/SPEC. LIMIT Rear wheel travel ——— (5.1) Swingarm pivot shaft runout ——— (0.01) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane R + M Gasoline containing MTBE (Methyl Tertiary Butyl Ether), E-03, -33 less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is per-…

• Page 416: Emission

  EMISSION CONTROL INFORMATION 9-1 EMISSION CONTROL INFORMATION CONTENTS FUEL INJECTION SYSTEM …………. 9- 2 EVAPORATIVE EMISSION CONTROL SYSTEM ……9- 2 CANISTER HOSE ROUTING …………9- 3 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION ..9- 4 PAIR (AIR SUPPLY) SYSTEM DIAGRAM……..9- 5 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ……

• Page 417: Fuel Injection System

  9-2 EMISSION CONTOROL INFORMATION FUEL INJECTION SYSTEM GSX-R750 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. EVAPORATIVE EMISSION CONTROL SYSTEM…

• Page 418: Canister Hose Routing

  EMISSION CONTROL INFORMATION 9-3 CANISTER HOSE ROUTING (Only for E-33)

• Page 419: Evaporative Emission Control System Inspection

  9-4 EMISSION CONTOROL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the seats and frame cover. • Remove the fuel tank. (4-51) HOSES Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. CANISTER Inspect the canister for damage to the body.

• Page 420: Pair (Air Supply) System Diagram

  EMISSION CONTROL INFORMATION 9-5 PAIR (AIR SUPPLY) SYSTEM DIAGRAM Air cleaner box PAIR control valve Throttle body PAIR reed valve FRESH AIR EXHAUST GAS NEGATIVE PRESSURE PAIR control valve OPEN CLOSE…

• Page 421: Pair (Air Supply) System Hose Routing

  9-6 EMISSION CONTOROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR valve vacuum hose (530 mm) To throttle body (N0.4 cylinder) PAIR valve hose R (50 mm) PAIR cleaner hose PAIR valve 10 N . m (1.0 kgf . m, 7.5 lb-ft) Matching mark PAIR valve hose L (30 mm) PAIR reed valve…

• Page 422: Pair (Air Supply) System Inspection

  EMISSION CONTROL INFORMATION 9-7 PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES • Inspect the hoses for wear or damage. • Inspect that the hoses and pipes are securely connected. PAIR REED VAVLE • Remove the PAIR valve cover. • Inspect the reed valve for the carbon deposit. •…

• Page 423: Gsx-R750K1 (’01-Model)

  GSX-R750K1 (’01-MODEL) 10-1 GSX-R750K1 (’01-MODEL) This chapter describes service data, service specifications and servicing procedures which differ from those of the GSX-R750Y (’00-model). CONTENTS SPECIFICATIONS …………….10- 2 SERVICE DATA …………….. 10- 3 CLUTCH ………………. 10-12 CLUTCH REASSEMBLY …………… 10-12 CLUTCH DRIVE PLATES INSPECTION ……..

• Page 424: Specifications

  10-2 GSX-R750K1 (’01-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………….2 040 mm (80.3 in) Overall width …………….715 mm (28.1 in) Overall height …………….1 135 mm (44.7 in) Wheelbase …………….1 410 mm (55.5 in) Ground clearance …………..130 mm ( 5.1 in) Seat height …………….

• Page 425: Service Data

  GSX-R750K1 (’01-MODEL) 10-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STD/SPEC. LIMIT Valve diam. ——— (1.14) ——— (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 –…

• Page 426
  10-4 GSX-R750K1 (’01-MODEL) ITEM STD/SPEC. LIMIT Camshaft journal O.D. 23.959 – 23.980 IN. & EX. ——— (0.9433 – 0.9441) 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 STD/SPEC.

• Page 427: Clutch

  GSX-R750K1 (’01-MODEL) 10-5 CONROD + CRANKSHAFT Unit: mm (in) ITEM STD/SPEC. LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5910 – 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 428
  10-6 GSX-R750K1 (’01-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STD/SPEC. LIMIT Primary reduction ratio 1.857 (78/42) ——— Final reduction ratio 2.470 (42/17) ——— Gear ratios 2.785 (39/14) ——— 2.052 (39/19) ——— 1.681 (37/22) ——— 1.450 (29/20) ———…
• Page 429
  GSX-R750K1 (’01-MODEL) 10-7 INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM STD/SPEC. NOTE 11 – 16 Ω at 20°C (68°F) Injector resistance Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec. Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm , 43 psi) set pressure FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR…
• Page 430
  10-8 GSX-R750K1 (’01-MODEL) THROTTLE BODY ITEM STD/SPEC. Bore size 42 mm I.D. No. 35 F1 (For E-33), 35 F0 (For the others) Idle r/min. 1 200 ± 100 r/min. Fast idle r/min. 3 500 r/min. (After warming up) Throttle cable play 2.0 –…
• Page 431
  GSX-R750K1 (’01-MODEL) 10-9 WATTAGE STD/SPEC. ITEM E-03, 24, 28, 33 The others ← Headlight 55 + 55 W ← 55 W Parking or position light ——— ← Brake light/Taillight 21/5 W × 2 ← Turn signal light 21 W × 4 ←…
• Page 432
  (9.61) Front fork oil level (without spring, ——— outer tube fully compressed) (4.06) Front fork oil type SUZUKI Fork oil SS-08 (#10) or an equivalent fork oil ——— Front fork oil capacity (each leg) 473 ml ——— (16.0/16.7 US/Imp oz)
• Page 433
  GSX-R750K1 (’01-MODEL) 10-11 ITEM STD/SPEC. LIMIT Rear wheel travel ——— (5.1) Swingarm pivot shaft runout ——— (0.01) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump R + M octane ( Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-…

• Page 434: Clutch Reassembly

  10-12 GSX-R750K1 (’01-MODEL) CLUTCH CLUTCH REASSEMBLY Direction of outside DRIVE PLATE: A No.1 Drive Plate ……..8 pcs. B No.2 Drive Plate ……..1 pc. C No.3 Drive Plate ……..1 pc. DRIVE PLATE: a No.1 Driven Plate ……..6 – 8 pcs. b No.2 Driven Plate ……..

• Page 435: Clutch Drive Plates Inspection

  GSX-R750K1 (’01-MODEL) 10-13 CLUTCH DRIVE PLATES INSPECTION NOTE: * Wipe off engine oil from the clutch drive plates with a clean rag. * Clutch drive plate No.1: Purple paint No.2: Green paint No.3: Dampers on claws • Measure the drive plates with a vernier calipers. •…

• Page 436: Fuel Pressure Inspection

  10-14 GSX-R750K1 (’01-MODEL) FUEL PRESSURE INSPECTION • Lift and support the fuel tank with its prop stay. • Place a rag under the fuel feed hose. • Remove the fuel feed hose 1 and install the special tools be- tween the fuel tank and fuel delivery pipe. [ 09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77330: Oil pressure gauge…

• Page 437: Throttle Stop Screw

  GSX-R750K1 (’01-MODEL) 10-15 THROTTLE STOP SCREW The throttle stop screw A is installed on the No.1 throttle body. • Remove the front seat. • Lift and support the fuel tank. • Ajust the engine idle speed. (2-15) AP SENSOR The AP sensor B (Atmospheric pressure sensor) is located over the ECM.

• Page 438: Engine Mounting Bolt And Nut

  10-16 GSX-R750K1 (’01-MODEL) ENGINE MOUNTING BOLT AND NUT Left Right LENGTH N . m kgf . m ITEM ITEM lb-ft 1.77 39.8 Bolt 2.17 54.0 8.46 16.5 Spacer 30.5 1.20 32.5 Adjuster 1.57…

• Page 439: Canister Hose Routing (For E-33)

  GSX-R750K1 (’01-MODEL) 10-17 CANISTER HOSE ROUTING (FOR E-33)

• Page 440: Gsx-R750K2 (’02-Model)

  • Any differences between the GSX-R750K1 (’01-model) and GSX-R750K2 (’02-model) in specifications and service data are indicated with an asterisk mark (*). • Please refer to the GSX-R750 Service Manual for details which are not given in this manual. CONTENTS SPECIFICATIONS …………….

• Page 441: Specifications

  11-2 GSX-R750K2 (’02-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………..2 040 mm (80.3 in) Overall width …………..715 mm (28.1 in) Overall height …………..1 135 mm (44.7 in) Wheelbase …………..1 410 mm (55.5 in) Ground clearance …………130 mm (5.1 in) Seat height …………..

• Page 442
  GSX-R750K2 (’02-MODEL) 11-3 CHASSIS Front suspension …………Inverted telescopic, coil spring, spring pre-load fully adjustable, rebound and compression damping force fully adjustable. Rear suspension …………Link type system, gas/oil damped, coil spring, spring pre-road fully adjustable, rebound and com- pression damping force fully adjustable. Caster …………….

• Page 443: Engine

  11-4 GSX-R750K2 (’02-MODEL) ENGINE CLUTCH The spring washer 1 and its seat 2 have been equipped and No. 3 Drive plate 3 has been changed as follows. No. 3 Drive plate A: 8.5 mm (0.33 in) Part No.: 21440 -39F00 K2-MODEL TIGHTENING TORQUE FOR CAM CHAIN TENSION ADJUSTER CAP…

• Page 444: Fi System And Intake Air System

  GSX-R750K2 (’02-MODEL) 11-5 FI SYSTEM AND INTAKE AIR SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 4 sec. after re- sensor ceiving the starter signal.

• Page 445
  11-6 GSX-R750K2 (’02-MODEL) Secondary throttle When no actuator control signal is supplied from the ECM or valve actuator communication signal does not reach ECM or operation voltage does not reach STVA motor, c28 is indicated. STVA can not operate. STVA lead wire/coupler. The sensor should produce following voltage.

• Page 446: C28″ Stv Actuator Circuit Malfunction

  GSX-R750K2 (’02-MODEL) 11-7 “C28” STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction. ECM does not receive communication signal from • STVA circuit open or short. the STVA. • STVA motor malfunction. INSPECTION •…

• Page 447: C29″ Stp Sensor Circuit Malfunction

  11-8 GSX-R750K2 (’02-MODEL) “C29” STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. • STP sensor maladjusted. Difference between actual throttle opening and • STP sensor circuit open or short. opening calculated by ECM in larger than specified •…

• Page 448
  GSX-R750K2 (’02-MODEL) 11-9 Turn the ignision switch OFF. Connect the STP sensor coupler. Insert the copper wires to the lead wire coupler. Disconnect the STVA lead wire coupler 1. Turn the ignition switch ON. Measure the STP sensor output voltage at the coupler (be- tween Yellow and Black wires) by turning the secondary throttle valve (close and open) with a finger.

• Page 449: Fuel Pump

  11-10 GSX-R750K2 (’02-MODEL) FUEL PUMP CONSTRUCTION N . m Kgf . m ITEM lb-ft 1 Fuel pressure regulator 2 O-ring 3 Fuel pump case/Fuel filter cartridge (For high pressure) 4 Thermistor 5 Fuel pump 6 Fuel mesh filter (For low pressure) REASSEMBLY •…

• Page 450
  GSX-R750K2 (’02-MODEL) 11-11 • Be sure to connecft the wires to the proper terminals. A ….+ terminal for fuel pump B ….For thermistor C ….- terminal for fuel pump Pass through the wires behind the thermistor.

• Page 451: Throttle Body

  11-12 GSX-R750K2 (’02-MODEL) THROTTLE BODY CONSTRUCTION 1 Vacuum hose 2 TP sensor 3 STP sensor 4 Throttle body (Nos. 3, 4) 5 Throttle body (Nos. 1, 2) 6 Synchronizing screw 7 Stay plate 8 Fast idle adjusting screw 9 Throttle stop screw 0 Fuel delivery pipe A O-ring B Dust seal…

• Page 452
  GSX-R750K2 (’02-MODEL) 11-13 THROTTLE BODY REMOVAL • Lift and support the fuel tank with its prop stay. • Disconnect the IAT sensor coupler 1 and PAIR hose 2. • Disconnect the IAP sensor coupler 3 and vacuum hose 4. • Disconnect the crankcase breather hose 5. •…
• Page 453
  11-14 GSX-R750K2 (’02-MODEL) • Disconnect the throttle cables from their drum. • Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank. • Disconnect the vacuum hose 1 from the PAIR valve. •…
• Page 454
  GSX-R750K2 (’02-MODEL) 11-15 THROTTLE BODY DISASSEMBLY • Disconnect the following parts. 1 Fuel feed hose 2 Vacuum hose 3 Vacuum hose 4 Purge hose (Only for E-33) • Disconnect the lead wire couplers. • Remove the fuel delivery pipe assembly 5 by removing its mounting screws.
• Page 455
  11-16 GSX-R750K2 (’02-MODEL) • Remove the nut 1. • Separate the throttle body assembly to a pair of two bodies (Nos. 1 . 2 and Nos. 3 . 4) by removing their connecting bolts. NOTE: Be careful not to lose the springs. Never remove the secondary throttle valve and throttle valve.
• Page 456
  GSX-R750K2 (’02-MODEL) 11-17 THROTTLE BODY CLEANING » Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
• Page 457
  11-18 GSX-R750K2 (’02-MODEL) • Install the stay plate 1. • Place the throttle body assembly on the surface plate and tighten the connecting bolts. ! Throttle body connecting bolt: 6 N . m (0.6 kgf . m, 4.5 lb-ft) • Install the fast idle link levers properly. •…
• Page 458
  GSX-R750K2 (’02-MODEL) 11-19 White color T PS and STPS resemble each other very closely in external appearance. Make sure to check the color of coupler before installing. STVA STPS 3.5 N . m (0.35 kgf . m, 2.5 lb-ft) 6 N . m (0.6 kgf .
• Page 459
  11-20 GSX-R750K2 (’02-MODEL) • Assemble the fuel delivery pipes. • Install the fuel delivery pipe assembly to the throttle body as- sembly. Never turn the fuel injectors while installing them. • Tighten the fuel delivery pipe mounting screws. ! Fuel delivery pipe mounting screw: 3.5 N . m (0.35 kgf .
• Page 460
  GSX-R750K2 (’02-MODEL) 11-21 THROTTLE BODY CLAMP POSITION Forward 25˚ ± 10˚ 10˚ ± 10˚ 10˚ ± 10˚ VIEW OF TOP STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor positioning as follows: •…
• Page 461
  11-22 GSX-R750K2 (’02-MODEL) THROTTLE POSITION SENSOR ADJUSTMENT 1. Adjust the engine rpm to 1 200 rpm. 2. Stop the engine and connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, loosen the screws and turn the throttle position sensor and bring the line to middle.

• Page 462: Throttle Valve Synchronization

  GSX-R750K2 (’02-MODEL) 11-23 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH GAUGE • Lift and support the fuel tank. • Start up the engine and run it in idling condition for warming up. •…

• Page 463
  11-24 GSX-R750K2 (’02-MODEL) • Remove the vacuum hose 1 from the No. 1 throttle body. • Connect one of the four rubber hoses of the vacuum balancer gauge to the nipple 2 on the No.1 throttle body. [ 09913-13121: Vacuum balancer gauge •…
• Page 464
  GSX-R750K2 (’02-MODEL) 11-25 THROTTLE VALVE SYNCHRONIZATION • Remove the PAIR vacuum hose 1 and connect a proper rub- ber cap to the nipple. • To synchronize throttle valves, remove the respective vacuum hoses 2 from each vacuum nipple and connect the vacuum balancer gauge hoses to the vacuum nipples respectively.

• Page 465: Chassis

  • Tighten the front axle to the specified torque. ! Front axle: 100 N . m (10.0 kgf . m, 72.5 lb-ft) SWINGARM PIVOT BOSS REMOVAL • Remove the swingarm. (6-52 of the GSX-R750 Service Manual) • Remove the swingarm pivot boss nut. NOTE: Remove the swingarm pivot boss when only replacing it.

• Page 466
  GSX-R750K2 (’02-MODEL) 11-27 INSTALLATION • Set the swingarm pivot boss by its set screws. • Tighten the swingarm boss nut to the specified torque. ! Swingarm pivot boss nut: 65 N . m (6.5 kgf . m, 47.0 lb-ft) 15 N . m 1.5 kgf .

• Page 467: Torque Link

  11-28 GSX-R750K2 (’02-MODEL) TORQUE LINK Front side of the torque link washer has been eliminated. In accor- dance with this elimination, the torque link mounting bolt has been changed. K2-model 19 mm (0.7 in) 34.5 mm (1.36 in)

• Page 468: Servicing Information

  GSX-R750K2 (’02-MODEL) 11-29 SERVICING INFORMATION WIRE HARNESS ROUTING…

• Page 469
  11-30 GSX-R750K2 (’02-MODEL) Clamp Wire harness Fix the wire harness Regulator/ clamp to the frame. rectifier Pass the neutral switch lead wire behind the bypass Clamp hose and breather hose. Wiring harness To the Fan motor fuel pump Wire harness Rear turn signal light (L) Clamp…
• Page 470
  GSX-R750K2 (’02-MODEL) 11-31…

• Page 471: Cooling System Hose Routing

  11-32 GSX-R750K2 (’02-MODEL) COOLING SYSTEM HOSE ROUTING…

• Page 472: Front Brake Hose Routing

  GSX-R750K2 (’02-MODEL) 11-33 FRONT BRAKE HOSE ROUTING…

• Page 473: Rear Brake Hose Routing

  11-34 GSX-R750K2 (’02-MODEL) REAR BRAKE HOSE ROUTING…

• Page 474: Canister Hose Routing (Only For E-33)

  GSX-R750K2 (’02-MODEL) 11-35 CANISTER HOSE ROUTING (Only for E-33)

• Page 475: Service Data

  11-36 GSX-R750K2 (’02-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STD/SPEC. LIMIT Valve diam. ——— (1.14) ——— (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 –…

• Page 476
  GSX-R750K2 (’02-MODEL) 11-37 ITEM STD/SPEC. LIMIT Camshaft journal O.D. 23.959 – 23.980 IN. & EX. ——— (0.9433 – 0.9441) 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 STD/SPEC.
• Page 477
  11-38 GSX-R750K2 (’02-MODEL) CONROD + CRANKSHAFT Unit: mm (in) ITEM STD/SPEC. LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5910 – 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 478
  GSX-R750K2 (’02-MODEL) 11-39 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STD/SPEC. LIMIT Primary reduction ratio 1.857 (78/42) ——— Final reduction ratio 2.470 (42/17) ——— Gear ratios 2.785 (39/14) ——— 2.052 (39/19) ——— 1.681 (37/22) ——— 1.450 (29/20) ———…
• Page 479
  11-40 GSX-R750K2 (’02-MODEL) INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM STD/SPEC. NOTE 11 – 16 Ω at 20°C (68°F) Injector resistance Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec. Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm , 43 psi) set pressure FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR…
• Page 480
  GSX-R750K2 (’02-MODEL) 11-41 THROTTLE BODY ITEM STD/SPEC. Bore size 42 mm I.D. No. * 35 F3 (For E-33), 35 F2 (The others) Idle r/min. 1 200 ± 100 r/min. + 200 Fast idle r/min. *1 800 r/min. (When engine is cold) –…
• Page 481
  11-42 GSX-R750K2 (’02-MODEL) WATTAGE STD/SPEC. ITEM E-03, 24, 28, 33 The others Headlight * 60 W × 2 55 + 55 W * 55 W × 2 55 W Parking or position light ——— ← Brake light/Taillight 21/5 W × 2 ←…
• Page 482
  (9.61) Front fork oil level (without spring, ——— outer tube fully compressed) (4.06) Front fork oil type SUZUKI Fork oil SS-08 (#10) or an equivalent fork oil ——— Front fork oil capacity (each leg) 473 ml ——— (16.0/16.7 US/Imp oz)
• Page 483
  11-44 GSX-R750K2 (’02-MODEL) ITEM STD/SPEC. LIMIT Rear wheel travel ——— (5.1) Swingarm pivot shaft runout ——— (0.01) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump R + M octane ( Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-…

• Page 484: Wiring Diagram

  WIRING DIAGRAM FI SYSTEM WIRING DIAGRAM WIRE COLOR : Black : Blue : Brown Dbr : Dark brown : Dark green : Green : Gray Lbl : Light blue : Light green : Orange : Pink : Red : Violet : White : Yellow B/Bl : Black with Blue tracer…

• Page 485
  WIRING DIAGRAM (Y-MODEL) FOR E-03, 28, 33 HANDLE SWITCH (R) T: TURN SIGNAL INDICATOR LIGHT FRONT B: HIGH BEAM INDICATOR LIGHT ENGINE BRAKE N: NEUTRAL INDICATOR LIGHT STOP STARTER LIGHT F: FUEL INDICATOR LIGHT OIL: OIL PRESSURE/ENGINE COOLANT IGNITION COIL/PLUG CAP PUSH TEMP./FI INDICATOR LIGHT SIDE-STAND…
• Page 486
  FOR E-24 (Y-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT ENGINE BRAKE B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT F: FUEL INDICATOR LIGHT IGNITION COIL/PLUG CAP PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH SPEEDOMETER…
• Page 487
  FOR E-02, 19 (Y-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT ENGINE BRAKE LIGHTING B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT F: FUEL INDICATOR LIGHT IGNITION COIL/PLUG CAP PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH…
• Page 488
  WIRING DIAGRAM (K1-MODEL) FOR E-03, 28, 33 HANDLE SWITCH (R) T: TURN SIGNAL INDICATOR LIGHT FRONT B: HIGH BEAM INDICATOR LIGHT ENGINE BRAKE N: NEUTRAL INDICATOR LIGHT STOP STARTER LIGHT F: FUEL INDICATOR LIGHT OIL: OIL PRESSURE/ENGINE COOLANT IGNITION COIL/PLUG CAP PUSH TEMP./FI INDICATOR LIGHT SIDE-STAND…
• Page 489
  FOR E-24 (K1-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT ENGINE BRAKE B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT F: FUEL INDICATOR LIGHT IGNITION COIL/PLUG CAP PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH SPEEDOMETER…
• Page 490
  THE OTHERS (K1-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT LIGHTING ENGINE BRAKE B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP F: FUEL INDICATOR LIGHT PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH SPEEDOMETER…
• Page 491
  STARTER SIDE-STAND WIRING DIAGRAM (K2-MODEL) BUTTON SWITCH FI SYSTEM WIRING DIAGRAM SIDE-STAND RELAY BATTERY MAIN SWITCH ENGINE STOP IGNITION COIL SWITCH FUEL PUMP STARTER MAIN RELAY RELAY FUSE IG 2 IG 3 IG 4 IG 1 SWITCH FUEL PUMP 10A 15A 15A W/Bl Gr/W Gr/B…
• Page 492
  FOR E-02, 19, 54 (K2-MODEL) HANDLE SWITCH (R) FRONT ENGINE BRAKE STOP LIGHT SIDE STAND : TURN SIGNAL INDICATOR LIGHT SWITCH LIGHTING : HIGH BEAM INDICATOR LIGHT SWITCH : NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP STARTER : FUEL INDICATOR LIGHT : OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SPEEDOMETER…
• Page 493
  FOR E-24 (K2-MODEL) HANDLE SWITCH (R) FRONT ENGINE BRAKE STOP LIGHT SIDE STAND : TURN SIGNAL INDICATOR LIGHT SWITCH : HIGH BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP STARTER : FUEL INDICATOR LIGHT : OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SPEEDOMETER IGNITION…
• Page 494
  FOR E-03, 28, 33 (K2-MODEL) HANDLE SWITCH (R) FRONT ENGINE BRAKE STOP LIGHT SIDE STAND : TURN SIGNAL INDICATOR LIGHT SWITCH : HIGH BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP STARTER : FUEL INDICATOR LIGHT : OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SPEEDOMETER IGNITION…
• Page 495
  Prepared by 3rd Ed. August, 2002 1st Ed. February, 2000 Part No. 99500-37112-03E Printed in Japan…

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Chapters

• Page 3
  FOREWORD This manual contains an introductory description on the SUZUKI GSX-R750 and procedures for its inspection/ser- vice and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
• Page 5
  TABLE OF CONTENTS Precautions…………… 00-i Precautions …………00-1 General Information ……….. 0-i General Information ……….0A-1 Maintenance and Lubrication ……… 0B-1 Service Data…………0C-1 Engine …………….. 1-i Precautions ………….. 1-1 Engine General Information and Diagnosis … 1A-1 Emission Control Devices ……..1B-1 Engine Electrical Devices……..1C-1 Engine Mechanical……….1D-1 Engine Lubrication System ……..
• Page 7
  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…
• Page 8
  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…
• Page 9
  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.
• Page 10
  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.
• Page 11
  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. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.
• Page 12
  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” in figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals “A”…
• Page 13
  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” and 2) Disconnect the connectors/couplers at both ends of “B”.
• Page 14
  : 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 15: General Information

  Spark Plug Inspection and Cleaning ….0B-9 Symbols ………….. 0A-1 Fuel Line Inspection ……….0B-10 Abbreviations …………0A-1 Evaporative Emission Control System SAE-to-Former SUZUKI Term ……0A-2 Inspection (E-33 only) ……..0B-10 Vehicle Side View ……….0A-3 Engine Oil and Filter Replacement ….0B-10 Vehicle Identification Number ……0A-4 Throttle Cable Play Inspection and Fuel and Oil Recommendation ……

• Page 16
  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.
• Page 17
  J1930 terms and abbreviations which may be used in GND: Ground this manual in compliance with SAE recommendations, GP Switch: Gear Position Switch as well as their former SUZUKI names. Ex. SAE term (Abbreviation): Former SUZUKI term HC: Hydrocarbons HO2 sensor: Heated Oxygen Sensor (HO2S)
• Page 18
  Gauge motorcycles may exist depending on the Fuel Pump (FP): Fuel Pump (FP) markets. Generator (GEN): Generator SUZUKI GSX-R750 (2008-model) Ground (GND): Ground (GND, GRD) Right Side Hydrocarbons (HC): Hydrocarbons Heated Oxygen Sensor (HO2S): Heated Oxygen Sensor (HO2S), O2 sensor Ignition Control Module (ICM): —…
• Page 19
  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.
• Page 20
  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.
• Page 21
  General Information: 0A-6 Country and Area Codes B838H20101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX-R750 K8 (E-02) U.K. JS1CW111100100001 – GSX-R750 K8 (E-19) E.U. JS1CW111100100001 – GSX-R750U2 K8 (E-19) E.U.
• Page 22
  0A-7 General Information: Warning, Caution and Information Labels Location B838H20101011 7, 9 1 (E-03, 33) 1 (E-24), 2 19, 21 10, 11 14, 15, 16, 17 12, 13 I838H1010001-01 1. Noise label (For E-03, 24, 33) 15. General warning label (French) (For GSX-R750UF E-19) 2.
• Page 23
  General Information: 0A-8 Component Location Electrical Components Location B838H20103001 I837H1010006-03 1. EXCV actuator 9. CMP sensor 17. Fuel pump relay 2. IAP sensor 10. PAIR control solenoid valve 18. Cooling fan relay 3. TP sensor 11. Starter relay/Main fuse 19. AP sensor 4.
• Page 24
  0A-9 General Information: I837H1010007-03 25. IAT sensor 31. Head light relay 37. Oil pressure switch 26. ISC valve 32. Turn signal/Side-stand relay 38. Generator 27. Secondary fuel injector 33. Steering damper solenoid valve 39. GP switch 28. Primary fuel injector 34.
• Page 25
  General Information: 0A-10 Specifications Specifications B838H20107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 040 mm (80.3 in) Overall width 715 mm (28.1 in) Overall height 1 125 mm (44.3 in) Wheelbase 1 405 mm (55.3 in) Ground clearance…

• Page 26: Front Suspension

  0A-11 General Information: Chassis Item Specification Remark Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 120 mm (4.7 in) Rear wheel travel 130 mm (5.1 in) Caster 23° 45’ Tail 97 mm (3.8 in) Steering angle…

• Page 27
  General Information: 0A-12 Special Tools and Equipment Special Tool B838H20108001 09900–06104 09900–06107 09900–06108 09900–18740 09900–20102 Snap ring pliers Snap ring pliers Snap ring pliers Hexagon socket (24 Vernier calipers (1/20 mm, 200 mm) 09900–20202 09900–20203 09900–20205 09900–20530 09900–20602 Micrometer (1/100 Micrometer (1/100 Micrometer (0 –…
• Page 28
  0A-13 General Information: 09913–50121 09913–70210 09915–40610 09915–64512 09915–74521 Oil seal remover Bearing installer set Oil filter wrench Compression gauge Oil pressure gauge hose 09915–74540 09915–77331 09916–10911 09916–14510 09916–14522 Oil pressure gauge Meter (for high Valve lapper set Valve spring Valve spring attachment pressure) compressor…
• Page 29
  General Information: 0A-14 09924–84521 09925–18011 09930–10121 09930–11920 09930–11940 Bearing installer set Steering bearing Spark plug wrench set Torx bit (JT40H) Bit holder installer 09930–11950 09930–30104 09930–34980 09930–44520 09930–44530 Torx wrench Rotor remover slide Rotor remover Rotor holder Rotor holder shaft 09930–82720 09940–14911 09940–14940…
• Page 30
  0A-15 General Information: 09944–28321 99565–01010–015 Hexagon socket (19 CD-ROM Ver.15…

• Page 31: Maintenance And Lubrication

  Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B838H20200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.

• Page 32
  0B-2 Maintenance and Lubrication: Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months — Brake fluid Replace every 2 years. — Brake hoses Replace every 4 years. Tires —…
• Page 33
  Maintenance and Lubrication: 0B-3 Repair Instructions Air Cleaner Element Replacement 3) Drain water from the air cleaner box by removing the B838H20206001 drain plug (1). Replace air cleaner element Every 18 000 km (11 000 miles, 36 months) Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”.

• Page 34: Exterior Parts

  0B-4 Maintenance and Lubrication: Exhaust Control Valve Inspection Valve Clearance Inspection and Adjustment B838H20206004 B838H20206005 Inspect exhaust control valve Inspect valve clearance Initially at 1 000 km (600 miles, 2 months) and every Initially every 24 000 km (14 500 miles, 48 months) 12 000 km (7 500 miles, 24 months) thereafter Inspection Inspect exhaust control valve as follows:…

• Page 35
  Maintenance and Lubrication: 0B-5 4) Remove the valve timing inspection cap (1). 5) Turn the crankshaft to bring the line “C” on the CKP sensor rotor to the rib “D” behind the clutch cover and also to bring the notches “E” on the left ends of both camshafts (EX and IN) to the positions as shown.
• Page 36
  0B-6 Maintenance and Lubrication: 7) Turn the crankshaft 360 degrees (one rotation) to 3) Check the figures printed on the shim. These figures bring the line on the CKP sensor rotor to the rib indicate the thickness of the shim, as illustrated. behind the clutch cover and also to bring the notches “E”…
• Page 37
  Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I837H1020015-02…
• Page 38
  0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I837H1020016-02…
• Page 39
  Maintenance and Lubrication: 0B-9 6) Install the camshafts and cam chain tension adjuster. Spark Plug Gap Refer to “Engine Top Side Assembly in Section 1D 1) Remove the spark plugs. Refer to “Ignition Coil / (Page 1D-27)”. Plug Cap and Spark Plug Removal and Installation in 7) Rotate the engine so that the tappet is depressed Section 1H (Page 1H-6)”.
• Page 40
  0B-10 Maintenance and Lubrication: Fuel Line Inspection Engine Oil Replacement B838H20206008 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).
• Page 41
  (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.
• Page 42
  0B-12 Maintenance and Lubrication: Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization B838H20206011 B838H20206013 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) Inspect and adjust the throttle cable play “a”…
• Page 43
  Maintenance and Lubrication: 0B-13 Engine Coolant Change Air Bleeding From the Cooling Circuit Refer to “Engine Coolant Description in Section 1F 1) Remove the right under cowling. Refer to “Exterior (Page 1F-1)”. Parts Removal and Installation in Section 9D (Page 9D-11)”. WARNING 2) Add engine coolant up to the radiator inlet.
• Page 44
  0B-14 Maintenance and Lubrication: Clutch Cable Play Inspection and Adjustment 5) Loosen the lock-nut (5) and turn out the adjusting B838H20206015 screw (6) two or three rotations. Inspect clutch cable play 6) From that position, slowly turn in the adjusting screw Every 6 000 km (4 000 miles, 12 months) (6) until resistance is felt.
• Page 45
  Maintenance and Lubrication: 0B-15 Drive Chain Inspection and Adjustment Drive Chain Length Inspection B838H20206016 1) Loosen the axle nut (1). Inspect drive chain 2) Loosen the left and right chain adjuster lock-nuts (2). Initially at 1 000 km (600 miles, 2 months) and every 3) Give tension to the drive chain fully by turning both 6 000 km (4 000 miles, 12 months) thereafter chain adjuster bolts (3).
• Page 46
  “drive chain oil”. Such oil can damage the I838H1020003-01 O-rings. • The standard drive chain is a RK 525ROZ5Y. SUZUKI recommends to use this standard drive chain as a replacement. “a” I649G1020036-02 5) After adjusting the drive chain, tighten the axle nut (1) to the specified torque.
• Page 47
  Maintenance and Lubrication: 0B-17 Brake System Inspection B838H20206018 Inspect brake system Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect brake hose and brake fluid “A” Every 6 000 km (4 000 miles, 12 months) WARNING •…
• Page 48
  0B-18 Maintenance and Lubrication: Front and Rear Brake Hose Inspection 4) Tighten the lock-nut (1) securely. Inspect the brake hoses and hose joints for crack, Tightening torque damage or brake oil leakage. If any defects are found, Rear master cylinder rod lock-nut (a): 18 N·m ( replace the brake hose with a new one.
• Page 49
  Maintenance and Lubrication: 0B-19 Tire Inspection CAUTION B838H20206019 The standard tire fitted on this motorcycle is Inspect tire 120/70 ZR17 M/C (58W) for front and 180/55 Every 6 000 km (4 000 miles, 12 months) ZR17 M/C (73W) for rear. The use of tires Tire Tread Condition other than those specified may cause Operating the motorcycle with excessively worn tires will…
• Page 50
  0B-20 Maintenance and Lubrication: Chassis Bolt and Nut Inspection Front Fork Inspection B838H20206021 B838H20206023 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 scratches on the outer surface of the inner tubes.
• Page 51
  Maintenance and Lubrication: 0B-21 I837H1020052-01 I837H1020055-01 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Rear shock absorber bracket nut 115 N⋅m (11.5 kgf-m, 83.0 lb-ft) Front axle bolt 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) Rear shock absorber mounting bolt/nut 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) Front axle pinch bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Front brake disc bolt 18 N⋅m (1.8 kgf-m, 13.0 lb-ft)
• Page 52
  0B-22 Maintenance and Lubrication: Compression Pressure Check B838H20206024 Refer to “Compression Pressure Check in Section 1D (Page 1D-3)”. Oil Pressure Check B838H20206025 Refer to “Oil Pressure Check in Section 1E (Page 1E- 5)”. SDS Check B838H20206026 Refer to “SDS Check in Section 1A (Page 1A-17)”. I837H1020058-01 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Brake caliper air bleeder valve 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)
• Page 53
  Maintenance and Lubrication: 0B-23 Special Tools and Equipment Recommended Service Material B838H20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-17) NOTE Required service material is also described in the following. “Lubrication Points (Page 0B-2)”…

• Page 54: Service Data

  0C-1 Service Data: Service Data General Information Specifications Service Data B838H20307001 Valve + Guide Unit: mm (in) Item Standard Limit 29.0 (1.14) — Valve diam. 23.0 (0.91) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —…

• Page 55
  Service Data: 0C-2 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 300 – 1 700 kPa (13 – 17 kgf/cm , 185 – 242 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —…
• Page 56
  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. 22.976 – 22.992 (0.9046 – 0.9052) — Oil Pump Item Standard Limit Oil pressure (at 60 °C, 140 °F) 100 –…
• Page 57
  Service Data: 0C-4 Thermostat + Radiator + 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 — 20 °C Approx.
• Page 58
  0C-5 Service Data: FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.28 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.7 V at idle speed TP sensor input voltage 4.5 –…
• Page 59
  Service Data: 0C-6 Throttle Body Item Specification Bore size 42 mm (1.65 in) I.D. No. 38H1 (For E-33), 38H0 (For the others) 1 200 ± 100 r/min Idle r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) Electrical Unit: mm Item…
• Page 60
  0C-7 Service Data: Wattage Unit: W Specification Item E-02, 19, 24 The other countries ← 60 x 2 Headlight ← ← Position light ← Brake light/Taillight ← Turn signal light 21 x 4 ← License plate light ← Combination meter light ←…
• Page 61
  Front fork oil level (Without spring, 115 (4.5) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 418 ml (14.1/14.7 US/lmp oz) — Front fork inner tube O.D 41 (1.6)
• Page 62
  0C-9 Service Data: Tightening Torque List B838H20307002 Engine Item N⋅m kgf-m lb-ft Exhaust pipe bolt 16.5 Exhaust pipe mounting bolt 16.5 Exhaust pipe bracket bolt 18.0 Muffler connecting bolt 16.5 Muffler cover bolt 0.55 Muffler mounting bolt 18.0 Speed sensor rotor bolt 18.0 Speed sensor bolt 0.45…
• Page 63
  Service Data: 0C-10 Item N⋅m kgf-m lb-ft Breather cover bolt Oil pan bolt Oil cooler mounting bolt Driveshaft bearing case bolt (LH and RH) Gearshift arm stopper 13.5 Gearshift cam stopper bolt Gearshift cam stopper plate bolt Driveshaft retainer bolt Gearshift cam bearing retainer screw Starter motor mounting bolt Starter motor lead wire mounting nut…
• Page 64
  0C-11 Service Data: Chassis Item N⋅m kgf-m lb-ft Steering stem head nut 65.0 Steering stem lock-nut 65.0 Steering damper bolt 16.5 Steering damper nut 16.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 25.5 Front fork inner rod lock-nut 14.5…
• Page 65
  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” (mm) N⋅m kgf-m lb-ft N⋅m kgf-m lb-ft 0.15 0.23 0.45 0.55…
• Page 66
  0C-13 Service Data:…

• Page 67: Table Of Contents

  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-78 Precautions for Engine………. 1-1 DTC “C28” (P1655): Secondary Throttle Engine General Information and Valve Actuator (STVA) Malfunction….1A-78 DTC “C29”…

• Page 68
  1-ii Table of Contents Emission Control Devices …… 1B-1 ECT Sensor Inspection ……..1C-5 IAT Sensor Removal and Installation….1C-5 Precautions…………1B-1 IAT Sensor Inspection………1C-6 Precautions for Emission Control Devices ..1B-1 AP Sensor Inspection……….1C-6 General Description ……….1B-1 AP Sensor Removal and Installation….1C-6 Fuel Injection System Description…….

• Page 69: Engine Lubrication System

  Table of Contents 1-iii Cam Chain Guide / Cam Chain Tensioner Oil Pump Inspection ……….1E-13 Removal and Installation………1D-37 Oil Pump Drive Gear Removal and Cam Chain Guide Inspection ……1D-37 Installation …………1E-13 Cam Chain Tensioner Inspection……1D-37 Specifications ………….1E-14 Cylinder Head Disassembly and Assembly ..1D-38 Service Data…………1E-14 Cylinder Head Related Parts Inspection …1D-42 Tightening Torque Specifications……1E-15…

• Page 70: Starting System

  1-iv Table of Contents Diagnostic Information and Procedures… 1G-4 Starter Motor Will Not Run ……..1I-2 Fuel System Diagnosis ……..1G-4 Starter Motor Runs But Does Not Crank The Engine …………..1I-2 Repair Instructions ……….1G-5 Fuel Pressure Inspection ……..1G-5 Repair Instructions ……….

• Page 71
  Table of Contents 1-v Exhaust System Components……1K-5 Exhaust System Inspection…….1K-14 EXCV Cable Removal and Installation….1K-6 Specifications ………….1K-14 EXCVA Removal and Installation ……. 1K-7 Service Data…………1K-14 EXCVA Inspection ……….1K-9 Tightening Torque Specifications……1K-15 EXCVA Pulley Inspection……..1K-9 Special Tools and Equipment ……1K-15 EXCVA Adjustment ……….

• Page 72: Precautions

  1-1 Precautions: Precautions Engine Precautions Precautions for Engine B838H21000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.

• Page 73: Engine General Information And Diagnosis

  Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine General Description Injection Timing Description B838H21101001 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.

• Page 74
  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 ATMOSPHERIC PRESSURE SENSOR SIGNAL the ECM and reduce the injection time (volume).

• Page 75: Self-Diagnosis Function

  Engine General Information and Diagnosis: 1A-3 Self-Diagnosis Function B838H21101002 The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.

• Page 76: Schematic And Routing Diagram

  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.

• Page 77
  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 Lg/G Speed sensor 53*1 Lg/Bl O/Bl 65*1 Gr/W Gr/B Gr/Y Gr/R…

• Page 78: Terminal Alignment Of Ecm Coupler

  1A-6 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B838H21102002 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) STVA signal (STVA, 1A) Fuel pump relay (FP relay) —…

• Page 79: Component Location

  Engine General Information and Diagnosis: 1A-7 Component Location FI System Parts Location B838H21103001 “L” “I” “K” “C” “A” “J” “F” “H” “G” I837H1110126-01 “A”: ECM “E”: Intake air pressure sensor (IAPS) “I”: Fuel pump relay (FP relay) “B”: Throttle position sensor (TPS) “F”: Exhaust control valve actuator (EXCVA) “J”: Fuel pump (FP) “C”: Secondary throttle position sensor (STPS)

• Page 80
  1A-8 Engine General Information and Diagnosis: “M” “O” “S” “A” “P” “T” “Z” “W” “N” “U” “X” “V” I837H1110127-01 “A”: ECM “Q”: Camshaft position sensor (CMPS) “V”: Speed sensor “M”: Cooling fan relay “R”: Ignition coil (IG coil) “W”: Atmospheric pressure sensor (APS) “N”: Cooling fan “S”: Secondary fuel injector “X”: Gear position switch (GP switch)

• Page 81: Diagnostic Information And Procedures

  Engine General Information and Diagnosis: 1A-9 Diagnostic Information and Procedures Engine Symptom Diagnosis B838H21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guide or poor seating of Repair or replace.

• Page 82
  1A-10 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensor or circuit. Repair or replace. (Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace.
• Page 83
  Engine General Information and Diagnosis: 1A-11 Condition Possible cause Correction / Reference Item Noisy engine (Noise Too much play on pump shaft bearing. Replace. seems to come from Worn or damaged impeller shaft. Replace. water pump) Worn or damaged mechanical seal. Replace.
• Page 84
  1A-12 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP switch. Replace.

• Page 85: Self-Diagnostic Procedures

  Engine General Information and Diagnosis: 1A-13 Self-Diagnostic Procedures 5) Check the DTC to determine the malfunction part. B838H21104002 Refer to “DTC Table (Page 1A-21)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select switch) • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming DTC (Diagnostic Trouble Code)

• Page 86
  1A-14 Engine General Information and Diagnosis: Use of SDS NOTE • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

• Page 87: Use Of Sds Diagnosis Reset Procedures

  Engine General Information and Diagnosis: 1A-15 5) Check the DTC to determine the malfunction part. 4) The previous malfunction history code (Past DTC) Refer to “DTC Table (Page 1A-21)”. still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS tool. NOTE 5) Click “Clear”…

• Page 88: Show Data When Trouble (Displaying Data At The Time Of Dtc)

  1A-16 Engine General Information and Diagnosis: Show Data When Trouble (Displaying Data at the Time of DTC) B838H21104004 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.

• Page 89: Sds Check

  Engine General Information and Diagnosis: 1A-17 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110270-01 SDS Check B838H21104005 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.

• Page 90
  1A-18 Engine General Information and Diagnosis: 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 I837H1110131-01 Data at 3 000 r/min under no load Approx.
• Page 91
  Engine General Information and Diagnosis: 1A-19 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 closes I823H1110210-02 Data of intake negative pressure during idling (100 °C)
• Page 92
  1A-20 Engine General Information and Diagnosis: Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XXX kPa I837H1110134-01…

• Page 93: Dtc Table

  Engine General Information and Diagnosis: 1A-21 Example of Trouble Three data; value 3 (current data 3), value 1 (past data 1) and value 2 (past data 2); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.

• Page 94
  1A-22 Engine General Information and Diagnosis: Code Malfunction Part Remarks C25 (P0352) Ignition signal #2 (IG coil #2) For #2 cylinder (Page 1A-78) C26 (P0353) Ignition signal #3 (IG coil #3) For #3 cylinder (Page 1A-78) C27 (P0354) Ignition signal #4 (IG coil #4) For #4 cylinder (Page 1A-78) C28 (P1655)

• Page 95: Fail-Safe Function Table

  Engine General Information and Diagnosis: 1A-23 Fail-Safe Function Table B838H21104007 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. Item Fail-Safe Mode Starting Ability Running Ability When camshaft position signal has failed…

• Page 96: Fi System Troubleshooting

  1A-24 Engine General Information and Diagnosis: 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. ECM stops controlling steering damper Vehicle speed sensor “YES”…

• Page 97
  Engine General Information and Diagnosis: 1A-25 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair / Cloudy / Rain / Snow / Always / Other Cold ( °C / °F) / Temperature Hot / Warm / Cool / Always Frequency Always / Sometimes ( times / day, month) / Only once…

• Page 98: Malfunction Code And Defective Condition Table

  1A-26 Engine General Information and Diagnosis: Malfunction Code and Defective Condition Table B838H21104009 Malfunction Detected Item Detected Failure Condition Check For Code NO FAULT — — CMP sensor wiring and The signal does not reach ECM for 3 sec. or mechanical parts CMP sensor P0340…

• Page 99
  Engine General Information and Diagnosis: 1A-27 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 ≤ Sensor voltage < 4.8 V connection In other than the above value, C23 (P1651) is TO sensor…
• Page 100
  1A-28 Engine General Information and Diagnosis: 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 pump relay is turned OFF.
• Page 101
  Engine General Information and Diagnosis: 1A-29 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. Speed sensor and ECM does not receive signal from the vehicle speedometer wiring/coupler Vehicle speed sensor P0500…

• Page 102: Dtc «C11» (P0340): Cmp Sensor Circuit Malfunction

  1A-30 Engine General Information and Diagnosis: DTC “C11” (P0340): CMP Sensor Circuit Malfunction B838H21104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • CMP sensor circuit open or short. receiving the starter signal.

• Page 103
  Engine General Information and Diagnosis: 1A-31 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. Refer to “Fuel Tank ground.
• Page 104
  1A-32 Engine General Information and Diagnosis: Step Action 5) Connect 3 new 1.5 V batteries in series, 1 kΩ resistor • B/Y, R or B/Br wire • Inspect that metal and the multi-circuit tester as shown in the figure. open or shorted to particles or foreign ground.

• Page 105: Dtc «C12» (P0335): Ckp Sensor Circuit Malfunction

  Engine General Information and Diagnosis: 1A-33 DTC “C12” (P0335): CKP Sensor Circuit Malfunction B838H21104011 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.

• Page 106
  1A-34 Engine General Information and Diagnosis: 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 in Section 1G (Page 1G-9)”. 3) Check the CKP sensor coupler (1) for loose or poor contacts.
• Page 107
  Engine General Information and Diagnosis: 1A-35 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 108: Dtc «C13» (P0105-H/L): Iap Sensor Circuit Malfunction

  1A-36 Engine General Information and Diagnosis: DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B838H21104012 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.

• Page 109
  Engine General Information and Diagnosis: 1A-37 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. Refer to “Fuel Tank coupler.
• Page 110
  1A-38 Engine General Information and Diagnosis: 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. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
• Page 111
  Engine General Information and Diagnosis: 1A-39 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. G/B wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. Check the continuity between the G/B wire and terminal “19”.
• Page 112
  1A-40 Engine General Information and Diagnosis: 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. Refer to “Fuel Tank ground.
• Page 113
  Engine General Information and Diagnosis: 1A-41 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/B wire open, G/ and Installation in Section 1C (Page 1C-1)”. B wire shorted to ground. 7) Insert the needle pointed probes to the lead wire coupler. Check the continuity between the R wire and terminal “7”.
• Page 114
  1A-42 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler. Go to Step 3. • Loose or poor contacts on the ECM 2) Turn the ignition switch OFF. coupler. 3) Lift and support the fuel tank. Refer to “Fuel Tank •…
• Page 115
  Engine General Information and Diagnosis: 1A-43 Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum hose for crack or 2) Connect the ECM coupler and IAP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •…
• Page 116
  1A-44 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. Refer to “IAP Sensor Removal ground, or poor “19”, IAP sensor with a new and Installation in Section 1C (Page 1C-3)”.

• Page 117: Dtc «C14» (P0120-H/L): Tp Sensor Circuit Malfunction

  Engine General Information and Diagnosis: 1A-45 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B838H21104013 Detected Condition and Possible Cause 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 opening •…

• Page 118
  1A-46 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. Refer to “Fuel Tank coupler.
• Page 119
  Engine General Information and Diagnosis: 1A-47 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. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
• Page 120
  1A-48 Engine General Information and Diagnosis: Step Action 7) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. P/B wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. Check the continuity between the P/B wire and terminal “6”.
• Page 121
  Engine General Information and Diagnosis: 1A-49 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and P/B wire open, or P/B wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
• Page 122
  1A-50 Engine General Information and Diagnosis: Step Action 7) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and P/B wire open, or and Installation in Section 1C (Page 1C-1)”. P/B wire shorted to ground. Check the continuity between the P/B wire and terminal “6”.
• Page 123
  Engine General Information and Diagnosis: 1A-51 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 special tool between the TP sensor and its ground, or poor “6”, sensor with a new one.

• Page 124: Dtc «C15» (P0115-H/L): Ect Sensor Circuit Malfunction

  1A-52 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B838H21104014 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤…

• Page 125
  Engine General Information and Diagnosis: 1A-53 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) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
• Page 126
  1A-54 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) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Check the ECT sensor coupler (1) for loose or poor contacts.
• Page 127
  Engine General Information and Diagnosis: 1A-55 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. •…
• Page 128
  1A-56 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. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication…

• Page 129: Dtc «C21» (P0110-H/L): Iat Sensor Circuit Malfunction

  Engine General Information and Diagnosis: 1A-57 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B838H21104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤…

• Page 130
  1A-58 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. Refer to “Fuel Tank coupler.
• Page 131
  Engine General Information and Diagnosis: 1A-59 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. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
• Page 132
  1A-60 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 in Section 1G (Page 1G-9)”. •…
• Page 133
  Engine General Information and Diagnosis: 1A-61 Step Action 10) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication…

• Page 134: Dtc «C22» (P1450-H/L): Ap Sensor Circuit Malfunction

  1A-62 Engine General Information and Diagnosis: DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction B838H21104016 Detected Condition and Possible Cause Detected Condition Possible Cause AP sensor voltage is not within the • Clogged vacuum passage with dust. following range. • AP sensor circuit open or shorted to ground. 0.5 V ≤…

• Page 135
  Engine General Information and Diagnosis: 1A-63 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. Refer to “Exterior Parts Removal coupler.
• Page 136
  1A-64 Engine General Information and Diagnosis: P1450-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. G/Y wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.
• Page 137
  Engine General Information and Diagnosis: 1A-65 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. G/Y wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. Check the continuity between the G/Y wire and terminal “20”.
• Page 138
  1A-66 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. Refer to “Exterior Parts Removal ground.
• Page 139
  Engine General Information and Diagnosis: 1A-67 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/Y wire open, G/ and Installation in Section 1C (Page 1C-1)”. Y wire shorted to ground. 7) Insert the needle pointed probes to the lead wire coupler. Check the continuity between the R wire and terminal “7”.
• Page 140
  1A-68 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the front seat. Refer to “Exterior Parts Removal coupler. and Installation in Section 9D (Page 9D-11)”. •…
• Page 141
  Engine General Information and Diagnosis: 1A-69 Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Check the vacuum port for crack or 2) Connect the ECM coupler and AP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •…
• Page 142
  1A-70 Engine General Information and Diagnosis: 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. Refer to “AP Sensor Removal ground, or poor “7”, AP sensor with a new and Installation in Section 1C (Page 1C-6)”.

• Page 143: Dtc «C23» (P1651-H/L): To Sensor Circuit Malfunction

  Engine General Information and Diagnosis: 1A-71 DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B838H21104017 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •…

• Page 144
  1A-72 Engine General Information and Diagnosis: 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. Refer to “Exterior Parts Removal “TO Sensor Removal and Installation in Section 9D (Page 9D-11)”.
• Page 145
  Engine General Information and Diagnosis: 1A-73 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. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.
• Page 146
  1A-74 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. B wire shorted to VCC, and Installation in Section 1C (Page 1C-1)”. or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. Check the continuity between the B wire and terminal “31”.
• Page 147
  Engine General Information and Diagnosis: 1A-75 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. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.
• Page 148
  1A-76 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or B wire open, or B and Installation in Section 1C (Page 1C-1)”. wire shorted to ground. 7) Insert the needle pointed probes to the lead wire coupler. Check the continuity between the R wire and terminal “7”.
• Page 149
  Engine General Information and Diagnosis: 1A-77 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. ground, or poor “7”, coupler.

• Page 150: Dtc «C24» (P0351), «C25» (P0352), «C26» (P0353) Or «C27» (P0354): Ignition System Malfunction

  1A-78 Engine General Information and Diagnosis: DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B838H21104018 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-5)” for details. DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction B838H21104019 Detected Condition and Possible Cause Detected Condition…

• Page 151
  Engine General Information and Diagnosis: 1A-79 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. 2) Remove the air cleaner box.
• Page 152
  1A-80 Engine General Information and Diagnosis: 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. shorted to ground, or coupler.
• Page 153
  Engine General Information and Diagnosis: 1A-81 Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” (1). I837H1110136-01 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.

• Page 154: Dtc «C29» (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction

  1A-82 Engine General Information and Diagnosis: DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B838H21104020 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •…

• Page 155
  Engine General Information and Diagnosis: 1A-83 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. Refer to “Fuel Tank coupler.
• Page 156
  1A-84 Engine General Information and Diagnosis: 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. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
• Page 157
  Engine General Information and Diagnosis: 1A-85 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Y/W wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Check the continuity between the Y/W wire and terminal “18”.
• Page 158
  1A-86 Engine General Information and Diagnosis: 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. Refer to “Fuel Tank ground.
• Page 159
  Engine General Information and Diagnosis: 1A-87 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or Y/W wire open, or and Installation in Section 1C (Page 1C-1)”. Y/W wire shorted to ground. 7) Check the continuity between the Y/W wire and terminal “18”.
• Page 160
  1A-88 Engine General Information and Diagnosis: 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 coupler and STP sensor coupler. ground, or poor “7”, STP sensor with a new 3) Disconnect the STVA lead wire coupler.

• Page 161: Dtc «C31» (P0705): Gp Switch Circuit Malfunction

  Engine General Information and Diagnosis: 1A-89 DTC “C31” (P0705): GP Switch Circuit Malfunction B838H21104021 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 162
  1A-90 Engine General Information and Diagnosis: 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. Refer to “Fuel Tank ground.

• Page 163: Dtc «C32» (P0201), «C33» (P0202), «C34» (P0203) Or «C35» (P0204): Primary Fuel Injector Circuit Malfunction

  Engine General Information and Diagnosis: 1A-91 DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction B838H21104022 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is •…

• Page 164
  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 in Section 1G (Page 1G-9)”.
• Page 165
  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 (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-11)”.

• Page 166: Dtc «C36» (P1764), «C37» (P1765), «C38» (P1766) Or «C39» (P1767): Secondary Fuel Injector Circuit Malfunction

  1A-94 Engine General Information and Diagnosis: DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction B838H21104023 Detected Condition and Possible Cause Detected Condition Possible Cause Some failure exists in the fuel injector signal in a high •…

• Page 167
  Engine General Information and Diagnosis: 1A-95 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 in Section 1G (Page 1G-9)”.
• Page 168
  1A-96 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 (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-11)”.

• Page 169: Dtc «C40» (P0505 / P0506 / P0507): Isc Valve Circuit Malfunction

  Engine General Information and Diagnosis: 1A-97 DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B838H21104024 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground. C40/P0505 unusual.

• Page 170
  1A-98 Engine General Information and Diagnosis: 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 in Section 1D (Page 1D-7)”. 3) Check the ISC valve coupler (1) for loose or poor contacts.
• Page 171
  Engine General Information and Diagnosis: 1A-99 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. Refer to faulty ECM. “Throttle Body Removal Special tool and Installation in (A): 09900–25008 (Multi-circuit tester set)
• Page 172
  1A-100 Engine General Information and Diagnosis: ACTIVE CONTROL INSPECTION (ISC RPM Check 2 CONTROL) 1) Click the button (4) and decrease the “Spec” (2) to 1 Check 1 100 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation 2) Check that the “Desired idle speed”…

• Page 173: Dtc «C41» (P0230-H/L): Fp Relay Circuit Malfunction

  Engine General Information and Diagnosis: 1A-101 Check 4 1) Click the button (6) and increase the “Spec” (2) to 1 900 rpm. 2) Check that the “Desired idle speed” (3) is approx. 1 900 rpm. 3) Check that the “Engine speed” (7) is close to 1 900 I837H1110087-01 If the ISC valve does not function properly, inspect the rpm.

• Page 174
  1A-102 Engine General Information and Diagnosis: Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”.
• Page 175
  Engine General Information and Diagnosis: 1A-103 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. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.

• Page 176: Dtc «C41» (P2505): Ecm Power Input Signal Malfunction

  1A-104 Engine General Information and Diagnosis: DTC “C41” (P2505): ECM Power Input Signal Malfunction B838H21104026 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the ECM. • Lead wire/coupler connection of ECM terminal to fuel fuse.

• Page 177
  Engine General Information and Diagnosis: 1A-105 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 in Section 9D (Page 9D-11)”. Refer to “DTC “C41”…

• Page 178: Dtc «C42» (P1650): Ig Switch Circuit Malfunction

  1A-106 Engine General Information and Diagnosis: DTC “C42” (P1650): IG Switch Circuit Malfunction B838H21104027 Detected Condition and Possible Cause Detected Condition Possible Cause Ignition switch signal is not input to the ECM. • Ignition system circuit open or short. • ECM malfunction. When the ID agreement is not verified.

• Page 179
  Engine General Information and Diagnosis: 1A-107 Troubleshooting (When Indicating C44/P0130:) CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”.
• Page 180
  1A-108 Engine General Information and Diagnosis: 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. 7) Check the continuity between the W/G wire and terminal “34”.
• Page 181
  Engine General Information and Diagnosis: 1A-109 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. 2) Warm up the engine enough. the power source, or Refer to “HO2 Sensor 3) Insert the needle pointed probes to the lead wire coupler.
• Page 182
  1A-110 Engine General Information and Diagnosis: 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-15)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.
• Page 183
  Engine General Information and Diagnosis: 1A-111 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. ground, or poor “41”…

• Page 184: Dtc «C46» (P1657-H/L Or P1658): Excv Actuator Circuit Malfunction

  1A-112 Engine General Information and Diagnosis: DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction B838H21104029 Detected Condition Possible Cause The operation signal does not reach the • EXCVA maladjusted. EXCV actuator. • EXCVA circuit open or short. EXCVA position sensor voltage low or •…

• Page 185
  Engine General Information and Diagnosis: 1A-113 C46 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Go to Step 6. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Check the EXCVA position sensor coupler (1) and EXCVA motor coupler (2) for loose or poor contacts.
• Page 186
  1A-114 Engine General Information and Diagnosis: 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) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
• Page 187
  Engine General Information and Diagnosis: 1A-115 Step Action 6) Disconnect the ECM coupler. Go to Step 4. Y wire shorted to VCC, or B/Br wire open. 7) Check the continuity between Y wire and terminal “14”. Also, check the continuity between B/Br wire and terminal “35”.
• Page 188
  1A-116 Engine General Information and Diagnosis: 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. wire shorted to ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
• Page 189
  Engine General Information and Diagnosis: 1A-117 Step Action 7) Disconnect the ECM coupler. Go to Step 2 and go to R or Y wire open, or Y Step 4. wire shorted to ground. Check the continuity between Y wire and terminal “14”. 9) Also, check the continuity between R wire and terminal “7”.
• Page 190
  1A-118 Engine General Information and Diagnosis: P1658 (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 6. Loose or poor contacts on the EXCV motor 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
• Page 191
  Engine General Information and Diagnosis: 1A-119 Step Action 5) Turn the ignition switch ON. Go to Step 3. • Loose or poor contacts on the ECM 6) Measure the voltage between the R wire and ground. coupler (terminal “7” 7) If OK, then measure the voltage between the R wire and or “35”).
• Page 192
  1A-120 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 ∞…
• Page 193
  Engine General Information and Diagnosis: 1A-121 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 position sensor coupler (1). inspect it again. 3) Disconnect the EXCVA motor coupler (2). 4) Measure the EXCVA position sensor output voltage at EXCV fully closed position and fully opened position.
• Page 194
  1A-122 Engine General Information and Diagnosis: Step Action Then, to set the EXCV to fully opened position, apply 12 Replace the ECM with a Go to Step 5. V to the terminals oppositely. known good one, and Positive wire – Gr wire terminal inspect it again.
• Page 195
  Engine General Information and Diagnosis: 1A-123 Step Action 1) If the EXCVA position sensor output voltage is 0.5 V and Replace the ECM with a Replace the EXCVA less at EXCV fully closed position, adjust the output known good one, and with a new one.
• Page 196
  1A-124 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 motor coupler (1). EXCVA or ECM • Inspect that the coupler (terminal “13”…
• Page 197
  Engine General Information and Diagnosis: 1A-125 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” (1). I837H1110164-01 4) Click each button (2). At this time, if an operation sound is heard from the EXCVA, the function is normal.

• Page 198: Dtc «C49» (P1656): Pair Control Solenoid Valve Circuit Malfunction

  1A-126 Engine General Information and Diagnosis: DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B838H21104030 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve voltage is not input to ECM. • PAIR control solenoid valve circuit open or short. •…

• Page 199
  Engine General Information and Diagnosis: 1A-127 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. Refer to Removal and Installation in Section 1D (Page 1D-7)”.
• Page 200
  1A-128 Engine General Information and Diagnosis: 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. poor “55”…

• Page 201: Dtc «C60» (P0480): Cooling Fan Relay Circuit Malfunction

  Engine General Information and Diagnosis: 1A-129 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B838H21104031 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •…

• Page 202
  1A-130 Engine General Information and Diagnosis: 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 front seat. Refer to “Exterior Parts Removal ground, or poor “42”…
• Page 203
  Engine General Information and Diagnosis: 1A-131 4) Click the “Operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. NOTE The cooling fan relay and cooling fan motor inspection is operational at any engine coolant temperature until reaching 100 °C (212 °F).

• Page 204: Dtc «C62» (P0443): Evap System Purge Control Solenoid Valve Circuit Malfunction (E-33 Only)

  1A-132 Engine General Information and Diagnosis: DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) B838H21104032 Detected Condition and Possible Cause Detected Condition Possible Cause EVAP system purge control valve voltage is not input to • EVAP system purge control valve circuit open or short. ECM.

• Page 205
  Engine General Information and Diagnosis: 1A-133 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. Refer to Removal and Installation in Section 1G (Page 1G-9)”.
• Page 206
  1A-134 Engine General Information and Diagnosis: 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. poor “61”…

• Page 207: Dtc «C91» (P0500): Vehicle Speed Sensor Circuit Malfunction

  Engine General Information and Diagnosis: 1A-135 DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction B838H21104033 Detected Condition and Possible Cause Detected Condition Possible Cause Speedometer does not receive signal from the vehicle • Speed sensor circuit open or short. speed sensor for more than 6 sec. when the motorcycle is •…

• Page 208
  1A-136 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. Refer to “Fuel Tank material stuck on the Removal and Installation in Section 1G (Page 1G-9)”.
• Page 209
  Engine General Information and Diagnosis: 1A-137 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. particles or foreign tester reading voltage changes (0 V →…

• Page 210: Dtc «C93» (P1769): Steering Damper Solenoid Valve Circuit Malfunction

  1A-138 Engine General Information and Diagnosis: DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction B838H21104034 Detected Condition and Possible Cause Detected Condition Possible Cause Steering damper control current does not flow to • Steering damper solenoid valve circuit the solenoid valve. With IG turned ON, ECM interrupter element shorted.

• Page 211
  Engine General Information and Diagnosis: 1A-139 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. If OK, then measure the steering damper solenoid valve resistance.
• Page 212
  1A-140 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • W wire shorted to • Low battery voltage VCC, or poor “26” or fuse is blown. 2) Measure the voltage between W wire and ground. connection failure.
• Page 213
  Engine General Information and Diagnosis: 1A-141 Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Raise the front wheel off the ground. 3) Turn the ignition switch ON. 4) Click “Steering damper solenoid operating control” (1). I837H1110123-03 5) Click each button (2) ON/OFF while turning the handlebars left and right.

• Page 214: Specifications

  1A-142 Engine General Information and Diagnosis: Specifications Service Data B838H21107001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.28 V and more…

• Page 215: Special Tools And Equipment

  Engine General Information and Diagnosis: 1A-143 Special Tools and Equipment Special Tool B838H21108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-32) / (Page 1A-109) / (Page 1A-34) / (Page 1A-111) / (Page 1A-35) / (Page 1A-115) / (Page 1A-110) / (Page 1A-117) / (Page 1A-111) /…

• Page 216
  1A-144 Engine General Information and Diagnosis: 09917–47011 09930–82720 Vacuum pump gauge Mode select switch (Page 1A-44) / (Page 1A-4) / (Page 1A- (Page 1A-70) 13) / (Page 1A-13) 99565–01010–015 CD-ROM Ver.15 (Page 1A-14) / (Page 1A-17)

• Page 217: Emission Control Devices

  Fuel Injection System Description B838H21201001 GSX-R750 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.

• Page 218: Crankcase Emission Control System Description

  1B-2 Emission Control Devices: Crankcase Emission Control System Description B838H21201002 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.

• Page 219: Exhaust Emission Control System Description

  Emission Control Devices: 1B-3 Exhaust Emission Control System Description B838H21201003 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 port through the PAIR control solenoid valve and PAIR reed valve.

• Page 220: Noise Emission Control System Description

  1B-4 Emission Control Devices: Noise Emission Control System Description B838H21201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: • The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or •…

• Page 221: Schematic And Routing Diagram

  Emission Control Devices: 1B-5 Schematic and Routing Diagram PAIR System Hose Routing Diagram B838H21202001 “a” “C” “A” “D” “A” “ b” “ b” “b” “B” I837H1120044-03 1. PAIR control solenoid valve “B”: Yellow marking “a”: 45° 2. PAIR reed valve “C”: Face the clamp end rearward.

• Page 222: Evap Canister Hose Routing Diagram

  1B-6 Emission Control Devices: EVAP Canister Hose Routing Diagram (Only for E-33) B838H21202002 “C” “A” “B” “F” “E” “D” “ a ” “G” “A” “H” “I” I837H1120045-02 1. EVAP system purge control solenoid valve 7. Seat rail “E”: Clamp the hoses and battery (+) lead wire at this part. 2.

• Page 223: Repair Instructions

  Emission Control Devices: 1B-7 Repair Instructions Heated Oxygen Sensor (HO2S) Removal and Installation Install the HO2 sensor in the reverse order of removal. Installation B838H21206001 Pay attention to the following points: Removal CAUTION WARNING Do not apply oil or other materials to the Do not remove the HO2 sensor while it is hot.

• Page 224
  1B-8 Emission Control Devices: 6) Disconnect the CMP sensor coupler (2) and remove 11) Remove the cylinder head cover. Refer to “Engine the cylinder head cover shield (3). Top Side Disassembly in Section 1D (Page 1D-25)”. 12) Remove the PAIR reed valves (7) with the gaskets. I837H1120004-02 7) Remove the radiator mounting bolts.

• Page 225: Pair Control Solenoid Valve Removal And Installation

  Emission Control Devices: 1B-9 PAIR Control Solenoid Valve Removal and 3) Inspect the PAIR hoses for wear or damage. If it is worn or damaged, replace the PAIR hose with a new Installation B838H21206004 one. Refer to “PAIR System Hose Routing Diagram (Page 1B-5)”.

• Page 226: Crankcase Breather (Pcv) Hose Inspection

  1B-10 Emission Control Devices: PAIR Control Solenoid Valve 4) Check the resistance between the terminals of the PAIR control solenoid valve. NOTE Special tool PAIR control solenoid valve can be checked (A): 09900–25008 (Multi-circuit tester set) without removing it from the motorcycle. Refer to “DTC “C49”…

• Page 227: Crankcase Breather (Pcv) Hose / Reed Valve / Cover Removal And Installation

  Emission Control Devices: 1B-11 Crankcase Breather (PCV) Hose / Reed Valve / Remove the EXCVA (4). Cover Removal and Installation B838H21206007 Removal 1) Lift and support the fuel tank with the prop stay. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

• Page 228: Crankcase Breather (Pcv) Cover Inspection

  1B-12 Emission Control Devices: Crankcase Breather (PCV) Cover Inspection Evaporative Emission Control System Removal B838H21206008 and Installation (Only for E-33) Inspect the crankcase breather (PCV) cover in the B838H21206010 following procedures: Hose Removal 1) Remove the crankcase breather (PCV) cover. Refer to “Crankcase Breather (PCV) Hose / Reed Valve / 1) Lift and support the fuel tank.

• Page 229
  Emission Control Devices: 1B-13 EVAP System Purge Control Solenoid Valve Fuel Shut-off Valve Removal Removal 1) Lift and support the fuel tank with the prop stay. 1) Remove the front seat. Refer to “Exterior Parts Refer to “Fuel Tank Removal and Installation in Removal and Installation in Section 9D (Page 9D- Section 1G (Page 1G-9)”.
• Page 230
  1B-14 Emission Control Devices: 9) Remove the rear fender (rear) plate (6) and rear 13) Disconnect the surge hose (10). fender (rear) (7). I837H1120038-02 14) Move the rear fender (front) backward. I837H1120034-02 10) Remove the rear fender (front) cover (8). 15) Disconnect the surge hose (11).
• Page 231
  Emission Control Devices: 1B-15 • Clamp the EVAP hoses at white taping point. EVAP System Purge Control Solenoid Valve NOTE EVAP system purge control solenoid valve can be checked without removing it from the motorcycle. Refer to “DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) in Section 1A (Page 1A-132)”.
• Page 232
  1B-16 Emission Control Devices: 3) Check the resistance between the terminals of the 1) When air is blown into the fuel shut-off valve with its EVAP system purge control solenoid valve. If the side “A” positioned upward, the air can pass through resistance is not within the standard range, replace to the canister side.

• Page 233: Specifications

  Emission Control Devices: 1B-17 Specifications Service Data B838H21207001 FI sensors Item Specification Note 0.4 V and less at idle speed HO2 sensor output voltage 0.6 V and more at 5 000 r/min 6.7 – 9.5 Ω at 23 °C (73 °F) HO2 sensor heater resistance PAIR control solenoid valve 20 –…

• Page 234: Engine Electrical Devices

  1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B838H21300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B838H21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

• Page 235: Cmp Sensor Inspection

  Engine Electrical Devices: 1C-2 CMP Sensor Inspection 5) Move the radiator forward. B838H21306002 6) Remove the front engine cover (3). Refer to “DTC “C11” (P0340): CMP Sensor Circuit 7) Disconnect the horn couplers (4). Malfunction in Section 1A (Page 1A-30)”. Remove the horn (5).

• Page 236: Ckp Sensor Inspection

  1C-3 Engine Electrical Devices: Installation IAP Sensor Inspection B838H21306006 Install the CMP sensor in the reverse order of removal. Refer to “DTC “C13” (P0105-H/L): IAP Sensor Circuit Pay attention to the following points: Malfunction in Section 1A (Page 1A-36)”. CAUTION IAP Sensor Removal and Installation When installing the CMP sensor, make sure B838H21306007…

• Page 237: Tp Sensor Adjustment

  Engine Electrical Devices: 1C-4 2) Remove the TP sensor (1) with the special tool. 5) If the TP sensor adjustment is necessary, remove the right under cowling. Refer to “Exterior Parts Special tool Removal and Installation in Section 9D (Page 9D- : 09930–11950 (Torx wrench) 11)”.

• Page 238: Ect Sensor Inspection

  1C-5 Engine Electrical Devices: Installation Special tool Install the ECT sensor in the reverse order of removal. (A): 09900–25008 (Multi-circuit tester set) Pay attention to the following points: Tester knob indication • Tighten the ECT sensor (1) to the specified torque. Resistance (Ω) CAUTION ECT sensor specification…

• Page 239: Iat Sensor Inspection

  Engine Electrical Devices: 1C-6 Installation AP Sensor Removal and Installation B838H21306016 Install the IAT sensor in the reverse order of removal. Removal Pay attention to the following point: 1) Remove the front seat. Refer to “Exterior Parts • Tighten the IAT sensor screw (1) to the specified Removal and Installation in Section 9D (Page 9D- torque.

• Page 240: Stp Sensor Inspection

  1C-7 Engine Electrical Devices: Installation 5) Close the secondary throttle valve by finger and Install the TO sensor in the reverse order of removal. measure the STP sensor output voltage. Pay attention to the following point: Special tool • When installing the TO sensor, bring the “UP” letters (A): 09900–25008 (Multi-circuit tester set) upward.

• Page 241: Stp Sensor Removal And Installation

  Engine Electrical Devices: 1C-8 Tighten the STP sensor mounting screw to the STV Actuator Inspection B838H21306022 specified torque. Refer to “DTC “C28” (P1655): Secondary Throttle Valve Tightening torque Actuator (STVA) Malfunction in Section 1A (Page 1A- STP sensor mounting screw: 3.5 N·m (0.35 kgf- 78)”.

• Page 242: Isc Valve Preset And Opening Initialization

  1C-9 Engine Electrical Devices: ISC Valve Preset and Opening Initialization NOTE B838H21306026 The leaned value of the ISC valve is set at When removing or replacing the ISC valve, set the ISC Preset position. valve to the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool.

• Page 243: Specifications

  Engine Electrical Devices: 1C-10 Specifications Service Data B838H21307001 FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.28 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.

• Page 244: Special Tools And Equipment

  1C-11 Engine Electrical Devices: Special Tools and Equipment Special Tool B838H21308001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1C-5) / (Page 1C- (Page 1C-7) 09930–11950 09930–82720 Torx wrench Mode select switch (Page 1C-4) / (Page 1C- (Page 1C-4) 4) / (Page 1C-7) / (Page 1C-8)

• Page 245: Engine Mechanical

  Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B838H21402001 I837H1140299-01…

• Page 246: Throttle Cable Routing Diagram

  1D-2 Engine Mechanical: Throttle Cable Routing Diagram B838H21402002 “A” “ a ” “B” “ a ” “ a ” “C” I837H1140300-01 1. Throttle cable No. 1 6. Throttle cable guide No. 2 2. Throttle cable No. 2 “A”: Pass the throttle cables to the front of brake hose. 3.

• Page 247: Diagnostic Information And Procedures

  Engine Mechanical: 1D-3 Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B838H21404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-9)”. Compression Pressure Check B838H21404002 The compression pressure reading of a cylinder is a good indicator of its internal condition.

• Page 248: Repair Instructions

  1D-4 Engine Mechanical: Repair Instructions Engine Components Removable with the Engine in Place B838H21406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal…

• Page 249
  Engine Mechanical: 1D-5 Engine Right Side Item Removal Inspection Installation Refer to “Exhaust Pipe / Refer to “Exhaust Pipe / Refer to “Exhaust System Muffler Removal and Muffler Removal and Exhaust pipes/Muffler Inspection in Section 1K Installation in Section 1K Installation in Section 1K (Page 1K-14)”.

• Page 250: Air Cleaner Element Removal And Installation

  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 in Section 9C (Page 9C-5)”. (Page 9C-6)”.

• Page 251: Air Cleaner Box Removal And Installation

  Engine Mechanical: 1D-7 Air Cleaner Box Removal and Installation 7) Disconnect the PAIR hose (6). B838H21406003 Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 9)”. 2) Remove the air cleaner box mounting bolt (1). I837H1140291-01 Remove the air cleaner box.

• Page 252: Throttle Body Components

  1D-8 Engine Mechanical: Throttle Body Components B838H21406008 I837H1140292-02 1. Fuel delivery pipe 5. STP sensor 9. ISC valve [A]: For E-33 only 2. Fuel delivery pipe T-joint 6. Secondary fuel injector 10. Air screw : 3.5 Nm (0.35 kgf-m, 2.5 lb-ft) 3.

• Page 253: Throttle Body Construction

  Engine Mechanical: 1D-9 Throttle Body Construction B838H21406009 “B” “A” “E” “3” “C” “5” “1” “2” “4” “D” “F” I838H1140001-02 1. Intake pipe 6. ISC valve hose “E”: Evenly tighten the bolts in the order of “1” to “5”. 2. Air cleaner outlet tube “A”: Face the clamp end backward.

• Page 254: Throttle Body Removal And Installation

  1D-10 Engine Mechanical: Throttle Body Removal and Installation 5) Disconnect the STP sensor lead wire coupler (2), B838H21406010 IAP sensor lead wire coupler (3) and STVA lead wire Removal coupler (4). 1) Remove the under cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

• Page 255: Throttle Body Disassembly And Assembly

  Engine Mechanical: 1D-11 11) Disconnect the purge hose from the EVAP system • Connect the throttle pulling cable (3) and throttle purge control solenoid valve (8). (E-33 only) returning cable (4) to the throttle cable drum. “ a ” “ a ” I837H1140013-01 I837H1140016-01 12) Disconnect the TP sensor lead wire coupler (9).

• Page 256
  1D-12 Engine Mechanical: 4) Remove the fuel delivery pipe assembly (6). 7) Remove the ISC valve hoses (10) and ISC valve (11). CAUTION Be careful not to twist the fuel delivery pipe T-joint (7) when removing the fuel delivery pipes, or joint part “A” of the fuel delivery pipe get damage.
• Page 257
  • Align the secondary throttle shaft end “A” with the groove “B” of the STP sensor. • Apply grease to the secondary throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1140024-01 Special tool CAUTION : 09930–11950 (Torx wrench)
• Page 258
  • Align the throttle shaft end “C” with the groove “D” of the TP sensor. • Apply grease to the throttle shaft end “C” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool : 09930–11950 (Torx wrench)

• Page 259: Throttle Body Inspection And Cleaning

  Engine Mechanical: 1D-15 • Assemble the fuel delivery pipes as shown in the • Install the fuel delivery pipe assembly to the throttle figure. body. • Tighten the fuel delivery pipe mounting screws (7) to CAUTION the specified torque. Be careful not to twist the fuel delivery pipe Tightening torque T-joint when installing the fuel delivery pipes, Fuel delivery pipe mounting screw (b): 3.5 N·m (…

• Page 260: Isc Valve Visual Inspection

  1D-16 Engine Mechanical: Inspection 5) Disconnect the respective vacuum hoses (1) from Check following items for any defects or clogging. each vacuum nipple on the throttle body. Replace the damaged part if necessary. • O-rings • Throttle valves • Secondary throttle valves •…

• Page 261
  Engine Mechanical: 1D-17 11) Click “Active control”. 15) Equalize the vacuum of the cylinders by turning each air screw (6) and keep it running at idling speed. 12) Click “ISC air volume control” (4). NOTE Always set the engine rpm at idle rpm. I837H1140294-02 13) Click “ON”…

• Page 262: Isc Valve Reset

  1D-18 Engine Mechanical: ISC Valve Reset NOTE B838H21406015 The learned value of the ISC valve is set at When removing or replacing the throttle body assembly, RESET position. reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tools.

• Page 263: Engine Assembly Removal

  Engine Mechanical: 1D-19 5) Click the “Reset” button (2) to clear the TP learned 2) Disconnect the battery (–) lead wire (1). value. I837H1140247-01 3) Jack up the motorcycle and fix it for safety. 4) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”.

• Page 264
  1D-20 Engine Mechanical: 11) Remove the oil cooler outlet hose (5). 17) Disconnect the GP switch lead wire coupler (13), ground lead wire coupler (14) and CKP sensor lead wire coupler (15). I837H1140286-01 12) Remove the muffler (6) and exhaust pipes (7) along with the HO2 sensor.
• Page 265
  Engine Mechanical: 1D-21 20) Disconnect the CMP sensor lead wire coupler (23), 24) Remove the engine sprocket cover (30). PAIR solenoid valve lead wire coupler (24) and PAIR solenoid valve hose (25). I837H1140257-02 25) Remove the clutch push rod (31). I837H1140254-01 21) Remove the PAIR solenoid valve (26).
• Page 266
  1D-22 Engine Mechanical: 30) Remove the engine mounting bolt (35). 36) Loosen the engine mounting thrust adjuster (41) fully. Special tool (A): 09940–14980 (Rotor remover) NOTE Do not remove the engine mounting bolts at this stage. I837H1140261-02 31) Remove the engine mounting nut (36). 32) Remove the engine mounting thrust adjuster lock- nut (37) with the special tool.

• Page 267: Engine Assembly Installation

  Engine Mechanical: 1D-23 Engine Assembly Installation • Tighten the engine mounting thrust adjuster lock-nuts B838H21406018 (3) and (4) to the specified torque with the special tool. Install the engine in the reverse order of engine removal. Tightening torque Pay attention to the following points: Engine mounting thrust adjuster lock-nut (b): 45 •…

• Page 268
  1D-24 Engine Mechanical: • Tighten the engine mounting pinch bolt to the specified torque, as shown in the following illustration. “ b ” “ a ” 2 “ e ” “ c” “ f ” “ f ” “ d ” I837H1140274-03 1.

• Page 269: Engine Top Side Disassembly

  Engine Mechanical: 1D-25 • Install the engine sprocket. Refer to “Engine Sprocket Engine Top Side Disassembly B838H21406019 Removal and Installation in Section 3A (Page 3A-2)”. It is unnecessary to remove the engine assembly from • Install the exhaust pipe assembly and muffler. Refer to the frame when servicing the cylinder head cover and “Exhaust Pipe / Muffler Removal and Installation in camshafts.

• Page 270
  1D-26 Engine Mechanical: Camshafts 3) Remove the cam chain tension adjuster (2). 1) Remove the valve timing inspection cap (1). I838H1140006-01 4) Remove the gasket (3). I837H1140201-01 2) Turn the crankshaft to bring the line “A” on the CKP sensor rotor to the rib “B” behind the clutch cover and also to bring the cams to the position as shown.

• Page 271: Engine Top Side Assembly

  Engine Mechanical: 1D-27 7) Remove the dowel pins. 4) Remove the cylinder head. Remove the intake camshaft (6) and exhaust 5) Remove the dowel pins (3) and cylinder head gasket camshaft (7). (4). I837H1140208-01 I837H1140211-01 Cylinder Head Engine Top Side Assembly B838H21406020 NOTE Assemble the engine top side in the reverse order of…

• Page 272
  1D-28 Engine Mechanical: • Tighten the cylinder head bolts (M10) to the specified Camshaft torque with a torque wrench sequentially and • The cam shafts are identified by the embossed letters. diagonally. IN: Intake camshaft • Additionally tighten the cylinder head bolts with the EX: Exhaust camshaft specified angles diagonally using an angular torque •…
• Page 273
  Engine Mechanical: 1D-29 • Pull the cam chain lightly. • Bind the cam chain and the sprocket with a proper clamp (2) to prevent the cam chain disengagement • Turn the exhaust camshaft so that the arrow is aligned while installing the camshaft journal holders. with the gasket surface of the cylinder head.
• Page 274
  1D-30 Engine Mechanical: • Apply engine oil to journals and cam faces. I837H1140226-02 I837H1140223-02 Embossed letter Cylinder • Install the dowel pins. No. 1 and No. 2 No. 3 and No. 4 • Install the cam chain guide No. 2 (4). •…
• Page 275
  Engine Mechanical: 1D-31 I837H1140228-01 • Remove the clamps. • Fit a new gasket (1). CAUTION Use a new gasket to prevent oil leakage. I837H1140229-01 Cam Chain Tension Adjuster • Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the I837H1140230-01 adjuster body until the outer circlip “A”…
• Page 276
  1D-32 Engine Mechanical: • Rotate the crankshaft (some turns) and recheck the NOTE valve timing. The cam chain tension adjuster can be serviced with the engine installed in the CAUTION frame. • Make sure that the adjuster works properly • Tighten the cam chain tension adjuster service cap (6) by checking no slack at point “C”.
• Page 277
  • Install a new gasket to the cylinder head cover. • Apply bond to the cam end cap points of the gasket as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) CAUTION Use a new gasket to prevent oil leakage.

• Page 278: Camshaft Inspection

  1D-34 Engine Mechanical: Camshaft Inspection Camshaft Runout B838H21406021 Measure the runout using the dial gauge. Replace the Refer to “Engine Top Side Disassembly (Page 1D-25)”. camshaft if the runout exceeds the limit. Refer to “Engine Top Side Assembly (Page 1D-27)”. Special tool (A): 09900–20607 (Dial gauge (1/100 mm, 10 Camshaft Identification…

• Page 279
  Engine Mechanical: 1D-35 4) Tighten the camshaft journal holder bolts in 7) If the camshaft journal oil clearance exceeds the ascending order of numbers to the specified torque. limit, measure the inside diameter of the camshaft Refer to “Engine Top Side Assembly (Page 1D-27)”. journal holder and the outside diameter of the camshaft journal.

• Page 280: Camshaft Sprocket

  1D-36 Engine Mechanical: Camshaft Sprocket NOTE B838H21406022 If it is difficult to compress the plunger Inspect the camshaft sprocket in the following because of internal engine oil, disassemble procedures: the adjuster by releasing the inner circlip “C” 1) Remove the intake and exhaust camshafts. Refer to and spill out the oil.

• Page 281: Cam Chain Guide / Cam Chain Tensioner Removal And Installation

  Engine Mechanical: 1D-37 Cam Chain Guide / Cam Chain Tensioner Cam Chain Guide Inspection B838H21406025 Removal and Installation Inspect the cam chain guide in the following procedures: B838H21406024 Removal 1) Remove the cam chain guides. Refer to “Cam Chain Guide / Cam Chain Tensioner Removal and 1) Remove the cylinder head cover.

• Page 282: Cylinder Head Disassembly And Assembly

  1D-38 Engine Mechanical: Cylinder Head Disassembly and Assembly 4) Remove the valve spring retainer (4) and valve B838H21406027 spring (5). Refer to “Engine Top Side Disassembly (Page 1D-25)”. 5) Pull out the valve (6) from the combustion chamber Refer to “Engine Top Side Assembly (Page 1D-27)”. side.

• Page 283
  I837H1140045-01 13) Remove the intake pipes (14). CAUTION Replace the O-rings with new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1140046-01 14) Remove the oil gallery plug (15). 15) Remove the cam chain tension adjuster service cap (16).
• Page 284
  1D-40 Engine Mechanical: • Apply thread lock to the intake pipe mounting bolts. • Install the thermostat (4). : Thread lock cement 99000–32110 NOTE (THREAD LOCK CEMENT SUPER 1322 or The air bleeder hole “A” of the thermostat equivalent) faces upside. “A”…
• Page 285
  Engine Mechanical: 1D-41 • Apply engine oil to the oil seal (8), and press-fit it into • Put on the valve spring retainer (9), and using the the position. special tools, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow CAUTION the cotter halves to wedge in between retainer and stem.

• Page 286: Cylinder Head Related Parts Inspection

  1D-42 Engine Mechanical: • Install the tappet shims and the tappets to their Valve Stem Runout original positions. Support the valve using V-blocks, as shown in the figure, and check its runout using the dial gauge. If the runout NOTE exceeds the service limit, replace the valve.

• Page 287
  Engine Mechanical: 1D-43 Valve Stem and Valve Face Wear Condition Valve Stem Wear Measure the valve stem O.D. using the micrometer. If it • Visually inspect each valve stem and valve face for is out of specification, replace the valve with a new one. wear and pitting.
• Page 288
  1D-44 Engine Mechanical: Valve Spring Valve Seat Width The force of the coil spring keeps the valve seat tight. A 1) Visually check for valve seat width on each valve weakened spring results in reduced engine power output face. If the valve face has worn abnormally, replace and often accounts for the chattering noise coming from the valve.

• Page 289: Valve Guide Replacement

  Engine Mechanical: 1D-45 Valve Seat Sealing Condition Valve Guide Replacement B838H21406029 1) Clean and assemble the cylinder head and valve 1) Remove the cylinder head. Refer to “Engine Top components. Side Disassembly (Page 1D-25)”. 2) Fill the intake and exhaust ports with gasoline to 2) Remove the valves.

• Page 290
  1D-46 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. Be sure to clean and oil the 150 °C (212 –…

• Page 291: Valve Seat Repair

  Engine Mechanical: 1D-47 Valve Seat Repair Engine Bottom Side Disassembly B838H21406030 B838H21406031 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°. the crankshaft and conrod.

• Page 292
  1D-48 Engine Mechanical: Starter Motor 3) Remove the thrust washer (5). Remove the starter motor (1). I837H1140075-01 I838H1140018-01 Gearshift System Clutch 1) Remove the snap ring (1) and washer (2) from the Remove the clutch component parts (1). Refer to “Clutch gearshift shaft.
• Page 293
  Engine Mechanical: 1D-49 Starter Idle Gear / Generator Cover Cam Chain / Cam Chain Tensioner / Cam Chain Guide 1) Remove the starter idle gear component parts (1). Refer to “Starter Clutch Removal and Installation in 1) While holding the generator rotor with the special Section 1I (Page 1I-10)”.
• Page 294
  1D-50 Engine Mechanical: Water Pump Oil Filter Remove the oil filter (1) with the special tool. 1) Remove the oil cooler water hose (1), cylinder inlet hose (2) and water inlet connector (3). Special tool 2) Remove the water pump (4). (A): 09915–40610 (Oil filter wrench) I837H1140084-01 I837H1140088-01…
• Page 295
  Engine Mechanical: 1D-51 Oil Pressure Regulator / Oil Strainer 1) Remove the oil pressure regulator (1). 2) Remove the oil strainer (2). I838H1140019-01 I837H1140091-01 Oil Pump 1) Remove the oil pump (1). 2) Remove the dowel pins (2) and O-ring (3). I837H1140095-01 5) Make sure that all of the bolts are removed.
• Page 296
  1D-52 Engine Mechanical: Transmission Piston Cooling Oil Jet Remove the transmission component. Refer to Remove the piston cooling oil jets (1) from the upper “Transmission Removal in Section 5B (Page 5B-3)”. crankcase. I837H1140097-01 I838H1140024-01 Piston / Conrod 1) Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase.
• Page 297
  Engine Mechanical: 1D-53 NOTE 2) Remove the piston pin circlip (1). • Do not remove the crankshaft journal bearings unless absolutely necessary. • Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions.
• Page 298
  1D-54 Engine Mechanical: 2) Remove the oil jet (2) (for transmission) from the Water Jacket Plug lower crankcase. Remove the water jacket plugs (1) from the upper crankcase. I837H1140115-03 I837H1140119-01 Oil Gallery Plug Oil seal / Bearing 1) Remove the oil gallery plug (1) from the lower Remove the oil seal and bearings if necessary.

• Page 299: Engine Bottom Side Assembly

  Engine Mechanical: 1D-55 Engine Bottom Side Assembly Oil Gallery Plug B838H21406032 • Tighten each plugs (for lower crankcase) to the Assemble the engine bottom side in the reverse order of specified torque. disassembly. Pay attention to the following points: CAUTION NOTE Replace the gaskets with new ones.

• Page 300
  1D-56 Engine Mechanical: Oil Jet Crankshaft Journal Bearing • Apply thread lock to the oil gallery jet (1) (for • When fitting the crankshaft journal bearings to the generator) and tighten it to the specified torque. upper and lower crankcases, be sure to fix the stopper part “A”…
• Page 301
  Engine Mechanical: 1D-57 Piston and Conrod • Apply a small quantity of molybdenum oil solution to the sliding surface of the pistons and cylinder walls. • Apply a small quantity of molybdenum oil solution onto each piston pin. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION)
• Page 302
  1D-58 Engine Mechanical: • Check that I.D. code “E” on each conrod faces intake • Install each piston cooling oil jet. side. NOTE CAUTION Apply a small quantity of thread lock to the bolts and tighten them to the specified Be sure to clean the conrod big end.
• Page 303
  Engine Mechanical: 1D-59 3) Set the crankshaft to the conrods and upper 7) Tighten the conrod cap bolt by using a 10 mm, 12 crankcase. point socket wrench in the following two steps. Tightening torque Conrod cap bolt: 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) then turn in 1/4 (90°) turn I838H1140036-01 4) Apply engine oil to each crank pin and bearing…
• Page 304
  1D-60 Engine Mechanical: 11) Insert the right and left-thrust bearings with the oil Balancer Shaft grooves “A” facing towards the crankshaft web. • Apply a molybdenum oil solution to each balancer shaft journal and bearing lightly. NOTE M/O: Molybdenum oil (MOLYBDENUM OIL •…
• Page 305
  • 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) I838H1140044-01 I837H1140281-02 : Apply bond.
• Page 306
  1D-62 Engine Mechanical: • Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in “B” the following two steps. CAUTION Fit new gasket washers to the bolts “A” to prevent oil leakage. Tightening torque Crankshaft journal bolt (M9): 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) then turn in 50°…
• Page 307
  : Thread lock cement 99000–32110 strainer (1) and oil pressure regulator (2) to the (THREAD LOCK CEMENT SUPER 1322 or crankcase. equivalent) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Use a new O-ring to prevent oil leakage. I837H1140146-01 Oil Pump •…
• Page 308
  Be careful not to apply bond to the hole of Oil Cooler thread end. • Apply grease to the O-ring (1). : Sealant 99000–31140 (SUZUKI BOND CAUTION No.1207B or equivalent) Use a new O-ring to prevent oil leakage. Tightening torque Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
• Page 309
  CAUTION Replace the O-ring with a new one. Use the new O-ring to prevent oil leakage. NOTE : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER…
• Page 310
  1D-66 Engine Mechanical: • Tighten the water inlet connector mounting bolts (3) to • Tighten the cam chain tensioner bolt (2) and cam the specified torque. chain guide No. 1 bolt (3). Tightening torque Tightening torque Water inlet connector mounting bolt (b): 10 N·m ( Cam chain tensioner bolt (a): 23 N·m (2.3 kgf-m, 1.0 kgf-m, 7.0 lb-ft) 16.5 lb-ft)
• Page 311
  Engine Mechanical: 1D-67 • While holding the generator rotor with the special tool, • Apply a small quantity of thread lock to the gearshift tighten the CKP sensor rotor/cam chain drive sprocket cam stopper bolt (2) and tighten it to the specified bolt (5) and tighten its bolt to the specified torque.
• Page 312
  1D-68 Engine Mechanical: • Apply a small quantity of thread lock to the gearshift • Install the gearshift shaft assembly (8) and washers cam stopper plate bolt (6) and tighten it to the (9) as shown. specified torque. NOTE : Thread lock cement 99000–32110 Pinch the gearshift arm stopper (7) with (THREAD LOCK CEMENT SUPER 1322 or return spring ends “D”.
• Page 313
  Engine Mechanical: 1D-69 • Install the oil pump drive sprocket (2) to the Starter Motor countershaft. • Install the starter motor (1). Refer to “Starter Motor Removal and Installation in Section 1I (Page 1I-4)”. NOTE Teeth “A” on the sprocket must face the clutch side.

• Page 314: Cylinder Inspection

  1D-70 Engine Mechanical: Cylinder Inspection B838H21406033 Refer to “Engine Top Side Disassembly (Page 1D-25)”. Refer to “Engine Top Side Assembly (Page 1D-27)”. Cylinder Distortion Check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places.

• Page 315
  Engine Mechanical: 1D-71 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 316: Piston And Piston Ring Inspection

  1D-72 Engine Mechanical: Piston and Piston Ring Inspection Piston Ring-to-groove Clearance B838H21406035 Measure the side clearances of the 1st and 2nd piston Refer to “Piston Ring Removal and Installation rings using the thickness gauge. If any of the clearances (Page 1D-70)”. exceed the limit, replace both the piston and piston rings.

• Page 317: Balancer Shaft Disassembly And Assembly

  Engine Mechanical: 1D-73 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. Next, fit the piston ring squarely into the small bore gauge.

• Page 318: Balancer Shaft Inspection

  1D-74 Engine Mechanical: 2) Remove the washers, balancer gear and dampers from the shaft. I838H1140054-01 Balancer Shaft Journal Bearing Removal and I838H1140054-01 Installation Assembly B838H21406038 Refer to “Engine Bottom Side Disassembly (Page 1D- Assembly is in the reverse order of disassembly. Pay 47)”.

• Page 319: Balancer Shaft Journal Bearing Inspection And Selection

  Engine Mechanical: 1D-75 Installation Inspection When installing the bearings to the crankcases, be sure Inspect the bearing surfaces for any signs of fusion, to install the tab “A” first, and then press in the other pitting, burn or flaws. If any, replace them with a opposite side of the bearing.

• Page 320
  1D-76 Engine Mechanical: 2) Mate the lower crankcase with the upper crankcase, 4) Check the corresponding crankcase journal I.D. and tighten the crankcase bolts (M8) and crankshaft code number “A”, [A] or [B] which is stamped on the journal bolts (M9) to the specified torque. rear of upper crankcase.

• Page 321: Conrod Crank Pin Bearing Removal And Installation

  Engine Mechanical: 1D-77 Special tool Conrod Crank Pin Bearing Removal and (B): 09900–20205 (Micrometer (0 – 25 mm)) Installation B838H21406040 Refer to “Engine Bottom Side Disassembly (Page 1D- 47)”. Refer to “Engine Bottom Side Assembly (Page 1D-55)”. Removal Remove the conrod crank pin bearings (1). NOTE •…

• Page 322: Conrod And Crankshaft Inspection

  1D-78 Engine Mechanical: Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B838H21406041 and measure the conrod big end width and crank pin Refer to “Engine Bottom Side Disassembly (Page 1D- width. Refer to “Engine Bottom Side Assembly 47)”.

• Page 323: Conrod Crank Pin Bearing Inspection And Selection

  Engine Mechanical: 1D-79 Conrod Crank Pin Bearing Inspection and 4) Remove the conrod cap bolts and measure the width of the compressed plastigauge using the envelope Selection B838H21406042 scale. This measurement should be taken at the Refer to “Engine Bottom Side Disassembly (Page 1D- widest part of the compressed plastigauge.

• Page 324
  1D-80 Engine Mechanical: 2) Check the corresponding crank pin O.D. code 4) Select the specified bearings from the bearing numbers ([1], [2] or [3]) “B”. selection table. CAUTION The bearings should be replaced as a set. Bearing selection table Crank pin O.D. “B ”…

• Page 325: Crankshaft Journal Bearing Inspection And Selection

  Engine Mechanical: 1D-81 Crankshaft Journal Bearing Inspection and 5) Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in Selection B838H21406043 the following two steps. Refer to “Engine Bottom Side Disassembly (Page 1D- 47)”.

• Page 326
  1D-82 Engine Mechanical: Selection Special tool (A): 09900–20202 (Micrometer (1/100 mm, 1) Check the corresponding crankcase journal I.D. 25 – 50 mm)) codes “A” ([A], [B] or [C]), which are stamped on the rear of the upper crankcase. “A” I837H1140195-01 4) Select the specified bearings from the bearing I838H1140073-02 selection table.

• Page 327: Crankshaft Thrust Clearance Inspection And Selection

  Engine Mechanical: 1D-83 Crankshaft Thrust Clearance Inspection and Selection Selection 1) Remove the right-side thrust bearing and measure B838H21406044 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, 47)”.

• Page 328
  1D-84 Engine Mechanical: 4) Select a left-side thrust bearing from the selection table. NOTE Right-side thrust bearing has the same specification as the GREEN (12228-17E00-0D0) of left-side thrust bearing. Left-side thrust bearing selection table Clearance before inserting Color “A” (Part No.) Thrust bearing thickness Thrust clearance the left-side thrust bearing…

• Page 329: Specifications

  Engine Mechanical: 1D-85 Specifications Service Data B838H21407001 Valve + Guide Unit: mm (in) Item Standard Limit 29.0 (1.14) — Valve diam. 23.0 (0.91) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —…

• Page 330
  1D-86 Engine Mechanical: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 300 – 1 700 kPa (13 – 17 kgf/cm , 185 – 242 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —…

• Page 331: Tightening Torque Specifications

  Engine Mechanical: 1D-87 Tightening Torque Specifications B838H21407002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft STP sensor mounting screw 0.35 (Page 1D-13) ISC valve mounting screw (Page 1D-14) TP sensor mounting screw 0.35 (Page 1D-14) Fuel delivery pipe mounting screw 0.35 (Page 1D-15) Engine mounting thrust adjuster…

• Page 332: Special Tools And Equipment

  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 B838H21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-13) /…

• Page 333
  Engine Mechanical: 1D-89 09900–20203 09900–20205 Micrometer (1/100 mm, 50 – Micrometer (0 – 25 mm) 75 mm) (Page 1D-72) (Page 1D-35) / (Page 1D-43) / (Page 1D-72) / (Page 1D-73) / (Page 1D-77) / (Page 1D-78) / (Page 1D-83) 09900–20530 09900–20602 Cylinder gauge set Dial gauge (1/1000 mm, 1…
• Page 334
  1D-90 Engine Mechanical: 09915–40610 09915–64512 Oil filter wrench Compression gauge (Page 1D-50) / (Page 1D-3) (Page 1D-64) 09916–10911 09916–14510 Valve lapper set Valve spring compressor (Page 1D-44) (Page 1D-38) / (Page 1D-41) 09916–14522 09916–33210 Valve spring compressor Valve guide reamer (4.5 attachment (Page 1D-38) / (Page 1D-46)

• Page 335: Engine Lubrication System

  Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B838H21500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-4)”.

• Page 336: Schematic And Routing Diagram

  1E-2 Engine Lubrication System: Schematic and Routing Diagram Engine Lubrication System Chart Diagram B838H21502001 CAMSHAFT JOURNALS, INTAKE CAMSHAFT CAMFACES AND TAPPETS CAM CHAIN OIL JET (#8) EXHAUST CAMSHAFT TENSION ADJUSTER CAM DRIVE CHAIN CAMSHAFT JOURNALS, CAMSHAFT JOURNAL HOLDER B CAMFACES AND TAPPETS SUB GALLERY #2 #1 PISTON COOLING #2 PISTON COOLING…

• Page 337: Engine Lubrication Circuit Diagram

  Engine Lubrication System: 1E-3 Engine Lubrication Circuit Diagram B838H21502002 I838H1150001-01…

• Page 338
  1E-4 Engine Lubrication System: I838H1150002-01…

• Page 339: Diagnostic Information And Procedures

  Engine Lubrication System: 1E-5 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B838H21504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler. Clean or replace.

• Page 340: Repair Instructions

  “Engine Assembly Removal in Section 1D CAUTION (Page 1D-19)”. Use the new O-rings to prevent oil leakage. 2) Remove the plate (1). 3) Remove the oil pan (2) and gasket. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1150006-01…

• Page 341: Oil Pressure Regulator / Oil Strainer Inspection

  Engine Lubrication System: 1E-7 • Install the oil pressure regulator (1) and oil strainer (2). : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or NOTE equivalent) When installing the oil strainer, fit the concave part “A” of the oil strainer onto the “D”…

• Page 342: Oil Cooler / Oil Cooler Hose Inspection

  Parts Removal and Installation in Section 9D (Page 9D-11)”. : Grease 99000–25010 (SUZUKI SUPER 2) Inspect the oil cooler for engine oil leakage. If any GREASE A or equivalent) defects are found, replace the oil cooler with a new one.

• Page 343: Oil Pressure Switch Removal And Installation

  Engine Lubrication System: 1E-9 Oil Pressure Switch Removal and Installation 2) Connect the oil pressure switch lead wire securely. B838H21506007 Refer to “Wiring Harness Routing Diagram in Refer to “Electrical Components Location in Section 0A Section 9A (Page 9A-3)”. (Page 0A-8)”. Tightening torque Oil pressure switch lead wire bolt (b): 1.5 N·m ( Removal…

• Page 344
  1E-10 Engine Lubrication System: Installation Oil Jet (For Cam Chain Tension Adjuster) Installation is in the reverse order of removal. Pay Removal attention to the following points: 1) Remove the throttle body. Refer to “Throttle Body • Fit the new O-ring (1) to each piston cooling oil jet and Removal and Installation in Section 1D (Page 1D- apply engine oil to them.

• Page 345: Oil Jet / Oil Gallery Jet Inspection

  Engine Lubrication System: 1E-11 Oil Jet (For Transmission) Installation Installation is in the reverse order of removal. Pay Removal attention to the following point: 1) Remove the engine assembly. Refer to “Engine • Apply thread lock to the oil gallery jet and tighten it to Assembly Removal in Section 1D (Page 1D-19)”.

• Page 346: Oil Pump Removal And Installation

  NOTE Use a new O-ring to prevent oil leakage. Be careful not to drop any parts into the crankcase. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Removal 1) Remove the oil pan, oil strainer and oil pressure regulator. Refer to “Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation (Page 1E-6)”.

• Page 347: Oil Pump Inspection

  Engine Lubrication System: 1E-13 3) Tighten the oil pump mounting bolts to the specified Oil Pump Inspection B838H21506012 torque. Inspect the oil pump in the following procedures: Tightening torque 1) Remove the oil pump. Refer to “Oil Pump Removal Oil pump mounting bolt (a): 10 N·m (1.0 kgf-m, and Installation (Page 1E-12)”.

• Page 348: Specifications

  1E-14 Engine Lubrication System: 3) Remove the oil pump drive sprocket (3) and chain • Install the oil pump drive sprocket (2) to the (4). countershaft. 4) Remove the thrust washer (5). NOTE Teeth “B” on the sprocket must face the clutch side.

• Page 349: Tightening Torque Specifications

  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 B838H21508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-6) /…

• Page 350: Engine Cooling System

  1F-1 Engine Cooling System: Engine Cooling System Engine Precautions Precautions for Engine Cooling System B838H21600001 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.

• Page 351: Schematic And Routing Diagram

  Engine Cooling System: 1F-2 Schematic and Routing Diagram Cooling Circuit Diagram B838H21602001 RESERVOIR THERMOSTAT CYLINDER HEAD ECT SENSOR TANK CYLINDER RADIATOR WATER PUMP Oil cooler I837H1160001-01…

• Page 352: Water Hose Routing Diagram

  1F-3 Engine Cooling System: Water Hose Routing Diagram B838H21602002 “b ” “a” “ a ” “A” “ a ” “B” “A” “C” “E” “D” “E” “I” “F” “G” “J” “H” “P” “K” “F” “I” “M” “O” “M” “F” “L” “L” “L”…

• Page 353: Diagnostic Information And Procedures

  Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B838H21604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.

• Page 354: Radiator Cap Inspection

  1F-5 Engine Cooling System: Radiator Cap Inspection Radiator Cleaning B838H21606002 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. 1) Remove the radiator cap. Refer to “Cooling Circuit CAUTION Inspection (Page 1F-4)”.

• Page 355: Water Hose Inspection

  Engine Cooling System: 1F-6 4) Disconnect the radiator outlet hose (3) and water Remove the cooling fan motor (8) from the radiator. bypass hose (4). I837H1160011-02 I837H1160007-01 Installation 5) Disconnect the radiator inlet hose (5) and oil cooler Install the radiator in the reverse order of removal. Pay water inlet hose (6).

• Page 356: Water Hose Removal And Installation

  1F-7 Engine Cooling System: 3) Any leakage from the connecting section should be Water Hose Removal and Installation B838H21606006 corrected by proper tightening. Refer to “Water Hose Removal Routing Diagram (Page 1F-3)”. 1) Remove the under cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

• Page 357: Radiator Reservoir Tank Removal And Installation

  Engine Cooling System: 1F-8 Radiator Reservoir Tank Removal and 2) Test the cooling fan motor for load current with an ammeter connected as shown in the figure. Installation B838H21606008 If the fan motor does not turn, replace the cooling fan Removal assembly with a new one.

• Page 358: Ect Sensor Removal And Installation

  1F-9 Engine Cooling System: 3) First check the insulation between “A” and “B” 4) Remove the thermostat cover (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 359: Thermostat Inspection

  Engine Cooling System: 1F-10 • Tighten the thermostat cover bolts to the specified 4) Immerse the thermostat (1) in the water contained in torque. a beaker and note that the immersed thermostat is in suspension. Tightening torque 5) Heat the water by placing the beaker on a stove and Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.0 observe the rising temperature on a thermometer lb-ft)

• Page 360: Water Pump Components

  1F-11 Engine Cooling System: Water Pump Components B838H21606015 I837H1160026-02 1. Water pump case : 8 N⋅m (0.8 kgf-n, 6.0 Ib-ft) : Apply molybdenum oil solution. 2. O-ring : 5.5 N⋅m (0.55 kgf-n, 4.0 Ib-ft) : Apply thread lock. 3. Impeller : 10 N⋅m (1.0 kgf-n, 7.0 Ib-ft) : Do not reuse.

• Page 361: Water Pump Construction

  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 cylinder inlet hose (1). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)

• Page 362: Water Pump Disassembly And Assembly

  1F-13 Engine Cooling System: • Install the water pump assembly with the slot on the 2) Remove the water pump case (2). pump shaft end “A” securely engaged with the flat “B” on the oil pump shaft. “B” “A” I837H1160031-01 3) Remove the O-ring (3).

• Page 363
  Special tool (A): 09921–20240 (Bearing remover set) I837H1160038-01 2) Apply a small quantity of the grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1160036-01 9) Remove the oil seal (10). NOTE If there is no abnormal condition, the oil seal removal is not necessary.
• Page 364
  1F-15 Engine Cooling System: 3) Install a new mechanical seal using a suitable size 6) Install the rubber seal (3) into the impeller. socket wrench. 7) After wiping off the oily or greasy matter from the mechanical seal ring (4), install it into the impeller. CAUTION NOTE The removed mechanical seal must be…

• Page 365: Water Pump Related Parts Inspection

  Engine Cooling System: 1F-16 10) Apply a small quantity of thread lock to the impeller 13) Tighten the water pump air bleeder bolt (10) to the securing bolt and tighten it to the specified torque. specified torque. : Thread lock cement 99000–32110 CAUTION (THREAD LOCK CEMENT SUPER 1322 or Use a new gasket washer to prevent engine…

• Page 366
  1F-17 Engine Cooling System: Oil Seal Impeller / Shaft Visually inspect the oil seal for damage, with particular Visually inspect the impeller and its shaft for damage. attention given to the lip. Replace the impeller or shaft if necessary. Replace the oil seal that shows indications of leakage. I837H1160050-01 I837H1160048-01 Impeller Shaft Journal…

• Page 367: Specifications

  Engine Cooling System: 1F-18 Specifications Service Data B838H21607001 Thermostat + Radiator + Fan + Coolant Item 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 —…

• Page 368: Special Tools And Equipment

  1F-19 Engine Cooling System: Special Tools and Equipment Recommended Service Material B838H21608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-12) / equivalent (Page 1F-14) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1F-15)

• Page 369: Fuel System

  Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B838H21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. •…

• Page 370: General Description

  1G-2 Fuel System: General Description Fuel Injection System Description B838H21701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filters (3) and (4), fuel feed hose (5), fuel delivery pipes (6) including fuel injectors (7) and (8), fuel pressure regulator (9). There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injectors installed in the fuel delivery pipe.

• Page 371: Schematic And Routing Diagram

  Fuel System: 1G-3 Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B838H21702001 “ a ” “ d ” “ b ” “c” “a” “A” “B” I837H1170001-03 1. Fuel tank water drain hose 6. Breather hose clamp (Except for E-33) “b”: 13 mm (0.5 in) 2.

• Page 372: Diagnostic Information And Procedures

  1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B838H21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.

• Page 373: Repair Instructions

  Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B838H21706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •…

• Page 374: Fuel Discharge Amount Inspection

  1G-6 Fuel System: Fuel Discharge Amount Inspection 6) Connect a proper lead wire into the fuel pump lead B838H21706003 wire coupler (fuel pump side) and apply 12 V to the WARNING fuel pump (between (+) Y/R wire and (–) B/W wire) for 10 seconds and measure the amount of fuel •…

• Page 375: Fuel Pump Relay Inspection

  Fuel System: 1G-7 Fuel Pump Relay Inspection Fuel Hose Inspection B838H21706004 B838H21706005 Refer to “Electrical Components Location in Section 0A Refer to “Fuel Line Inspection in Section 0B (Page 0B- (Page 0A-8)”. 10)”. Inspect the fuel pump relay in the following procedures: Fuel Level Gauge Inspection 1) Remove the front seat.

• Page 376: Fuel Tank Construction

  1G-8 Fuel System: Fuel Tank Construction B838H21706007 “A” “B” “B” “B” I837H1170032-02 1. Fuel tank heat shield 3. Fuel tank front bracket “A”: Insert to the fuel tank heat shield bracket. : Aluminum film side should face the engine side. 2.

• Page 377: Fuel Tank Removal And Installation

  Fuel System: 1G-9 Fuel Tank Removal and Installation 6) Place a rag under the fuel feed hose (4) and B838H21706008 disconnect the fuel feed hose from the fuel tank. Removal CAUTION When removing the fuel tank, do not leave WARNING the fuel feed hose on the fuel pump side.

• Page 378: Fuel Pump Components

  1G-10 Fuel System: Fuel Pump Components B838H21706009 I837H1170033-02 1. Fuel level gauge 4. Fuel pump case : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Do not reuse. 2. Fuel filter cartridge 5. Fuel mesh filter : Apply engine oil. 3. Fuel pump 6.

• Page 379: Fuel Pump Disassembly And Assembly

  Fuel System: 1G-11 Fuel Pump Disassembly and Assembly 5) Remove the fuel filter cartridge (4). B838H21706010 Disassembly CAUTION 1) Remove the fuel tank. Refer to “Fuel Tank Removal Never remove the fuel pressure regulator (5) and Installation (Page 1G-9)”. from the holder. 2) Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.

• Page 380
  1G-12 Fuel System: Remove the O-ring (10) and lead wires (11). I837H1170025-01 • Connect all lead wires securely so as not to cause I837H1170022-01 9) Remove the fuel mesh filter (12). contact failure. 10) Remove the fuel pump (13). I837H1170026-01 I837H1170023-01 Assembly…

• Page 381: Fuel Mesh Filter Inspection And Cleaning

  • Install a new O-ring and apply grease to it. 2) If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of : Grease 99000–25010 (SUZUKI SUPER engine power. Such a filter should be cleaned by GREASE A or equivalent) blowing with compressed air.

• Page 382: Specifications

  1G-14 Fuel System: Specifications Service Data B838H21707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 167 ml (5.6/5.9 US/lmp oz) and more/10 sec. Fuel pressure regulator operating Approx.

• Page 383: Special Tools And Equipment

  Fuel System: 1G-15 Special Tools and Equipment Recommended Service Material B838H21708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-13) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-10)”…

• Page 384: Ignition System

  1H-1 Ignition System: Ignition System Engine General Description Immobilizer Description (For E-02, 19, 24) Operation B838H21801001 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.

• Page 385: Drive Mode Selector Description

  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. judgment again as there is possible 1) Turn on the ignition switch and engine stop switch.

• Page 386: Schematic And Routing Diagram

  1H-3 Ignition System: Schematic and Routing Diagram Ignition System Diagram B838H21802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery sensor sensor switch I837H1180001-02 Ignition System Components Location B838H21802002 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

• Page 387: Diagnostic Information And Procedures

  Ignition System: 1H-4 Diagnostic Information and Procedures Ignition System Symptom Diagnosis B838H21804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defective ignition coil/plug caps.

• Page 388: No Spark Or Poor Spark

  1H-5 Ignition System: No Spark or Poor Spark B838H21804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.

• Page 389: Repair Instructions

  Ignition System: 1H-6 Repair Instructions Ignition Coil / Plug Cap and Spark Plug Removal 5) Remove the spark plugs with a spark plug wrench. and Installation Special tool B838H21806001 (A): 09930–10121 (Spark plug wrench set) Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch.

• Page 390: Spark Plug Inspection And Cleaning

  1H-7 Ignition System: • Install the ignition coil/plug caps and connect their 2) Disconnect all ignition coil/plug caps. Refer to lead wire couplers. “Ignition Coil / Plug Cap and Spark Plug Removal and Installation (Page 1H-6)”. CAUTION Do not hit the ignition coil/plug cap with a plastic hammer when installing it.

• Page 391
  Ignition System: 1H-8 5) Insert the needle pointed probe to the lead wire 7) Measure the ignition coil primary peak voltage in the coupler. following procedures: CAUTION WARNING Use the special tool to prevent the rubber of Do not touch the tester probes and spark the water proof coupler from damage.

• Page 392: Ckp Sensor Inspection

  1H-9 Ignition System: Ignition Coil / Plug Cap Resistance 2) Disconnect the CKP sensor coupler (1). 1) Remove the ignition coil/plug caps. Refer to “Ignition NOTE Coil / Plug Cap and Spark Plug Removal and Be sure that all of the couplers are connected Installation (Page 1H-6)”.

• Page 393: Ckp Sensor Removal And Installation

  Ignition System: 1H-10 5) Repeat the b) procedure several times and measure 4) After measuring the CKP sensor resistance, connect the highest CKP sensor peak voltage. the CKP sensor coupler. 5) Reinstall the fuel tank. Refer to “Fuel Tank Removal CKP sensor peak voltage and Installation in Section 1G (Page 1G-9)”.

• Page 394: Ignition Switch Removal And Installation

  1H-11 Ignition System: Ignition Switch Removal and Installation Installation B838H21806008 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 • Tighten the ignition switch mounting bolts (1), right Box Removal and Installation in Section 1D and left with the special tools.

• Page 395: Drive Mode Selector Inspection

  Ignition System: 1H-12 Drive Mode Selector Inspection B838H21806009 Inspect the drive mode selector in the following procedures: 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Date monitor”. 4) Make sure each of “Driving mode selection”…

• Page 396: Specifications

  1H-13 Ignition System: Specifications Service Data B838H21807001 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 ⋅ 4 ⋅ 3 Firing order NGK: CR9EIA-9 Type Spark plug DENSO: IU27D 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. 142 –…

• Page 397: Special Tools And Equipment

  Ignition System: 1H-14 Special Tools and Equipment Recommended Service Material B838H21808001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1H-11) 1322 or equivalent Special Tool B838H21808002 09900–25008 09900–25009 Multi-circuit tester set…

• Page 398: Starting System

  1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B838H21902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Ignition Engine stop switch switch Fuse (30 A) ignition coil Gear position Starter Fuse Starter switch button motor Starter relay…

• Page 399: Starter Motor Will Not Run

  Starting System: 1I-2 Starter Motor Will Not Run B838H21904002 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. Go to Step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”…

• Page 400: Repair Instructions

  1I-3 Starting System: Repair Instructions Starter Motor Components B838H21906001 I837H1190035-03 1. O-ring 6. Starter motor case : 3.5 N⋅m (0.35 kgf-m, 2.5 lb-ft) 2. Housing end (Inside) 7. Housing end (Outside) : Apply grease to sliding surface. 3. O-ring 8. Starter motor lead wire nut : Apply moly paste to sliding surface.

• Page 401: Starter Motor Removal And Installation

  Disassemble the starter motor as shown in the starter motor components diagram. Refer to “Starter Motor • Apply grease to the O-ring. Components (Page 1I-3)”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Assembly Reassemble the starter motor in the reverse order of CAUTION removal.

• Page 402: Starter Motor Inspection

  Starter motor housing bolt (a): 3.5 N·m (0.35 kgf- m, 2.5 lb-ft) I837H1190005-01 • Apply a small quantity of moly paste to the armature shaft. I837H1190007-03 : Moly paste 99000–25140 (SUZUKI MOLY Starter Motor Inspection PASTE or equivalent) B838H21906004 Refer to “Starter Motor Disassembly and Assembly (Page 1I-4)”.

• Page 403: Starter Relay Removal And Installation

  Starting System: 1I-6 Commutator Oil Seal Inspect the commutator for discoloration, abnormal wear Check the seal lip for damage. or undercut “A”. If any damage is found, replace the housing end. If the commutator is abnormally worn, replace the armature assembly. If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth.

• Page 404: Starter Relay Inspection

  1I-7 Starting System: Starter Relay Inspection 3) Measure the relay coil resistance between the B838H21906006 terminals using the multi-circuit tester. If the Inspect the starter relay in the following procedures: resistance is not within the specified value, replace 1) Remove the starter relay. Refer to “Starter Relay the starter relay with a new one.

• Page 405: Side-Stand / Ignition Interlock System Parts Inspection

  Starting System: 1I-8 Side-stand / Ignition Interlock System Parts 5) Connect the side-stand switch coupler. Inspection 6) Install the removed parts. B838H21906008 Check the interlock system for proper operation. If the Turn Signal / Side-stand Relay interlock system does not operate properly, check each The turn signal/side-stand relay is composed of the turn component for damage or abnormalities.

• Page 406
  1I-9 Starting System: Diode inspection Gear Position Switch 1) Remove the turn signal/side-stand relay. Refer to 1) Lift and support the fuel tank. Refer to “Fuel Tank “Turn Signal / Side-stand Relay Removal and Removal and Installation in Section 1G (Page 1G- Installation (Page 1I-7)”.

• Page 407: Starter Clutch Removal And Installation

  Starting System: 1I-10 7) Measure the voltage between P and B/W lead wires 3) Remove the shaft (4), bearing (5), starter idle gear using the multi-circuit tester when shifting the (6) and thrust washer (7). gearshift lever from low to top. Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe…

• Page 408
  1I-11 Starting System: Remove the starter driven gear (12). Installation Install the starter clutch in the reverse order of removal. Pay attention to the following points: • When inserting the one way clutch (1) into the starter clutch guide (2), fit the flange “A” in the step of the starter clutch guide (2).

• Page 409: Starter Clutch Inspection

  Replace to the O-ring with a new one. Tightening torque Starter clutch bolt (a): 13 N·m (1.3 kgf-m, 9.5 lb-ft) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1190028-02 • Apply engine oil to the bushing of the starter driven I837H1190031-01 gear.

• Page 410: Starter Button Inspection

  1I-13 Starting System: Starter Clutch Starter Button Inspection B838H21906011 1) Install the starter driven gear onto the starter clutch. Inspect the starter button in the following procedures: 2) Turn the starter driven gear by hand to inspect the 1) Remove the air cleaner box. Refer to “Air Cleaner starter clutch for a smooth movement.

• Page 411: Specifications

  Starting System: 1I-14 Specifications Service Data B838H21907001 Electrical Unit: mm Item Specification Note Standard 10.0 (0.39) Starter motor brush length Limit 6.5 (0.26) 3 – 6 Ω Starter relay resistance Tightening Torque Specifications B838H21907002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Starter motor mounting bolt…

• Page 412: Special Tools And Equipment

  SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-4) equivalent (Page 1I-5) / (Page 1I- Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1I-5) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1I-12) / (Page 1I- NOTE Required service material is also described in the following.

• Page 413: Charging System

  Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B838H21A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B838H21A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B838H21A04001 Condition…

• Page 414: Battery Runs Down Quickly

  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 operation.

• Page 415: Repair Instructions

  Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection 3) Measure the DC voltage between the battery (+) and B838H21A06001 (–) 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 416: Generator Removal And Installation

  1J-4 Charging System: 3) Measure the resistance between the three lead 4) Using the multi-circuit tester, measure the voltage wires. between three lead wires. If the resistance is out of specified value, replace the If the tester reads under the specified value, replace stator with a new one.

• Page 417
  Charging System: 1J-5 4) Remove the starter idle gear No. 1 component parts Hold the generator rotor with the special tool. (2). Refer to “Starter Clutch Removal and Installation Special tool in Section 1I (Page 1I-10)”. (A): 09930–44520 (Rotor holder) 9) Remove the generator rotor bolt.
• Page 418
  I837H11A0016-02 • Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I837H11A0014-02 • Degrease the tapered portion “A” of generator rotor and also the crankshaft “B”.
• Page 419
  • Route the generator lead wire. Refer to “Wiring Harness Routing Diagram in Section 9A (Page 9A-3)”. I837H11A0019-02 • Apply grease to the starter motor O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the O-ring with a new one.

• Page 420: Regulator / Rectifier Construction

  1J-8 Charging System: Regulator / Rectifier Construction B838H21A06005 “A” “B” “C” I837H11A0027-02 1. Regulator/rectifier 4. Clamp “B”: Pass the regulator/rectifier harness between the bracket and frame. 2. Regulator/rectifier bracket mold 5. Frame “C”: After the clamp has contacted to the projection on the bracket, tighten the bolt.

• Page 421: Regulator / Rectifier Removal And Installation

  Charging System: 1J-9 Regulator / Rectifier Removal and Installation B838H21A06006 Removal 1) Turn the ignition switch OFF. 2) Lift the air cleaner box upside. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-7)”. 3) Remove the left under cowling. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”. 4) Disconnect the regulator/rectifier couplers (1).

• Page 422: Regulator / Rectifier Inspection

  1J-10 Charging System: Regulator / Rectifier Inspection B838H21A06007 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch OFF. 2) Disconnect the regulator/rectifier couplers. Refer to “Regulator / Rectifier Removal and Installation (Page 1J-9)”. 3) Measure the voltage between the terminals using the multi-circuit testers as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

• Page 423: Battery Components

  Charging System: 1J-11 Battery Components 2) Remove the caps (2) from the electrolyte container. B838H21A06008 NOTE • Do not remove or pierce the sealed areas “B” of the electrolyte container. • After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes.

• Page 424
  1J-12 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 NOTE If no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times.

• Page 425: Battery Removal And Installation

  Charging System: 1J-13 Battery Recharging 4) Install the battery to the motorcycle. Refer to “Battery Removal and Installation (Page 1J-13)”. CAUTION Do not remove the caps on the battery top while recharging. NOTE When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.

• Page 426: Battery Visual Inspection

  1J-14 Charging System: Battery Visual Inspection • Tighten the battery lead wire mounting bolts securely. B838H21A06011 Inspect the battery in the following procedures: 1) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

• Page 427: Special Tools And Equipment

  Charging System: 1J-15 Special Tools and Equipment Recommended Service Material B838H21A08001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1J-7) equivalent Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1J-7) Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140…

• Page 428: Exhaust System

  1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B838H21B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipes and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.

• Page 429: Exhaust Control System Operation

  Exhaust System: 1K-2 Exhaust Control System Operation B838H21B01002 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 430
  1K-3 Exhaust System: FULL OPEN I837H11B0043-02…

• Page 431: Repair Instructions

  Exhaust System: 1K-4 Repair Instructions Exhaust Control System Construction B838H21B06001 “ a ” “ b ” “A” “c” I837H11B0040-02 1. EXCV cable No. 1 “A”: When loosening or tightening the pulley bolt, : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) “b”: 60 – 61 mm (2.36 – 2.40 in) be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

• Page 432: Exhaust System Components

  1K-5 Exhaust System: Exhaust System Components B838H21B06002 “A” I837H11B0041-04 1. Exhaust pipe gasket “A”: When loosening or tightening the pulley bolt, be sure to fix the : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) pulley with an adjustable wrench, or EXCVA may get damaged. 2.

• Page 433: Excv Cable Removal And Installation

  Exhaust System: 1K-6 EXCV Cable Removal and Installation 9) Loosen the lock-nut (5) on the No. 1 cable (6) and B838H21B06003 turn in the cable adjuster (4) fully. Removal 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 9)”.

• Page 434: Excva Removal And Installation

  1K-7 Exhaust System: Installation 6) Connect the other end of EXCV cable No. 1 (1) and No. 2 (2) to the EXCVA pulley. CAUTION The cable slots of EXCVA pulley must be located adjustment position. 1) Temporarily connect the EXCV cable No. 1 (37H0CL) (1) and No.

• Page 435
  Exhaust System: 1K-8 5) After turning the mode select switch ON, turn the 11) Hold the pulley with an adjustable wrench, and ignition switch ON. loosen the pulley mounting bolt (5). Special tool CAUTION (A): 09930–82720 (Mode select switch) • When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

• Page 436: Excva Inspection

  1K-9 Exhaust System: • Hold the pulley with an adjustable wrench, and then EXCVA Adjustment B838H21B06007 tighten the pulley mounting bolt (1) to the specified Inspect the EXCVA operation and adjust it if necessary torque. in the following steps: Tightening torque EXCVA pulley mounting bolt (a): 5 N·m (0.5 kgf- Step 1 m, 3.5 lb-ft)

• Page 437
  Exhaust System: 1K-10 Step 3 7) If the measured voltage is less than specification, adjust the No. 1 cable adjuster as follows: 1) Turn the ignition switch OFF. a) Set the EXCVA to the adjustment position. Refer 2) Disconnect the EXCVA motor coupler (1). to “EXCV Cable Removal and Installation 3) To set the EXCV to fully closed position, apply 12 V (Page 1K-6)”.

• Page 438: Exhaust Pipe / Muffler Removal And Installation

  1K-11 Exhaust System: 2) Measure the position sensor output voltage at fully Exhaust Pipe / Muffler Removal and Installation B838H21B06008 opened position. Special tool Removal (A): 09900–25008 (Multi-circuit tester set) 1) Remove the right under cowling. Refer to “Exterior (B): 09900–25009 (Needle pointed probe Parts Removal and Installation in Section 9D set) (Page 9D-11)”.

• Page 439
  Exhaust System: 1K-12 Disconnect the EXCV cables (5) from the EXCV pulley. 9) Remove the EXCV cables (5) with the bracket (6). I837H11B0007-01 I837H11B0004-01 10) Remove the radiator mounting bolts. I837H11B0008-01 13) Remove the exhaust pipe gaskets (7). I837H11B0005-01 I837H11B0009-03 14) Remove the HO2 sensor (8) from the exhaust pipe.
• Page 440
  1K-13 Exhaust System: Installation • Tighten the exhaust pipe bolts and exhaust pipe Installation is in the reverse order of removal. Pay mounting bolts to the specified torque. attention to the following points: Tightening torque • Tighten the HO2 sensor to the specified torque. Exhaust pipe bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb- Tightening torque Exhaust pipe mounting bolt (c): 23 N·m (2.3 kgf-…

• Page 441: Exhaust System Inspection

  Exhaust System: 1K-14 • Install the connector (2). • Tighten the muffler mounting nut (3) and muffler connecting bolt (4) to the specified torque. CAUTION Tightening torque Replace the connectors with new one. Muffler mounting nut (e): 25 N·m (2.5 kgf-m, 18.0 lb-ft) NOTE Muffler connecting bolt (f): 23 N·m (2.3 kgf-m,…

• Page 442: Tightening Torque Specifications

  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 B838H21B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-14)

• Page 443
  Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ……….2-1 Swingarm Removal and Installation….2C-10 Swingarm Related Parts Inspection ….2C-12 Precautions…………. 2-1 Swingarm Bearing Removal and Installation ..2C-13 Precautions for Suspension ……..2-1 Specifications ………….2C-15 Suspension General Diagnosis….2A-1 Service Data…………2C-15 Tightening Torque Specifications……2C-15 Diagnostic Information and Procedures….2A-1 Special Tools and Equipment ……2C-16…

• Page 444: Precautions

  2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B838H22000001 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. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.

• Page 445: Suspension General Diagnosis

  Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B838H22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

• Page 446: Front Suspension

  2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B838H22206001 I838H1220001-01 1. Front fork cap bolt 10. Outer tube 19. Compression damping force adjuster 2. O-ring 11. Oil seal retainer : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3. O-ring 12.

• Page 447: Front Fork Removal And Installation

  Front Suspension: 2B-2 Front Fork Removal and Installation 6) Loosen the handlebar clamp bolt (3). B838H22206002 NOTE NOTE The right and left front forks are installed • Slightly loosen the front fork cap bolt (4) to symmetrically and therefore the removal facilitate later disassembly.

• Page 448
  2B-3 Front Suspension: 2) Tighten the front fork cap bolt (2) to the specified 7) Tighten the handlebar clamp bolt (4). torque. Tightening torque Tightening torque Handlebar clamp bolt (d): 23 N·m (2.3 kgf-m, Front fork cap bolt (a): 35 N·m (3.5 kgf-m, 25.5 16.5 lb-ft) lb-ft) 3) Loosen the lower clamp bolts.

• Page 449: Front Suspension Adjustment

  Front Suspension: 2B-4 Front Suspension Adjustment Compression damping force (High speed) B838H22206003 Fully turn the compression damping force (High speed) After installing the front fork, adjust the spring pre-load adjuster (1) clockwise. From that position (stiffest), turn it and three kinds of damping force as follows: out to standard setting position.

• Page 450: Front Fork Disassembly And Assembly

  2B-5 Front Suspension: Front Fork Disassembly and Assembly 5) Compress the fork spring with the special tool (A) B838H22206004 and remove the special tool (B). Refer to “Front Fork Removal and Installation (Page 2B- Special tool 2)”. (A): 09940–94930 (Front fork spacer holder) NOTE (B): 09940–94922 (Front fork spring stopper plate)

• Page 451
  Front Suspension: 2B-6 9) Remove the outer tube from the inner tube. 14) Remove the compression damping force adjuster (12). I838H1220017-01 10) Remove the dust seal (7) and oil seal stopper ring I838H1220021-01 (8). 15) Remove the damper rod bolt with the special tool. Special tool (D): 09940–30221 (Front fork assembling tool)
• Page 452
  2) Apply fork oil to the oil seal lip. I823H1220025-01 5) Install the oil seal stopper ring (2). : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) CAUTION Make sure that the oil seal stopper ring is fitted securely.
• Page 453
  2) Compress it fully. 3) Pour specified front fork oil up to the top level of the outer tube. : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) Front fork oil capacity (each leg) 418 ml (14.1/14.7 lmp oz)
• Page 454
  2B-9 Front Suspension: 4) Move the inner rod slowly with the special tool (A) 7) Hold the front fork vertically and adjust fork oil level more than ten times until bubbles do not come out with the special tool. from the oil. NOTE NOTE When adjusting the fork oil level, remove the…
• Page 455
  3) Apply fork oil to the O-ring. CAUTION Use a new O-ring to prevent oil leakage. : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) 4) Insert the adjuster rod (1) in to the front fork cap bolt I838H1220032-01 (2).

• Page 456: Front Fork Parts Inspection

  Use a new O-ring to prevent oil leakage. Front fork spring free length Service limit: 259 mm (10.2 in) : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) I837H1220037-01 Damper Rod…

• Page 457: Specifications

  Front fork oil level (Without spring, 115 (4.5) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 418 ml (14.1/14.7 US/lmp oz) — Front fork inner tube O.D 41 (1.6)

• Page 458: Special Tools And Equipment

  2B-13 Front Suspension: Special Tools and Equipment Recommended Service Material B838H22208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL SS-05 or P/No.: 99000–99001– (Page 2B-7) / (Page 2B- equivalent 7) / (Page 2B-8) / (Page 2B-8) /…

• Page 459: Rear Suspension

  Rear Suspension: 2C-1 Rear Suspension Suspension Repair Instructions Rear Suspension Components B838H22306001 I837H1230055-05 1. Rear shock absorber 9. Swingarm pivot nut : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft) 2. Rear shock absorber mounting nut 10. Swingarm : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 3.

• Page 460: Rear Suspension Assembly Construction

  2C-2 Rear Suspension: Rear Suspension Assembly Construction B838H22306002 “ a ” “a” “ b ” “ b ” “b” “ b ” “ a ” “ a ” I837H1230056-02 1. Rear shock absorber mounting bolt (Upper) 6. Swingarm pivot shaft : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft) 2.

• Page 461: Rear Shock Absorber Removal And Installation

  Rear Suspension: 2C-3 Rear Shock Absorber Removal and Installation 7) Remove the rear shock absorber upward. B838H22306003 Removal 1) Remove the under cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”. 2) Support the motorcycle with a jack to relieve load on the rear shock absorber.

• Page 462: Rear Suspension Inspection

  2C-4 Rear Suspension: • Tighten the cushion rod rear mounting bolt and nut. Tightening torque Cushion rod rear mounting nut (d): 78 N·m (7.8 kgf-m, 56.5 lb-ft) I837H1230009-01 3) Install the rear shock absorber. Refer to “Rear Shock Absorber Removal and Installation (Page 2C-3)”. Rear Suspension Adjustment I837H1230007-02 B838H22306006…

• Page 463: Rear Shock Absorber Disposal

  Rear Suspension: 2C-5 Rebound side Gas Pressure Release Turn the damping force adjuster (1) to the desired Make sure to observe the following precautions: position. WARNING STD position 1-3/4 turns out from stiffest position • Never apply heat or disassemble the damper unit since it can explode or oil can splash hazardously.

• Page 464: Cushion Lever Removal And Installation

  2C-6 Rear Suspension: Cushion Lever Removal and Installation Spacer B838H22306008 1) Remove the spacers from the cushion lever. 2) Inspect the spacers for any flaws or other damage. If Removal any defects are found, replace the spacers with new 1) Remove the under cowlings. Refer to “Exterior Parts ones.

• Page 465: Cushion Lever Bearing Removal And Installation

  Rear Suspension: 2C-7 Cushion Lever Bearing Removal and Installation Installation CAUTION B838H22306010 The removed bearings must be replaced with Removal new ones. 1) Remove the cushion lever. Refer to “Cushion Lever Removal and Installation (Page 2C-6)”. 1) Press the bearings into the cushion lever at 1 mm 2) Remove the cushion lever bearings with the special (0.04 in) depth “A”…

• Page 466: Cushion Rod Removal And Installation

  2) Apply grease to the bearings. Installation Install the cushion rod in the reverse order of removal. : Grease 99000–25010 (SUZUKI SUPER Pay attention to the following points: GREASE A or equivalent) • Tighten each bolts and nuts to the specified torque.

• Page 467: Cushion Rod Bearing Removal And Installation

  Inspect the cushion lever for damage. If any defect is found, replace the cushion rod with a new one. “A” I837H1230030-01 2) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1230028-01 Cushion Rod Bearing Removal and Installation B838H22306013 Removal 1) Remove the cushion rod.

• Page 468: Swingarm Removal And Installation

  2C-10 Rear Suspension: Swingarm Removal and Installation 7) Remove the swingarm pivot shaft lock-nut with the B838H22306014 special tool. Special tool Removal (A): 09940–14940 (Swingarm pivot thrust 1) Cut the drive chain. Refer to “Drive Chain adjuster socket wrench) Replacement in Section 3A (Page 3A-7)”. 2) Remove the rear wheel assembly.

• Page 469
  Rear Suspension: 2C-11 12) Remove the plate (10). • Adjust swingarm pivot thrust clearance in the following procedures: – Insert the swingarm pivot shaft (2) and tighten it to the specified torque. Special tool (A): 09944–28321 (Hexagon socket (19 mm)) Tightening torque Swingarm pivot shaft (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)

• Page 470: Swingarm Related Parts Inspection

  2C-12 Rear Suspension: Swingarm Related Parts Inspection – Tighten the swingarm pivot lock-nut (4) to the B838H22306015 specified torque with the special tool. Refer to “Swingarm Removal and Installation (Page 2C- 10)”. Special tool (B): 09940–14940 (Swingarm pivot thrust Spacers adjuster socket wrench) 1) Remove the spacers from the swingarm.

• Page 471: Swingarm Bearing Removal And Installation

  Rear Suspension: 2C-13 Swingarm Bearing Swingarm Bearing Removal and Installation B838H22306016 1) Insert the spacers into bearings. 2) Check the play by moving the spacers up and down. Removal If excessive play is noted, replace the bearing with a 1) Remove the swingarm. Refer to “Swingarm Removal new ones.

• Page 472
  2C-14 Rear Suspension: Installation 3) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) The removed bearings must be replaced with new ones. 1) Install the center spacer. 2) Press the bearings into the swingarm pivot with the special tool.

• Page 473: Specifications

  Rear Suspension: 2C-15 Specifications Service Data B838H22307001 Suspension Unit: mm (in) Item Standard Limit Rear shock absorber spring pre-set 182.3 (7.18) — length Rebound 1-3/4 turns from stiffed position — Rear shock absorber damping force Lo: 2 turns from stiffest position adjuster Compression —…

• Page 474: Special Tools And Equipment

  2C-16 Rear Suspension: Special Tools and Equipment Recommended Service Material B838H22308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-8) / (Page 2C- equivalent 9) / (Page 2C-14) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110…

• Page 475: Wheels And Tires

  Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B838H22400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •…

• Page 476: Repair Instructions

  2D-2 Wheels and Tires: Repair Instructions Front Wheel Components B838H22406001 I837H1240035-02 1. Front axle 6. Spacer 11. Collar : Apply thread lock to the thread part. 2. Brake disc bolt 7. Air valve 12. Front axle bolt : Do not reuse. 3.

• Page 477: Front Wheel Assembly Construction

  Wheels and Tires: 2D-3 Front Wheel Assembly Construction B838H22406002 “ a ” I837H1240036-01 1. Brake disk bolt “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake caliper mounting bolt : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) : Apply grease. 3.

• Page 478: Front Wheel Assembly Removal And Installation

  2D-4 Wheels and Tires: Front Wheel Assembly Removal and Installation Remove the collar (4) (RH only). B838H22406003 NOTE Removal After removing the front wheel, fit the 1) Remove the under cowlings. Refer to “Exterior Parts calipers temporarily to the original positions. Removal and Installation in Section 9D (Page 9D- 11)”.

• Page 479
  Wheels and Tires: 2D-5 3) Tighten the brake caliper mounting bolts (2) to the 6) Move the front fork up and down 4 or 5 times. specified torque. Tightening torque Front brake caliper mounting bolt (a): 39 N·m ( 3.9 kgf-m, 28.0 lb-ft) WARNING After remounting the brake calipers, pump the brake lever until the pistons push the…

• Page 480: Special Tool

  2D-6 Wheels and Tires: Front Wheel Related Parts Inspection Wheel B838H22406004 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 2D-4)”. 2) Make sure that the wheel runout checked as shown in the figure does not exceed the service limit.

• Page 481: Front Wheel Dust Seal / Bearing Removal And Installation

  CAUTION The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1240011-01 3) Remove the bearings (2) using the special tool. Special tool (B): 09921–20240 (Bearing remover set)

• Page 482
  CAUTION The sealed cover of the bearing must face outside. I837H1240015-01 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1240014-01 I837H1240016-01 5) Install the front wheel assembly. Refer to“Front Wheel Assembly Removal and Installation (Page 2D-4)”.

• Page 483: Rear Wheel Components

  Wheels and Tires: 2D-9 Rear Wheel Components B838H22406006 I837H1240038-01 1. Rear axel nut 9. Spacer : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Spacer 10. Air valve : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Dust seal 11. Rear wheel : 60 N⋅m (6.0 kgf-m, 43.0 lb-ft) 4.

• Page 484: Rear Wheel Assembly Construction

  2D-10 Wheels and Tires: Rear Wheel Assembly Construction B838H22406007 “ a” I837H1240039-03 1. Rear sprocket nut “a”: Clearance : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 2. Rear axle nut : 60 N⋅m (6.0 kgf-m, 43.0 lb-ft) : Apply grease. 3. Brake disc bolt : 100 N⋅m (10 kgf-m, 72.5 lb-ft) : Apply thread lock to the thread part.

• Page 485: Rear Wheel Assembly Removal And Installation

  Wheels and Tires: 2D-11 Rear Wheel Assembly Removal and Installation Installation B838H22406008 1) Install the spacer (1) and collar (2). Removal 1) Loosen the axle nut (1). 2) Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block. CAUTION Make sure that the motorcycle is supported securely.

• Page 486
  2D-12 Wheels and Tires: Sprocket Wheel Refer to “Drive Chain Related Components in Section 1) Remove the rear brake pads. Refer to “Rear Brake 3A (Page 3A-1)”. Pad Replacement in Section 4C (Page 4C-2)”. 2) Make sure that the wheel runout checked as shown Dust Seal in the figure does not exceed the service limit.

• Page 487: Rear Wheel Dust Seal / Bearing Removal And Installation

  I837H1240027-02 Installation CAUTION The removed dust seal and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. I837H1240024-02 4) Remove the wheel dampers (3). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1240025-02 I649G1240019-02…

• Page 488
  The sealed cover of the bearing must face outside. I837H1240028-01 4) Install the rear sprocket mounting drum assembly (2). 5) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240030-02 I838H1240004-01 “ a” I837H1240030-01 6) Install the rear wheel assembly.

• Page 489: Tire Removal And Installation

  Wheels and Tires: 2D-15 Tire Removal and Installation Installation B838H22406011 Removal CAUTION The most critical factor of a tubeless tire is the seal Do not reuse the valve which has been once between the wheel rim and the tire bead. For this removed.

• Page 490: Wheel / Tire / Air Valve Inspection And Cleaning

  2D-16 Wheels and Tires: 4) Install the valve core and inflate the tire. Wheel / Tire / Air Valve Inspection and Cleaning B838H22406012 Refer to “Tire Removal and Installation (Page 2D-15)”. WARNING Wheel • Do not inflate the tire to more than 400 kPa Wipe the wheel clean and check for the following points: (4.0 kgf/cm , 57 psi).

• Page 491: Air Valve Removal And Installation

  Wheels and Tires: 2D-17 Air Valve Installation Inspect the air valve for peeling and damage. If any Install the air valve in the reverse order of removal. Pay defect is found, replace the air valve with a new one. attention to the following points: Refer to “Air Valve Removal and Installation (Page 2D- •…

• Page 492: Wheel Balance Check And Adjustment

  2D-18 Wheels and Tires: Wheel Balance Check and Adjustment 5) Recheck the wheel balance. B838H22406014 6) Install the mounting drum to the rear wheel. (For rear Check and adjust the wheel balance in the following wheel) procedures: Refer to “Rear Wheel Assembly Removal and 1) Removal the wheel assembly.

• Page 493: Specifications

  Wheels and Tires: 2D-19 Specifications Service Data B838H22407001 Wheel Unit: mm (in) Item Standard Limit Axial Wheel rim runout — 2.0 (0.08) Radial Front Wheel axle runout — 0.25 (0.010) Rear Front 17 M/C x MT3.50 — Wheel rim size Rear 17 M/C x MT5.50 —…

• Page 494: Special Tools And Equipment

  2D-20 Wheels and Tires: Special Tools and Equipment Recommended Service Material B838H22408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-7) / (Page 2D- equivalent / (Page 2D-13) / (Page 2D-14) NOTE Required service material is also described in the following.

• Page 495
  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-4 Precautions for Driveline / Axle ……3-1 Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation……..3A-5 Drive Chain / Drive Train / Drive Shaft…

• Page 496: Precautions

  • 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 RK 525SMOZ7Y. Suzuki recommends to use this standard drive chain as a replacement.

• Page 497: Drive Chain / Drive Train / Drive Shaft

  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 B838H23104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

• Page 498: Engine Sprocket Removal And Installation

  3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 7) Remove the speed sensor rotor (6) by removing its B838H23106002 bolt while depressing the rear brake pedal. Removal 1) Remove the gearshift link arm (1) by removing the bolt.

• Page 499: Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation

  • Before installing the engine sprocket cover, apply a small quantity of grease to the clutch push rod. Removal : Grease 99000–25010 (SUZUKI SUPER 1) Remove the rear wheel assembly by disengaging GREASE A or equivalent) the drive chain. Refer to “Rear Wheel Assembly Removal and Installation in Section 2D (Page 2D- 11)”.

• Page 500: Drive Chain Related Parts Inspection

  • Apply grease to the contacting surface between the rear wheel hub and rear sprocket mounting drum. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Apply a special tire lubricant or neutral soapy liquid to the wheel damper surface.

• Page 501: Sprocket Mounting Drum Dust Seal / Bearing Removal And Installation

  Drive Chain / Drive Train / Drive Shaft: 3A-5 Engine Sprocket and Rear Sprocket Sprocket Mounting Drum Dust Seal / Bearing Inspect the sprocket teeth for wear. If they are worn as Removal and Installation shown, replace the engine sprocket, rear sprocket and B838H23106005 drive chain as a set.

• Page 502
  Special tool (B): 09921–20240 (Bearing remover set) I837H1310022-01 3) Apply grease to the retainer before installing the rear sprocket mounting drum. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1310021-02 Installation CAUTION The removed dust seal and bearing must be replaced with new ones.

• Page 503: Drive Chain Replacement

  Drive Chain / Drive Train / Drive Shaft: 3A-7 6) Install the spacer. Drive Chain Cutting 1) Set up the special tool as shown in the figure. I837H1310024-01 I649G1310024-02 7) Install the rear wheel assembly. Refer to “Rear 1. Tool body Wheel Assembly Removal and Installation in Section 2.

• Page 504
  3A-8 Drive Chain / Drive Train / Drive Shaft: 4) Tighten the pressure bolt [A] (3) with the bar. Drive Chain Connecting WARNING Do not use joint clip type of drive chain. The joint clip may have a chance to drop which may cause severe damage to motorcycle and severe injury.
• Page 505
  Drive Chain / Drive Train / Drive Shaft: 3A-9 4) Apply grease on the recessed portion of the joint Continue pressing the joint plate until the distance plate holder (3) and set the joint plate (10). between the two joint plates comes to the specification.

• Page 506: Specifications

  3A-10 Drive Chain / Drive Train / Drive Shaft: 2) Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [A] (3) with the bar until the pin end diameter becomes the specified dimension. CAUTION • After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.

• Page 507: Special Tools And Equipment

  Drive Chain / Drive Train / Drive Shaft: 3A-11 Special Tools and Equipment Recommended Service Material B838H23108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-3) / (Page 3A- equivalent 4) /…

• Page 508
  3A-12 Drive Chain / Drive Train / Drive Shaft:…
• Page 509
  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 ……… 4-1 Front Brakes ……….4B-1 Brake Control System and Diagnosis …

• Page 510: Precautions

  4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B838H24000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B838H24000002 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 511: Brake Control System And Diagnosis

  Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B838H24102001 “a” “C” “B” “B” “ b ” “ c” “A” “ d ” I837H1410054-03 1. Hose clamp “B”: Clamp the brake hose firmly. “b”: 15°…

• Page 512: Rear Brake Hose Routing Diagram

  4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B838H24102002 “a” “ c” “b” “A” “ d” “B” I837H1410055-01 1. Stopper : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) “a”: 28° : After the brake hose union has contacted to the stopper, tighten the union bolt.

• Page 513: Diagnostic Information And Procedures

  Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B838H24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.

• Page 514: Repair Instructions

  4A-4 Brake Control System and Diagnosis: Repair Instructions Brake Pedal Height Inspection and Adjustment 2) Disconnect the rear brake light switch lead wire B838H24106001 coupler (1). Refer to “Brake System Inspection in Section 0B (Page 0B-17)”. Front Brake Light Switch Inspection B838H24106002 Inspect the front brake light switch in the following procedures:…

• Page 515: Brake Fluid Level Check

  Brake Control System and Diagnosis: 4A-5 Brake Fluid Level Check 3) Squeeze and release the brake lever several times B838H24106005 in rapid succession and squeeze the lever fully Refer to “Brake System Inspection in Section 0B without releasing it. (Page 0B-17)”. Brake Hose Inspection B838H24106006 Refer to “Brake System Inspection in Section 0B…

• Page 516
  4A-6 Brake Control System and Diagnosis: Fill the reservoir with brake fluid to the upper mark of • Fill the reservoir with brake fluid to the upper mark of the reservoir. the reservoir. Place the reservoir cap to prevent dirt from entering.

• Page 517: Brake Fluid Replacement

  Brake Control System and Diagnosis: 4A-7 • Fill the reservoir with brake fluid to the upper mark of 6) Loosen the air bleeder valve and pump the brake the reservoir. lever until the old brake fluid flows out of the brake system.

• Page 518
  4A-8 Brake Control System and Diagnosis: Fill the reservoir with brake fluid to the upper mark of 7) Loosen the air bleeder valve and pump the brake the reservoir. pedal until the old brake fluid flows out of the brake system.

• Page 519: Front Brake Hose Removal And Installation

  Brake Control System and Diagnosis: 4A-9 9) Fill the reservoir with brake fluid to the upper mark of Rear Brake Hose Removal and Installation B838H24106010 the reservoir. Removal 1) Remove the brake fluid reservoir tank mounting bolt. 2) Drain brake fluid. Refer to “Brake Fluid Replacement (Page 4A-7)”.

• Page 520: Front Brake Master Cylinder Components

  4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Components B838H24106011 I837H1410056-02 1. Reservoir cap 8. Brake lever : 1 N⋅m (0.1 kgf-m, 0.7 lb-ft) 2. Insulator 9. Brake lever pivot bolt : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 3.

• Page 521: Front Brake Master Cylinder Assembly Removal And Installation

  Brake Control System and Diagnosis: 4A-11 Front Brake Master Cylinder Assembly Removal Installation Install the front brake master cylinder in the reverse and Installation B838H24106012 order of removal. Pay attention to the following points: • When installing the master cylinder (1) onto the Removal handlebars (2), align the master cylinder holder’s 1) Drain brake fluid.

• Page 522: Front Brake Master Cylinder / Brake Lever

  4A-12 Brake Control System and Diagnosis: • Bleed air from the master cylinder in the same manner 2) Remove the brake light switch (5) and brake lever as caliper side. (6). NOTE If air is trapped in the master cylinder, bleed air from the master cylinder first.

• Page 523
  I837H1410032-01 7) Remove the connector (17), O-ring (18) and air bleeder valve (19). I837H1410035-01 • Apply grease to the push rod. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) I837H1410033-01 Assembly Assemble the master cylinder in the reverse order of disassembly.

• Page 524: Front Brake Master Cylinder Parts Inspection

  4A-14 Brake Control System and Diagnosis: • Tighten the pivot bolt (1) and lock-nut (2) to the Front Brake Master Cylinder Parts Inspection B838H24106014 specified torque. Refer to “Front Brake Master Cylinder / Brake Lever Tightening torque Disassembly and Assembly (Page 4A-12)”. Brake lever pivot bolt (a): 1 N·m (0.1 kgf-m, 0.7 lb-ft) Master Cylinder…

• Page 525: Rear Brake Master Cylinder Components

  Brake Control System and Diagnosis: 4A-15 Rear Brake Master Cylinder Components B838H24106015 I837H1410057-02 1. Reservoir cap 6. Brake hose 11. Push rod : Apply silicone grease. 2. Insulator 7. Brake hose union bolt 12. Dust boot : Apply thread lock to the thread part. 3.

• Page 526: Rear Brake Master Cylinder Assembly Removal And Installation

  4A-16 Brake Control System and Diagnosis: Rear Brake Master Cylinder Assembly Removal • Apply thread lock to the master cylinder mounting and Installation bolts (1) and tighten them to the specified torque. B838H24106016 Refer to “Rear Brake Hose Routing Diagram (Page 4A- : Thread lock cement 99000–32110 2)”.

• Page 527
  BF: Brake fluid (DOT 4) Special tool : 09900–06108 (Snap ring pliers) I649G1410036-02 • Apply grease to the push rod end. : Grease 99000–25100 (SUZUKI Silicone I837H1410047-01 Grease or equivalent) 5) Remove the push rod (8), piston/cup set (9) and spring (10).

• Page 528: Rear Brake Master Cylinder Parts Inspection

  4A-18 Brake Control System and Diagnosis: Rear Brake Master Cylinder Parts Inspection Piston / Rubber Parts B838H24106018 Inspect the piston surface for any scratches or other Refer to “Rear Brake Master Cylinder Disassembly and damage. Assembly (Page 4A-16)”. Inspect the primary cup, secondary cup and dust boot for wear or damage.

• Page 529: Rear Brake Pedal Removal And Installation

  Brake Control System and Diagnosis: 4A-19 Rear Brake Pedal Removal and Installation Installation B838H24106020 Removal CAUTION 1) Remove the master cylinder assembly. Refer to Replace the snap ring with a new one. “Rear Brake Master Cylinder Assembly Removal and Installation (Page 4A-16)”. Install the rear brake pedal as shown in the rear brake 2) Disconnect the rear brake light switch lead wire pedal construction.

• Page 530: Special Tools And Equipment

  4A-20 Brake Control System and Diagnosis: Special Tools and Equipment Recommended Service Material B838H24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-7) / (Page 4A- / (Page 4A-13) / (Page 4A-17) Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100…

• Page 531: Front Brakes

  Front Brakes: 4B-1 Front Brakes Brake Repair Instructions Front Brake Components B838H24206001 I837H1420022-02 1. O-ring 7. Front brake disc : Apply thread lock to the thread part. 2. Piston seal : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) : Apply brake fluid. 3.

• Page 532: Front Brake Pad Inspection

  4B-2 Front Brakes: Front Brake Pad Inspection 4) Clean up the caliper especially around the caliper B838H24206002 piston. The extent of brake pads wear can be checked by 5) Install the spring to caliper, bring its wider side of observing the grooved limit line “A” on the pads. When pawl “A”…

• Page 533: Front Brake Caliper Removal And Installation

  Front Brakes: 4B-3 Tighten the front brake caliper mounting bolts (4) and 2) Remove the brake hose from the caliper by front brake pad mounting pins (5) to the specified removing the union bolt (1) and catch the brake fluid torque.

• Page 534: Front Brake Caliper Disassembly And Assembly

  4B-4 Front Brakes: Installation Front Brake Caliper Disassembly and Assembly B838H24206005 Install the brake caliper in the reverse order of removal. Refer to “Front Brake Caliper Removal and Installation Pay attention to the following points: (Page 4B-3)”. • Tighten each bolt to the specified torque. NOTE Tightening torque The right and left calipers are installed…

• Page 535
  Front Brakes: 4B-5 4) Place a rag over the pistons to prevent it from Assembly popping out and then force out the pistons using Assemble the caliper in the reverse order of compressed air. disassembly. Pay attention to the following points: •…

• Page 536: Front Brake Caliper Parts Inspection

  4B-6 Front Brakes: • Install a new O-ring and reassemble caliper halves. Front Brake Caliper Parts Inspection B838H24206006 Refer to “Front Brake Caliper Disassembly and CAUTION Assembly (Page 4B-4)”. Replace the O-ring with a new one. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage.

• Page 537: Front Brake Disc Removal And Installation

  Front Brakes: 4B-7 Brake Pad Spring Installation Inspect the brake pad spring for damage and excessive Install the front brake disc in the reverse order of bend. If any damage is found, replace it with a new one. removal. Pay attention to the following points: •…

• Page 538: Specifications

  4B-8 Front Brakes: Brake Disc Runout 1) Dismount the front brake caliper. Refer to “Front Brake Caliper Removal and Installation (Page 4B- 3)”. 2) Measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit.

• Page 539: Special Tools And Equipment

  Front Brakes: 4B-9 Special Tools and Equipment Recommended Service Material B838H24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) / (Page 4B- Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130 (Page 4B-7)

• Page 540: Rear Brakes

  4C-1 Rear Brakes: Rear Brakes Brake Repair Instructions Rear Brake Components B838H24306001 I837H1430022-02 1. Rear caliper 7. Rear brake disc : 35 N⋅m (3.5 kgf-m, 2.5 lb-ft) 2. Piston seal 8. Brake pad spring : Apply silicone grease to sliding surface. 3.

• Page 541: Rear Brake Pad Inspection

  Rear Brakes: 4C-2 Rear Brake Pad Inspection 3) Remove the brake pads (3) with the rear caliper B838H24306002 pivoted up. The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When NOTE the wear exceeds the grooved limit line, replace the When removing the pads, push the piston all…

• Page 542: Rear Brake Caliper Removal And Installation

  4C-3 Rear Brakes: 6) Tighten the caliper mounting bolt (4) and pad 4) Pivot the caliper up and remove the caliper from the mounting pin (5) to the specified torque. caliper bracket. Tightening torque Rear brake caliper mounting bolt (a): 18 N·m ( 1.8 kgf-m, 13.0 lb-ft) Rear brake pad mounting pin (b): 16 N·m (1.6 kgf-m, 11.5 lb-ft)

• Page 543: Rear Brake Caliper Disassembly And Assembly

  Rear Brakes: 4C-4 Rear Brake Caliper Disassembly and Assembly 5) Remove the dust seal (7) and piston seal (8). B838H24306005 Refer to “Rear Brake Caliper Removal and Installation (Page 4C-3)”. Disassembly 1) Remove the pad spring (1), rubber boot (2) and sliding pin (3).

• Page 544: Rear Brake Caliper Parts Inspection

  • Install the brake caliper to its bracket. I649G1420013-02 I837H1430020-01 • Apply grease to the inside of the rubber boot. Rear Brake Caliper Parts Inspection : Grease 99000–25100 (SUZUKI Silicone B838H24306006 Grease or equivalent) Refer to “Rear Brake Caliper Disassembly and Assembly (Page 4C-4)”.

• Page 545: Rear Brake Disc Removal And Installation

  Rear Brakes: 4C-6 Brake Caliper Sliding Pin Rear Brake Disc Removal and Installation B838H24306007 Inspect the brake caliper sliding pin for wear and other damage. If any damage is found, replace the sliding pin Removal with a new one. 1) Remove the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation in Section 2D (Page 2D-11)”.

• Page 546: Rear Brake Disc Inspection

  4C-7 Rear Brakes: Rear Brake Disc Inspection 2) Measure the runout using the dial gauge. B838H24306008 Replace the disc if the runout exceeds the service Brake Disc Thickness limit. Check the brake disc for damage or cracks and measure Special tool the thickness using the micrometer.

• Page 547: Special Tools And Equipment

  Rear Brakes: 4C-8 Special Tools and Equipment Recommended Service Material B838H24308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-4) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-5) / (Page 4C-…

• Page 548
  4C-9 Rear Brakes:…
• Page 549
  Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ……….5-1 Specifications ………….5B-20 Service Data…………5B-20 Precautions…………. 5-1 Tightening Torque Specifications……5B-20 Precautions for Transmission / Transaxle….. 5-1 Special Tools and Equipment ……5B-21 Manual Transmission……5B-1 Recommended Service Material …….5B-21 Special Tool …………5B-21 Diagnostic Information and Procedures….5B-1 Manual Transmission Symptom Diagnosis ..

• Page 550: Precautions

  5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B838H25000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

• Page 551: Manual Transmission

  Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B838H25204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.

• Page 552: Repair Instructions

  5B-2 Manual Transmission: Repair Instructions Transmission Components B838H25206001 I837H1520070-03 1. 2nd drive gear 11. 5th driven gear : 115 N⋅m (11.5 kgf-m, 83.0 lb-ft) 2. 6th drive gear 12. 1st driven gear : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 3. 3rd/4th drive gears 13.

• Page 553: Transmission Removal

  Manual Transmission: 5B-3 Transmission Removal Gearshift Fork and Gearshift Cam B838H25206002 1) Remove the screws (1). 1) Remove the engine assembly from the frame. Refer 2) Remove the gearshift fork shaft (2). to “Engine Assembly Removal in Section 1D 3) Remove the gearshift cam (3) along with its bearing (Page 1D-19)”.

• Page 554
  5B-4 Manual Transmission: 5) Remove the dowel pin (5). Bearing and Oil Seal 1) Remove the gearshift cam bearing (1) with the special tools. CAUTION Be careful not to lean the bearing remover. Special tool (A): 09923–74511 (Bearing remover) (B): 09930–30104 (Rotor remover slide shaft) I837H1520006-01 6) Remove the driveshaft right bearing case bolts.

• Page 555: Transmission Installation

  Manual Transmission: 5B-5 4) Remove the driveshaft left bearing (4) with the Transmission Installation B838H25206003 special tool. Install the transmission in the reverse order of removal. Special tool Pay attention to the following points: (D): 09913–70210 (Bearing installer set) Bearing and Oil Seal CAUTION Replace the removed bearings and oil seals with new ones.

• Page 556
  I837H1520019-03 • Install the dowel pin (3). • Apply grease to the oil seal lip. • Apply grease to the O-ring (4). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the O-ring (4) with a new one.
• Page 557
  : Thread lock cement 99000–32110 Replace the O-ring (6) with a new one. (THREAD LOCK CEMENT SUPER 1322 or equivalent) : Grease 99000–25010 (SUZUKI SUPER Tightening torque GREASE A or equivalent) Driveshaft left bearing case bolt (b): 12 N·m (1.2 •…
• Page 558
  5B-8 Manual Transmission: • With engaging each fork end to the cam groove, insert • Install the countershaft assembly to the upper the fork shaft (3). crankcase. • Apply thread lock to the screws and tighten them to NOTE the specified torque. Align the C-ring with the groove of bearing : Thread lock cement 99000–32110 and the bearing pin with the indent on the…

• Page 559: Transmission Construction

  Manual Transmission: 5B-9 Transmission Construction B838H25206004 I837H1520068-01 1. Countershaft 2. Driveshaft Countershaft Gear / Driveshaft Gear • Remove the 6th drive gear snap ring (1) from its Disassembly and Assembly groove and slide it towards the 3rd/4th drive gears (2). B838H25206005 Refer to “Transmission Removal (Page 5B-3)”…

• Page 560
  Refer to “Transmission Construction (Page 5B-9)”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • When installing a new snap ring (1), pay attention to its direction. Fit it to the side where the thrust is as shown in the figure.

• Page 561: Transmission Related Parts Inspection

  Manual Transmission: 5B-11 Driveshaft • When installing the gear bushing onto the countershaft, align the shaft oil hole “A” with the • When installing the gear bushings onto the driveshaft, bushing oil hole “B”. align the shaft oil holes “A” with the bushing oil hole “B”.

• Page 562
  5B-12 Manual Transmission: Gearshift Fork Groove Width Driveshaft Bearing Measure the gearshift fork groove width using the • Inspect the driveshaft left bearing for abnormal noise vernier calipers. and smooth rotation while it is in the case. Replace the bearing if there is anything unusual. Special tool Refer to “Transmission Removal (Page 5B-3)”…

• Page 563: Gear Position (Gp) Switch Inspection

  Align the gear position switch pin “A” with Removal and Installation in Section 1G (Page 1G- the gearshift cam hole “B”. 9)”. : Grease 99000–25010 (SUZUKI SUPER 3) Remove the engine sprocket cover. Refer to “Engine GREASE A or equivalent) Sprocket Removal and Installation in Section 3A (Page 3A-2)”.

• Page 564: Gearshift Lever Construction

  5B-14 Manual Transmission: Gearshift Lever Construction B838H25206009 “a” “b” “A” “c ” I837H1520073-02 “A”: Footrest top surface “b”: 30 mm (1.2 in) : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) : Apply grease. “a”: Approx. 4° 50’ “c”: 65 – 75 mm (2.6 – 3.0 in) : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) Gearshift Lever Removal and Installation B838H25206010…

• Page 565: Gearshift Shaft / Gearshift Cam Plate Components

  Manual Transmission: 5B-15 Gearshift Shaft / Gearshift Cam Plate Components B838H25206012 I837H1520072-06 1. Gearshift shaft : 19 N⋅m (1.9 kgf-m, 13.5 lb-ft) : Apply thread lock to the thread part. 2. Gearshift cam drive plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft) : Apply thread lock to the thread part.

• Page 566: Gearshift Shaft / Gearshift Cam Plate Removal And Installation

  5B-16 Manual Transmission: Gearshift Shaft / Gearshift Cam Plate Removal 6) Remove the gearshift cam plate bolt (11) and gearshift cam plate (12). and Installation B838H25206014 7) Remove the gearshift cam stopper (13). Remove the gearshift arm stopper (14). Removal 1) Remove the engine sprocket cover.

• Page 567
  Manual Transmission: 5B-17 • Install the gearshift cam stopper (1), bolt (2), collar (3) • Apply a small quantity of thread lock to the gearshift and return spring (4). cam stopper plate bolt and tighten it to the specified torque. •…

• Page 568: Gearshift Linkage Inspection

  5B-18 Manual Transmission: • Install the washer (6) and gearshift shaft assembly (7) Gearshift Linkage Inspection B838H25206015 as shown in the figure. Refer to “Gearshift Shaft / Gearshift Cam Plate Removal and Installation (Page 5B-16)”. NOTE Pinch the gearshift arm stopper (8) with Gearshift Shaft return spring ends “F”.

• Page 569: Gearshift Shaft Oil Seal / Bearing Removal And Installation

  (A): 09921–20210 (Bearing remover) (B): 09930–30104 (Rotor remover slide shaft) I837H1520069-01 • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER I837H1520065-01 GREASE A or equivalent) Installation Install the oil seal and bearing in the reverse order of removal.

• Page 570: Specifications

  5B-20 Manual Transmission: Specifications Service Data B838H25207001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.761 (74/42) — Final reduction ratio 2.647 (45/17) — 2.785 (39/14) — 2.052 (39/19) — 1.714 (36/21) — Gear ratios 1.500 (36/24) —…

• Page 571: Special Tools And Equipment

  Manual Transmission: 5B-21 Special Tools and Equipment Recommended Service Material B838H25208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-6) / (Page 5B- equivalent 6) / (Page 5B-7) / (Page 5B-7) /…

• Page 572
  5B-22 Manual Transmission: 09930–30104 Rotor remover slide shaft (Page 5B-4) / (Page 5B-…

• Page 573: Clutch

  Clutch: 5C-1 Clutch Transmission / Transaxle Precautions Precautions for Clutch System B838H25300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Schematic and Routing Diagram Clutch Cable Routing Diagram B838H25302001 Refer to “Throttle Cable Routing Diagram in Section 1D (Page 1D-2)”. Diagnostic Information and Procedures Clutch System Symptom Diagnosis B838H25304001…

• Page 574: Repair Instructions

  5C-2 Clutch: Repair Instructions Clutch Lever Position Switch Inspection Clutch Cable Inspection B838H25306001 B838H25306002 Inspect the clutch lever position switch in the following Refer to “Clutch Cable Play Inspection and Adjustment procedures: in Section 0B (Page 0B-14)”. 1) Disconnect the clutch lever position switch lead Clutch Cable Removal and Installation wires (1).

• Page 575: Clutch Control System Components

  Clutch: 5C-3 Clutch Control System Components B838H25306004 I837H1530049-04 1. Push rod 4. Clutch cable : 10 N⋅m (1.0 kgf-m, 0.7 lb-ft) 2. Clutch release camshaft : 1 N⋅m (0.1 kgf-m, 0.7 lb-ft) : Apply grease. 3. Clutch release arm : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Do not reuse.

• Page 576: Clutch Components

  5C-4 Clutch: Clutch Components B838H25306005 I837H1530047-02 1. Clutch pressure plate 8. Spring washer 15. Primary driven gear assembly 2. Clutch push piece 9. Spring washer seat 16. Push rod 3. No. 2 drive plate 10. Clutch sleeve hub : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 4.

• Page 577: Clutch Removal

  Clutch: 5C-5 Clutch Removal 6) Remove the clutch springs and pressure plate (4). B838H25306006 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 2) Lift and support the fuel tank with the prop stay. little and diagonally.

• Page 578
  5C-6 Clutch: 9) Remove the thrust washer (9), bearing (10) and 13) Remove the clutch sleeve hub nut. clutch push piece (11). I837H1530010-02 14) Remove the conical spring washer (13), washer (14) I837H1530007-01 10) Remove the clutch push rod (12). and clutch sleeve hub (15).

• Page 579: Clutch Installation

  Clutch: 5C-7 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. I837H1530014-01 I837H1530018-02 18) Remove the spacer (21) and bearing (22). 3) Install the thrust washer (4). 19) Remove the primary driven gear assembly (23).

• Page 580
  5C-8 Clutch: 7) Install the clutch lifter drive cam (8). 10) Tighten the clutch sleeve hub nut to the specified torque. Tightening torque Clutch sleeve hub nut (a): 95 N·m (9.5 kgf-m, 68.7 lb-ft) I837H1530020-02 Install the clutch sleeve hub (9), washer (10) and spring washer (11).
• Page 581
  Clutch: 5C-9 13) Install the clutch push piece (13), bearing (14) and thrust washer (15) to the countershaft. NOTE Thrust washer (15) is located between the pressure plate and bearing (14). “C” 21 22 I837H1530029-01 18. No. 2 drive plate 19.
• Page 582
  NOTE as shown in the figure. When install the pressure plate, fit the : Sealant 99000–31140 (SUZUKI BOND convex part “E” of the pressure plate onto No.1207B or equivalent) the concave part “F” of the clutch sleeve hub.

• Page 583: Clutch Parts Inspection

  Clutch: 5C-11 24) 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. NOTE Special tool Fit the new gasket washer to the bolt “G”. (A): 09900–20102 (Vernier calipers (1/20 mm, 200 mm)) Clutch drive plate claw width…

• Page 584
  5C-12 Clutch: Clutch Spring Clutch Sleeve Hub and Primary Driven Gear Measure the free length of each coil spring with a vernier Assembly calipers, and compare the length with the specified limit. Inspect the slot of the clutch sleeve hub and primary Replace all the springs if any spring is not within the driven gear assembly for damage or wear caused by the limit.

• Page 585: Clutch Lifter Pin Inspection And Adjustment

  Clutch: 5C-13 Clutch Lifter Pin Inspection and Adjustment 3) Inspect the height “A” of clutch lifter adjusting pin B838H25306009 screws at three positions using the thickness gauge. Refer to “Clutch Removal (Page 5C-5)” and “Clutch If the measurement is out of the specification, adjust Installation (Page 5C-7)”.

• Page 586: Specifications

  5C-14 Clutch: 7) Slowly turn in the adjusting pin screw (1) until resistance is felt. Tighten the lock-nut (2). Tightening torque Clutch lifter lock-nut: 23 N·m (2.3 kgf-m, 16.5 lb- I837H1530042-01 I837H1530046-02 Specifications Service Data B838H25307001 Clutch Unit: mm (in) Item Standard Limit…

• Page 587: Special Tools And Equipment

  Clutch: 5C-15 Special Tools and Equipment Recommended Service Material B838H25308001 Material SUZUKI recommended product or Specification Note Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 5C-7) Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 5C-10) / equivalent (Page 5C-10) NOTE Required service material is also described in the following.

• Page 588
  5C-16 Clutch:…
• Page 589
  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….6A-1 Inspection…………6B-9 Steering System Inspection ……6B-10 Diagnostic Information and Procedures….6A-1 Steering Stem Bearing Removal and…

• Page 590: Precautions

  6-1 Precautions: Precautions Steering Precautions Precautions for Steering B838H26000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

• Page 591: Steering General Diagnosis

  Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B838H26104001 Condition Possible cause Correction / Reference Item Heavy steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.

• Page 592: Steering / Handlebar

  6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Components B838H26206001 “A” I837H1620038-01 1. Throttle grip 5. Right handlebar “A”: Apply handle grip bond. 2. Grip rubber 6. Left handlebar : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Right handlebar switch box 7.

• Page 593: Handlebar Removal And Installation

  Steering / Handlebar: 6B-2 Handlebar Removal and Installation 3) Loosen the handlebar clamp bolts (10) and front fork B838H26206002 upper clamp bolts (11). Removal 1) Remove the following parts from the left handlebar. a) Left handlebar switch box (1) b) Handlebar balancer (2) c) Grip rubber (3) d) Disconnect the clutch cable (4) e) Clutch lever (5)

• Page 594
  • Install the front brake master cylinder. Refer to “Front Brake Master Cylinder Assembly Removal and Installation in Section 4A (Page 4A-11)”. • Apply grease to the end of the throttle cables and cable pulley. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)

• Page 595: Handlebars Inspection

  Steering / Handlebar: 6B-4 • Insert the projection “C” of the right handlebar switch • After installing the steering, the following adjustments box into the hole of the handlebars. are required before driving. – Throttle cable routing (Refer to “Throttle Cable Routing Diagram in Section 1D (Page 1D-2)”) –…

• Page 596: Steering Components

  6B-5 Steering / Handlebar: Steering Components B838H26206004 I837H1620039-02 1. Steering stem head nut 7. Dust seal cover : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 2. Steering stem upper bracket 8. Dust seal : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 3. Handlebars 9.

• Page 597: Steering Damper Construction

  Steering / Handlebar: 6B-6 Steering Damper Construction B838H26206005 I837H1620040-01 1. Steering damper 2. Dust seal 3. Bearing : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply grease. Steering / Steering Damper Removal and 6) Remove the steering damper (6). Installation B838H26206006 Removal Steering damper…

• Page 598
  6B-7 Steering / Handlebar: 6) Lift and support the fuel tank. Refer to “Fuel Tank 12) It is not necessary to remove the ignition switch from Removal and Installation in Section 1G (Page 1G- the upper bracket when servicing the steering 9)”.
• Page 599
  • Apply grease to the bearings, bearing races and dust bearings seat properly. seals before remounting the steering stem. • Loosen the steering stem nut 1/4 – 1/2 turn “a”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE This adjustment will vary from motorcycle to motorcycle.

• Page 600: Steering / Steering Damper Related Parts Inspection

  4) 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) I837H1620028-01 I823H1620019-02…

• Page 601: Steering System Inspection

  Steering / Handlebar: 6B-10 Bearing Steering System Inspection B838H26206008 • Bearing wear or damage Refer to “Steering System Inspection in Section 0B • Abnormal bearing noise (Page 0B-19)”. • Race wear or damage Steering Stem Bearing Removal and Installation • Bearing lower seal damage B838H26206009 Removal 1) Remove the steering stem lower bracket.

• Page 602: Steering Tension Adjustment

  6B-11 Steering / Handlebar: Installation Steering Tension Adjustment B838H26206010 Install the steering stem bearings in the reverse order of Check the steering movement in the following removal. Pay attention to the following points: procedures: CAUTION 1) By supporting the motorcycle with a jack, lift the front wheel unit is off the floor 20 –…

• Page 603: Specifications

  Steering / Handlebar: 6B-12 Specifications Tightening Torque Specifications B838H26207001 Tightening torque Fastening part Note N⋅m kgf-m lb-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) / 65.0 (Page 6B-9) Steering stem nut 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) then turn back (Page 6B-8)

• Page 604: Special Tools And Equipment

  6B-13 Steering / Handlebar: Special Tools and Equipment Recommended Service Material B838H26208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-3) / (Page 6B- equivalent / (Page 6B-9) Handle grip bond Handle Grip Bond (commercially —…

• Page 605
  Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ……….9-1 Passing Light Switch Inspection……9B-13 Dimmer Switch Inspection………9B-14 Precautions…………. 9-1 Specifications ………….9B-14 Precautions for Electrical System ……9-1 Service Data…………9B-14 Component Location ……….9-1 Tightening Torque Specifications……9B-14 Electrical Components Location ……9-1 Special Tools and Equipment ……9B-15 Wiring Systems……..
• Page 606
  9-ii Table of Contents Body Structure……… 9E-1 Rear Fender Construction……..9D-4 Frame Cover Construction ……..9D-5 Repair Instructions ……….9E-1 Frame Side Cover Cushion Attachment….9D-6 Body Frame Construction ……..9E-1 Fuel Tank Cover Cushion Attachment ….9D-7 Front Footrest Bracket Construction ….9E-2 Rear View Mirror Construction ……9D-8 Side-stand Construction……..9E-3 Rear View Mirror Cushion Attachment….9D-9 Pillion Footrest Construction …….9E-3…

• Page 607: Precautions

  Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B838H29000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B838H29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

• Page 608: Wiring Systems

  9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B838H29102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”.

• Page 609
  Wiring Systems: 9A-2 For E-03, 28, 33 I837H2910901-02…

• Page 610: Wiring Harness Routing Diagram

  9A-3 Wiring Systems: Wiring Harness Routing Diagram B838H29102002 “B” “A” “C” “D” “E” “G” “F” I837H1910901-03 1. Horn 10. Clamp 19. IAP sensor : Bind the wiring harness, CKP sensor lead wire, rear brake light switch lead wire, HO2 sensor lead wire and side-stand switch lead wire with the clamp.

• Page 611
  Wiring Systems: 9A-4 “ a ” “ a ” “A” “C” “B” “D” I837H1910902-02 1. ECM cushion 7. Clamp “B”: Do not slacken the lead wires. : Bind the wiring harness and battery (–) lead wire with the clamp. Set the lock part of the clamp to inside. 2.
• Page 612
  9A-5 Wiring Systems: “C” “B” “A” I837H1910903-04 1. CMP sensor 7. Clamp : 14 N⋅m (1.4 kgf-m, 10 lb-ft) : Fix the clamp in parallel with the cover surface. 2. CKP sensor “A”: White tape : 6.5 N⋅m (0.65 kgf-m, 4.7 lb-ft) 3.
• Page 613
  Wiring Systems: 9A-6 “C” “B” “A” I837H1910904-04 1. HO2 sensor “B”: Pass the HO2 sensor lead wire between the frame and engine. 2. Clutch cable “C”: Pass the HO2 sensor lead wire rear of the clutch cable. 3. Oil pan : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) “A”: Pass the HO2 sensor lead wire inside the right side cowling.

• Page 614: Specifications

  9A-7 Wiring Systems: Specifications Service Data B838H29107001 Electrical Item Specification Note 15 A Headlight 10 A Ignition 15 A Fuse size Signal 10 A Fuel 10 A 15 A Main 30 A Tightening Torque Specifications B838H29107002 NOTE The specified tightening torque is also described in the following. “Wiring Harness Routing Diagram (Page 9A-3)”…

• Page 615: Lighting Systems

  Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B838H29206001 I837H1920001-02 1. Headlight Low beam bulb (12 V 55 W, H11) 2. Headlight High beam bulb (12 V 60 W, HB3 x 2) 3. Position light bulb (12 V 5 W)

• Page 616: Headlight Removal And Installation

  9B-2 Lighting Systems: Headlight Removal and Installation 6) Remove the headlight assembly (7) from body B838H29206002 cowling (8). Removal 1) Remove the body cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”. “A” 2) Remove the air intake pipes. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

• Page 617
  Lighting Systems: 9B-3 3) Remove the headlight bulb/socket (Low beam) (2) Disconnect the position light coupler (5). by turning it counterclockwise. I837H1920011-02 9) Remove the back cover assembly (6) by turning it I837H1920007-01 4) Replace the headlight bulb (Low beam) with a new coupler clockwise.

• Page 618: Headlight Beam Adjustment

  9B-4 Lighting Systems: Headlight Beam Adjustment B838H29206004 Adjust the headlight beam, both horizontally and vertically. NOTE To adjust the headlight beam, adjust the beam horizontally first, then vertically. “B” I837H1920015-01 “B”: Horizontal adjuster “A” I837H1920014-02 “A”: Vertical adjuster Front Turn Signal Light Components B838H29206005 I837H1920016-02 1.

• Page 619: Front Turn Signal Light Removal And Installation

  Lighting Systems: 9B-5 Front Turn Signal Light Removal and Front Turn Signal Light Bulb Replacement B838H29206007 Installation B838H29206006 CAUTION Removal When you touch the bulb with your bare 1) Remove the turn signal light assembly (1). hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

• Page 620: Rear Lighting System Construction

  9B-6 Lighting Systems: Rear Lighting System Construction B838H29206008 I837H1920021-03 1. License plate light assembly : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Reflex reflector (E-03, 28, 33 only) : 1.8 N⋅m (0.18 kgf-m, 1.5 lb-ft) 3. Rear combination light screw : 2.8 N⋅m (0.28 kgf-m, 2.0 lb-ft) 4.

• Page 621: Rear Combination Light Removal And Installation

  Lighting Systems: 9B-7 Rear Combination Light Removal and Installation Install the rear combination light in the reverse order of Installation B838H29206009 removal. Pay attention to the following point: Removal • Tighten the combination light mounting bolts (1) to the 1) Remove the frame cover assembly. Refer to specified torque.

• Page 622: Rear Combination Light Replacement

  9B-8 Lighting Systems: Rear Combination Light Replacement B838H29206010 CAUTION If LED operation is abnormal, replace the rear combination light with a new one. License Plate Light Components B838H29206011 I837H1920025-01 1. License plate light bulb (12 V 5 W) 3. Lens 2.

• Page 623: License Plate Light Bulb Replacement

  Lighting Systems: 9B-9 Installation License Plate Light Bulb Replacement B838H29206013 Install the license plate light in the reverse order of CAUTION removal. Pay attention to the following point: • Tighten the license plate light mounting nuts (1) to the When you touch the bulb with your bare specified torque.

• Page 624: Rear Turn Signal Light Components

  9B-10 Lighting Systems: Rear Turn Signal Light Components B838H29206014 I837H1920034-02 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 B838H29206015 frame cover (4).

• Page 625: Rear Turn Signal Light Bulb Replacement

  Lighting Systems: 9B-11 Installation 1) Remove the rear turn signal light lens (1). Install the rear turn signal light in the reverse order of removal. Pay attention to the following point: • Insert the convex part “A” of the side frame cover to the hole “B”…

• Page 626: Headlight Relay Inspection

  9B-12 Lighting Systems: Headlight Relay Inspection Turn Signal / Side-Stand Relay Removal and B838H29206018 Installation Refer to “Electrical Components Location in Section 0A B838H29206020 (Page 0A-8)”. Removal Inspect the headlight relay in the following procedure: 1) Remove the frame cover. Refer to “Exterior Parts 1) Remove the frame cover.

• Page 627: Turn Signal Switch Inspection

  Lighting Systems: 9B-13 3) Inspect the hazard switch for continuity with a tester. Passing Light Switch Inspection B838H29206023 If any abnormality is found, replace the left Inspect the passing light switch in the following handlebar switch assembly with a new one. Refer to procedures: “Handlebar Removal and Installation in Section 6B 1) Remove the air cleaner box.

• Page 628: Dimmer Switch Inspection

  9B-14 Lighting Systems: Dimmer Switch Inspection 3) Inspect the dimmer switch for continuity with a tester. B838H29206024 If any abnormality is found, replace the left Inspect the dimmer switch in the following procedures: handlebar switch assembly with a new one. 1) Remove the air cleaner box.

• Page 629: Special Tools And Equipment

  Lighting Systems: 9B-15 Special Tools and Equipment Recommended Service Material B838H29208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9B-7) / (Page 9B- 1322 or equivalent Special Tool B838H29208002 09900–25008 Multi-circuit tester set…

• Page 630: Combination Meter / Fuel Meter / Horn

  9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B838H29301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).

• Page 631: Repair Instructions

  Combination Meter / Fuel Meter / Horn: 9C-2 Repair Instructions Combination Meter Components B838H29306001 I838H1930001-01 1. Combination meter unit 2. Combination meter case 3. Combination meter cover Combination Meter Removal and Installation Installation B838H29306002 Install the combination meter in the reverse order of Removal removal.

• Page 632: Combination Meter Inspection

  9C-3 Combination Meter / Fuel Meter / Horn: Combination Meter Inspection 2) With the ADJ button (1) pressed, turn the ignition B838H29306004 switch ON. LED Inspection 3) Keep pushing the ADJ button for more than 3 to 5 Check that the LEDs (FI, fuel, engine RPM, indicator sec.

• Page 633: Ect Sensor Removal And Installation

  Combination Meter / Fuel Meter / Horn: 9C-4 3) Connect a variable resistor (2) between the terminals. I718H1930009-05 4) Turn the ignition switch ON. 5) Check the engine coolant temperature meter (3) and indicator light (LED) (4) operations when the resistance is adjusted to the specified values.

• Page 634: Fuel Level Indicator Inspection

  9C-5 Combination Meter / Fuel Meter / Horn: Fuel Level Indicator Inspection 3) Install the fuel pump. Refer to “Fuel Pump B838H29306007 Disassembly and Assembly in Section 1G (Page 1G- If the fuel level indicator light does not function properly, 11)”.

• Page 635: Speed Sensor Inspection

  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. The voltage readings should cycle as follows (0 V → 12 V or 12 V Pay attention to the following points: →…

• Page 636: Oil Pressure Switch Removal And Installation

  9C-7 Combination Meter / Fuel Meter / Horn: 4) Check if the oil pressure indicator (LED) (2) will light Ignition Switch Inspection B838H29306015 up and LCD (3) will flicker when grounding the lead Inspect the ignition switch in the following procedures: wire (1).

• Page 637: Ignition Switch Removal And Installation

  Combination Meter / Fuel Meter / Horn: 9C-8 Ignition Switch Removal and Installation Horn Inspection B838H29306016 1) Disconnect the horn coupler (1). Refer to “Ignition Switch Removal and Installation in Section 1H (Page 1H-11)”. Horn Inspection B838H29306017 NOTE If the horn sound condition is normal, it is not necessary to inspect the horn button continuity.

• Page 638: Specifications

  9C-9 Combination Meter / Fuel Meter / Horn: Specifications Service Data B838H29307001 Wattage Unit: W Specification Item E-02, 19, 24 The other countries ← Combination meter light ← Turn signal indicator light ← High beam indicator light ← Neutral position indicator light FI indicator light/Oil pressure ←…

• Page 639: Exterior Parts

  Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B838H29406001 “A” “B” “B” “A” “A” “A” “A” I837H1940026-02 “A”: To frame “B”: To headlight assembly : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)

• Page 640: Body Cowling Cushion Attachment

  9D-2 Exterior Parts: Body Cowling Cushion Attachment B838H29406002 I837H1940027-01 1. Cushion 2. Velcro fastening 3. Body cowling…

• Page 641: Under Cowling Heat Shield / Cushion Attachment

  Exterior Parts: 9D-3 Under Cowling Heat Shield / Cushion Attachment B838H29406003 “ a ” I837H1940028-01 1. Cushion 2. Heat shield 3. Heat shield 4. Cushion “a”: 15 mm (0.59 in)

• Page 642: Rear Fender Construction

  9D-4 Exterior Parts: Rear Fender Construction B838H29406004 I837H1940029-02 1. Rear fender (Front) 3. Plate 5. Rear fender (Lower) 7. Rivet 2. Rear fender (Rear) 4. Bracket 6. Bracket (For E-24) 8. Hooking…

• Page 643: Frame Cover Construction

  Exterior Parts: 9D-5 Frame Cover Construction B838H29406005 “ a ” “ b ” Outside I837H1940030-02 1. Frame cover (Rear) 3. Frame cover (Center) 5. Frame cover (LH/RH) 7. Rear fender front cover “a”: 3 mm (0.12 in) 2. Cushion 4. Cushion 6.

• Page 644: Frame Side Cover Cushion Attachment

  9D-6 Exterior Parts: Frame Side Cover Cushion Attachment B838H29406006 “ a ” I837H1940031-02 1. Frame side cover 3. Cushion “a”: 15 mm (0.59 in) 2. Cushion 4. Double-faced adhesive tape : Adhere the cushion along the rib of the cover.

• Page 645: Fuel Tank Cover Cushion Attachment

  Exterior Parts: 9D-7 Fuel Tank Cover Cushion Attachment B838H29406007 I837H1940032-01 1. Fuel tank cover No. 2 2. Cushion 3. Velcro fastenings…

• Page 646: Rear View Mirror Construction

  9D-8 Exterior Parts: Rear View Mirror Construction B838H29406008 I837H1940033-01 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 lb-ft) : Locate the turn signal lead wire coupler (5) between the mirror cover (6) and mirror body (7).

• Page 647: Rear View Mirror Cushion Attachment

  Exterior Parts: 9D-9 Rear View Mirror Cushion Attachment B838H29406009 “ a ” I837H1940034-03 1. Tape affix mark rib 4. Cushion : Align the cushion corner to the indicated point. 2. Tape “a”: 1.5 mm (0.06 in) : Tape should not run over the indicated line. 3.

• Page 648: Fastener Removal And Installation

  9D-10 Exterior Parts: Fastener Removal and Installation Type B B838H29406010 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”. 2) Pull out the fastener (2).

• Page 649: Exterior Parts Removal And Installation

  Exterior Parts: 9D-11 Exterior Parts Removal and Installation B838H29406011 Seat Tail Cover Front Seat Removal Remove the front seat by removing the bolts. I838H1940002-01 Installation Slide the seat hooks into the seat hook retainers and I837H1940001-03 push down firmly until the seat snaps into the locked Installation position.

• Page 650
  9D-12 Exterior Parts: Installation Inner Under Cowling Install the windscreen in the reverse order of removal. Removal Pay attention to the following point: 1) Remove the body cowling cover. 2) Remove the inner under cowlings (1). NOTE The screws “A” are 3 mm shorter than the others.
• Page 651
  Exterior Parts: 9D-13 3) Pull out the hooked points “A” from each lug hole 6) Disconnect the lead wire coupler (2) and remove the and remove the side cowling (2). wire clamp (3). “A” I837H1940011-04 I837H1940016-01 7) Disconnect the steering damper lead wire coupler “A”: Hooked point (4).
• Page 652
  9D-14 Exterior Parts: Installation Cowling Brace Install the body cowling in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the body cowling. • Fit the lead wire clamp to the screw “A”. 2) Remove the cowling brace (1). “A”…

• Page 653: Specifications

  Exterior Parts: 9D-15 4) Remove the following fasteners. Installation Install the frame cover assembly in the reverse order of removal. Front Fender Removal Refer to “Front Fork Removal and Installation in Section 2B (Page 2B-2)”. Installation Refer to “Front Fork Removal and Installation in Section 2B (Page 2B-2)”.

• Page 654: Body Structure

  9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction B838H29506001 I837H1950001-03 1. Frame 5. Adjuster : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Seat rail 6. Adjuster lock-nut : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) 3. Seat rail bolt 7.

• Page 655: Front Footrest Bracket Construction

  Body Structure: 9E-2 Front Footrest Bracket Construction B838H29506002 “A” I837H1950002-03 1. Footrest bracket bolt 8. Rear brake pedal : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Rear master cylinder bolt 9. Footrest bracket No. 2 (Left) : 4.5 N⋅m (0.45 kgf-m, 3.0 lb-ft) 3.

• Page 656: Side-Stand Construction

  9E-3 Body Structure: Side-stand Construction B838H29506003 I837H1950003-02 : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) : Apply grease to sliding surface. Pillion Footrest Construction B838H29506004 I837H1950004-03 1. Footrest 2.

• Page 657: Side-Stand Removal And Installation

  Body Structure: 9E-4 Side-stand Removal and Installation B838H29506005 Removal 1) Support the motorcycle with a jack or wooden block. CAUTION • Do not support the motorcycle with the exhaust pipes. • Make sure that the motorcycle is supported securely. 2) Remove the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction (Page 9E-3)”. Installation Install the side-stand as shown in the side-stand construction.

• Page 658
  Prepared by February, 2008 Part No. 99500-37140-03E Printed in U.S.A.