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• 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.

1. Manuals
2. Brands
3. Suzuki Manuals
4. Motorcycle
5. GSX-R750
6. Service manual

• Page 1
  GSX-R750 9 9 5 0 0 — 3 7 1 3 0 — 0 1 E…

• Page 2: General Information

  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 compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.

• 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
  Use engine coolant. wise specified. 99000-99032-11X (Except USA) Apply molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKI 99000-99001-SS5 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent grease. Apply or use brake fluid.

• Page 5: Abbreviations Used In This Manual

  ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Engine Control Module : Alternating Current Engine Control Unit (ECU) : Air Cleaner, Air Cleaner Box (FI Control Unit) : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp.

• Page 6
  : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor…
• Page 7
  WIRE COLOR : Black : Green :Pink : Blue : Gray : Red : Brown : Light blue : White : Dark green : Light green : Yellow : Dark gray : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer B/Lg…

• Page 8: Table Of Contents

  GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE…………….. 1- 2 GENERAL PRECAUTIONS …………….1- 2 SUZUKI GSX-R750K6 (’06-MODEL)…………1- 4 SERIAL NUMBER LOCATION …………..1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION……. 1- 5 FUEL (FOR USA AND CANADA)…………1- 5 FUEL (FOR OTHER COUNTRIES) …………1- 5 ENGINE OIL (FOR USA)…………….

• Page 9: Warning/Caution/Note

  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. …

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

• Page 11: Suzuki Gsx-R750K6 (’06-Model)

  GENERAL INFORMATION SUZUKI GSX-R750K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustrations and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.

• Page 12: Fuel, Oil And Engine Coolant Recommendation

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

• Page 13: Front Fork Oil

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

• Page 14: Break-In Procedures

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

• Page 15: Information Labels

  GENERAL INFORMATION INFORMATION LABELS GSX-R750 GSX-R750UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Fuel information label…

• Page 16: Specifications

  GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………….2 040 mm (80.3 in) Overall width …………….715 mm (28.1 in) Overall height …………….1 125 mm (44.3 in) Wheelbase …………….1 400 mm (55.1 in) Ground clearance…………..130 mm (5.1 in) Seat height …………….

• Page 17: Chassis

  1-10 GENERAL INFORMATION CHASSIS Front suspension …………..Inverted telescopic, coil spring, oil damped Rear suspension …………..Link type, coil spring, oil damped Front fork stroke…………..120 mm (4.7 in) Rear wheel travel …………..130 mm (5.1 in) Steering angle…………….. 27° Caster ………………

• Page 18
  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- 7 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. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. IMPORTANT (For E-28): The periodic maintenance intervals and service requirements have been estab- lished 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 and Side-stand pivot Drive chain gearshift lever pivot…

• Page 21: Maintenance And Tune-Up Procedures

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

• Page 22: Spark Plug

  PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). Replace every 12 000 km (7 500 miles, 24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) •…

• Page 23
  PERIODIC MAINTENANCE SPARK PLUG GAP • Measure the spark plug gap with a thickness gauge. • Adjust the spark plug gap if necessary.  Spark plug gap: Standard: 0.7 – 0.8 mm (0.028 – 0.031 in)  09900-20803: Thickness gauge ELECTRODE’S CONDITION •…

• Page 24: Valve Clearance

  PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-14) • Disconnect the CMP sensor coupler 1. •…

• Page 25
  PERIODIC MAINTENANCE • 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 notches A on the left ends of both camshafts (Ex. and In.) to the positions as shown.
• Page 26
  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. (3-14) • Remove the tappet and shim by fingers or magnetic hand. •…
• Page 27
  2-10 PERIODIC MAINTENANCE (INTAKE SIDE)
• Page 28
  PERIODIC MAINTENANCE 2-11 (EXHAUST SIDE)

• Page 29: Engine Oil And Oil Filter

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

• Page 30: Exhaust Control Valve

  Oil and filter change : 2.5 L (2.6/2.2 US/Imp qt) Engine overhaul : 2.9 L (3.1/2.6 US/Imp qt)  ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.

• Page 31: Fuel Line

  2-14 PERIODIC MAINTENANCE • Remove the under cowlings. (8-5) • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. FUEL LINE Inspect initially 6 000 km (4 000 miles, 12 months). • Inspect the fuel feed hose 1 for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.

• Page 32: Throttle Valve Synchronization

  PERIODIC MAINTENANCE 2-15 THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths). • Inspect the throttle valve synchronization periodically. (5-26) EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) Inspect every 12 000 km (7 500 miles, 24 months).

• Page 33: Clutch

  2-16 PERIODIC MAINTENANCE CLUTCH Inspect every 6 000 km (4 000 miles, 12 months). • Lift and support the fuel tank with its prop stay. (5-3) • Turn in the adjuster 1 all the way into the clutch lever assem- bly.

• Page 34: Cooling System

  PERIODIC MAINTENANCE 2-17 COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir.

• Page 35
  2-18 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •…
• Page 36
  PERIODIC MAINTENANCE 2-19 RADIATOR HOSES • Remove the under cowlings. (8-5) • Lift and support the fuel tank. (5-3) • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one.

• Page 37: Drive Chain

  2-20 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below.

• Page 38
  PERIODIC MAINTENANCE 2-21 • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the 1 2 3 19 20 21 service limit, the chain must be replaced.  Drive chain 20-pitch length: Service limit: 319.4 mm (12.57 in) ADJUSTING •…
• Page 39
  • After washing and drying the chain, oil it with a heavyweight motor oil.  * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is RK525ROZ5Y. Suzuki recommends to use this standard drive chain as a replacement.

• Page 40: Brake

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

• Page 41
  2-24 PERIODIC MAINTENANCE BRAKE PADS Front 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 the new ones. (8-65) …
• Page 42
  PERIODIC MAINTENANCE 2-25 BRAKE LIGHT SWITCH • Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
• Page 43
  2-26 PERIODIC MAINTENANCE FRONT BRAKE (Master cylinder side) • Bleed air from the master cylinder in the same manner as front brake (caliper side).  Air bleeder valve: 6.0 N·m (0.6 kgf-m, 4.3 Ib-ft) NOTE: If air is trapped in the master cylinder, bleed air from the master cylinder first.

• Page 44: Tires

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

• Page 45: Front Fork

  2-28 PERIODIC MAINTENANCE FRONT FORK Inspect every 12 000 km (7 500 miles, 24 months). • Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (8-18) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months).

• Page 46: Exhaust Pipe Bolt And Nut

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

• Page 47: Chassis Bolts And Nuts

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

• Page 48
  PERIODIC MAINTENANCE 2-31…

• Page 49: Compression Pressure Check

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

• Page 50: Oil Pressure Check

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

• Page 51: Sds Check

  2-34 PERIODIC MAINTENANCE SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.

• Page 52: Data At The Time Of Racing

  PERIODIC MAINTENANCE 2-35 Data at 3 000 r/min under no load 3 000 r/min Check the manifold absolute pressure. XXX mmHg Data at the time of racing Throttle: Slowly open Throttle: Quick wide open Secondary throttle valve opens closes in according with the engine r/min.

• Page 53
  2-36 PERIODIC MAINTENANCE Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. Approx. XXX mmHg Data of secondary throttle valve operation at the time of starting Closes fully in approx. XX sec.
• Page 54
  ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION……….3- 3 ENGINE REMOVAL …………….3- 3 ENGINE INSTALLATION …………..3-10 ENGINE DISASSEMBLY …………….3-14 ENGINE COMPONENTS INSPECTION AND SERVICE……3-27 CYLINDER HEAD COVER…………..3-27 CMP SENSOR ………………

• Page 55: Engine Components Removable With Engine In Place

  ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION 11-7…

• Page 56: Engine Removal And Installation

  ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Remove the under cowlings. (8-5) •…

• Page 57
  ENGINE RADIATOR • Disconnect the by-pass hose 1 and radiator inlet hose 2. • Disconnect the oil cooler outlet hose 3. • Disconnect the cooling fan coupler 4. • Remove the radiator mounting bolts. • Remove the radiator 5.  Be careful not to bent the radiator fins.
• Page 58
  ENGINE EXHAUST PIPE AND MUFFLER • Remove the EXCV cables along with the bracket 1. • Loosen the muffler connecting bolt. • Remove the HO2 sensor 2 (For E-02, 19). (4-107) • Remove the exhaust pipe bolts. • Remove the exhaust pipe. •…
• Page 59
  ENGINE • Disconnect the following couplers. 3 GP switch lead wire 4 CKP sensor lead wire 5 Ground lead wire 6 Starter motor lead wire 7 Speed sensor lead wire 8 ECT sensor • Disconnect the ignition coil/plug cap lead wire couplers. …
• Page 60
  ENGINE ENGINE SPROCKET AND GEARSHIFT LEVER • Disengage the gearshift lever 1. • Remove the engine sprocket cover 2. • Remove the clutch push rod 3. • Remove the speed sensor rotor 4. • Remove the engine sprocket nut 5 and the washer 6. •…
• Page 61
  ENGINE • Remove the engine sprocket 0. ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolt A. • Loosen the engine mounting pinch bolt 1. • Remove the engine mounting bolt B.
• Page 62
  ENGINE • Remove the engine mounting nut 2. • Remove the engine mounting thrust adjuster lock-nut 3 with the special tool. • Loosen the engine mounting thrust adjuster 4 fully.  09940-14980: Engine mounting thrust adjuster socket wrench • Remove the engine mounting nut 5. •…

• Page 63: Engine Installation

  3-10 ENGINE 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 spacers 1. •…

• Page 64
  ENGINE 3-11  LENGTH ITEM N·m kgf-m lb-ft ITEM 40.0 1.77 16.5 2.17 Bolt 16.5 8.46 32.5 8.07 54.0 Spacer 30.5 1.20 Adjuster 1.57 a LH b RH…
• Page 65
  • Tighten the speed sensor rotor bolt 4 to the specified torque.  Speed sensor rotor bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the clutch push rod end.  99000-25010: SUZUKI SUPER GREASE “A”…
• Page 66
  ENGINE 3-13 • Tighten the muffler mounting bolts, exhaust pipe bolts and muffler connecting bolt to the specified torque.  Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •…

• Page 67: Engine Disassembly

  3-14 ENGINE ENGINE DISASSEMBLY  Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the spark plugs. (2-5) STARTER MOTOR •…

• Page 68
  ENGINE 3-15 • 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. • Remove the cam chain tension adjuster 2. •…
• Page 69
  3-16 ENGINE CYLINDER HEAD • Remove the thermostat cover 1. • Remove the thermostat 2 and thermostat conector 3. THERMOSTAT INSPECTION (7-9) • Remove the ECT sensor 4. ECT SENSOR INSPECTION (7-7) • Remove the cylinder head bolts (M6) 5. •…
• Page 70
  ENGINE 3-17 • 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 71
  3-18 ENGINE • Hold the clutch sleeve hub with the special tool.  09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the washers C, D and E from the clutch sleeve hub. • Remove the wave spring washers F and clutch lifter driven cam G.
• Page 72
  ENGINE 3-19 OIL PUMP DRIVE SPROCKET • Remove the spacer 1. • Remove the oil pump drive sprocket 2 and chain 3. • Remove the thrust washer 4. GEARSHIFT SYSTEM • With the snap ring 1 and washer removed, remove the gear- shift shaft assembly 2.
• Page 73
  3-20 ENGINE • Remove the shaft 4, bearing 5 and thrust washer 6. • Remove the generator cover. • Remove the dowel pins and gasket. • Remove the starter idle gear No. 2 7 and shaft 8. CAM CHAIN/CAM CHAIN TENSIONER/CAM CHAIN GUIDE •…
• Page 74
  ENGINE 3-21 GENERATOR ROTOR AND STARTER DRIVEN GEAR • Hold the generator rotor with the special tool.  09930-44520: Rotor holder • Remove the generator rotor bolt. • Install a bolt A of suitable size to the left end of crankshaft. SUITABLE BOLT A [M12, length: 28 –…
• Page 75
  3-22 ENGINE GEAR POSITION SWITCH • Remove the gear position switch 1. CRANKCASE BREATHER (PCV) COVER • Remove the crankcase breather cover 1. • Remove the gasket 2. OIL PRESSURE SWITCH • Remove the oil pressure switch 1. OIL FILTER •…
• Page 76
  ENGINE 3-23 OIL COOLER • Remove the oil cooler 1. OIL PAN • Remove the plate 1 and oil pan. • Remove the gasket. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL STRAINER • Remove the oil strainer 2. OIL PUMP •…
• Page 77
  3-24 ENGINE • Remove the upper crankcase bolts. • Remove the lower crankcase bolts (M8). • Remove the crankshaft journal bolts (M9). • Remove the lower crankcase assembly. • Remove the dowel pins and O-ring 2. BALANCER SHAFT • Remove the balancer shaft 1 and oil seal 2. COUNTERSHAFT •…
• Page 78
  ENGINE 3-25 • Remove the C-ring 6 and bearing pin 7. CRANKSHAFT • Loosen the conrod bearing cap bolts by using a 10 mm, 12-point socket wrench, and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap. •…
• Page 79
  3-26 ENGINE • Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the piston head.

• Page 80: Engine Components Inspection And Service

  ENGINE 3-27 ENGINE COMPONENTS INSPECTION AND SERVICE  Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER •…

• Page 81: Crankcase Breather Reed Valve

  3-28 ENGINE INSPECTION • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. CRANKCASE BREATHER REED VALVE REMOVAL • Remove the crankcase breather reed valve 1 from the crank- case breather cover.

• Page 82: Camshaft

  ENGINE 3-29 CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against let- ters “IN” (for intake). CAM WEAR • Check the camshaft for wear or damage. •…

• Page 83: Camshaft Runout

  3-30 ENGINE NOTE: Do not rotate the camshaft with the plastigauge in place. • Remove the camshaft holders, and read the width of the com- pressed plastigauge with envelope scale. • This measurement should be taken at the widest part. •…

• Page 84: Cam Chain Tension Adjuster

  ENGINE 3-31 CAM CHAIN TENSION ADJUSTER INSPECTION • Holding the cam chain tension adjuster as shown, compress the plunger by turning the adjuster body until the outer circlip A fits the groove B. NOTE: * Wipe off engine oil from the plunger head and thumb so that they may not to be slippery.

• Page 85: Cam Chain Guide

  3-32 ENGINE CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guide No. 1 and No. 2. • If they are worn or damaged, replace them with the new ones. CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY •…

• Page 86
  ENGINE 3-33 CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.
• Page 87
  3-34 ENGINE VALVE STEM DEFLECTION • Lift the valve about 10 mm 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 88
  ENGINE 3-35 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 °C – 150 °C (212 °F – 302 °F) with a hot plate.  Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
• Page 89
  3-36 ENGINE • If the seat width W measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter.  Valve seat width W: Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) If the valve seat is out of specification, re-cut the seat.
• Page 90
  ENGINE 3-37 VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • Check the valve spring for proper strength by measuring its free length and also by the force required to compress it.
• Page 91
  3-38 ENGINE • Put on the valve spring retainer 2, and using the special tool 3, press down the spring, fit the cotter halves 4 to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.

• Page 92: Clutch

  ENGINE 3-39 • Apply SUZUKI SUPER GREASE “A” to the O-rings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the intake pipes. • Apply THREAD LOCK to the bolts.  99000-32050: THREAD LOCK “1342” CLUTCH CLUTCH DRIVE PLATE INSPECTION…

• Page 93: Clutch Lifter

  3-40 ENGINE CLUTCH SPRING INSPECTION • Measure the free length of each coil spring with a vernier cali- pers, and compare the length with the specified limit. • Replace all the springs if any spring is not within the limit. …

• Page 94
  ENGINE 3-41 CLUTCH LIFTER PIN ADJUSTMENT NOTE: When adjusting the clutch lifter, it is not necessary to install the clutch onto the countershaft. • Assemble the following parts into the primary driven gear assembly. (3-90 to -93) * Clutch sleeve hub * Spring washer seat, Spring washer * Clutch drive plates, Clutch driven plates * Pressure plate…

• Page 95: Oil Pump

  3-42 ENGINE WAVE SPRING WASHER INSPECTION • Measure the free height H of each wave spring washer with a vernier calipers. • If each wave spring washer height H is not within the speci- fied limit, replace it with a new one. …

• Page 96
  ENGINE 3-43 DISASSEMBLY • With holding the rotor with the special tool remove the starter clutch bolts.  09930-44520: Rotor holder • Remove the one way clutch 1 and guide 2 from the rotor. REASSEMBLY • When fitting the one way clutch 1 to the guide 2, position flange side A of one way clutch to the rotor side.

• Page 97: Generator

  3-44 ENGINE GENERATOR INSPECTION (9-10) REASSEMBLY • When installing the generator stator set bolts, tighten them to the specified torque.  Generator stator set bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) NOTE: Be sure to install the grommet 1 to the generator cover. WATER PUMP 7-11 GEARSHIFT SYSTEM…

• Page 98: Oil Pressure Regulator

  ENGINE 3-45 • Install the following parts to the gearshift shaft/gearshift arm as shown in the illustration. 1 Washer 5 Plate return spring 2 Snap ring 6 Washer 3 Gearshift shaft return spring 7 Screw 4 Gearshift cam drive plate OIL PRESSURE REGULATOR •…

• Page 99: Transmission

  3-46 ENGINE TRANSMISSION DRIVESHAFT REMOVAL (3-52) DISASSEMBLY Disassemble the countershaft and driveshaft. Pay attention to the following points: • Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2. • Slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, then remove the 2nd drive gear circlip 5.

• Page 100
  Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE “A” to it.  99000-25010: SUZUKI SUPER GREASE “A”…
• Page 101
  3-48 ENGINE TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft…

• Page 102: Cylinder

  ENGINE 3-49 CYLINDER CRANKCASE SERVICING (3-52) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set.

• Page 103: Piston And Piston Ring

  3-50 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. …

• Page 104: Piston Ring Groove Width

  ENGINE 3-51 PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings.  09900-20803: Thickness gauge 09900-20205: Micrometer (0 –…

• Page 105: Crankcase

  3-52 ENGINE CRANKCASE DRIVESHAFT AND GEARSHIFT CAM Removal • Remove the screws. • Remove the gearshift fork shaft 1, gearshift cam 2 and gearshift forks 3. • Remove the spacer 4. • Remove the driveshaft left bearing dust seal 5. •…

• Page 106
  ENGINE 3-53 • Remove the driveshaft assembly 8. GEARSHIFT FORK-TO-GROOVE CLEARANCE • Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. • The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. …
• Page 107
  3-54 ENGINE BEARING AND DUST SEAL Inspection • Inspect the gearshift cam bearing 1 for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Inspect the gearshift cam bearing 2, gearshift shaft bearings 3 (LH) and 4 (RH) for abnormal noise and smooth rotation while they are in the crankcase.
• Page 108
  ENGINE 3-55 • Inspect the driveshaft left bearing dust seal for wear and dam- age. • Replace the dust seal if there is anything unusual. Removal • Remove the gearshift cam bearing with the special tools.  09923-74511: Bearing remover 09930-30104: Sliding shaft …
• Page 109
  • Install new oil seal with the special tool.  09913-70210: Bearing installer set (22) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the bearing with the special tool.
• Page 110
   99000-32050: THREAD LOCK “1342”  Bearing retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the dowel pin. • Apply SUZUKI SUPER GREASE “A” to the O-ring and fit the driveshaft left bearing case 6.  Replace the O-ring with a new one.
• Page 111
    Driveshaft left bearing case bolt: 12 N·m (1.2 kgf-m, 8.7 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip and O-ring. • Apply THREAD LOCK to the bolts and tighten them to the specified torque.
• Page 112
  ENGINE 3-59 • Remove the oil jet 2 (for transmission) from the lower crank- case. • Remove the oil jet 3 (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • Check the oil jets for clogging. •…
• Page 113
  3-60 ENGINE • Install the oil jet (for transmission). • Apply engine oil to the O-ring.  Use new O-ring to prevent oil pressure leakage. • Install the oil jet (for cam chain tension adjuster). PLUG Removal • Remove the oil gallery plugs 1 and 2. •…
• Page 114
  • Apply engine coolant to the O-rings of the water jacket plugs 5 and 6.  99000-99032-11X: SUZUKI COOLANT (Except USA) • Tighten each plug to the specified torque.  1 Oil gallery plug: 10 N·m (1.0 kgf-m, 7.0 lb-ft) 2 Oil gallery plug: 22 N·m (2.2 kgf-m, 16.0 lb-ft)

• Page 115: Balancer Shaft

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

• Page 116
  ENGINE 3-63 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge.  Balancer shaft journal oil clearance: Standard: 0.028 –…
• Page 117
  3-64 ENGINE INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part A first and press the other end.  Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.

• Page 118: Crankshaft And Conrod

  ENGINE 3-65 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 119
  3-66 ENGINE CONROD-BIG END BEARING INSPECTION • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. CONROD-BIG END BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown.
• Page 120
  ENGINE 3-67 • 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 Crank pin O.D. B Code Green Black Brown Conrod I.D A Black Brown…
• Page 121
  3-68 ENGINE  Crank pin O.D. Code O.D. specification 32.992 – 33.000 mm (1.2989 – 1.2992 in) 32.984 – 32.992 mm (1.2986 – 1.2989 in) 32.976 – 32.984 mm (1.2983 – 1.2986 in)  09900-20202: Micrometer (25 – 50 mm) …

• Page 122: Crankshaft Journal Bearing

  ENGINE 3-69 CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and lower crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown.  09900-22301: Plastigauge  Never rotate the crankshaft when a piece of plasti- gauge is installed.

• Page 123
  3-70 ENGINE • Check the corresponding crankcase journal I.D. code number A, “A”, “B” or “C” which is stamped on the rear of upper crankcase. • Check the corresponding crankshaft journal O.D. code num- ber B, “A”, “B” or “C” which is stamped on the crankshaft. …
• Page 124
  ENGINE 3-71  Crankshaft journal O.D. specification Code O.D. specification 31.994 – 32.000 mm (1.2596 – 1.2598 in) 31.988 – 31.994 mm (1.2594 – 1.2596 in) 31.982 – 31.988 mm (1.2591 – 1.2594 in)  09900-20202: Micrometer (25 – 50 mm) …

• Page 125: Crankshaft Thrust Bearing

  3-72 ENGINE 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. L: Left-side thrust bearing R: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.

• Page 126
  ENGINE 3-73  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 127: Engine Reassembly

  3-74 ENGINE ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. •…

• Page 128
  ENGINE 3-75 • 1st ring 4 and 2nd ring 3 have letters “IR” and “R” marked on one side. Be sure to bring the marked side upward when fitting them to the piston. • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
• Page 129
  3-76 ENGINE • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent C of each piston head must be brought to the exhaust side.  Be careful not to damage the cylinder wall and piston jet by the conrod.
• Page 130
  ENGINE 3-77 • Set the crankshaft to the conrods and upper crankcase. • Apply engine oil to the crank pin and bearing surface.  Be sure to clean the conrod big end. • When fitting the conrod cap, make sure that I.D. code A on each conrod faces intake side.
• Page 131
  3-78 ENGINE • Insert the right and left thrust bearings with oil groove B fac- ing the crank web. NOTE: Right thrust bearing has green painting. BALANCER SHAFT • Install the thrust washers 1, 2 and oil seal 3. • Apply a MOLYBDENUM OIL SOLUTION to each balancer shaft journal and bearing lightly.
• Page 132
  ENGINE 3-79 • Turn the bearing to fit the bearing dowel pin in the position A. • Install the dowel pin and oil seal 3. • Install the gearshift shaft and fork 4, bushing 5 and retainer…
• Page 133
  • Install the dowel pins. • Install the dowel pins, O-ring 1 and cap 2.  Replace the O-ring with a new one. • Apply SUZUKI BOND to the mating surface of the lower crankcase.  99000-31110: SUZUKI BOND “1215” (or equivalent bond)
• Page 134
  ENGINE 3-81 • Tighten the crankshaft journal bolts (M9) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure in the following two steps.  Crankshaft journal bolt: (M9) Initial : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Final : 50°…
• Page 135
   Oil pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) OIL STRAINER AND OIL PRESSURE REGULATOR • Apply SUZUKI SUPER GREASE “A” to the O-rings and press in the oil strainer and oil pressure regulator to the crankcase.  99000-25010: SUZUKI SUPER GREASE “A”…
• Page 136
   99000-31140: 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 to the hole of thread end. OIL COOLER • Apply SUZUKI SUPER GREASE “A” to the O-ring and install the oil cooler.
• Page 137
  • Install the crankcase breather cover 2.  Crankcase breather cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) GEAR POSITION SWITCH • Apply SUZUKI SUPER GREASE “A” to the O-ring. NOTE: Align the gear position switch pin A with the gearshift cam hole …
• Page 138
  ENGINE 3-85 WATER PUMP • Apply SUZUKI SUPER GREASE “A” to the O-ring.  Use a new O-ring to prevent oil leakage.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the water pump. NOTE: Set the water pump shaft end A to the oil pump shaft B as shown.
• Page 139
  3-86 ENGINE GENERATOR ROTOR AND STARTER DRIVEN GEAR • Degrease the tapered portion A of generator rotor and also the crankshaft B. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. • Install the generator rotor onto the crankshaft. •…
• Page 140
  STARTER IDLE GEAR • Install the starter idle gear No. 2 1 and shaft 2. • Apply SUZUKI BOND lightly to the mating surfaces A at the parting line between the upper and lower crankcases.  99000-31140: SUZUKI BOND “1207B”…
• Page 141
  • Install the starter idle gear No. 1 shaft 5, thrust washer 6, bearing 7, starter idle gear No. 1 8, washer 9, and spring washer 0. • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •…
• Page 142
  ENGINE 3-89 • Install the gearshift cam stopper plate 5. NOTE: Align the gearshift cam pin B with the gearshift cam stopper plate hole C . • Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque. …
• Page 143
  3-90 ENGINE • Install the oil pump drive sprocket 1 to the countershaft. NOTE: Teeth A on the sprocket must face the clutch side. • Pass the chain between the oil pump drive and driven sprock- ets. CLUTCH • Install the primary driven gear assembly 1. NOTE: * Before assembling the clutch, adjust the clutch lifter.
• Page 144
  ENGINE 3-91 • Install the clutch sleeve hub assembly onto the countershaft. • Install the washer 9 and spring washer 0. NOTE: * Before installing the washer 9 , visually inspect the washer surface for wear and damage. If necessary, replace it with a new one.
• Page 145
  3-92 ENGINE • Install the clutch push rod C into the countershaft. • Install the clutch push piece D, bearing E and thrust washer F to the countershaft. NOTE: Thrust washer F is located between the pressure plate and bearing E . •…
• Page 146
  ENGINE 3-93 *1: Direction of outside *2: Paint DRIVE PLATE: a No. 2 Drive plate ..1 pc. [Black paint/I.D. 111 mm (4.4 in)] b No. 1 Drive plate ..7 pcs. [Purple paint/I.D. 111 mm (4.4 in)] c No. 3 Drive plate ..1 pc. [NIL/I.D. 118 mm (4.6 in)] NOTE: No.3 drive plate can be distinguished by the inside diameter (I.D.).
• Page 147
  3-94 ENGINE CLUTCH COVER • Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.  99000-31140: SUZUKI BOND “1207B” • Install new gasket 1 and dowel pin.  Use a new gasket to prevent oil leakage.
• Page 148
  ENGINE 3-95 • Place the cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Tighten the cylinder head bolts (M10) in the following four-step. Step 1: • Tighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagonally.
• Page 149
  3-96 ENGINE • Apply engine coolant to the O-ring. • Install the thermostat conector 3.  Use a new O-ring to prevent engine coolant leakage.  Thermostat conector bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the thermostat 4. NOTE: The jiggle valve A of thermostat faces upside.
• Page 150
  ENGINE 3-97 The camshafts are identified by the embossed letters. • Before replacing the camshafts on cylinder head, apply MOLYBDENUM OIL SOLUTION to their journals and cam faces. • Apply a MOLYBDENUM OIL SOLUTION to the camshaft jour- nal holders. …
• Page 151
  3-98 ENGINE • Install the dowel pins. • Install O-rings 3 to the camshaft journal holders.  Replace the O-rings with new ones. • Install the camshaft journal holders. NOTE: * Each camshaft journal holder is identified with an embossed letter.
• Page 152
  ENGINE 3-99 • Tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque.  Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)  The camshaft journal holder bolts are made of a spe- cial material and much superior in strength, compared with other types of high strength bolts.
• Page 153
  3-100 ENGINE • Fit a new gasket 1.  Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster.  Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Turn the crankshaft approx. 180° counterclockwise to make 180˚…
• Page 154
  ENGINE 3-101 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Page 155
   Replace the gaskets with new ones. • Install a new gasket to the cylinder head cover. • Apply SUZUKI BOND to the cam end cap points of the gasket as shown.  99000-31140: SUZUKI BOND “1207B” …
• Page 156
  • Tighten the head cover bolts to the specified torque.  Head cover bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft) STARTER MOTOR • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •…
• Page 157
  FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING …………..4- 3 ELECTRICAL PARTS …………….4- 3 FUSE………………….. 4- 4 ECM/VARIOUS SENSORS …………..4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE……4- 6 USING THE MULTI-CIRCUIT TESTER……….4- 9 FI SYSTEM TECHNICAL FEATURES…………4-10 INJECTION TIME (INJECTION VOLUME) ……….
• Page 158
  FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION……4-75 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION ……. 4-77 “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION….4-80 “C41”…

• Page 159: Precautions In Servicing

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

• Page 160: Fuse

  FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.

• Page 161
  FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

• Page 162: Electrical Circuit Inspection Procedure

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

• Page 163
  FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
• Page 164
  FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.

• Page 165: Using The Multi-Circuit Tester

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

• Page 166: Fi System Technical Features

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

• Page 167: Compensation Of Injection Time (Volume)

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

• Page 168: Fi System Parts Location

  4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A Throttle position sensor (TPS) B Secondary throttle position sensor (STPS) C Secondary throttle valve actuator (STVA) D Intake air pressure sensor (IAPS) E Exhaust control valve actuator (EXCVA) F HO2 sensor (For E-02, 19) G Crankshaft position sensor (CKPS) H Fuel pump relay (FP relay) I Fuel pump (FP)

• Page 169
  FI SYSTEM DIAGNOSIS 4-13 J Cooling fan relay K Cooling fan L Intake air temperature sensor (IATS) M PAIR control solenoid valve N Camshaft position sensor (CMPS) O Ignition coil (IG COIL) P Secondary fuel injector Q Primary fuel injector R Engine coolant temperature sensor (ECTS) S Speed sensor T Atmospheric pressure sensor (APS)

• Page 170: Fi System Wiring Diagram

  4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM…

• Page 171: Ecm Terminal

  FI SYSTEM DIAGNOSIS 4-15 ECM TERMINAL (Black) (Gray) ECM couplers TERMINAL TERMINAL CIRCUIT CIRCUIT STVA signal (STVA. 2A) STVA signal (STVA. 2B) STVA signal (STVA. 1A) STVA signal (STVA. 1B) EXCVA power (MO–) STP sensor signal (STP) Ignition switch signal EXCVA power (MO+) [For E-03, 28, 33] EXCVA position sensor (MPS)

• Page 172
  4-16 FI SYSTEM DIAGNOSIS (Black) (Gray) ECM couplers TERMINAL TERMINAL CIRCUIT CIRCUIT — — — — — — Tachometer — Fuel pump relay (FP Relay) — Immobilizer communication Immobilizer communication [For E-02, 19, 24] [For E-02, 19, 24] HO2 sensor heater (OXH) Mode select switch [For E-02, 19] Starter relay…

• Page 173: Self-Diagnosis Function

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

• Page 174: Dealer Mode

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

• Page 175
  FI SYSTEM DIAGNOSIS 4-19 CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air temperature sensor (IATS) Atmospheric pressure sensor (APS) Tip-over sensor (TOS) Ignition signal #1 (IG coil #1)

• Page 176: Tps Adjustment

  4-20 FI SYSTEM DIAGNOSIS TPS ADJUSTMENT 1. Adjust the engine rpm to 1 200 r/min. (2-14) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, remove the aircleaner box and lift up the throttle body.

• Page 177: Fail-Safe Function

  FI SYSTEM DIAGNOSIS 4-21 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY CMP sensor When camshaft position signal has…

• Page 178
  4-22 FI SYSTEM DIAGNOSIS STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY Secondary injection signal #1 Fuel-cut (secondary side) — “YES” #2, #3 & #4 cylinders can run. #2 Fuel-cut (secondary side) — “YES” #1, #3 & #4 cylinders can run. #3 Fuel-cut (secondary side) —…

• Page 179: Fi System Troubleshooting

  FI SYSTEM DIAGNOSIS 4-23 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

• Page 180: Visual Inspection

  4-24 FI SYSTEM DIAGNOSIS MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (…

• Page 181: Self-Diagnostic Procedures

  FI SYSTEM DIAGNOSIS 4-25 SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

• Page 182: Use Of Sds Diagnostic Procedures

  4-26 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSTIC PROCEDURES * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

• Page 183: Use Of Sds Diagnosis Reset Procedure

  FI SYSTEM DIAGNOSIS 4-27 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.

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

  4-28 FI SYSTEM DIAGNOSIS SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.

• Page 185: Malfunction Code And Defective Condition

  FI SYSTEM DIAGNOSIS 4-29 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

• Page 186
  4-30 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated.
• Page 187
  FI SYSTEM DIAGNOSIS 4-31 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated.
• Page 188
  4-32 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM HO2 sensor HO2 sensor output voltage is not input HO2 sensor circuit open or (For E-02, to ECM during engine operation and shorted to ground running condition. (Sensor voltage <…

• Page 189: C11″ (P0340) Cmp Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-33 “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CMP sensor and rotor tip •…

• Page 190
  4-34 FI SYSTEM DIAGNOSIS 6) Under this condition, if a suitable screwdriver touching the pick-up surface of the CMP sensor is moved, the tester read- ing voltage changes (0.8 V and less ↔ 4.3 V and more). Is the voltage OK? ECM couplers (Harness side) •…

• Page 191: C12″ (P0335) Ckp Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-35 “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip •…

• Page 192
  4-36 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground.  CKP sensor continuity: ∞ Ω (Infinity) (B – Ground) (G – Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.
• Page 193
  FI SYSTEM DIAGNOSIS 4-37 Is the voltage OK? ECM couplers (Harness side) • G/W or O/BI wire open or shorted to ground. (Black) (Gray) • Loose or poor contacts on the CKP sensor cou- pler or ECM coupler (terminal D or U). •…

• Page 194: C13″ (P0105-H/L) Iap Sensor Circuit Malfunction

  4-38 FI SYSTEM DIAGNOSIS “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage < 4.85 V •…

• Page 195
  FI SYSTEM DIAGNOSIS 4-39 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the R wire A and B/Br wire B.
• Page 196
  4-40 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between G/B wire C and terminal 9. If OK, then check the continuity between B/Br wire B and ter- minal S.  IAPS lead wire continuity: Continuity () …
• Page 197
  FI SYSTEM DIAGNOSIS 4-41 7) Disconnect the ECM coupler. Check the continuity between R wire A and terminal A. 9) Also, check the continuity between G/B wire C and terminal  IAPS lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Gray) (Black)
• Page 198
  4-42 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 –…
• Page 199
  FI SYSTEM DIAGNOSIS 4-43 Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg) 3.1 – 3.6 2 000 2 001 2.8 – 3.4 5 000 1 524 5 001…

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

  4-44 FI SYSTEM DIAGNOSIS “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •…

• Page 201
  FI SYSTEM DIAGNOSIS 4-45  TP sensor input voltage: 4.5 – 5.5 V (+ R – — Ground) (+ R – — B/Br)  09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. •…
• Page 202
  4-46 FI SYSTEM DIAGNOSIS Is the continuity OK? Go to Step 2. P/B wire shorted to VCC, or B/Br wire open 9) After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 1 (When indicating P0120-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank.
• Page 203
  FI SYSTEM DIAGNOSIS 4-47 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Install the test harness to the TP sensor. 4) Check the continuity between terminal A and ground.  TP sensor continuity: ∞ Ω (Infinity) (Terminal A –…
• Page 204
  4-48 FI SYSTEM DIAGNOSIS Step 3 1) Connect the TP sensor coupler 1 to the test harness. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the coupler (between + P/B and — B/Br) by turning the throttle grip. …

• Page 205: C15″ (P0115-H/L) Ect Sensor Circuit Malfunction

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

• Page 206
  4-50 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-H:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
• Page 207
  FI SYSTEM DIAGNOSIS 4-51 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 4) Disconnect the ECT sensor coupler.
• Page 208
  4-52 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance.  ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal)  09900-25008: Multi-circuit tester set …

• Page 209: C21″ (P0110-H/L) Iat Sensor Circuit Malfunction

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

• Page 210
  4-54 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-H:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
• Page 211
  FI SYSTEM DIAGNOSIS 4-55 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
• Page 212
  4-56 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance.  IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Is the resistance OK? ECM couplers (Harness side) •…

• Page 213: C22″ (P1450-H/L) Ap Sensor Circuit Malfunction

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

• Page 214
  4-58 FI SYSTEM DIAGNOSIS 4) Disconnect the AP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the R wire A and B/Br wire B.
• Page 215
  FI SYSTEM DIAGNOSIS 4-59 6) Disconnect the ECM coupler. 7) Check the continuity between G/Y wire C and terminal P. If OK, then check the continuity between B/Br wire B and ter- minal S.  APS lead wire continuity: Continuity () …
• Page 216
  4-60 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. Check the continuity between R wire A and terminal A. 9) If OK, then check the continuity between G/Y wire C and ter- minal P.  APS lead wire continuity: Continuity () …
• Page 217
  FI SYSTEM DIAGNOSIS 4-61 Step 3 1) Remove the AP sensor. 2) Connect the vacuum pump gauge to the vacuum port of the AP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 – 5.0 V) and connect — terminal to the ground terminal 2 and + terminal to the VCC terminal 3.
• Page 218
  4-62 FI SYSTEM DIAGNOSIS Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg) 3.1 – 3.6 2 000 2 001 2.8 – 3.4 5 000 1 524 5 001…

• Page 219: C23″ (P1651-H/L) To Sensor Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-63 “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON.

• Page 220
  4-64 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-H:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (8-8) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
• Page 221
  FI SYSTEM DIAGNOSIS 4-65 Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (8-8) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.

• Page 222: C24″ (P0351), «C25» (P0352), «C26» (P0353) Or «C27» (P0354) Ignition System Malfunction

  4-66 FI SYSTEM DIAGNOSIS Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage between B and B/Br wires. …

• Page 223: C28″ (P1655) Stv Actuator Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-67 “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. •…

• Page 224
  4-68 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground.  STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between terminal A and terminal B) and (between terminal C and terminal …
• Page 225
  FI SYSTEM DIAGNOSIS 4-69 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. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.

• Page 226: C29″ (P1654-H/L) Stp Sensor Circuit Malfunction

  4-70 FI SYSTEM DIAGNOSIS “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is •…

• Page 227
  FI SYSTEM DIAGNOSIS 4-71 Step 1 (When indicating P1654-H:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
• Page 228
  4-72 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1654-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
• Page 229
  FI SYSTEM DIAGNOSIS 4-73 Step 2 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Disconnect the STP sensor coupler. 4) Check the continuity between each terminal and ground.  STP sensor continuity: ∞ Ω (Infinity) (Terminal –…
• Page 230
  4-74 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between + Y wire and — B wire) by turning the secondary throttle valve (close and open) with a finger.

• Page 231: C31″ (P0705) Gp Switch Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-75 “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short Switch voltage is not within the following range. • Gear Position switch malfunction Switch voltage >…

• Page 232
  4-76 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM couplers (Harness side) • P wire open or shorted to ground (Black) (Gray) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.

• Page 233: C32″ (P0201), «C33» (P0202), «C34» (P0203) Or «C35» (P0204) Primary Fuel Injector Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-77 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short interrupted by 4 times or more continuously. •…

• Page 234
  4-78 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground.  Injector continuity: ∞ Ω (Infinity)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. Replace the injector with a new one.
• Page 235
  FI SYSTEM DIAGNOSIS 4-79 Is the voltage OK? ECM couplers (Harness side) • Gr/W wire open or shorted to ground, or poor h (Black) (Gray) connection (#1 cylinder side) • Gr/B wire open or shorted to ground, or poor g connection (#2 cylinder side) •…

• Page 236: C36″ (P1764), «C37» (P1765), «C38» (P1766) Or «C39» (P1767) Secondary Fuel Injector Circuit Malfunction

  4-80 FI SYSTEM DIAGNOSIS “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Some failure exists in the fuel injector signal in a • Injector circuit open or short high load, high revolution condition. •…

• Page 237
  FI SYSTEM DIAGNOSIS 4-81 5) If OK, then check the continuity between each terminal and ground.  Injector continuity: ∞ Ω (Infinity)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. Replace the injector with a new one.
• Page 238
  4-82 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM couplers (Harness side) • Lg wire open or shorted to ground, or poor x (Black) (Gray) connection (#1 cylinder side) • Lg/W wire open or shorted to ground, or poor w connection (#2 cylinder side) •…

• Page 239: C41″ (P0230-H/L) Fp Relay Circuit Malfunction

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

• Page 240
  4-84 FI SYSTEM DIAGNOSIS Is the FP relay OK? ECM couplers (Harness side) • Y/B or O/W wire open or short or poor ] con- (Black) (Gray) nection • Y/R or R/Bl wire open, shorted or poor W con- nection •…
• Page 241
  FI SYSTEM DIAGNOSIS 4-85 Step 1 (When indicating P0230-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (5-7) Is the FP relay OK? ECM couplers (Harness side) •…

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

  4-86 FI SYSTEM DIAGNOSIS “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION 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 243: C44″ (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction (For E-02, 19)

  FI SYSTEM DIAGNOSIS 4-87 “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (For E-02, 19) DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0130) to ECM during engine operation and •…

• Page 244
  4-88 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. Check the continuity between W/G wire A and terminal B. 9) Also, check the continuity between B/Br wire B and terminal S.  HO2S lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set …
• Page 245
  FI SYSTEM DIAGNOSIS 4-89 Is the voltage OK? ECM couplers (Harness side) • W/G wire or B/Br wire open or shorted to ground, or poor B or S connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •…
• Page 246
  4-90 FI SYSTEM DIAGNOSIS Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probe to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W (O/W) wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.

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

  FI SYSTEM DIAGNOSIS 4-91 “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the • EXCVA maladjusted EXCV actuator. • EXCVA circuit open or short EXCVA position sensor voltage low or •…

• Page 248
  4-92 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-H:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (5-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
• Page 249
  FI SYSTEM DIAGNOSIS 4-93 Step 1 (When indicating P1657-L:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (5-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
• Page 250
  4-94 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1658:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (5-8) 3) Check the EXCVA motor coupler for loose or poor contacts. Is the contacting OK? Go to Step 6. Loose or poor contacts on the EXCV motor cou- pler 4) After repairing the trouble, clear the DTC using SDS tool.
• Page 251
  FI SYSTEM DIAGNOSIS 4-95 Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Y wire and ground.  Position sensor continuity: ∞ Ω (Infinity) 3) If OK, then measure the position sensor resistance. 4) Connect the position sensor coupler. 5) Set the EXCVA to adjustment position.
• Page 252
  4-96 FI SYSTEM DIAGNOSIS Step 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler. 3) Measure the position sensor output voltage at fully close posi- tion and fully open position. 4) Insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler.
• Page 253
  FI SYSTEM DIAGNOSIS 4-97 Step 5 1) If the position sensor output voltage is 0.5 V and less at fully close position, adjust the output voltage to specified by turn- ing out the No. 1 cable adjuster 1. 2) Repeat the above procedure (Step 4) until the out put voltage becomes specified value.
• Page 254
  4-98 FI SYSTEM DIAGNOSIS Step 6 1) Turn the ignition switch OFF. 2) Disconnect the motor lead wire coupler of the EXCVA. 3) Apply 12 V to the terminal and check the operation of EXCVA. 12 V 4) Then, swap the wires supplied 12 V and check the operation of EXCVA.
• Page 255
  FI SYSTEM DIAGNOSIS 4-99 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. 4) Click each button 2. At this time, if an operation sound is heard from the EXCVA, the function is normal.

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

  4-100 FI SYSTEM DIAGNOSIS “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction •…

• Page 257
  FI SYSTEM DIAGNOSIS 4-101 Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground.  PAIR valve voltage: Battery voltage (+ O/W – — Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? ECM couplers (Harness side) •…
• Page 258
  4-102 FI SYSTEM DIAGNOSIS 4) Click each button 2. At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.

• Page 259: C60″ (P0480) Cooling Fan Relay Circuit Malfunction

  FI SYSTEM DIAGNOSIS 4-103 “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short • ECM malfunction Engine stop Side-stand Ignition Cooling fan switch relay switch…

• Page 260
  4-104 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4) Click the operate button 2. At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal.

• Page 261: Sensors

  FI SYSTEM DIAGNOSIS 4-105 SENSORS CMP SENSOR INSPECTION The camshaft position sensor is installed on the cylinder head cover. (4-33) CMP SENSOR REMOVAL AND INSTALLATION • Remove the CMP sensor. (3-26) • Install the CMP sensor in the reverse order of removal. …

• Page 262: Ect Sensor Inspection

  4-106 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the cylin- der head. (4-49) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor. (7-7) • Install the ECT sensor in the reverse order of removal. …

• Page 263: Stp Sensor Adjustment

  FI SYSTEM DIAGNOSIS 4-107 STP SENSOR ADJUSTMENT • Adjust the STP sensor. (5-22) HO2 SENSOR INSPECTION (For E-02, 19) The heated oxygen sensor is installed to the exhaust pipe. (4-87) HO2 SENSOR REMOVAL AND INSTALLATION • Remove the right under cowling. (8-5) •…

• Page 264
  FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM…………….5- 2 FUEL SYSTEM………………… 5- 3 FUEL TANK LIFT-UP …………….5- 3 FUEL TANK REMOVAL……………. 5- 4 FUEL TANK INSTALLATION …………… 5- 4 FUEL PRESSURE INSPECTION …………5- 4 FUEL PUMP INSPECTION …………..

• Page 265: Fuel Delivery System

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

• Page 266: Fuel System

  FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seats. (8-7 and -8) • Take out the fuel tank prop stay 1. • Remove the fuel tank bolt. • Lift and support the fuel tank with the fuel tank prop stay.

• Page 267: Fuel Tank Removal

  FUEL SYSTEM AND THROTTLE BODY FUEL TANK REMOVAL • Lift and support the fuel tank. (above) • Disconnect the fuel pump lead wire coupler 1. • Disconnect the fuel tank breather hose 2 and fuel tank drain hose 3. • Place a rag under the fuel feed hose 4 and disconnect the fuel feed hose.

• Page 268: Fuel Pump Inspection

  FUEL SYSTEM AND THROTTLE BODY • Install the special tools between the fuel tank and fuel delivery pipe.  09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77331: Oil pressure gauge 09915-74521: Oil pressure gauge hose Turn the ignition switch ON and check the fuel pressure. …

• Page 269: Fuel Discharge Amount Inspection

  FUEL SYSTEM AND THROTTLE BODY FUEL DISCHARGE AMOUNT INSPECTION  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Lift and support the fuel tank. (5-3) • Turn the ignition switch OFF. • Disconnect the battery — lead wire. •…

• Page 270: Fuel Pump Relay Inspection

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

• Page 271: Fuel Pump And Fuel Filter Removal

  FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION  1 Fuel level gauge 5 Holder 2 Fuel pump case/Fuel filter cartridge 6 Fuel mesh filter ITEM N·m kgf-m lb-ft 3 Fuel pump 7 O-ring 4 Rubber cushion A Fuel pump mounting bolt…

• Page 272
  FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the fuel tank. (5-4) • Remove the fuel pump assembly 1 by removing its mounting bolts diagonally.  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the nuts. •…

• Page 273: Fuel Mesh Filter Inspection And Cleaning

  5-10 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel mesh filter 7. • Remove the fuel pump 8 from the fuel pump case/fuel filter cartridge 9. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

• Page 274
  • Be sure to connect the wires to the proper terminals. A (Bl) ..+ terminal for fuel pump B (R)..+ terminal for fuel level gauge • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it.  99000-25010: SUZUKI SUPER GREASE “A”…
• Page 275
  5-12 FUEL SYSTEM AND THROTTLE BODY • When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers.  Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: Apply a small quantity of the THREAD LOCK to the thread por- tion of fuel pump mounting bolts.

• Page 276: Throttle Body

  FUEL SYSTEM AND THROTTLE BODY 5-13 THROTTLE BODY CONSTRUCTION Only for E-33 1 TP sensor 8 Fast idle adjusting screw 2 STP sensor 9 Throttle stop screw  3 STVA 0 Vacuum hose 4 Fuel delivery pipe A Fuel delivery pipe mounting screw ITEM N·m kgf-m lb-ft 5 O-ring…

• Page 277: Air Cleaner Box Removal And Installation

  5-14 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX REMOVAL AND INSTAL- LATION REMOVAL • Lift and support the fuel tank. (5-3) • Disconnect the fuel pump relay 1, cooling fan relay 2 and IAT sensor lead wire coupler 3. •…

• Page 278: Throttle Body Removal

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

• Page 279: Throttle Body Disassembly

  5-16 FUEL SYSTEM AND THROTTLE BODY • Remove the throttle body assembly. THROTTLE BODY DISASSEMBLY  Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. •…

• Page 280
  FUEL SYSTEM AND THROTTLE BODY 5-17 • Remove the TP sensor and STP sensor with the special tool.  09930-11950: Torx wrench NOTE: Prior to disassembly, mark the each sensor’s original position with a paint or scribe for accurate reinstallation. …

• Page 281: Throttle Body Cleaning

  5-18 FUEL SYSTEM AND THROTTLE BODY 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 282: Throttle Body Reassembly

  * Apply thin coat of the engine oil to the O-ring. * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary.  99000-25010: SUZUKI SUPER GREASE “A”…

• Page 283
  5-20 FUEL SYSTEM AND THROTTLE BODY • Install the fuel injector 5 by pushing it straight to the delivery pipe 6. NOTE: Align the boss E of the injector with the groove F of the delivery pipe.  Never turn the injector while pushing it. •…

• Page 284: Throttle Body Installation

  FUEL SYSTEM AND THROTTLE BODY 5-21 THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector.

• Page 285: Stp Sensor Adjustment

  5-22 FUEL SYSTEM AND THROTTLE BODY STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor output voltage and adjust the STP sensor position as follows: • Remove the air cleaner box . (5-14) • Loosen the throttle body clamp screws at the intake pipe side. •…

• Page 286: Fuel Injector Removal

  FUEL SYSTEM AND THROTTLE BODY 5-23 FUEL INJECTOR REMOVAL • Remove the air cleaner box. (5-14) • With battery negative cable disconnected, disconnect the injector couplers. • Remove the fuel delivery pipe assemblies. (5-16) • Remove the primary and secondary fuel injectors #1, #2, #3 and #4.

• Page 287: Fast Idle

  5-24 FUEL SYSTEM AND THROTTLE BODY FAST IDLE The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.

• Page 288
  FUEL SYSTEM AND THROTTLE BODY 5-25 • Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened. Example: TP sensor output voltage with the STV fully open Minus TP sensor output voltage at idle is 0.030 V STV fully open 1.155 V Idle…

• Page 289: Throttle Valve Synchronization

  5-26 FUEL SYSTEM AND THROTTLE BODY THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. Step 1 • Lift and support the fuel tank. (5-3) • Start up the engine and run it in idling condition for warming up. •…

• Page 290: Throttle Position Sensor (Tps) Setting

  FUEL SYSTEM AND THROTTLE BODY 5-27 Step 3 • Turn in all the idle air screws to the complete close position. • Check for difference of vacuum between #1 and #2. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower.

• Page 291
  EXHAUST SYSTEM EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM………………6- 2 EXHAUST CONTROL SYSTEM …………6- 2 OPERATION………………6- 3 EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)……….6- 4 EXCVA REMOVAL…………….6- 4 EXCVA PULLEY INSPECTION…………. 6- 5 EXCVA INSTALLATION …………… 6- 5 EXCVA INSPECTION…………….

• Page 292: Exhaust System

  EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exhaust control system (EXCS) consists of the exhaust control valve (EXCV), exhaust control valve actuator (EXCVA) and exhaust control valve cables (EXCV cables). EXCV is installed the exhaust pipes. EXCVA is mounted on the right side of the seat rail. The EXCV is oper- ated by the EXCVA via the cables.

• Page 293: Operation

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

• Page 294: Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)

  EXHAUST SYSTEM EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA REMOVAL • Turn the ignition switch OFF. • Remove the frame cover. (8-8) • Connect the special tool (Mode select switch) to the dealer mode coupler. (4-18) •…

• Page 295: Excva Pulley Inspection

  EXHAUST SYSTEM • Hold the EXCVA pulley with an adjustable wrench, and loosen the pulley mounting bolt.  * When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged. * Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA.

• Page 296: Excva Inspection

  EXHAUST SYSTEM • Tighten the EXCVA mounting bolts to the specified torque.  EXCVA mounting bolt: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft) • Turn in the two cable adjusters fully. • Connect the No.1 cable 1 (01H0CL) and No.2 cable 2 (01H0OP) to the EXCVA pulley.

• Page 297: Excv Cable Replacement

  EXHAUST SYSTEM EXCV CABLE REPLACEMENT • Lift and support the fuel tank. (5-3) • Check the EXCVA to adjustment position. (6-4)  Before disconnecting the EXCV cables, be sure to set the EXCVA to the ADJUSTMENT setting position. • Disconnect the EXCV cables from the EXCVA pulley. (6-4) •…

• Page 298: Excva Adjustment

  EXHAUST SYSTEM • Connect the No.1 cable 1 and No.2 cable 2 to the EXCVA pulley. No. 1 cable • Loosen the lock-nut 9 and turn the No.2 cable adjuster 0 in or out until the thread length D becomes 11.0 – 12.0 mm (0.43 –…

• Page 299
  EXHAUST SYSTEM • To set the EXCV to fully close position, apply 12 V to A and B terminals. Battery + terminal–– A (Pink lead wire) terminal Battery — terminal–– B (Gray lead wire) terminal  To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully close position.

• Page 300: Excv/Exhaust Pipe, Muffler Removal

  6-10 EXHAUST SYSTEM Measure the position sensor output voltage at fully open posi- tion.  Position sensor output voltage EXCV is fully open: 3.7 output voltage 4.5 (V) (+ Yellow – — B/Br) If the measured voltage is more than specification, adjust the No.2 cable adjuster as follows: •…

• Page 301
  EXHAUST SYSTEM 6-11 • Loosen the exhaust pipe connector bolt 5. • Remove the muffler mounting bolts 6. • Loosen the exhaust pipe bolts 7. • Remove the muffler body A. • Remove the exhaust pipe bolts 7. • Remove the exhaust pipe B. NOTE: When an exhaust pipe separates, not to throw or drop, have by hand and remove carefully.

• Page 302: Excv Inspection

  6-12 EXHAUST SYSTEM EXCV INSPECTION • Turn the EXCV by hand and check that it moves smoothly. • If it does not move smoothly, replace the EXCV together with the exhaust pipe. • Decarbonize the EXCV if necessary.  * Do not attempt to disassemble the EXCV. * The EXCV is available only as the exhaust pipe assembly.

• Page 303
  EXHAUST SYSTEM 6-13 • Tighten the radiator mounting bolts to the specified torque.  Radiator mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the EXCV cables. (6-7)
• Page 304
  6-14 EXHAUST SYSTEM * When adjusting the No. 1 and No. 2 cables, the cable slots of EXCVA pulley must be located to adjustment position. * Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA.
• Page 305
  COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ………………7- 2 COOLING CIRCUIT ………………7- 3 COOLING CIRCUIT INSPECTION…………7- 3 RADIATOR AND WATER HOSES ………….. 7- 4 RADIATOR REMOVAL …………….. 7- 4 RADIATOR CAP INSPECTION…………. 7- 4 RADIATOR INSPECTION AND CLEANING………

• Page 306: Engine Coolant

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

• Page 307: Cooling Circuit

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

• Page 308: Radiator And Water Hoses

  COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowlings. (8-5) • Drain the engine coolant. (2-17) • Remove the radiator assembly. (3-4) • Remove the reservoir tank 1, cooling fan 2 from the radia- tor.

• Page 309: Radiator Installation

  COOLING AND LUBRICATION SYSTEM Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. RADIATOR INSTALLATION • Install the cooling fan.  Cooling fan mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) •…

• Page 310: Cooling Fan

  COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL (7-4) INSPECTION • Remove the right under cowling. (8-5) • Disconnect the cooling fan coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. •…

• Page 311: Cooling Fan Relay Inspection

  COOLING AND LUBRICATION SYSTEM COOLING FAN RELAY INSPECTION Cooling fan relay is located on the air cleaner box (left side one). • Lift and support the fuel tank. (8-3) • Remove the cooling fan relay 1. First check the insulation between A and B terminals with tester.

• Page 312: Installation

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

• Page 313: Thermostat

  COOLING AND LUBRICATION SYSTEM THERMOSTAT REMOVAL • Drain engine coolant. (2-17) • Lift and support the fuel tank. (5-3) • Place a rag under the thermostat cover. • Remove the thermostat cover 1. • Remove the thermostat 2. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner.

• Page 314: Installation

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

• Page 315: Water Pump

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

• Page 316
  7-12 COOLING AND LUBRICATION SYSTEM • Remove the mechanical seal ring 4 and rubber seal 5 from the impeller. • Remove the impeller shaft 6 and washer 7. • Remove the mechanical seal with the special tool.  09921-20240: Bearing remover set (12 mm) NOTE: If there is no abnormal condition, the mechanical seal removal is not necessary.

• Page 317: Inspection

  COOLING AND LUBRICATION SYSTEM 7-13 INSPECTION MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. • Replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. OIL SEAL •…

• Page 318: Reassembly And Installation

   09913-70210: Bearing installer set (22) NOTE: The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A”…

• Page 319
  NOTE: * Apply engine coolant to the O-ring 6 . * Apply SUZUKI SUPER GREASE “A” to the O-ring 7 .  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten the water pump cover screws to the specified torque.
• Page 320
  7-16 COOLING AND LUBRICATION SYSTEM • Install the water pump. NOTE: Set the water pump shaft end F to the oil pump shaft G as shown. • 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 321: Lubrication System

  • Remove the oil cooler 1. INSTALLATION Install the oil cooler in the reverse order of removal. Pay atten- tion to the following points: • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) …

• Page 322: Oil Pressure

  7-18 COOLING AND LUBRICATION SYSTEM OIL PRESSURE 2-33 OIL FILTER 2-13 OIL PRESSURE REGULATOR 3-44 OIL STRAINER 3-44 OIL JET 3-58 OIL PUMP 3-41 OIL PRESSURE SWITCH 9-34…

• Page 323: Oil Pressure Switch

  COOLING AND LUBRICATION SYSTEM 7-19 ENGINE LUBRICATION SYSTEM CHART 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 BALANCER SHAFT SUB GALLERY #2 BEARING #1 PISTON COOLING #2 PISTON COOLING…

• Page 324: Engine Lubrication System

  7-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM…

• Page 325
  COOLING AND LUBRICATION SYSTEM 7-21…
• Page 326
  CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ………………8- 3 FASTENER REMOVAL AND INSTALLATION……..8- 3 BODY COWLING COVER AND LOWER BRACKET COVER ….. 8- 5 INNER UNDER COWLING…………..8- 5 UNDER COWLING …………….8- 5 SCREEN ………………..8- 6 BODY COWLING ……………… 8- 6 AIR INTAKE PIPE ……………..
• Page 327
  CHASSIS CHASSIS CONTENTS REMOVAL ………………… 8-49 INSPECTION ………………8-51 REAR SHOCK ABSORBER SCRAPPING PROCEDURE ….8-51 INSTALLATION………………8-52 SUSPENSION SETTING …………… 8-53 REAR SUSPENSION ………………. 8-54 CONSTRUCTION ……………… 8-54 REMOVAL ………………… 8-55 INSPECTION ………………8-56 DISASSEMBLY ………………8-59 REASSEMBLY AND INSTALLATION ……….8-60 FINAL INSPECTION AND ADJUSTMENT ………..

• Page 328: Exterior Parts

  CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece 1. • Pull out the fastener a. Installation • Let the center piece stick out toward the head so that the pawls 2 close.

• Page 329
  CHASSIS Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. • Push in the head of center piece.

• Page 330: Body Cowling Cover And Lower Bracket Cover

  CHASSIS BODY COWLING COVER AND LOWER BRACKET COVER REMOVAL • Remove the body cowling cover 1 by removing the screws and fasteners. • Remove the lower bracket cover 2 by removing the bolts. INSTALLATION • Install the lower bracket cover and body cowling cover in the reverse order of removal.

• Page 331: Screen

  CHASSIS SCREEN REMOVAL • Remove the screen 1 by removing the screws. INSTALLATION • Install two nuts (middle ones) as shown. • Install the window screen. BODY COWLING REMOVAL • Remove the left and right under cowlings. (8-5) • Remove the screen. (Above) •…

• Page 332: Air Intake Pipe

  CHASSIS AIR INTAKE PIPE REMOVAL • Remove the body cowling. (8-6) • Remove the fasteners. • Remove the air intake pipes 1. (LH/RH) INSTALLATION • Install the air intake pipes in the reverse order of removal. COWLING BRACE REMOVAL • Remove the body cowling. (8-6) •…

• Page 333: Rear Seat/Seat Tail Cover

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

• Page 334: Front Wheel

  CHASSIS FRONT WHEEL CONSTRUCTION  1 Brake disc 6 Front axle 2 Collar 7 Front wheel ITEM N·m kgf-m lb-ft 3 Dust seal A Front axle bolt 10.0 72.5 4 Bearing B Brake disc bolt 16.5 5 Spacer…

• Page 335: Removal And Disassembly

  8-10 CHASSIS REMOVAL AND DISASSEMBLY • Remove the brake calipers.  Do not operate the brake lever while removing the cal- ipers. • Loosen two axle pinch bolts 1 on the right front fork leg. • Remove the front axle bolt 2. •…

• Page 336
  CHASSIS 8-11 • Remove the brake discs, left and right. • Remove the dust seals on both sides with the special tool.  09913-50121: Oil seal remover  The removed dust seals must be replaced with new ones. • Remove the wheel bearings with the special tool. …

• Page 337: Inspection

  8-12 CHASSIS INSPECTION TIRE INSPECTION (8-85) BRAKE DISC INSPECTION (8-70) AXLE SHAFT • Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.  09900-20607: Dial gauge (1/100) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) …

• Page 338: Reassembly And Installation

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

• Page 339
  Clearance Spacer • Install the dust seal with the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) BRAKE DISC • Make sure that the brake disc is clean and free of any greasy matter.
• Page 340
  CHASSIS 8-15 • Install the collar 1 in the right side. WHEEL • Install the front wheel with the front axle and hand-tighten the front axle bolt temporarily.  The directional arrow on the tire should point to the wheel rotation, when remounting the wheel. BRAKE CALIPER •…
• Page 341
  8-16 CHASSIS • Tighten two axle pinch bolts on the left front fork leg to the specified torque.  Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Page 342: Front Fork

  CHASSIS 8-17 FRONT FORK CONSTRUCTION 1 Adjuster rod 9 Oil seal stopper ring 2 Spring retainer 0 Dust seal  3 Spacer A Inner tube 4 Spring A Front fork cap bolt ITEM N·m kgf-m lb-ft 5 Inner rod/Damper rod (cartridge) B Lock-nut 25.5 6 Outer tube…

• Page 343: Removal And Disassembly

  8-18 CHASSIS REMOVAL AND DISASSEMBLY • Remove the under cowling cover and the lower bracket cover. (8-5) • Remove the front wheel. (8-10) • Disconnect the brake hose from the brake hose guides at the front fender. • Remove the front fender. •…

• Page 344
  CHASSIS 8-19 • Remove the front fork cap bolt from the inner rod by loosening the lock nut. • Compress the fork spring with the special tool and remove the special tool. • Remove the front fork cap bolt 5, adjuster rod 6, spring retainer 7, spacer 8 and spring 9.
• Page 345
  8-20 CHASSIS • Remove the damper rod bolt with the special tool and a hexa- gon wrench.  09940-30221: Front fork assembling tool • Remove the inner rod/damper rod (cartridge) B.  Do not disassemble the inner rod/damper rod (car- tridge).

• Page 346: Inspection

  CHASSIS 8-21 • Remove the oil seal E with the special tool.  09913-50121: Oil seal remover  The removed oil seal must be replaced with a new one. • Remove the oil seal retainer F. INSPECTION INNER AND OUTER TUBES •…

• Page 347: Reassembly

  8-22 CHASSIS DAMPER ROD • Move the inner rod by hand to examine it for smoothness. • If any defects are found, replace inner rod/damper rod (car- tridge) with a new one. REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL •…

• Page 348
  • Place the front fork vertically without spring. • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube.  Capacity (each leg): 408 ml (13.8/14.4 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 or an equivalent fork oil…
• Page 349
  8-24 CHASSIS • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.  09940-52841: Inner rod holder NOTE: Refill front fork oil up to the top of the outer tube so that bubbles are visible while bleeding air.
• Page 350
  CHASSIS 8-25 • Insert the adjuster rod to the front fork cap bolt. • Apply fork oil to the O-ring.  The removed O-ring must be replaced with a new one. • Be sure to check or adjust the height D of the rebound damp- ing force adjuster as follows.

• Page 351: Installation

  8-26 CHASSIS INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Set the upper surface of the outer tube height A at 5.0 mm (0.196 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts 1 to the specified torque.

• Page 352: Suspension Setting

  CHASSIS 8-27 SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT Turn the damping force adjuster 1 counterclockwise fully. It is at softest position and turn it out to standard setting position. …

• Page 353: Steering Damper

  8-28 CHASSIS STEERING DAMPER CONSTRUCTION  1 Steering damper Convex curve side of the washer 2 Dust seal faces down side. ITEM N·m kgf-m lb-ft 3 Steering stem head nut A Damper rod bolt 16.5 B Damper rod nut 65.0…

• Page 354: Removal

  Do not remove the bolt A. INSTALLATION Install the steering damper in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the bearings and dust seals.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •…

• Page 355: Steering

  8-30 CHASSIS STEERING CONSTRUCTION  1 Steering stem upper bracket 8 Steering stem lower bracket 2 Handlebars A Steering stem head nut ITEM N·m kgf-m lb-ft 3 Handlebar balancer B Steering stem lock-nut 65.0 4 Steering stem nut C Front fork upper clamp bolt 58.0 5 Dust seal cover D Handlebar clamp bolt…

• Page 356: Removal

  CHASSIS 8-31 REMOVAL • Remove the under cowling. (8-5) • Support the motorcycle with a jack or a wooden block.  Do not work by using side stand. Do not support the motorcycle with exhaust pipe. Make sure that the motorcycle is supported securely.

• Page 357: Inspection And Disassembly

  8-32 CHASSIS • Remove the dust seal cover 1, dust seal 2, steering stem upper bearing inner race 3 and bearing 4. 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…

• Page 358: Reassembly

  INSTALLATION Install the steering stem in the reverse order of removal. Pay attention to the following points: BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings and bearing races.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the lower bearing to the steering stem lower bracket.

• Page 359
  8-34 CHASSIS • Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will be 1/4 – 1/2 turn seated properly. • Loosen the stem nut by 1/4 – 1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle.

• Page 360: Steering Tension Adjustment

  CHASSIS 8-35 STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). •…

• Page 361: Handlebars

  8-36 CHASSIS HANDLEBARS CONSTRUCTION 1 Left handle grip 5 Handlebar (RH)  2 Right handle throttle grip 6 Handlebar (LH) 3 Right handle switch 7 Handle balancer ITEM N·m kgf-m lb-ft 4 Left handle switch A Handlebar clamp bolt 16.5 REMOVAL •…

• Page 362: Installation

  CHASSIS 8-37 • Remove the left handle switch 5 and disconnect the clutch lever switch lead wire. • Remove the handle balancer 6. • Remove the left handle grip 7. • Disconnect the clutch cable 8. • Remove the clutch lever holder 9. •…

• Page 363
  8-38 CHASSIS • Insert the protrusion A of the handlebars into the hole B of the steering stem upper bracket. • Tighten the front fork upper clamp bolts 1 and handlebar clamp bolts 2 to the specified torque.  Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •…
• Page 364
  CHASSIS 8-39 • Apply the SUZUKI SUPER GREASE “A” to the throttle cables and cable drum.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • When remounting the right and left handle switches, engage the stopper with the handlebar hole.

• Page 365: Rear Wheel

  8-40 CHASSIS REAR WHEEL CONSTRUCTION 1 Rear axle 0 Sprocket mounting drum 2 Brake disc A Sprocket 3 Collar B Bearing 4 Dust seal C Dust seal  5 Rear wheel D Collar 6 Spacer A Brake disc bolt ITEM N·m kgf-m lb-ft…

• Page 366: Removal

  CHASSIS 8-41 REMOVAL • Remove the cotter pin. (For E-03, 28, 33) • Loosen the axle nut 1. • Remove the under cowling. (8-5) • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. •…

• Page 367: Inspection And Disassembly

  8-42 CHASSIS • Remove the dust seal with the special tool.  09913-50121: Oil seal remover  The removed dust seal must be replaced with a new one. • Remove the dust seal with the special tool.  09913-50121: Oil seal remover …

• Page 368
  CHASSIS 8-43 SPROCKET • Inspect the sprocket teeth for wear. • If they are worn as shown, replace the two sprockets and drive chain as a set. A Normal wear B Excessive wear BEARINGS • Inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place.

• Page 369: Reassembly And Installation

  8-44 CHASSIS REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 93 N·m 35 N·m (9.3 kgf-m, 67.5 lb-ft) (3.5 kgf-m, 25.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) E-02, 19, 24 E-03, 28, 33…

• Page 370
  CHASSIS 8-45 BEARINGS • Apply SUZUKI SUPER GREASE “A” to the bearings before installing.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the new bearing to the sprocket mounting drum with the special tool.  09913-70210: Bearing installer set •…
• Page 371
  DUST SEALS • Install the new dust seal with the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lip before assembling rear wheel.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) REAR SPROCKET AND SPROCKET MOUNTING DRUM •…
• Page 372
  CHASSIS 8-47 BRAKE DISC • Apply THREAD LOCK to the disc bolts and tighten them to the specified torque. NOTE: Make sure that the brake disc is clean and free of any greasy matter.  99000-32130: THREAD LOCK SUPER “1360” …

• Page 373: Rear Shock Absorber

  8-48 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION  Rear shock absorber mount- 1 Rear shock absorber ing bolt/nut ITEM N·m kgf-m lb-ft Rear shock absorber bracket 36.0 2 Rear shock absorber bracket 11.5 83.0…

• Page 374: Removal

  CHASSIS 8-49 REMOVAL • Remove the front seat. (8-5) • Remove the fuel tank. (5-4) • Disconnect the HO2 sensor lead wire coupler. (4-107) • Remove the under cowling. (8-5) • Remove the exhaust muffler. (6-10) • Loosen the axle nut. •…

• Page 375
  8-50 CHASSIS • Remove the brake fluid reservoir mounting bolt. • Loosen the rear shock absorber bracket. • Remove the rear shock absorber upper and lower mounting bolts and nuts. • Remove the rear shock absorber.

• Page 376: Inspection

  CHASSIS 8-51 INSPECTION Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one.  Do not attempt to disassemble the rear shock absorber unit. It is unserviceable. REAR SHOCK ABSORBER SCRAPPING PROCEDURE …

• Page 377: Installation

  8-52 CHASSIS • Press the valve with a screwdriver to bleed out the nitrogen gas.  * Releasing high pressure gas from the rear shock absorber unit can be hazardous. Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit.

• Page 378: Suspension Setting

  CHASSIS 8-53 SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The set length 176.4 mm (6.94 in) provides the maximum spring pre-load. The set length 186.4 mm (7.34 in) provides the minimum spring pre-load.

• Page 379: Rear Suspension

  8-54 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 0 Plate  2 Rear cushion rod Rear shock absorber mounting 3 Rear cushion lever bolt/nut ITEM N·m kgf-m lb-ft 4 Spacer B Rear cushion lever bolt/nut 36.0 5 Bearing C Rear cushion rod bolt/nut 71.0 6 Chain cover D Swingarm pivot shaft…

• Page 380: Removal

  CHASSIS 8-55 REMOVAL • Cut the drive chain. (8-89 and -90) NOTE: It is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • Remove the rear shock absorber. (8-49 and -50) • Remove the cushion lever mounting bolt/nut 1. •…

• Page 381: Inspection

  8-56 CHASSIS • Remove the plate 0. INSPECTION SWINGARM PIVOT SHAFT • Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit.  Swingarm pivot shaft runout: Service limit: 0.3 mm (0.01 in) …

• Page 382
  CHASSIS 8-57 SWINGARM • Inspect the swingarm for damage. If any damages are found, replace the swingarm with a new one. CUSHION ROD • Inspect the cushion rod for damage and distortion. • If any defects are found, replace the cushion rod with a new one.
• Page 383
  8-58 CHASSIS SWINGARM BEARING • Insert the spacer into bearing and check the play when mov- ing the spacer up and down. • If excessive play is noted, replace the bearing with a new one. CUSHION ROD BEARING • Insert the spacer into bearing and check the play when mov- ing the spacer up and down.

• Page 384: Disassembly

  CHASSIS 8-59 DISASSEMBLY SWINGARM BEARING • Draw out the swingarm pivot bearings with the special tool.  09921-20240: Bearing remover set ( 28 mm)  The removed bearings must be replaced with new ones. • Remove the center spacer. CUSHION ROD BEARING •…

• Page 385: Reassembly And Installation

  115 N·m (11.5 kgf-m, 83.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 1 mm (0.04 in) 1 mm (0.04 in) Apply SUZUKI SUPER GREASE “A” 78 N·m to the bearings, washers and dust seals. (7.8 kgf-m, 56.5 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft)

• Page 386
  • Press the bearings into the cushion lever with the special tool.  09924-84521: Bearing installer set NOTE: When installing the bearing, stamped mark on the bearing must face outside. • Apply SUZUKI SUPER GREASE “A” to the bearings, spacers.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
• Page 387
  8-62 CHASSIS • Remount the plate 1. • Remount the chain cases 2 chain buffer 3 and rear fender (lower) 4. SWINGARM PIVOT THRUST CLEARANCE ADJUSTMENT Adjust swingarm pivot thrust clearance in the following procedure. • Insert the swingarm pivot shaft and tighten to the specified torque.

• Page 388: Final Inspection And Adjustment

  CHASSIS 8-63 SHOCK ABSORBER, CUSHION LEVER AND CUSHION ROD MOUNTING BOLT/NUT • Install the cushion lever. • Tighten the cushion lever mounting nut 1 to the specified torque.  Cushion lever mounting nut: 98 N·m (9.8 kgf-m, 71.0 lb-ft) • Install the cushion rod. •…

• Page 389: Front Brake

  8-64 CHASSIS FRONT BRAKE CONSTRUCTION  1 Brake lever A Master cylinder mounting bolt 2 Dust boot B Brake hose union bolt ITEM N·m kgf-m lb-ft 3 Piston set C Caliper mounting bolt 4 Piston seal D Caliper air bleeder valve 16.5 5 Dust seal E Caliper housing bolt…

• Page 390: Brake Pad Replacement

  CHASSIS 8-65  * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

• Page 391: Brake Fluid Replacement

  8-66 CHASSIS • Install the spring to the caliper, bring its wider side of pawl A facing top. • Install the new brake pads. • Install the brake caliper. • Tighten each bolt to the specified torque.  Pad mounting pin 1: 15 N·m (1.5 kgf-m, 11.0 lb-ft) Front brake caliper mounting bolt 2: 35 N·m (3.5 kgf-m, 25.5 lb-ft) NOTE:…

• Page 392: Caliper Removal

  CHASSIS 8-67 CALIPER REMOVAL • Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta- cle. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid.

• Page 393: Caliper Inspection

  8-68 CHASSIS • Remove the dust seals 4 and piston seals 5.  Avoid reusing 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.

• Page 394: Caliper Installation

  CHASSIS 8-69 PISTON SEAL • Install the piston seals as shown in the illustration. Dust seal Caliper body Piston seal O-RING • Install the new O-ring 1 and reassemble caliper halves.  Replace the O-ring with a new one. • Temporarily tighten the air bleeder valve 2. •…

• Page 395: Brake Disc Inspection

  8-70 CHASSIS BRAKE DISC INSPECTION • Visually check the brake disc for damage or cracks. • Measure the thickness with a micrometer. • Replace the disc if the thickness is less than the service limit or if damage is found. …

• Page 396: Master Cylinder Removal And Disassembly

  CHASSIS 8-71 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain the brake fluid. (8-66) • Disconnect the front brake light switch lead wires 1. • Place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose.

• Page 397: Master Cylinder Inspection

  8-72 CHASSIS • Remove the dust boot 9 push rod 0 and snap ring A. • Remove the following parts. B Secondary cup C Piston D Primary cup E Return spring F Return spring guide G Air bleeder valve • Remove the dust rubber H and snap ring I. •…

• Page 398: Master Cylinder Reassembly

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

• Page 399: Master Cylinder Installation

  8-74 CHASSIS • Apply SUZUKI SILICONE GREASE to the brake lever pivot bolt.  99000-25100: SUZUKI SILICONE GREASE  Brake lever pivot bolt: 1 N·m (0.1 kgf-m, 0.7 lb-ft) Brake lever lock-nut: 6 N·m (0.6 kgf-m, 4.5 lb-ft) • Align the convex part A of brake light switch with the hole B of master cylinder when installing the brake light switch.

• Page 400: Rear Brake

  CHASSIS 8-75 REAR BRAKE CONSTRUCTION  1 Brake pedal A Caliper air bleeder valve 2 Piston/Cup set B Brake hose union bolt ITEM N·m kgf-m lb-ft 3 Reservoir hose C Brake caliper mounting bolt 0.75 4 Brake hose D Brake master cylinder mounting bolt 16.5 5 Brake pad E Brake master cylinder rod lock-nut…

• Page 401: Brake Pad Replacement

  8-76 CHASSIS  * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

• Page 402: Brake Fluid Replacement

  CHASSIS 8-77 BRAKE FLUID REPLACEMENT • Remove the brake fluid reservoir mounting bolt 1. • Place a rag underneath the brake fluid reservoir to catch any split brake fluid. Remove the brake fluid reservoir cap 2. • Replace the brake fluid in the same manner as the front brake.

• Page 403
  8-78 CHASSIS • Remove the brake pad spring. • Remove the caliper air bleeder valve 4. • Remove the spacer 5 and rubber boot 6 from the caliper. • Place a rag over the piston to prevent it from popping out and then force out the pistons using compressed air.

• Page 404: Caliper Inspection

  CHASSIS 8-79 CALIPER INSPECTION BRAKE CALIPER AND BRAKE CALIPER PISTON • Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. • Inspect the brake caliper piston surface for any scratches and other damage.

• Page 405: Caliper Reassembly

  Caliper body Piston seal SLIDING PIN • Install the rubber boot 1. • Apply SUZUKI SILICONE GREASE to the inside of the boot.  99000-25100: SUZUKI SILICONE GREASE • Install the spacer 2. • Install the caliper air bleeder valve.

• Page 406: Caliper Installation

  CHASSIS 8-81 CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Tighten each bolt to the specified torque.  Brake hose union bolt 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Brake caliper mounting bolt 2: 17 N·m (1.7 kgf-m, 12.5 lb-ft) Brake caliper pin bolt 3: 32 N·m (3.2 kgf-m, 23.0 lb-ft) •…

• Page 407
  8-82 CHASSIS • Remove the reservoir cap 7, insulator 8, diaphragm 9 and reservoir tank 0. • Remove the snap ring A with the special tool.  09900-06108: Snap ring pliers • Remove the connector B. • Remove the O-ring C. …

• Page 408: Master Cylinder Inspection

  * Do not wipe the components with a rag. * Apply brake fluid to the cylinder bore and all the component to be inserted into the bore.  Specification and classification: DOT 4 • Apply SUZUKI SILICONE GREASE to the push rod end.  99000-25100: SUZUKI SILICONE GREASE…

• Page 409: Master Cylinder Installation

  8-84 CHASSIS MASTER CYLINDER INSTALLATION Install the master cylinder in the reverse order of removal. Pay attention to the following points: • Apply THREAD LOCK to the master cylinder mounting bolts.  99000-32110: THREAD LOCK SUPER “1322” (or equivalent thread lock) •…

• Page 410: Tire And Wheel

  CHASSIS 8-85 TIRE AND WHEEL TIRE REMOVAL The most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

• Page 411: Valve Inspection

  8-86 CHASSIS VALVE INSPECTION • Inspect the valve after the tire is removed from the rim. • Replace the valve with a new one if the seal A rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.

• Page 412: Tire Installation

  CHASSIS 8-87 TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points.  * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant.

• Page 413: Balancer Weight Installation

  8-88 CHASSIS • In this condition, check the “rim line” B cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.

• Page 414: Drive Chain

  CHASSIS 8-89 DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain.  09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.

• Page 415: Drive Chain Connecting

  8-90 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 416
  CHASSIS 8-91 • 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, its stamp mark must face the joint plate holder 3 side. •…
• Page 417
  8-92 CHASSIS • 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.  Pin end diameter specification D 5.45 – 5.85 mm (0.215 – 0.230 in) …
• Page 418
  ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING …………….. 9- 3 CONNECTOR ………………9- 3 COUPLER………………..9- 3 CLAMP ………………..9- 3 FUSE…………………. 9- 3 SEMI-CONDUCTOR EQUIPPED PART ……….9- 4 BATTERY ………………..9- 4 CONNECTING THE BATTERY…………. 9- 4 WIRING PROCEDURE…………….
• Page 419
  ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS TURN SIGNAL/SIDE-STAND RELAY ……….9-37 STARTER RELAY …………….. 9-37 FUEL PUMP RELAY …………….9-37 COOLING FAN RELAY…………….. 9-37 IGNITION SWITCH REMOVAL …………. 9-38 IGNITION SWITCH INSTALLATION…………. 9-38 SWITCHES INSPECTION …………..9-39 BATTERY ………………..9-40 SPECIFICATIONS …………….. 9-40 INITIAL CHARGING …………….

• Page 420: Cautions In Servicing

  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 Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

• Page 421: Semi-Conductor Equipped Part

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

• Page 422: Using The Multi-Circuit Tester

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

• Page 423: Location Of Electrical Components

  ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Fuel pump relay (5-7) 9 Fuel pump (5-8) 2 IAT sensor (4-53) 0 Regulator/Rectifier 3 Cooling fan relay (7-7) A Oil pressure switch 4 PAIR control solenoid valve (11-7) B Generator 5 CMP sensor (4-33) C Speed sensor 6 Ignition coil (No.1, 2, 3, 4) D GP switch…

• Page 424
  ELECTRICAL SYSTEM 1 Battery 0 STP sensor (4-70) 2 AP sensor (4-57) A TP sensor (4-44) 3 Mode selection switch coupler (4-18) B IAP sensor (4-38) 4 Fuse Box C Starter relay/Main fuse 5 ECM (Engine Control Module) D Turn signal/Side-stand relay 6 Secondary fuel injector (4-80) E EXCVA (6-4) 7 Primary fuel injector (4-77)

• Page 425: Charging System

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

• Page 426: Inspection

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

• Page 427
  9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. (8-7) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the + and — battery termi- nals using the multi-circuit tester.
• Page 428
  ELECTRICAL SYSTEM 9-11 GENERATOR NO-LOAD PERFORMANCE • Lift and support the fuel tank. (5-3) • Disconnect the generator coupler. • Start the engine and keep it running at 5 000 r/min. • Using the multi-circuit tester, measure the voltage between three lead wires.

• Page 429: Starter System And Side-Stand/Ignition Interlock System

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

• Page 430: Starter Motor Removal

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

• Page 431: Starter Motor Disassembly

  9-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration.  1 O-ring 4 Armature 2 Housing end (inside) 5 Housing end (outside) ITEM N·m kgf-m lb-ft 3 Starter motor case A Lead wire mounting bolt STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness…

• Page 432: Starter Motor Reassembly

  STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •…

• Page 433: Starter Relay Inspection

  9-16 ELECTRICAL SYSTEM • Tighten the starter motor lead wire mounting bolt to the speci- fied torque.  Lead wire mounting bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft) STARTER RELAY INSPECTION • Remove the front seat. (8-7) • Disconnect the battery — lead wire from the battery. •…

• Page 434: Side Stand/Ignition Interlock System Parts Inspection

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

• Page 435
  9-18 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Remove the front seat. • Disconnect the battery — lead wire from the battery. • Lift and support the fuel tank. (5-3) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmis- sion in “NEUTRAL”.
• Page 436
  ELECTRICAL SYSTEM 9-19 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the front seat.(8-7) • Disconnect the battery — lead wire from the battery. • Remove the frame cover. (8-8) •…

• Page 437: Ignition System

  9-20 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Side- stand Power source relay circuit Fuse sensor Waveform arrangement Ignition circuit switch Fuse Waveform arrangement sensor circuit Battery sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 14 500 r/min, this circuit cuts off fuel at the fuel injector.

• Page 438: Immobilizer (Except For E-03, 28, 33)

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

• Page 439
  9-22 ELECTRICAL SYSTEM Operation When the ignition switch is turned ON with the engine stop switch in ON, the immobi-antenna and ECM are powered ON. The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID.

• Page 440: Troubleshooting

  ELECTRICAL SYSTEM 9-23 TROUBLESHOOTING No spark or poor spark NOTE: Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.

• Page 441
  9-24 ELECTRICAL SYSTEM Step 5 1) Inspect the ignition coil/plug caps. (9-26) Is the ignition coil/plug cap OK? Go to Step 6. • Poor connection of the ignition coil/plug cap(-s). • Faulty ignition coil/plug cap(-s). Step 6 1) Measure the CKP sensor peak voltage and its resistance. (9-27 to -28) NOTE: The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.

• Page 442: Inspection

  ELECTRICAL SYSTEM 9-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. (5-14) • Disconnect all the ignition coil/plug cap lead wire couplers before removing the ignition coil/plug caps. • Remove all of the ignition coil/plug caps. …

• Page 443
  9-26 ELECTRICAL SYSTEM NOTE: Use the special tool, to prevent the rubber of the water proof coupler from damage. • Shift the transmission into neutral and turn ignition switch “ON”. • Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage.
• Page 444
  ELECTRICAL SYSTEM 9-27 CKP SENSOR PEAK VOLTAGE • Remove the front seat. (8-7) NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Disconnect the both couplers 1. • Connect the multi-circuit tester with peak volt adaptor as fol- lows.
• Page 445
  9-28 ELECTRICAL SYSTEM If the peak voltage is lower than the standard range, check the peak voltage at the CKP sensor lead wire coupler. Black • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) • Disconnect the CKP sensor lead wire coupler and connect the multi-circuit tester with the peak volt adaptor.

• Page 446: Combination Meter

  ELECTRICAL SYSTEM 9-29 COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition. The rpm pointer is driven by the stepping motor.

• Page 447: Removal And Disassembly

  9-30 ELECTRICAL SYSTEM REMOVAL AND DISASSEMBLY • Remove the screw 1. • With the hooked parts 2 of the combination meter pulled from the headlight housing, disconnect the combination meter lead wire coupler. • Remove the combination meter.  When disconnecting and reconnecting the combina- tion meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

• Page 448: Inspection

  ELECTRICAL SYSTEM 9-31 INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights [FI light, Fuel level indicator light, Engine RPM indicator light and immobilizer indi- cator light (For E-02, 19, 24)] immediately after turning the ignition switch on. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.

• Page 449
  9-32 ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection (7-7) • Remove the front seat.(8-7) • Lift and support the fuel tank. (5-3) • Disconnect the ECT sensor coupler 1.  When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
• Page 450
  ELECTRICAL SYSTEM 9-33 FUEL LEVEL GAUGE INSPECTION • Remove the fuel pump assembly. (5-9) • Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. Float position Resistance 182 ±…
• Page 451
  9-34 ELECTRICAL SYSTEM SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. SPEED SENSOR •…

• Page 452: Lamps

  ELECTRICAL SYSTEM 9-35 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 55 W H7 1 12 V 65 W H9 2 POSITION LIGHT 3 12 V 5 W × 2 BRAKE LIGHT/TAILLIGHT: LED LICENCE PLATE LIGHT 4 12 V 5 W TURN SIGNAL LIGHT 5 12 V 21 W ×…

• Page 453
  9-36 ELECTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. NOTE: * Use a screw driver + for adjuster A and B . * To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. A: Horizontal adjuster B: Vertical adjuster To adjust the beam horizontally: •…

• Page 454: Relays

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

• Page 455: Ignition Switch Removal

  9-38 ELECTRICAL SYSTEM IGNITION SWITCH REMOVAL • Remove the air cleaner box. (5-14) • Disconnect the ignition switch lead wire coupler (Green) 1. • Disconnect the immobilizer lead wire coupler (Black) 2. (For E-02, 19, 24) • Remove the cable guide 3. •…

• Page 456: Switches Inspection

  ELECTRICAL SYSTEM 9-39 SWITCHES INSPECTION Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. PUSH HAZARD SWITCH HORN BUTTON Color Position Color B/Bl (OFF) Position (ON) PUSH…

• Page 457: Battery

  9-40 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YT12A-BS Capacity 12V,36kC (8Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes A.

• Page 458
  ELECTRICAL SYSTEM 9-41 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.

• Page 459: Servicing

  9-42 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.

• Page 460
  SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING …………….10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION..10- 2 ENGINE ………………..10- 6 RADIATOR (COOLING SYSTEM) …………10-12 CHASSIS ………………… 10-13 BRAKES ………………..10-14 ELECTRICAL ………………10-15 BATTERY ……………….. 10-16 WIRING HARNESS, CABLE AND HOSE ROUTING……..

• Page 461: Troubleshooting

  10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

• Page 462
  SERVICING INFORMATION 10-3 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated.
• Page 463
  10-4 SERVICING INFORMATION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated. Sensor voltage is higher than specified STP sensor circuit shorted to value.
• Page 464
  SERVICING INFORMATION 10-5 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM HO2 sensor HO2 sensor output voltage is not input HO2 sensor circuit open or (For E-02, to ECM during engine operation and shorted to ground running condition. (Sensor voltage < 0.55 V) P0130 In other than the above value, C44 (P0130) is indicated.

• Page 465: Engine

  10-6 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of adjustment Adjust. 2. Worn valve guides or poor seating of valves Repair or replace. 3.

• Page 466
  SERVICING INFORMATION 10-7 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace.
• Page 467
  10-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace.
• Page 468
  SERVICING INFORMATION 10-9 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust.
• Page 469
  10-10 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinders Replace.
• Page 470
  SERVICING INFORMATION 10-11 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 471: Radiator (Cooling System)

  10-12 SERVICING INFORMATION RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats 1. Not enough engine coolant Add coolant. 2. Radiator core clogged with dirt or scale Clean. 3. Faulty cooling fan Repair or replace. 4. Defective cooling fan relay, or open- or short- Repair or replace.

• Page 472: Chassis

  SERVICING INFORMATION 10-13 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 473: Brakes

  10-14 SERVICING INFORMATION 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 474: Electrical

  SERVICING INFORMATION 10-15 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective spark plugs Replace. 3. Defective CMP sensor Replace. 4. Defective CKP sensor Replace. 5. Defective ECM Replace. 6. Defective TO sensor Replace.

• Page 475: Battery

  10-16 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates Battery runs down…

• Page 476: Wiring Harness, Cable And Hose Routing

  SERVICING INFORMATION 10-17 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Wiring harness Brake light switch HO2 sensor (E-02, 19) Wiring harness Starter motor lead wire Clamp 1 Integrated clamp 8 Protector 2 Cooling fan relay *1 To ECT sensor 3 Fuel pump relay *2 Cut the tip after clamping.

• Page 477
  10-18 SERVICING INFORMATION 6 N·m Guide (0.6 kgf-m, 4.5 lb-ft) Handlebar switch (RH) Iginition switch Clamp Wiring harness Battery — lead wire Wiring harness Position light (LH) Turn signal light (RH) Clamp 1 Rear combination light 8 Brake light switch 2 EXCVA 9 Horn 3 AP sensor…
• Page 478
  SERVICING INFORMATION 10-19 6 N·m (0.6 kgf-m, 4.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 5 N·m (0.5 kgf-m, 3.5 lb-ft) 11 N·m (1.1 kgf-m, 8.0 lb-ft) 7 N·m (0.7 kgf-m, 5.0 lb-ft) 14 N·m (1.4 kgf-m, 10 lb-ft) 1 Battery — lead wire *1 Fix the clamp in parallel with the cover surface.

• Page 479: Ho2 Sensor Harness Routing (For E-02, 19)

  10-20 SERVICING INFORMATION HO2 SENSOR HARNESS ROUTING (For E-02, 19) 48 N·m (4.8 kgf-m, 34.5 lb-ft) 1 HO2 sensor Clamp the HO2 sensor lead wire so as not to over- 2 Clutch cable lap the oil inspection window. 3 Oil pan Pass the HO2 sensor lead wire through between 4 Under cowling the frame and engine.

• Page 480: Cable Routing

  SERVICING INFORMATION 10-21 CABLE ROUTING 0 mm 0 mm 0 mm 1 Clutch cable *1 Clutch cable must be clamped on the grommet. 2 Throttle cable No.1 *2 Pass the throttle cables above the clutch cable. 3 Throttle cable No.2 *3 Pass the throttle cable No.2 outer from No.1.

• Page 481: Fuel Tank Hose Routing

  10-22 SERVICING INFORMATION FUEL TANK HOSE ROUTING Pass the fuel tank drain hose and breather hose 1 Fuel tank water drain hose through behind the PCV hose. Set the fuel tank drain hose and breather hose with 2 Fuel tank breather hose lengthwise backward.

• Page 482: Cooling System Hose Routing

  SERVICING INFORMATION 10-23 COOLING SYSTEM HOSE ROUTING 90˚ 90˚ 90˚ 1 Reservoir tank overflow hose *1 Clamp should face downward. 2 Reservoir tank inlet hose *2 Clamp should face right side. 3 Oil cooler outlet hose *3 Yellow marking 4 Clearance *4 White marking 5 Radiator inlet hose *5 Clamp should face backward.

• Page 483: Front Brake Hose Routing

  10-24 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING 1 – 2 mm (0.04 – 0.08 in) 14˚ 42˚ 42˚ 1 Brake hose guide *4 Clamp the brake hose firmly. After positioning the clamp with stopper, tighten *1 Clamp should face downward. the clamp bolt.

• Page 484: Rear Brake Hose Routing

  SERVICING INFORMATION 10-25 REAR BRAKE HOSE ROUTING 28˚ 23 N . m 2.3 kgf-m 16.5 lb-ft 28˚ 28˚ 23 N . m 2.3 kgf-m 16.5 lb-ft 1 Rear brake hose *2 Pass the reservoir hose above the brake hose. 2 Brake fluid reservoir hose *3 Position the brake union with the stopper before tightening.

• Page 485: Fuel Tank Installation

  10-26 SERVICING INFORMATION FUEL TANK INSTALLATION 1 Velcro fastening 4 Fuel tank side cushion 2 Frame cover cushion Apply adhesive agent. 3 Fuel tank front cover (equivalent to ARONALPHA 201) COWLING INSTALLATION…

• Page 486: Frame Cover Installation

  SERVICING INFORMATION 10-27 Intake cover (RH) To head light Air intake pipe (RH) Side cowling (LH) Under cowling cover (RH) Intake cover (LH) To frame Air intakepipe (LH) To oil pan Wind screen Under cowling cover (LH) Side cowling (RH) Under cowling (LH) headlight Heat shield…

• Page 487: Seat Lock Cable Routing

  10-28 SERVICING INFORMATION SEAT LOCK CABLE ROUTING REAR FENDER INSTALLATION…

• Page 488
  SERVICING INFORMATION 10-29 1 Seat rail 4 Rear fender (rear) 2 Rear fender (front) 5 Rear fender (lower) 3 Rear fender cover (front) 6 Swingarm…

• Page 489: Side-Stand Installation

  10-30 SERVICING INFORMATION SIDE-STAND INSTALLATION 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) 1 Side-stand spring No.1 2 Side-stand spring No.2 UNDER COWLING CUSHION RUBBER/HEAT SHIELD INSTALLATION Max. 3 mm (0.12 in) 2 mm (0.08 in)

• Page 490: Front Footrest Installation

  SERVICING INFORMATION 10-31 FRONT FOOTREST INSTALLATION 18 N . m (1.8 kgf-m, 13.0 lb-ft) 18 N . m (1.8 kgf-m, 13.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 46 N . m (4.6 kgf-m, 33.5 lb-ft) 23 N·m 23 N·m (2.3 kgf-m, 16.5 lb-ft) (2.3 kgf-m, 16.5 lb-ft)

• Page 491: Rear View Mirror Installation

  10-32 SERVICING INFORMATION REAR VIEW MIRROR INSTALLATION 1 Body cowling 5 Turn signal lead wire coupler 2 Cowling brace 6 Mirror cover 3 Cushion 7 Mirror body Locate the turn signal lead wire coupler 5 4 Turn signal lead wire between the mirror cover 6 and mirror body 7.

• Page 492: Special Tools

  SERVICING INFORMATION 10-33 SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-06107 09900-06108 Hexagon socket 09900-20102 Micrometer Snap ring pliers Snap ring pliers (24 mm) Vernier calipers (25 – 50 mm) 09900-20203 09900-20205 09900-20602 09900-20605 Micrometer Micrometer 09900-20508 Dial gauge Dial calipers (50 – 75 mm) (0 –…

• Page 493
  10-34 SERVICING INFORMATION 09910-20115 09913-10750 09913-50121 09913-70210 09915-40610 Conrod stopper Adapter Oil seal remover Bearing installer set Oil filter wrench 09915-64512 09915-74521 09915-74540 09915-77331 Compression gauge Oil pressure gauge Oil pressure gauge Meter 09916-10911 hose attachment (for high pressure) Valve lapper set 09916-14530 09916-20640 09916-33210…
• Page 494
  SERVICING INFORMATION 10-35 09917-47011 09920-34830 09920-53740 Vacuum pump 09919-28610 Starter clutch Clutch sleeve hub 09921-20210 gauge Sleeve protector holder holder Bearing remover 09922-22711 09921-20240 Drive chain cutting 09923-74511 09924-84510 09924-84521 Bearing remover set and joining tool Bearing remover Bearing installer set Bearing installer set 09925-18011 Steering bearing…
• Page 495
  10-36 SERVICING INFORMATION 09940-30221 09940-40211 09940-40220 09940-14940 09940-14990 Front fork assem- Fuel pressure Fuel pressure gauge Swingarm pivot Engine mounting bling tool gauge adaptor hose attachment thrust adjuster thrust adjuster socket wrench socket wrench 09940-52841 09940-52861 09940-94922 09940-94930 Front fork inner Front fork oil seal 09940-92720 Front fork spring…

• Page 496: Tightening Torque

  SERVICING INFORMATION 10-37 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Exhaust pipe bolt 16.5 Muffler connecting bolt 16.5 Muffler mounting bolt 16.5 Speed sensor rotor bolt 18.0 Speed sensor bolt 0.45 Engine sprocket nut 11.5 83.0 Engine mounting bolt (Cylinder) 39.8 Engine mounting nut (Crankcase) 54.0…

• Page 497: Fi System And Intake Air System

  10-38 SERVICING INFORMATION ITEM N·m kgf-m lb-ft Crankcase bolt (Initial) (M: 6) (Final) (Initial) 11.0 (M: (Final) 19.0 Crankcase bolt (Inner hexagon) (Initial) 11.0 (M: (Final) 16.0 Crankshaft journal bolt (M: 9) 16.0 Oil gallery plug (M: 6) (M: 10) 13.0 (M: 12)

• Page 498: Chassis

  SERVICING INFORMATION 10-39 CHASSIS N·m kgf-m lb-ft ITEM Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt and nut 16.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 25.5 Front fork inner rod lock-nut 14.5 Front fork damper rod bolt…

• Page 499: Tightening Torque Chart

  10-40 SERVICING INFORMATION N·m kgf-m lb-ft ITEM Seat rail bolt 36.0 Rear view mirror nut TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7”…

• Page 500: Service Data

  SERVICING INFORMATION 10-41 SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 29.0 — (1.14) 23.0 — (0.91) Valve clearance (when cold) 0.08 – 0.18 — (0.0031 – 0.0071) 0.18 – 0.28 — (0.0071 – 0.0110) Valve guide to valve stem 0.010 –…

• Page 501
  10-42 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 000 kPa (13 – 17 kgf/cm², 185 – 242 psi) (10 kgf/cm , 142 psi) Compression pressure difference 200 kPa —…
• Page 502
  SERVICING INFORMATION 10-43 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5909 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –…
• Page 503
  10-44 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/2 turn back — Drive plate thickness 2.72 – 2.88 2.42 No. 1, 2 and 3 (0.107 – 0.113) (0.095) Drive plate claw width 13.85 –…
• Page 504
  SERVICING INFORMATION 10-45 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 82 °C (180 °F) — ature Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) — ECT sensor resistance 20 °C Approx.
• Page 505
  10-46 SERVICING INFORMATION FI SENSORS ITEM 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 506
  SERVICING INFORMATION 10-47 THROTTLE BODY ITEM SPECIFICATION Bore size 42 mm I.D. No. 02H1 (For E-33), 02H0 (For the others) Idle r/min 1 200 ± 100 r/min Fast idle r/min 1 500 – 2 000 r/min (When cold engine) Throttle cable play 2.0 –…
• Page 507
  10-48 SERVICING INFORMATION WATTAGE Unit: W STANDARD/SPECIFICATION ITEM E-03, 28, 33 Others ← Headlight ← ← Position/Parking light 5 × 2 ← Brake light/Taillight ← Turn signal light 21 × 4 ← License plate light ← Combination meter light ← Turn signal indicator light ←…
• Page 508
  SERVICING INFORMATION 10-49 ITEM STANDARD LIMIT Wheel rim runout Axial — (0.08) Radial — (0.08) Wheel rim size Front 17 M/C × MT 3.50 — Rear 17 M/C × MT 5.50 — Wheel axle runout 0.25 Front — (0.010) 0.25 Rear —…
• Page 509
  (10.22) Front fork oil level (without spring, — outer tube fully compressed) (4.41) Front fork oil type SUZUKI FORK OIL SS-05 or equivalent fork oil — Front fork oil capacity (each leg) 408 ml — (13.8/14.4 US/Imp oz) Front fork inner tube O.D.
• Page 510
  EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ……………11- 2 FUEL INJECTION SYSTEM…………..11- 2 CRANKCASE EMISSION CONTROL SYSTEM……..11- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) …..11- 4 NOISE EMISSION CONTROL SYSTEM……….11- 5 PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION ……….11- 6 PAIR HOSES………………11- 6 PAIR REED VALVE …………….11- 6…

• Page 511: Emission Control Systems

  EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM GSX-R750 motocycles are equipped with a fuel injection system for emission level control. This fuel injec- tion system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With a view to reducing CO, NOX and HC, all of the fuel injection volumes are stringently controlled with the programmed injection maps in the ECM by varying engine conditions.

• Page 512: Crankcase Emission Control System

  EMISSION CONTROL INFORMATION 11-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.

• Page 513: Exhaust Emission Control System (Pair System)

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

• Page 514: Noise Emission Control System

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

• Page 515: Pair (Air Supply) System And Emission Control System Inspection

  11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses is securely connected. PAIR REED VALVE • Remove the cylinder head cover. (3-14) •…

• Page 516: Pair Control Solenoid Valve

  EMISSION CONTROL INFORMATION 11-7 PAIR CONTROL SOLENOID VALVE • Remove the air cleaner box. (5-14) • Disconnect the PAIR control solenoid valve lead wire coupler 1 and PAIR hoses. • Remove the PAIR control solenoid valve 2. • Check that air flows through the air inlet port to the air outlet port.

• Page 517: Pair (Air Supply) System Hose Routing

  11-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Approx. 0˚ Approx. 0˚ Approx. 0˚ 1 PAIR control solenoid valve *1 White marking 2 PAIR reed valve *2 Yellow marking (Opposite side)

• Page 518: Ho2 Sensor Inspection (For E-02, 19)

  EMISSION CONTROL INFORMATION 11-9 HO2 SENSOR INSPECTION (For E-02, 19) The HO2 sensor coupler 1 is located under the fuel tank. • Inspect the HO2 sensor and its circuit referring to flow table of the malfunction code C44 (P0130/P0135). • Check the resistance between the terminals of the HO2 sen- sor.

• Page 519
  WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. IGNITION IGNITION IGNITION IGNITION COIL #4 PAIR CONTROL COIL #1 COIL #2 COIL #3 SOLENOID HANDLEBAR SWITCH (R) ENGINE STOP FRONT BRAKE STARTER SIDE-STAND : TURN SIGNAL INDICATOR LIGHT SWITCH SWITCH BUTTON…
• Page 520
  E-03, 28, 33 IGNITION IGNITION IGNITION IGNITION COIL #4 PAIR CONTROL COIL #1 COIL #2 COIL #3 SOLENOID HANDLEBAR SWITCH (R) ENGINE STOP STARTER FRONT BRAKE : TURN SIGNAL INDICATOR LIGHT SIDE-STAND SWITCH BUTTON SWITCH SWITCH : HI BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT PUSH FREE…
• Page 521
  Prepared by December, 2005 Part No. 99500-37130-01E Printed in Japan…
• Page 522
  Printed in Japan…