FOREWORD This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMA TION 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.
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. \ \ \,--- COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view.
SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL ~ l!r lIr ~ DEFINITION Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE "A".
ABBREVIATIONS USED IN THIS MANUAL E A ABDC : After Bottom Dead Center AC : Alternating Current ACL : Air Cleaner, Air Cleaner Box API : American Petroleum Institute ATDC : After Top Dead Center ATM Pressure: Atmospheric Pressure : Atmospheric Pressure sensor (APS, AP Sensor) A/F : Air Fuel Mixture ECM : Engine Control Module Engine Control Unit (ECU) (FI Control Unit) ECT Sensor : Engine Coolant Temperature Sensor (ECTS), Water Temp.
M MAL-Code Max MIL Min : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum N NOX : Nitrogen Oxides o OHC OPS : Over Head Camshaft : Oil Pressure Switch PCV : Positive Crankcase Ventilation (Crankcase Breather) p R RH ROM : Right Hand : Read Only Memory S : Society of Automotive Engineers : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS) : Secondary Throttle Valve (STV) ST Valve STV Actuator : Secondary Throttl
SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names.
SAE TERM FULL TERM FORMER SUZUKI TERM ABBREVIATION G Generator GEN Generator Ground GND Ground (GND, GRD) Idle Speed Control ISC - Ignition Control IC Electronic Spark Advance (ESA) Ignition Control Module ICM - Intake Air Temperature IAT Intake Air Temperature (IAT), Air Temperature I I M Malfunction Indicator Lamp MIL LED Lamp Malfunction Indicator Lamp (MIL) Manifold Absolute Pressure MAP Intake Air Pressure (lAP), Intake Vacuum Mass Air Flow MAF Air Flow OBD Self-Diagnos
WIRE COLOR B BI Br Dg G BIBI BIG BIR BN BI/G BI/W GIB G/W GrlB Gr/W OIB OIR ON P/w RIBI WIB WIR YIBI YIR : Black : Blue : Brown : Dark green : Green Gr Lbl Lg 0 P : Gray : Light blue : Light green : Orange : Pink : Black with Blue tracer : Black with Green tracer : Black with Red tracer : Black with Yellow tracer : Blue with Green tracer : Blue with White tracer : Green with Black tracer : Green with White tracer : Gray with Black tracer : Gray with White tracer : Orange with Black tracer : Oran
GENERAL INFORMATION I 1·1 GENERALWFORMATION CONTENTS WARNING/CAUTION/NOTE 1- 2 GENERAL PRECAUTIONS.....................................................................•..... 1- 2 SUZUKI GSX-R1000K3 ('03-MODEL) .......................•.................................. 1- 4 SERIAL NUMBER LOCA TION............•......................................................... 1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDA TlON.........••.............1- 5 FUEL (FOR USA AND CANADA)....................................
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. I CAUTION I Indicates a potential hazard that could result in motorcycle damage.
GENERAL INFORMATION !CAUTIONI * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant.
1-4 GENERAL INFORMATION SUZUKI GSX-R1000K3 ('03-MODEL) -- RIGHT SIDE LEFT SIDE • Difference between photographs and actual motorcycles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) CD is stamped on the right side of the steering head pipe. The engine serial number (2) is located on the rear side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
GENERAL INFORMATION 1·5 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (FOR USA AND CANADA) R M Use only unleaded gasoline of at least 90 pump octane ( ~ ). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible. FUEL (FOR OTHER COUNTRIES) Gasoline used should be graded 95 octane (Research Method) or higher. An unleaded gasoline is recommended.
1·6 GENERAL INFORMATION FRONT FORK OIL Use fork oil L01 or an equivalent fork oil. -- ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze.
GENERAL INFORMATION 1-7 BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.
1-8 GENERAL INFORMATION INFORMATION LABELS o o G) Noise label Cllinformation label @ Vacuum hose routing label @ Fuel caution label @ Fuel information label @ Manual notice label (f) Frame caution plate @ Warning screen label ® Warning steering label (j]) Tire air pressure label ® Warning safety label W ICES Canada label @ ID plate ® E-191D label dID Safety plate GSX-R1000 For E-03, 24, 33 For E-03, 28, 33 For E-33 For E-02, 24 o GSX-R1000UF o 0 o 0 For E-03, 33 0 0 0 0 0 0 0 0 0 0 o For E-2
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry mass . 2070 mm (81.5 in) . 715 mm (28.1 in) .. 1145 mm(45.1 in) . 1 410 mm (55.5 in) . 130 mm (5.1 in) . 820 mm (32.3 in) . 168 kg (370 Ibs) 169 kg (372Ibs) .......... E-33 ENGINE Type Number of cylinders Bore Stroke Displacement Compression ratio Fuel system Air cleaner Starter system Lubrication system Idle speed . .. . . . . . . . . .
1·10 GENERAL INFORMATION CHASSIS Front suspension Rear suspension Front fork stroke...................................................................... Rear wheel travel...... Steering angle......................................................................... Caster..................................................................................... Trail......................................................................................... Turning radius Front brake....... Rear brake.............
GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country (-ies) and area (-s). MODEL GSX-R1000 GSX-R1000UF CODE E-02 E-03 E-19 E-24 E-28 E-33 E-19 COUNTRY or AREA U.K. U.S.A. (Except for california) EU Australia Canada California (U.S.A.
PERIODIC MAINTENANCE 2-1 I PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE...•..•.•••.•...••....•...............................2- 2 PERIODIC MAINTENANCE CHART ....................•.•......•.....•.......•.••.......2- 2 LUBRICATION POINTS ...................................................................•......2- 4 MAINTENANCE AND TUNE-UP PROCEDURES.....................•...•...............2- 5 AIR CLEANER 2- 5 SPARK PLUG •..••..••....•..••..•..••.......••..••....•..•.•.....•..•..............
2·2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, miles and time for your convenience. IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.
PERIODIC MAINTENANCE ~I Item miles km months Brake fluid Tires Steering Front forks Rear suspension Exhaust pipe bolts and muffler bolt and nut Chassis bolts and nuts 600 1 000 1 I T T NOTE: t-tnsoect and clean, adjust, replace or lubricate as necessary; R=Replace; T=Tighten 4 000 7500 11 000 12 000 18 000 6 000 12 18 6 I I I Replace every 2 years.
2-4 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. ~~ o ~ Brake pedal pivot and footrest pivot A Clutch lever holder NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
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 (4000 miles, 6 months). Replace every 18 000 km (11 000 miles, 18 months). • Remove the front and rear seats. (c::::rS-6) • Lift and support the fuel tank. (c::::rS-S) • Remove the air cleaner element by removing the screws. • Carefully use air hose to blow the dust from the cleaner element.
2-6 PERIODIC MAINTENANCE SPARK PLUG Inspect at 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7500 miles, 12 months) thereafter. SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front and rear seat. (c:::7'8-6) • Lift and support the fuel tank. (c:::7'5-5) • Remove the air cleaner box. (c:::7'5-15) • Disconnect all lead wire couplers from ignition coil/plug caps.
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) I-fcXiti 09900-20803: Thickness gauge ELECTRODE'S CONDITION • Check the condition of the electrode. • If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc. \Sl I ICAUTION! Confirm the thread size and reach when replacing the plug.
2·8 PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (15 000 miles, 24 months). • • • • • Remove the right under cowling. (c::::Ta-3) Remove the front and rear seats. (c::::Ta-6) Lift and support the fuel tank. (c::::TS-S) Remove the spark plugs. (c::::T2-6) Remove the cylinder head covers. (c::::T3-1S) The valve clearance specification is different for intake and exhaust valves.
PERIODIC MAINTENANCE • Turn the crankshaft to bring the "Top" line on the starter clutch to the index mark and also to bring the notches ® on the left ends of both camshafts (Ex and In) to the positions as shown. ® Front <¢:::l • In this condition, read the valve clearance at the valves ® (In and Ex of No.4 cylinder, Ex of No.3 and In of No.2). • If the clearance is out of specification, adjust the clearance.
2-10 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (c::::r3-16) • Remove the tappet and shim by fingers or magnetic hand. • Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated. • Select a replacement shim that will provide a clearance within the specified range.
-- ( -:::: Z -f TAPPET SHIM SELECTION TABLE [INTAKE] TAPPET SHIM NO. (12892-05COO-XXX) » "m ~ I TAPPET SHIM SET (12800-05830) I SUFFIX NO. MEASURED VALVE CLEARANCE (mm) PRESENT SHIM SIZE (mm) 120 125 130 135 140 145 150 155 160 165 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 <. <, 170 175 180 185 190 195 200 205 210 215 220 ,7() 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.(;jQ 1.65 1.70 1.
->< ~ m TAPPET SHIM SELECTION TABLE [EXHAUST] TAPPET SHIM NO. (12892-05COO-XXX) N ::I: :tao "'tJ m c:: en :D !a c (") oC -I I TAPPET SHIM SET (12800-05830) I SUFFIX NO. MEASURED VALVE CLEARANCE (mm) 0.05-0.09 0.10-0.14 0.15-0.19 PRESENT SHIM SIZE (mm) 120 125 130 135 140 145 150 155 160 170 165 175 180 185 190 195 200 205 210 215 s: - » m Z ...... z » z (') m 220 m 1.20 i- 1.60 ~.~ 1.65 1.70 1.75 1.65 1.30 1.35 1.40 1.45 1.50 1.35 1.40 1.45 1.
PERIODIC MAINTENANCE I i! ~ ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 1 months) and every 18 000 km (11 000 miles, 18 months) thereafter. ENGINE OIL REPLACEMENT • Remove the under cowling. (c:=ra-3) • Keep the motorcycle upright.
2-14 PERIODIC MAINTENANCE OIL FILTER REPLACEMENT • Drain the engine oil as described in the engine oil replacement procedure. • Remove the oil filter G) with the special tool. l;!fotl 09915-40610: Oil filter wrench • Apply engine oil lightly to the gasket of the new oil filter before installation. • Install the new oil filter. Turn it by hand until you feel that the oil filter gasket contacts the oil filter mounting surface. Then, tighten the oil filter two full turns with the special tool.
PERIODIC MAINTENANCE • Remove the two bolts and cover. • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. FUEL LINE Inspect initially at 6 000 km (4000 miles, 6 months). Replace every 4 years. • Inspect the fuel hose G) for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 1 month) and every 6000 km (4 000 miles, 6 months) thereafter.
2·16 PERIODIC MAINTENANCE THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 1 months) (E-33 only) and every 12 000 km (7 500 miles, 12 moths). Inspect the throttle valve synchronization periodically. (c::::TS-2S) EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) Inspect every 12 000 km (7500 miles, 12 months). Replace vapor hose every 4 years. Inspect the evaporative emission control system periodically.
PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Adjust the throttle cable play ® as follows. MINOR ADJUSTMENT 1st step: • Loosen the lock-nut CD of the throttle returning cable (2) and fully turn in the adjuster @. 2nd step: • Loosen the lock-nut @ of the throttle pulling cable @. • Turn the adjuster @ in or out until the throttle cable play (at the throttle grip) ® is between 2.0 - 4.0 mm (0.08 - 0.
2·18 PERIODIC MAINTENANCE MAJOR ADJUSTMENT • Lift and support the fuel tank with its prop stay. (c::::::r5-5) • Loosen the lock-nuts CD of the throttle returning cable CZl. • Turn the returning cable adjuster @ to obtain proper cable play. • Loosen the lock-nuts @ of the throttle pulling cable @. • Turn the pulling cable adjuster @ in or out until the throttle cable play ® should be 2.0 - 4.0 mm (O.OS - 0.16 in) at the throttle grip. • Tighten the lock-nuts @ securely while holding the adjuster @.
~ PERIODIC MAINTENANCE I COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 6 months). Replace engine coolant every 2 years. Replace radiator hoses every 4 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Remove the under cowling. (c::::ra-3) • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir.
2·20 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. • Start up the engine and bleed air from the radiator inlet completely. • Add engine coolant up to the radiator inlet. • Repeat the above procedure until no air cames from the radiator inlet.
PERIODIC MAINTENANCE RADIATOR HOSES • Remove the under cowling. (c::::T8-3) • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one.
2-22 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.
PERIODIC MAINTENANCE • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. _ Drive chain 20-pitch length: Service limit: 319.4 mm (12.57 in) ADJUSTING • Loosen or tighten both chain adjuster bolts CD until there is 20 - 30 mm (0.8 - 1.2 in) of slack at the middle of the chain between the engine and rear sprockets as shown.
2-24 PERIODIC MAINTENANCE CLEANING AND LUBRICATING • Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. I CAUTION I Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings. Use only kerosine to clean the drive chain. • After washing and drying the chain, oil it with a heavyweight motor oil. I CAUTION I * Do not use any oil sold commercially as "drive chain oil". Such oil can damage the O-rings.
PERIODIC MAINTENANCE BRAKE r l i (BRAKE) Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years. Replace fluid every 2 years. BRAKE FLUID LEVEL CHECK • Keep the motorcycle upright and place the handlebars straight. • Check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs.
2-26 PERIODIC MAINTENANCE Rear brake • The extent of brake pad wear can be checked by observing the grooved limit line ® on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (c::::T"8-65) I CAUTION I Replace the brake pads as a set, otherwise braking performance will be adversely affected. - BRAKE PEDAL HEIGHT • Loosen the lock-nut CD, • Turn the push rod ~ until the brake pedal is 60 - 70 mm (2.4 - 2.8 in) ® below the top of the footrest.
PERIODIC MAINTENANCE AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by "sponginess" of the brake lever and also by lack of braking force.
2-28 PERIODIC MAINTENANCE REAR BRAKE • Bleed air from the rear brake system in the same manner as front brake. NOTE: The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal. TIRES Inspect every 6 000 km (4 000 miles, 6 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation.
, '--' PERIODIC MAINTENANCE STEERING Inspect initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground.
2·30 PERIODIC MAINTENANCE EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7500 miles, 12 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque. <0 ~ . 1 tJo"", t!J 23 N·m ( 2.3 kgt-m) 16.5Ib-ft ~ ~. t!J 25 Nrn ~ ~:\ v / 2.5 kgt-m) ( 18.0 Ib-ft \~ ~ ') ~ t!J 23 N·m 2.3 kgt-m) ( 16.5Ib-ft "<, ~ ./(@C@ 8 ~." ~~ t!J 23 Nrn 2.3 kgt-m) ( 16.
PERIODIC MAINTENANCE 2·31 CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 1 month) and every 6000 km (4000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-32 for the locations of the following nuts and bolts on the motorcycle.
2·32 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE 2-33 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
2-34 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 100 - 400 kPa (1.0 - 4.0 kgf/cm 2 , 14 - 57 psi) at 3 000 r/min., Oil temp. at 60°C (140 OF) If the oil pressure is lower or higher than the specification, the following causes may be considered.
ENGINE 3·1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE 3- 2 ENGINE REMOVAL AND INSTALLATION....................•..............................3- 3 ENGINE REMOVAL ..................................................•.............................3- 3 ENGINE INSTALLA TION.................•............••...........••...........•...............3-10 ENGINE DiSASSEMBLy.......................................................•.......................
3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions.
ENGINE 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. (c:::::TS-3) • Remove the front and rear seats (seat tail cover). (c:::::TS-6) • Lift and support the fuel tank with the prop stay. (c:::::TS-S) • Disconnect the battery 8 lead wire. • Drain engine oil.
3·4 ENGINE • Remove the air cleaner box. (c::::T5-15) • Remove the throttle body. (c::::T5-16) OIL COOLER • Remove the oil cooler pipes. • Remove the oil cooler. RADIATOR • Disconnect the reservoir inlet hoses.
ENGINE • Disconnect the cooling fan coupler CD. • Disconnect the cooling fan thermo-switch coupler (2). • Remove the radiator mounting bolts. • Remove the radiator. I CAUTION I I Be careful not to bent the radiator fin. • Remove the front engine cover. EXHAUST PIPE AND MUFFLER • Remove the exhaust pipe bolts. • With the muffler connecting bolt loosened, remove the exhaust pipe.
3·6 ENGINE • Remove the radiator mounting bracket G) and the oil cooler mounting bracket (2). ELECTRIC PARTS • Disconnect the oil pressure switch lead wire G) and remove it from the clamps. • Disconnect the starter motor lead wire (2). • Disconnect the ground lead wire @. • Disconnect the crankshaft position sensor coupler @. • Disconnect the gear position switch coupler @. • Disconnect the ECT sensor coupler @. • Disconnect the generator coupler (J).
ENGINE • Disconnect the couplers from each ignition coil/plug cap and camshaft position sensor. ! CAUTION I Do not remove the ignition coil/plug cap before disconnecting its coupler. • Remove the ignition coils/plug caps. I CAUTION I * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage. * Be careful not to drop the ignition coil/plug cap to prevent its short or open circuit. ENGINE SPROCKET AND GEAR SHIFT LEVER • Remove the gearshift lever.
3-8 ENGINE • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut @. • Loosen the left and right chain adjusters @. • Push the rear wheel forward and make sure that the drive chain has enough slack. • Disengage the drive chain from the rear sprocket. • Remove the engine sprocket @. ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolts ® and ©. i_ .
ENGINE • Loosen the engine mounting pinch bolts CD and (2). • Remove the engine mounting bolts @ and ©. • Remove the engine mounting nut @. • Remove the engine mounting thrust adjuster lock-nut (f) with the special tool. • Loosen the engine mounting thrust adjuster @ fully. Ir1iotl 09940-14990: Engine mounting thrust adjuster socket wrench • Remove the engine mounting nut @. • Loosen the engine mounting thrust adjuster lock-nut @ with the special tool. • Loosen the engine mounting thrust adjuster ®.
3·10 ENGINE • Remove the engine mounting bolts and gradually lower the front side of the engine. Then, take off the drive chain from the driveshaft. • Remove the engine assembly. ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: Be careful not to damage the frame and engine when installing the engine. • Before installing the engine, install the spacer CD.
ENGINE • Tighten all engine mounting bolts and nuts to the specified torque. (c:::::r3-12) NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. • Tighten the engine mounting pinch bolt to the specified torque.
3-12 ENGINE Left¢::l c::> Right @ © r==r===r=;==r--- @ @ ~====="~/n(® ~ ITEM N·m kgf-m Ib-ft ®@©© 55 5.5 39.8 @@ 75 7.5 54.0 (1)(2) 23 2.3 16.5 ®® 23 2.3 16.5 CV@ 45 4.5 32.5 LENGTH ITEM mm in ®© @© 45 1.77 55 2.17 ®® 215 8.46 Spacer @@ 30.5 1.20 Adjuster ®® 40 1.
ENGINE • Install the engine sprocket and the washer. • Apply a small quantity of THREAD LOCK to the drive shaft thread portion. ~99000-32050: THREAD LOCK "1342" • Tighten the engine sprocket nut CD to the specified torque. ~ Engine sprocket nut: 115 N·m (11.5 kgf-m, 83.2 Ib-ft) 1,,-, • Install the speed sensor rotor. • Tighten the speed sensor rotor bolt to the specified torque. ~ Speed sensor rotor bolt: 23 N·m (2.3 kgf-m, 16.
3-14 ENGINE • Install the radiator mounting bracket CD and oil cooler bracket ~. • Install the exhaust pipe. I CAUTION I I Replace the gaskets with new ones. ~ Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) ~ Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) • Fit the new a-ring @. • Apply THREAD LOCK to the bolts, install the oil cooler pipe union. 'ttD 99000-32050: THREAD LOCK "1342" ~ Oil cooler union bolt: 10 N·m (1.0 kgf-m, 7.
ENGINE ENGINE DISASSEMBLY I CAUTION I Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions. • Remove the spark plugs. ([72-6) STARTER MOTOR • Remove the starter motor. PAIR CONTROL VALVE • Remove the PAIR control valve CD. CYLINDER HEAD COVER • Remove the cylinder head cover and its gaskets.
3·16 ENGINE • Remove the dowel pins and O-rings. CAMSHAFTS • Remove the valve timing inspection cap CD. • Turn the crankshaft to bring the line ® on the starter clutch to the index mark ® of the valve timing inspection hole and also to bring the cams to the position as shown. • Remove the cam chain tension adjuster cap bolt ~. • Remove the cam chain tension adjuster with the spring and ball.
ENGINE • • • • Remove Remove Remove Remove the the the the cam chain guide @, intake camshaft journal holder @. exhaust camshaft journal holder @. dowel pins. I CAUTION ! Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally. • Remove the intake camshaft @. • Remove the exhaust camshaft (f). I~ CYLINDER HEAD • Remove the water hose CD. • Remove the thermostat cover ~ and thermostat.
3·18 ENGINE CLUTCH • Remove the clutch cover. • Hold the clutch housing with the special tool. I CAUTION I Do not damage the clutch plates by the special tool. i-Mot, 09920-53740: Clutch sleeve hub holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. • Remove the pressure plate and clutch drive plates and driven plates. • Remove the spring washer CD and washer (2). • Remove the clutch push piece @, bearing @ and the thrust washer@.
ENGINE • Unlock the clutch sleeve hub nut. • Hold the clutch sleeve hub with the special tool. ,Qt. 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the concaved washer @, washer @, clutch sleeve hub @ and washer 0. • Remove the spacer @ and bearing ®. • Remove the primary driven gear assembly @. NOTE: If it is difficult to remove the primary driven gear, rotate the crankshaft. • Remove the oil pump drive gear gear assembly W. • Remove the thrust washer @.
3·20 ENGINE OIL PUMP • Remove the snap ring CD. • Remove the oil pump driven gear (2). NOTE: Do not drop the circlip crankcase. CD, the pin @ and the washer @ into the • Remove the pin @ and the washer @. • Remove the oil pump @. GEAR SHIFT SYSTEM • With the snap ring CD and washer removed, remove the gearshift shaft assembly (2). • Remove the gearshift cam plate bolt @ and gearshift cam plate @. • Remove the gearshift cam stopper @.
ENGINE STARTER IDLE GEAR • Remove the starter idle gear cover. • Remove the dowel pins and gasket. • Remove the shaft CD, washer r2), starter idle gear No.1 @, concaved washer, bearing and washer. • Remove the starter clutch cover and clamp. • Remove the dowel pins and gasket. • Remove the wave washer @, the starter idle gear No.2, @ and its shaft @.
3-22 ENGINE STARTER CLUTCH • Hold the starter clutch with the special tool. iKiOti 09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. • Remove the starter clutch assembly and washer. CAM CHAIN, CAM CHAIN TENSIONER, CAM CHAIN GUIDE • Remove the cam chain tensioner CD and cam chain guide ~. • Remove the cam chain @ and cam chain drive sprocket @. CKP SENSOR CKP SENSOR INSPECTION (L7'4-28) • Remove the CKP sensor CD.
ENGINE GENERATOR COVER • Remove the generator cover. GENERATOR ROTOR • Hold the generator rotor with the special tool. Irut. 09930-44520: Rotor holder • Remove the generator rotor bolt. ® of suitable size to the left end of crankshaft. SUITABLE BOLT ® [M12, length: 28 - 38 mm] • Install a bolt • Remove the generator rotor with the special tool. IrThit. 09930-34980: Rotor remover 28-38 mm WATER PUMP • Disconnect the clamp CD. • Remove the water hose (2) and inlet cover @.
3-24 ENGINE GEAR POSITION SWITCH • Remove the gear position switch CD. • Remove the switch contacts ~ and springs @. BREATHER COVER • Remove the breather cover CD. OIL FILTER • Remove the oil filter with the special tool. (c:::::r2-14) ,;!Oot, 09915-40610: Oil filter wrench OIL PAN • Remove the oil pan CD.
ENGINE Oil PRESSURE REGULATOR • Remove the oil pressure regulator CD. Oil PRESSURE SWITCH • Remove the oil pressure switch (2). Oil STRAINER • Remove the oil strainer @ and O-ring. lOWER CRANK CASE • Remove the lower crankcase bolts (6 mm). l~ • Remove the lower crankcase bolts (8 mm). • Remove the lower crankcase assembly. TRANSMISSION • Remove the transmission and O-rings.
3·26 ENGINE MIDDLE CRANKCASE • Remove the crankcase bolts. NOTE: Loosen the crankcase bolts diagonally with the smaller sizes first. • Remove the crankcase bolts (8 mm). • Remove the crankshaft journal bolts (9 mm). BALANCER SHAFT • Remove the balancer shaft CD. CRANKSHAFT • Loosen the bearing cap bolts by using 12 mm, 12 point socket wrench, and tap the bearing cap bolt lightly with plastic hammer to remove the bearing cap. • Remove the O-ring CD. • Remove the crankshaft and thrust washers (2).
ENGINE PISTON AND CONROD • Push the conrad upward and remove the piston and conrad from the upper crankcase. I CAUTION I Be careful not to damage the cylinder wall by the conrod. • Remove the piston pin circlip. • Separate the piston and conrad by driving out the piston pin. NOTE: Scribe the cylinder number on the head of the piston.
3·28 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE I CAUTION I 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 CAM POSITION SENSOR • Install the oil seal CD and cam position sensor (2). NOTE: When installing, clean the cam position sensor's face. ~ Cam position sensor bolt: 8 N·m (0.8 kgf-m, 5.
ENGINE PAIR CONTROL VALVE • Inspect that air flows through the PAIR control valve air inlet port to the air outlet ports. • If air does not flow out, replace the PAIR valve with a new one. • Connect the vacuum pump gauge to the vacuum port of the control valve as shown in the photograph. • Apply negative pressure of the specification slowly to the control valve and inspect the air flow. • If air does not flow out, the control valve is in normal condition.
3·30 ENGINE CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge to read the clearance at the widest portion, which is specified as follows: _ Camshaft journal oil clearance: Service Limit: (IN & EX): 0.150 mm (0.0059 in) lrUt! 09900-22301: Plastigauge 09900-22302: Plastigauge NOTE: Install camshaft journal holders to their original positions.
ENGINE • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. LD Journal holder 1.0.: Standard: (IN & EX): 24.012 - 24.025 mm (0.9454 - 0.9459 in) IrUt! 09900-20602: Dial gauge (111000, 1 mm) 09900-22403: Small bore gauge (18 - 35 mm) LD Camshaft journal 0.0.: Standard (IN & EX): 23.
3-32 ENGINE CAM CHAIN TENSIONER INSPECTION • Check the contacting surface of the cam chain tensioner. • If it is worn or damaged, replace it with a new one. CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guides. • If they are worn or damaged, replace them with the new ones. CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY • Remove the tappets G) and shims (2) by fingers or magnetic hand. I CAUTION I Identify the position of each removed part.
ENGINE • Using special tools, compress the valve springs and remove the two cotter halves @ from valve stem. ITUti 09916-14510: Valve lifter 09916-14910: Valve lifter attachment 09916-84511: Tweezers I CAUTION I Be careful not to damage the tappet sliding surface with the special tool. • Remove the valve spring retainer @ and valve springs • Pull out the valve from the other side. • Remove the oil seal ®. CD and the spring seat (2). I CAUTION I I Do not reuse the removed oil seal.
3-34 ENGINE CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head. ~ Cylinder head distortion: Service Limit: 0.20 mm (0.
I ,f. , , ENGINE VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. • Measure the valve stem deflection in two directions, perpendicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one. ~ Valve stem deflection (IN & EX): Service Limit: 0.35 mm (0.014 in) .root.
3·36 ENGINE VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. ,rootl 09916-53310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No. 11115-11070) • Re-finish the valve guide holes in cylinder head with the reamer and handle.
ENGINE VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure. • Check that the transferred blue on the valve face is uniform all around and in center of the valve face.
3-38 ENGINE • When installing the solid pilot CD, rotate it slightly. Seat the pilot snugly. Install the 45 0 cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45 0 cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width @ after every cut. """" " 45 • If the valve seat is pitted or burned, use the 45 dition the seat some more.
ENGINE I r~ BOTTOM NARROWING CUT • If the contact area ® is too wide or too low, use the 60 0 cutter to narrow and raise the contact area. I , , ",, ", 600(:~ FINAL SEAT CUT • If the contact area ® is too low or too narrow, use the 45 cutter to raise and widen the contact area. 0 NOTE: After cutting the 15 0, 30 0 and 60 0 angles, it is possible that the valve seat (45 0 ) is too narrow. If so, re-cut the valve seat to the correct width.
3·40 ENGINE • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. A WARNING Always use extreme caution when handling gasoline. VALVE STEM END CONDITION • Check the valve stem end face for pitting and wear. VALVE SPRING The force of the coil springs keeps the valve seat tight.
ENGINE VALVE AND VALVE SPRING REASSEMBLY • Install the valve spring seats. • Apply MOLYBDENUM OIL SOLUTION to each oil seal and press-fit them into position. CD, lIr MOLYBDENUM OIL SOLUTION I CAUTION I I Do not reuse the removed oil seals. • Insert the valves, with their stems coated with MOLYBDENUM OIL SOLUTION all around and along the full stem length without any break. I CAUTION I When inserting each valve, take care not to damage the lip of the oil seal.
3-42 ENGINE • Install the tappet shims and the tappets to their original position. NOTE: * Apply engine oil to the shim and tappet before fitting them. * When seating the tappet shim, be sure the figure printed surface faces the tappet. INTAKE PIPE • Remove the intake pipe. • Install the intake pipe in the following procedure. • Apply SUZUKI SUPER GREASE to the a-rings. • Apply THREAD LOCK to the screw and install the intake pipes.
ENGINE CLUTCH CLUTCH DRIVE PLATES INSPECTION NOTE: * Wipe off engine oil from the clutch drive plates with a clean rag. * Clutch drive plate NO.1: Green paint * Clutch drive plate NO.2: Brown paint • Measure the thickness of drive plates with a vernier calipers. • If each drive plate thickness is less than the limit, replace it with a new one. ~ Drive plate thickness: Service Limit: 2.42 mm (0.095 in) j£t1 09900-20102: Vernier calipers • Measure the claw width of drive plates with a vernier calipers.
3-44 ENGINE CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY • Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one. OIL PUMP INSPECTION • Rotate the oil pump by hand and check that it moves smoothly. • If it does not move smoothly, replace the oil pump assembly. !CAUTIONI * Do not attempt to disassemble the oil pump assembly. * The oil pump is available only as an assembly.
ENGINE WATER PUMP (c::?7-14) GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. CD Washer @ Plate return spring (2) Snap ring @ Washer @ Gearshift shaft return spring (J) Snap ring @ Gearshift cam drive plate GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION • Inspect the gearshift shaft/gearshift arm for wear or bend. • Inspect the return springs for damage or fatigue. • Replace the arm or spring if there is anything unusual.
3·46 ENGINE OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regulator with a new one. OIL STRAINER • Inspect the oil strainer body for damage. • Clean the oil strainer if necessary.
ENGINE TRANSMISSION • Disassemble the countershaft and drive shaft. Pay attention to the following point. • Remove the 6th drive gear circlip from its groove and slide it towards the 3rd/4th drive gear. • Slide the 6th CD and 2nd C2l drive gears toward the 3rd/4th drive gears, then remove the 2nd drive gear circlip @.
3-48 ENGINE REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE: * Rotate the bearings by hand to inspect for smooth rotation. Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE to it.
ENGINE 3·49 TRANSMISSION PARTS LOCATION C9J 8 ~~ 8 @_.. . .
3·50 ENGINE CYLINDER CRANKCASE SERVICING (c::=r3-53) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder. _ Cylinder distortion: Service Limit: 0.20 mm (0.
ENGINE 3·51 PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) from the piston skirt end. • If the measurement is less than the limit, replace the piston. _ Piston diameter: Service Limit: 72.880 mm (2.8693 in) at 15 mm (0.6 in) from the skirt end iT'Oot, 09900-20203: Micrometer (50 - 75 mm) PISTON TO CYLINDER CLEARANCE • Subtract the piston diameter from the cylinder bore diameter.
3·52 ENGINE PISTON RING TO GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceed the limit, replace both the piston and piston rings. 1.:&1.09900-20803: Thickness gauge 09900-20205: Micrometer (0 - 25 mm) _ Piston ring to groove clearance: Service Limit (1st) : 0.18 mm (0.0071 in) (2nd): 0.15 mm (0.0059 in) _ Piston ring groove width: Standard (1st) : 1.01 - 1.03 mm (0.0398 - 0.0406 in) (2nd): 0.81 - 0.83 mm (0.
ENGINE CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer fork retainer ~ from the lower crankcase. CD and gearshift • Remove the gearshift fork shafts and gearshift forks from the lower crankcase. • Remove the gear shift cam and its bearing. GEARSHIFT FORK TO GROOVE CLEARANCE • Using a thickness gauge, check the gearshift fork clearance in the groove of its gear.
3·54 ENGINE GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier calipers. ~ Shift fork thickness: Standard: 4.8 - 4.9 mm (0.189 - 0.193 in) ,roEt, 09900-20102: Vernier calipers • Inspect the gearshift cam bearing for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Inspect the gearshift cam bearing CD, and gearshift shaft bearings (2), @ for abnormal noise and smooth rotation while they are in the crankcase.
ENGINE • Remove the oil seal @. • Remove the gearshift shaft bearing with the special tool. jT'OOt, 09921-20240: Bearing remover set (15 mm) Installation • Install the bearings with the special tool. j.;!oot, 09913-70210: Bearing installer set (15 mm) NOTE: The stamped mark side of the gearshift shaft bearing faces outside. • Install the oil seal CD. • Install the gearshift cam with the bearing. NOTE: The stamped mark side of the gearshift cam bearing faces outside.
3·56 ENGINE • Install the gearshift forks and their shafts as shown. CD For 3rd/4th drive gears (2) For 6th driven gear @ For 5th driven gear • Apply a small quantity of THREAD LOCK to the bearing retainer screws and the shift fork shaft retainer bolt. • Tighten them to the specified torque. ~ 99000-32050: THREAD LOCK "1342" ~ Bearing retainer screw: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) Gearshift fork shaft retainer bolt: 19 N·m (1.9 kgf-m, 13.7Ib-ft) . ' - .
ENGINE OIL JET Removal • Remove the piston cooling oil jets case. eD from the upper crank- • Remove the oil jet (for transmission) from the lower crankcase. • Remove the oil jet (2) (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • Check the oil jets for clogging. • If they are clogged, clean their oil passage with a proper wire and compressed air.
3-58 ENGINE Installation • Fit the new O-rings CD to each piston cooling oil jets as shown and apply engine oil to them. [CAUTION I Use the new O-rings to prevent oil pressure leak. NOTE: Be sure the oil holes ® on each piston cooling oil jet faces the top when installing them. • Install each piston cooling oil jet with the bolt. NOTE: Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque. ~ 99000-32050: THREAD LOCK "1342" ~ Piston cooling oil jet bolt: 10 N·m (1.
ENGINE PLUGS • Install each plug. ~ G) Water jacket plug: 9.5 N·m (0.95 kgf-m, 6.9 Ib-ft) ell Oil gallery plug (upper crankcase): 18 N·m (1.8 kgf-m, 13.0 Ib-ft) @ Oil gallery plug (lower crankcase): 35 N·m (3.5 kgf-m, 25.3Ib-ft) @ Oil gallery plug (cylinder head): 10 N·m (1.0 kgf-m, 7.0 Ib-ft) NOTE: Apply engine coolant to the a-ring. I, I ~.
3-60 ENGINE BALANCER SHAFT DISASSEMBLY • Draw out the balancer gear and damper 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. 1r MOLYBDENUM OIL SOLUTION • Set the dampers and install the balancer shaft to balancer gear. NOTE: * Fit the stopper of the balancer shaft between the dampers. * Align the line ® on the balancer shaft with the punch @ on the balancer gear.
ENGINE • Remove the lower crankcase and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. _ Balancer shaft journal oil clearance: Standard: 0.020 - 0.044 mm (0.00079 - 0.00173 in) Service Limit: 0.080 mm (0.031 in) • If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table. • Check the corresponding crankcase journal 1.0.
3·62 ENGINE INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part ® first and press the other end. I CAUTION I Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.
ENGINE CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with "V" blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. • Replace the crankshaft if the runout is greater than the limit. _ Crankshaft runout: Service Limit: 0.05 mm (0.002 in) 'TiKI 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) CONROD SMALL END I.D.
3·64 ENGINE CONROD BIG END SIDE CLEARANCE • Inspect the conrad side clearance by using a thickness gauge. • If the clearance exceeds the limit, remove the conrad and inspect the conrad big end width and the crank pin width. • If the width exceed the limit, replace conrad or crankshaft. _ Conrod big end side clearance: Service Limit: 0.30 mm (0.012 in) IT'OOti 09900-20803: Thickness gauge _ Conrod big end width: Standard: 19.95 - 20.00 mm (0.7854 - 0.
ENGINE • Remove the bearing caps and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. _ Conrod big end oil clearance: Standard: 0.032 - 0.056 mm (0.0013 - 0.0022 in) Service Limit: 0.080 mm (0.0031 in) • If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table. • Check the corresponding conrod I.D. code number ("1" or "2") ®.
3-66 ENGINE B Crank pin 0.0. 0.0. specification 34.992 - 35.000 mm (1.3776 - 1.3780 in) 34.984 - 34.992 mm (1.3773 - 1.3776 in) 34.976 - 34.984 mm (1.3770 - 1.3773 in) Code 1 2 3 IroOt! 09900-20202: B Micrometer (25 - 50 mm) Bearing thickness Color (Part No.) Green (12164-40FOO-OAO) Black (12164-40FOO-OBO) Brown (12164-40FOO-OCO) Yellow (12164-40FOO-ODO) Thickness 1.480 - 1.484 mm (0.0583 - 0.0584 in) 1.484 - 1.488 mm (0.0584 - 0.0586 in) 1.488 - 1.492 mm (0.0586 - 0.0587 in) 1.492 - 1.496 mm (0.
t ENGINE 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. 1m 09900-22301: Plastigauge [CAUTION I Never rotate the crankshaft when a piece of plastigauge is installed. • Mate the lower crankcase with the upper crankcase, and tighten the crankcase bolts (M9) in the following two steps in the indicated order.
3·68 ENGINE • Check the corresponding crankcase journal I.D. code number @, "A" or "B" which is stamped on the rear of upper crankcase. • Check the corresponding crankshaft journal O.D. code number @, "A", "B" or "C" which is stamped on the crankshaft. _ Bearing selection table Crankshaft journal 0.0. @ Code A B Crankcase 1.0. @ _ A Green Black B Black Brown C Brown Yellow Crankcase 1.0. specification Code A B 1.0. specification 38.000 - 38.008 mm (1.4961 - 1.4964 in) 38.008 - 38.016 mm (1.
ENGINE _ Crankshaft journal 0.0. specification 0.0. specification 34.992 - 35.000 mm (1.3776 - 1.3780 in) 34.984 - 34.992 mm (1.3773 - 1.3776 in) 34.976 - 34.984 mm (1.3770 - 1.3773 in) Code A B C !Tuh 09900-20202: _ Micrometer (25 - 50 mm) Bearing thickness specification Color (Part No.) Green (12229-40FOO-OAO) Black (12229-40FOO-OBO) Brown (12229-40FOO-OCO) Yellow (12229-40FOO-ODO) Thickness 1.488 - 1.492 mm (0.0586 - 0.0587 in) 1.492 - 1.496 mm (0.0587 - 0.0589 in) 1.496 - 1.500 mm (0.0589 - 0.
3·70 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. ®: Right-side thrust bearing CD: Left-side thrust bearing NOTE: Pull the crankshaft to the right-side, so that there is no clearance on the right-side thrust bearing. _ Thrust clearance: Standard: 0.070 - 0.110 mm (0.0028 - 0.0043 in) iT'Oot.
ENGINE _ Thrust bearing selection table Clearance before inserting left-side thrust bearing 2.570 - 2.590 mm (0.1012 - 0.1020 in) 2.550 - 2.570 mm (0.1004 - 0.1012 in) 2.530 - 2.550 mm (0.0996 - 0.1004 in) 2.510 - 2.530 mm (0.0988 - 0.0996 in) 2.490 - 2.510 mm (0.0980 - 0.0988 in) 2.470 - 2.490 mm (0.0972 - 0.0980 in) 2.440 - 2.470 mm (0.0961 - 0.0972 in) Color (Part No.
3·72 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 reassembling. • Be sure to install the following items to the crankcase. * Crankshaft journal bearing (c:::.:r3-67) * Gearshift fork (c:::.:r3-56) * Gearshift fork shaft (c:::.:r3-56) * Gearshift shaft bearing (c:::.:r3-54) * Gearshift cam bearing (c:::.
ENGINE • 1st ring and 2nd ring have letters "R" and "RN" marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located. EX • Upper side rail • Top ring IN • Spacer PISTON AND CONROD • Rub a small quantity of MOLYBDENUM OIL SOLUTION onto each piston pin. 1Ir MOLYBDENUM OIL SOLUTION • Assemble the piston and conrod.
3·74 ENGINE • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent must be brought to the exhaust side. ® of each piston head I CAUTION I Be careful not to damage the cylinder wall and piston jet by the conrod. • Check that ID code ® on the each conrod faces intake side. I CAUTION I I Be sure to clean the conrod big end. • Apply MOLYBDENUM OIL SOLUTION to the crank pin bearings surface.
ENGINE • Set the crankshaft to the conrods and upper crankcase. • Apply MOLYBDENUM OIL SOLUTION to the crank pin and bearing surface. 1r MOLYBDENUM OIL SOLUTION I CAUTION I I Be sure to clean the conrod big end. • When fitting the conrod cap, make sure that I.D. code each conrod faces intake valve side. ® on • Apply engine oil to the bearing cap bolts. • Tighten the bearing cap bolt by using a 12 mm, 12 point socket wrench in the following two steps. ~ Conrod bearing cap bolt: Initial: 21 N·m (2.
3·76 ENGINE • Insert the right and left-thrust bearings with oil groove ing the crank web. ® fac- NOTE: Right-thrust bearing has green painting. BALANCERSHAFT • Install the thrust washers CD, CZl and oil seal @. • Apply MOLYBDENUM OIL SOLUTION to each balancershaft journal lightly. ""if MOLYBDENUM OIL SOLUTION • Set the balancershaft so that its punch mark the index ® on crankshaft. ® is aligned with CRANKCASE • Clean the mating surfaces of the crankcases.
ENGINE • Apply SUZUKI BOND to the mating surface of the middle crankcase. ~99104-31140: SUZUKI BOND "1207B" (USA) II(iffiJ 99000-31110: SUZUKI BOND "1215" (Others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes. * Take extreme care not to apply any BOND to the oil hole, oil groove and bearing.
3·78 ENGINE • Tighten the other crankcase bolts a little at a time to equalize the pressure. ~ Crankcase bolt: (M8) initial: 15 N·m (1.5 kgf-m, 10.8Ib-ft) Final : 26 N·m (2.6 kgf-m, 19.0 Ib-ft) ~ Crankcase bolt: (M6) initial: 6 N·m (0.6 kgf-m, 4.5 Ib-ft) Final : 11 N·m (1.1 kgf-m, 8.0 Ib-ft) NOTE: Fit the new gasket to the crankcase bolt ®. NOTE: After the crankcase bolts have been tightened, check if the crankshaft rotates smoothly.
ENGINE TRANSMISSION • Install the bearing pins crankcase. CD and the C-ring (2) on the upper • Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove on the bearing and the bearing pin with the indent on the bearing. • Install the driveshaft assembly on the upper crankcase. NOTE: Align the bearing ring with the groove on the crankcase and the bearing pin with the indent on the bearing. • Install the oil seal @.
3·80 ENGINE • Apply SUZUKI BOND to the mating surface of the lower crankcase. • 12078]99104-31140: SUZUKI BOND "1207B" (USA) 1I(!ffiJ99000-31110: SUZUKI BOND "1215" (Others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes. * Take extreme care not to apply any BOND to the oil hole, oil groove and bearing.
ENGINE • Tighten the crankcase bolts a little at a time to equalize the pressure. ~ Crankcase bolt: (M6) initial: 6 Final : 11 (M8) initial: 15 Final: 26 N·m (0.6 kgf-m, 4.5 Ib-ft) N·m (1.1 kgf-m, 8.0 Ib-ft) N·m (1.5 kgf-m, 10.8 Ib-ft) N.m (2.6 kgf-m, 19.0 Ib-ft) NOTE: * Fit the new copper washer to the crankcase bolts ®. * Fit the new gasket washer to the crankcase bolts @. • Check that the driveshaft and countershaft rotate smoothly.
3-82 ENGINE OIL STRAINER • Install the O-ring. • Apply SUZUKI SUPER GREASE to the O-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) I-C-A-UT-I-O-N I Use the new O-ring to prevent oil leakage. • Install the oil strainer as shown. ~ Oil strainer bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) OIL PRESSURE REGULATOR • Apply SUZUKI SUPER GREASE to the O-ring and press in the oil pressure regulator to the crankcase.
ENGINE • Install the oil pan. -.-/ NOTE: Fit the gasket washer to the oil pan bolt ®. • Tighten the oil pan bolts diagonally to the specified torque. ~ Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) OIL PRESSURE SWITCH • Apply SUZUKI BOND to the thread part of the oil pressure switch CD and tighten it to the specified torque . • 1207~ 99104-31140: SUZUKI BOND "1207B" (USA) 99000-31140: SUZUKI BOND "1207B" (Others) ~ Oil pressure switch: 14 N·m (1.4 kgf-m, 10.
3·84 ENGINE GEAR POSITION SWITCH • Install the gear position switch contacts G) and the springs 12). • Apply the SUZUKI SUPER GREASE to the O-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the gear position switch @ as shown.
ENGINE WATER PUMP • Apply SUZUKI SUPER GREASE to the G-ring. ICAUTIONl Use the new O-ring to prevent oil leakage. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000·25010: SUZUKI SUPER GREASE "A" (Others) • Tighten the water pump mounting bolts to the specified torque. (!J Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) NOTE: Pass the gear position switch lead wire under the water pump lib ®. • Apply engine coolant to the G-ring. • Install the water inlet cover 0).
3·86 ENGINE • Install the generator rotor onto the crankshaft. • Install the rotor bolt with the washer. • Hold the generator rotor with the special tool and tighten its bolt to the specified torque. ,rodt, 09930-44520: Rotor holder ~ Generator rotor bolt: 120 N·m (12.0 kgf-m, 88.5 Ib-ft) GENERATOR COVER • Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.
ENGINE • Apply SUZUKI BOND light to the groove of the signal generator lead wire gromet. ~99104-31140: SUZUKI BOND "1207B" (USA) 99000-31140: SUZUKI BOND "1207B" (Others) CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft. CAM CHAIN TENSIONER AND CAM CHAIN GUIDE • Install the cam chain . • Apply a small quantity of THREAD LOCK to the cam chain tensioner bolt and cam chain guide bolt. • Install the cam chain tensioner CD, washer ~ and cam chain guide @.
3·88 ENGINE • Install the starter clutch assembly onto the crankshaft. NOTE: When install the starter clutch assembly, fit the concave part ® of the starter clutch onto the convex part @ of the crankshaft. • Install the starter clutch bolt with the washer. • Hold the starter clutch with special tool and tighten its bolt to the specified torque. ir'&5ti 09920-34830: Starter clutch holder ~ Starter clutch bolt: 55 N·m (5.5 kgf-m, 40.0 Ib-ft) STARTER IDLE GEAR • Install the starter idle gear NO.
ENGINE • Install the starter clutch cover and tighten its bolt as shown. NOTE: * Fit the wire clamp to the starter clutch cover bolt ® as shown. * Fit the new gasket washer to the starter clutch cover bolt @ as shown. I CAUTION I Use the new gasket washer to prevent oil leakage. (!J Starter idle gear cover bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) • Install the starter idle gear NO.1 shaft @, starter idle gear NO.1 ({), washer @, thrust washer @, bearing @ and con caved washer@.
3·90 ENGINE NOTE: Hook the return spring end to the stopper@. • Check the gearshift cam stopper moves smoothly. • Rocate the gearshift cam in the neutral position. • Install the gearshift cam stopper plate after aligning the gearshift cam pin ® with the gearshift cam stopper plate hole ®. I • Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque. ~ 99000-32050: THREAD LOCK "1342" ~ Gearshift cam stopper plate bolt: 13 N·m (1.3 kgf-m, 9.
ENGINE • Install the gearshift shaft/gearshift arm @ with the washers as shown. NOTE: Pinch the gearshift arm stopper(J) with return spring ends ©. • Install the washer @ and snap ring ®. OIL PUMP • Install the O-ring to the oil pump and apply grease to it. I CAUTION I Use the new O-ring to prevent oil leakage. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) NOTE: Set the oil pump shaft end to the water pump shaft.
3·92 ENGINE CLUTCH • Install the thrust washer onto the countershaft. NOTE: The chamfer side ® of the thrust washer faces inner side. • Install the oil pump drive gear CD to the primary driven gear assembly. NOTE: Be careful not to contact the primary driven gear with the crankweb when installing the clutch housing. • Install the primary driven gear assembly. NOTE: Be sure to engage the oil pump drive gear with driven gear and primary drive gear with driven gear.
ENGINE • Install the clutch sleeve hub @ onto the countershaft. • Install the washer @ and spring washer ([). NOTE: The convex side of the spring washer ([) faces outside. • Install the clutch sleeve hub nut. • Hold the clutch sleeve hub with the special tool. I.;oK, 09920-53740: Clutch sleeve hub holder • Tighten the clutch sleeve hub nut to the specified torque. ~ Clutch sleeve hub nut: 150 N·m (15.0 kgf-m, 108Ib-ft) • Lock the clutch sleeve hub nut with a center punch.
3·94 ENGINE • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. NOTE: Insert the outermost NO.1 drive plate claws ® of clutch housing as shown. ® to the other slits Direction of outside DRIVE PLATE: Drive Plate @ NO.2 Drive plate ® NO.1 .. 8 pcs [Green paint] 2 pes [Brown paint] DRIVE PLATE: @ No.1 Driven plate (Thickness): 2.3 mm (0.091 in) © No.2 Driven plate (Thickness): 2.0 mm (0.079 in) © No.1 Driven plate (Thickness): 2.6 mm (0.
ENGINE • Install the clutch pressure plate. • Install the clutch springs. • Hold the clutch housing with the special tool. I CAUTION I Be careful not to damage the clutch housing or clutch plates. i-footl 09920-53740: Clutch sleeve hub holder • Tighten the clutch spring set bolts to the specified torque. ~ Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) NOTE: Tighten the clutch spring set bolts diagonally.
3·96 ENGINE CYLINDER HEAD • Fit the dowel pins the cylinder. CD and the new cylinder head gasket ~ to I CAUTION I Use the new gasket to prevent gas leakage. • Place the cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Tighten the cylinder head bolts (M10) to the specified two-step torque with a torque wrench sequentially and diagonally. ~ Cylinder head bolt (M10): Initial: 25 N·m (2.5 kgf-m, 18.0 Ib-ft) Final: 51 N·m (5.1 kgf-m, 37.
ENGINE • Fit the gasket ® and tighten the EeT sensor gauge. (!J Water temp. gauge: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) • Install the thermostat. (c:r7-10) • Install the thermostat cover @. (!J Thermostat cover bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) NOTE: Fit the clamp to the bolt ®. • Install the water hose @.
3-98 ENGINE Camshaft • Turn the crankshaft clockwise with the box wrench and align the line ® on the starter clutch with the index mark @ of the valve timing inspection hole while keeping the cam chain pulled upward. I CAUTION I Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. I CAUTION I To adjust the camshaft timing correctly, be sure to align the line ® with the index mark @ and hold this position when installing the camshafts.
[ ENGINE f • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked "1" ®. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. • Bind the cam chain and the sprocket with a proper wire clamp CD to prevent the cam chain disengagement while installing the camshaft journal holders. • The other arrow marked "2" @ should now be pointing straight up.
3·100 ENGINE • Install the dowel pins CD. • Install the camshaft journal holders, intake and exhaust, and cam chain guide. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. NOTE: * Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly. * Each camshaft journal holder is identified with a cast-on letter ®.
I ENGINE Cam chain tension adjuster • Retract the push rod by pushing the stopper CD. • Install the ball C2l to the cam chain tension adjuster. • Install the new gasket. I CAUTION I Use the new gasket to prevent oil leakage. • Install the cam chain tension adjuster @ and tighten the mounting bolt. ~ Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) • Install the spring @. • Install the gasket @ and cam chain tension adjuster cap bolt @.
3·102 ENGINE / ~ 23N·m (2.3 kgf-m, 16.5Ib-ft) 10 N·m (1.0 kgf-m, 7.
ENGINE • Tighten the valve timing inspection plug (f) to the specified torque. ~ Valve timing inspection plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft) CYLINDER HEAD COVER • Pour engine oil in each oil pocket in the cylinder head. NOTE: Be sure to check the valve clearance. rc::=r2-8) • Install the dowel pins. • Install the a-rings. • Install the new gaskets to the cylinder head cover. • Apply SUZUKI BOND to the cam end caps of the gaskets as shown.
3·104 'I ENGINE PAIR CONTROL VALVE • Install the PAIR control valve CD. STARTER MOTOR • Apply SUZUKI SUPER GREASE to the O-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the starter motor CD. ~ Starter motor mounting bolt: 10 N·m (1.0 kgf-m, 7 Ib-ft) • Install the spark plugs.
FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERViCiNG 4- 2 ELETRICAL PARTS ..............................................•.....•.......................... 4FUSE ..•.....•...................•..................................•............•...........••............. 4ECMNARIOUS SENSORS..............................................................•...... 4ELECTRICAL CIRCUIT INSPECTION PROCEDURE 4USING TESTERS.•....................•.............................................................
FI SYSTEM DIAGNOSIS 4-1 "C41" FP RELA Y CIRCUIT MALFUNCTION .4-53 "C42" IG SWITCH CIRCUIT MALFUNCTlON .4-53 "C46" EXCV ACTUATOR CIRCUIT MALFUNCTION..........••.••.....•.....•.4-54 SENSORS 4-60 CMP SENSOR INSPECTION•.................................................................4-60 .4-60 CMP SENSOR REMOVAL AND INSTALLATlON CKP SENSOR INSPECTION ....•....•......•.................................................4-60 CKP SENSOR REMOVAL AND INSTALLATION ...•.................•............
4·2 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. ELETRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt. • With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully till the works when connecting it.
FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female terminal. Never push in the probe where male terminal is supposed to fit. • Check the male connector for bend and female connector for excessive opening.
4-4 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the Fl system instantly when reverse power is applied. • Removing any battery terminal of a running engine is strictly prohibited.
FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully. • Loose connection of connector/coupler.
4·6 FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler @ (between ® and © in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals ® and ©. • Disconnect the coupler @ and measure resistance between couplers ® and @. If no continuity is indicated, the circuit is open between couplers ® and @. If continuity is indicated, there is an open circuit between couplers @' and © or an abnormality in coupler @' or coupler ©.
FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts. Otherwise, diagnosis will be misled.
4·8 FI SYSTEM DIAGNOSIS USING TESTERS • Use the Suzuki multi-circuit tester set (09990-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the CB and 8 probes may cause the inside of the tester to burnout. • If the voltage and current are not known, make measurements using the highest range. • When measuring the resistance with the multi-circuit tester, 00 will be shown as 10.
FI SYSTEM DIAGNOSIS 4-9 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.
4·10 FI SYSTEM DIAGNOSIS COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL ATMOSPHERIC PRESSURE SENSOR SIGNAL DESCRIPTION When atmospheric pressure is low, the sensor sends the signal to the ECM and reduce the injection time (volume). ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (volume) is increased.
FI SYSTEM DIAGNOSIS 4-11 INJECTION TIMING The system employs a sequential, four-cylinder independent injection type, using the crankshaft position sensor (signal generator) to determine the piston position (injection timing and ignition timing) and the camshaft position sensor to identify the cylinder during operation, and these information are sent to the ECM. This makes it possible to inject the optimum volume of fuel in the best timing for the engine operating conditions.
"en- -< en -I m s: ""C » :x:J -I en r- o o » ::! o z ® Speedometer @ Engine coolant temperature sensor (ECTS) © Ignition coil (IG COIL) © Speed sensor ® Atmospheric pressure sensor (APS) eEl Camshaft position sensor (CMPS) © Intake air pressur sensor (lAPS) <8l Fuel injector (FI) CD Tip over sensor (TOS) i'" ......
:!! en ~ m Q) Intake air temperature sensor (IATS) ® Throttle position sensor (TPS) CD Crankshaft position sensor (CKPS) CMl Secondary throttle valve actuator (STVA) eM! Fuel pump (FP) C> :z o en en f" ......
en "'T1 -< en -I Camshaft position sensor (CMPS) m s: Speedometer -~ zC> C » :c Fuel injector (FI) o~ Fuel pump Engine stop switch I Crankshaft position sensor (CKPS) / C> :c 10A 1_2 » s: Throttle position sensor (TPS)~ 111-+ {) 111-+ Secondary throttle position sensor (STPS) Ignition coil (IG COIL) 111-+ ' 111-+ Intake air pressure sensor /0 (lAPS) ECM ·-1 6 5 : I ~ Gear position switch Atomospheric pressure sensor (APS) Engine coolant temperature sensor (ECTS) Intake air
FI SYSTEM DIAGNOSIS 4-15 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 (Fllight). To check the function of the individual FI system devices, the dealer mode is prepared. In this check, the special tool is necessary to read the code of the malfunction items.
4·16 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. ,rodt, 09930-82720: Mode select switch [CAUTION I Before checking the malfunction code, do not disconnect the ECM lead wire couplers.
FI SYSTEM DIAGNOSIS CODE COO C11 C12 C13 C14 C15 C21 C22 C23 C24 C25 C26 C27 C28 C29 C31 C32 C33 C34 C35 C41 C42 C46 MALFUNCTION PART None Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Intake air pressure sensor (lAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air temperature sensor (lATS) Atmospheric pressure sensor (APS) Tip over sensor (TOS) Ignition signal #1 (IG coil #1) Ignition signal #2 (IG coil #2) Ignition signal #3 (IG coil #3) Ignition s
4·18 FI SYSTEM DIAGNOSIS TPS ADJUSTMENT 1.Adjust the engine rpm to 1 150 rpm. (c::::::r2-15) 2.Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3.lf the throttle position sensor adjustment is necessary, loosen the screws and turn the throttle position sensor and bring the line to middle. 4.Then, tighten the screws to fix the throttle position sensor. ,mob 09930-11950: Torx wrench 09930-82720: Mode select switch The LCD indicates 0.4 sec.
FI SYSTEM DIAGNOSIS 4·19 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. ITEM Camshaft position sensor Crankshaft position sensor FAIL-SAFE MODE When camshaft position signal has failed during running, the ECM determines cylinder as # before occurrence of such a failure. The motorcycle stops.
4·20 FI SYSTEM DIAGNOSIS ITEM FAIL-SAFE MODE STARTING ABILITY RUNNING ABILITY Secondary throttle valve actuator Secondary throttle valve is fixed to full close position. When motor disconnection or lock occurs, power from ECM is shut off. "YES" "YES" Secondary throttle position sensor Secondary throttle valve is fixed to full close position. "YES" "YES" Exhaust control valve actuator Exhaust control valve is fixed to full open position.
FI SYSTEM DIAGNOSIS 4-21 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Date of issue: Malfunction indicator lamp condition (LED) Malfunction display/code (LCD) Model: Date Reg.
4-22 FI SYSTEM DIAGNOSIS MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Temperature Frequency Road Engine condition Motorcycle condition o Fair o Cloudy o Rain o Snow o Always o Other 0c) o Always °F/ o Hot o Warm o Cool o Cold ( day, month) o Only once o Always o Sometimes ( times/ o Under certain condition o Urban o Suburb o Highway o Mountainous (0 Uphill o Downhill) o Tarmacadam o Gravel o Other Motorcycle condition Warming up phase o Warmed up o Always o Oth
FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES • Don't disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized information in ECM memory. • Malfunction code stored in ECM memory can be checked by the special tool.
4-24 FI SYSTEM DIAGNOSIS MALFUNCTION CODe AND DEFECTIVE CONDITION MALFUNCTION CODE coo DETECTED ITEM NO FAULT Camshaft position sensor C11 C12 C13 C14 Crankshaft position sensor Intake air pressure sensor Throttle position sensor Engine coolant temperature sensor C15 C21 C22 Intake air temperature sensor Atmospheric pressure sensor Tip over sensor C23 Ignition signal C24/C25 C26/C27 DETECTED FAILURE CONDITION CHECK FOR The signal does not reach ECM for 4 sec, and more, after receiving the
FI SYSTEM DIAGNOSIS MALFUNCTION CODE DETECTED ITEM Secondary throttle valve actuator C28 Secondary throttle position sensor C29 Gear position signal C31 Fuel injector C32/C33 C34/C35 Fuel pump relay C41 C42 Ignition switch Exhaust control valve actuator C46 4-25 DETECTED FAILURE CONDITION CHECK FOR When no actuator control signal is supplied from the ECM or communication signal does not reach ECM or operation voltage does not reach STVA motor, C28 is indicated. STVA can not operate.
4·26 FI SYSTEM DIAGNOSIS "C11" CMP SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION The signal does not reach ECM for 4 sec. and more, • Metal particles or foreign material being attached on the CMP sensor and rotor tip. after receiving the starter signal. • CMP sensor circuit open or short. • CMP sensor malfunction. • ECM malfunction. INSPECTION Step1 1) Lift and support the fuel tank with its prop stay. (c:::rS-S) 2) Remove the air cleaner box. (c:::rS-1S) 3) Turn the ignition switch OFF.
FI SYSTEM DIAGNOSIS Step2 1) Disconnect the CMP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CMP sensor peak voltage at the sensor. _ CMP sensor peak voltage: 0.5 V and more (@ BN- Br 8) 3) Repeat the above test procedure a few times and measure the highest peak voltage. If OK, then measure the CMP sensor peak voltage at the ECM terminals.
4-28 FI SYSTEM DIAGNOSIS "C12" CKP SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION The signal does not reach ECM for 4 sec. and more, • Metal particles or foreign materiel being attached after receiving the starter signal. on the CKP sensor and rotor tip. • CKP sensor circuit open or short. • CKP sensor malfunction. • ECM malfunction. INSPECTION Step1 1) Lift and support the fuel tank with its prop stay. (c::?5-5) 2) Turn the ignition switch OFF.
FI SYSTEM DIAGNOSIS Step2 1) Disconnect the CKP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. _ CKP sensor peak voltage: 0.5 V and more «(±) Black - 8 Green) 3) Repeat the above test procedure a few times and measure the highest peak voltage. If OK, then measure the CKP sensor peak voltage at the ECM terminals.
4·30 FI SYSTEM DIAGNOSIS "C13" lAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION lAP sensor voltage low or high. 0.5 V ~ Sensor voltage < 4.85 V (without the above range.) POSSIBLE CAUSE • Clogged vacuum passage between throttle body and lAP sensor. • Air being drawn from vacuum passage between throttle body and lAP sensor. NOTE: Note that atmospheric pressure varies depending on • lAP sensor circuit open or shorted to ground . • lAP sensor malfunction . weather conditions as well as altitude.
FI SYSTEM DIAGNOSIS 4-31 Step 2 1) Connect the lAP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. Start the engine at idle speed. 3) Measure the lAP sensor output voltage at the wire side coupler (between G/B and B/Br wires). _ lAP sensor output voltage: Approx. 2.6 V at idle speed (ffi GIB - 8 B/Br) 'T'OOti 09900·25008: Multi circuit tester set 09900-25009: Needle pointed probe set ~ Tester knob indication: Voltage (:-::-::) YES NO Go to Step 3.
4·32 FI SYSTEM DIAGNOSIS Output voltage (Vee voltage 4.5 - 5.0 V, ambient temp. 2030°C, 68 - 86 OF) ALTITUDE (Reference) (ft) 0 (m) 0 ATMOSPHERIC PRESSURE kPa (mmHg) 760 100 I I I I 2000 2001 610 707 707 94 94 611 OUTPUT VOLTAGE (V) I I I I 5000 5001 1 524 1 524 634 634 85 85 I I I I 8000 8001 2438 2439 567 567 76 76 I I I I 10000 3048 526 70 3.1 - 3.6 2.8 - 3.4 2.6 - 3.1 2.4 - 2.
FI SYSTEM DIAGNOSIS "C14" TP SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION Output voltage low or high Difference between actual throttle opening and opening calculated by ECM in larger than specified value. 0.2 V ;;;;; Sensor voltage < 4.8V (without the above range.) • • • • TP sensor maladjusted. TP sensor circuit open or short. TP sensor malfunction. ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (c::::T5-5) 2) Turn the ignition switch OFF.
4·34 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Check the continuity between terminal _ TP sensor continuity: ® and ground. 0 (Infinity) (Terminal ® - Ground) 00 4) If OK, then measure the TP sensor resistance at the terminal (between ® and @). 5) Turn the throttle grip and measure the resistance. _ TP sensor resistance Throttle valve is closed : Approx. 1.1 kO Throttle valve is opened: Approx. 4.
,-------- ------------------------------------FI SYSTEM DIAGNOSIS Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the injectorlTP sensor lead wire coupler. 3) Turn the ignition switch ON. Measure the TP sensor output voltage at the coupler (between CB PIS and 8 S/Sr) by turning the throttle grip. _ TP sensor output voltage Throttle valve is closed : Approx. 1.1 V Throttle valve is opened: Approx. 4.
4-36 FI SYSTEM DIAGNOSIS "C15" ECT SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION Output voltage low or high 0.15 ;;;;;; Sensor voltage < 4.85 V (without the above range.) • ECT sensor circuit open or short. • ECT sensor malfunction. • ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (c::::r5-5) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts.
FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the ECT sensor resistance. _ 2 ECT sensor resistance: Approx. 2.3 - 2.6 kO at 20°C (68 OF) (Terminal - Terminal) ,gb 09900-25008: Multi circuit tester set ~ Tester knob indication: Resistance (0) Refer to page 7-8 for details. Is the resistance OK? YES NO • BIBI or BIBr wire open or shorted to ground, or poor ® or ®J connection. • If wire and connection are OK, intermittent trouble or faulty ECM.
4·38 FI SYSTEM DIAGNOSIS "C21" IAT SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION Output voltage low or high 0.15 ~ Sensor voltage < 4.85 V (without the above range.) • IAT sensor circuit open or short. • IAT sensor malfunction. • ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (c:::?5-5) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then measure the IAT sensor voltage at the wire side coupler.
FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. _ 2 IAT sensor resistance: Approx. 2.2 - 2.7 kO at 20°C (68 OF) (Terminal - Terminal) ,root, 09900-25008: Multi circuit tester set ~ Tester knob indication: Resistance (0) Is the resistance OK? -- • YES • • NO Dg or B/Br wire open or shorted to ground, or poor ® or ~ connection. If wire and connection are OK, intermittent trouble or faulty ECM.
4·40 FI SYSTEM DIAGNOSIS "C22" AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE AP sensor voltage low or high. 0.5 V ;;;;; Sensor voltage < 4.S5 V (without the above range.) • Clogged air passage with dust. • Red wire circuit open or shorted to ground . • B/Br or G/Y wire circuit shorted to ground. NOTE: • AP sensor malfunction. Note that atmospheric pressure varies depending on • ECM malfunction. weather conditions as well as altitude.
FI SYSTEM DIAGNOSIS Step 2 1) Connect the AP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. Turn the ignition switch ON. 3) Measure the AP sensor output voltage at the wire side coupler (between GIY and B/Br wires). _ AP sensor output voltage: Approx. 2.6 V at 760 mmHg (100 kPa) (@ GN - 8 BIBr) ,roOt, 09900-25008: Multi circuit tester set 09900-25009: Needle pointed probe set ~ Tester knob indication: Voltage (::-::-::) YES Go to Step 3.
4-42 FI SYSTEM DIAGNOSIS Output voltage (Vee voltage 4.5 - 5.0 V, ambient temp. 20- 30°C, 68 - 86 OF) ALTITUDE (Reference) ATMOSPHERIC PRESSURE (ft) (m) (mmHg) kPa 0 0 760 100 I I I I 2000 2001 610 707 94 611 707 94 I I I I 5000 5001 1 524 1 524 634 634 85 85 I I I I 8000 8001 2438 2439 567 567 76 76 I I I I 10 000 3048 526 70 OUTPUT VOLTAGE (V) 3.1 - 3.6 2.8 - 3.4 2.6 - 3.1 2.4 - 2.
FI SYSTEM DIAGNOSIS 4·43 "C23" TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ---------+-------------------1 Output voltage low or high • TO sensor circuit open or short. 0.2 ;;;;; Sensor voltage < 4.8 V • TO sensor malfunction. (without the above range.) _ _ _ _ _ _ _ _---J.-• ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (c::::rS-S) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts.
4-44 FI SYSTEM DIAGNOSIS Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Black and BIBr wires. _ TO sensor voltage: 0.4 - 1.4 V (CB Black - 8 B/Br) Also, measure the voltage when leaning of the motorcycle. 5) Dismount the TO sensor from its bracket and measure the voltage when it is leaned more than 65 0, left and right, from the horizontal level.
FI SYSTEM DIAGNOSIS "C28" STY ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION The operation voltage does not reach the STVA. ECM does not receive communication signal from the STVA. POSSIBLE CAUSE • STVA malfunction. • STVA circuit open or short. • STVA motor malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (c::::T'5-5) 2) Remove the air cleaner element. 3) Turn the ignition switch OFF. 4) Check the STVA lead wire coupler for loose or poor contacts.
4·46 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each wire and ground. _ STVA continuity: 00 n (Infinity) If OK, then measure the STVA resistance. (between Pink and Black wires) and (between W/BI and Green wires) _ STVA resistance: Approx. 6.
FI SYSTEM DIAGNOSIS "C29" STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION Signal voltage low or high. Difference between actual throttle opening and opening calculated by ECM in larger than specified value. 0.15 V ~ Sensor voltage < 4.85 V (without the above range.) • • • • POSSIBLE CAUSE STP sensor maladjusted. STP sensor circuit open or short. STP sensor malfunction. ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay.
4-48 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Remove the air cleaner element. 3) Disconnect the STP sensor coupler (White color). 4) Check the continuity between Yellow wire and ground. _ STP sensor continuity: 0 (Infinity) (Yellow wire - Ground) 00 5) If OK, then measure the STP sensor resistance at the coupler (between Yellow and Black wires). 6) Close and open the secondary throttle valve by finger, and measure the valve closing and opening resistance.
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 lead wire 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 ffi Yellow and 8 Black wires) by turning the secondary throttle valve (close and open) with a finger. _ STP sensor output voltage Throttle valve is closed : Approx. 0.5 V Throttle valve is opened: Approx. 3.
4·50 FI SYSTEM DIAGNOSIS "C31" GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION No Gear Position switch voltage Switch voltage low. Sensor voltage> 0.6 V (without the above range.) POSSIBLE CAUSE • Gear Position switch circuit open or short. • Gear Position switch malfunction. • ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (C7"5-5) 2) Turn the ignition switch OFF. 3) Check the GP switch coupler for loose or poor contacts.
FI SYSTEM DIAGNOSIS "C32", "C33", "C34" or "C35" FUEL INJECTOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION CKP signals produced but fuel injector signal is interrupted continuous by 4 times or more. • • • Injector circuit open or short. Injector malfunction. ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (CTS-S) 2) Turn the ignition switch OFF. 3) Check the injector coupler for loose or poor contacts. If OK, then measure the injector resistance.
4-52 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch ON. 2) Measure the injector voltage between Y/R wire and ground. _ Injector voltage: Battery voltage (cB VIR - 8 Ground) NOTE: Injector voltage can be detected only 3 seconds after ignition switch is turned ON. ,mob 09900-25008: Multi circuit tester set ~ Tester knob indication: Voltage (::-:-::) Is the voltage OK? • GrlW, Gr/B, Gr/Y, Gr/R or Y/R wire open or shorted to ground, or poor @, @, @, ([) or @ YES • • NO connection.
FI SYSTEM DIAGNOSIS "C41" FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although fuel • Fuel pump relay circuit open or short. pump relay is turned ON, or voltage is applied to fuel • Fuel pump relay malfunction. pump although fuel pump relay is turned OFF. • ECM malfunction. INSPECTION Step 1 1) Remove the frame cover. (c::::7"8-6) 2) Turn the ignition switch OFF. 3) Check the FP relay coupler for loose or poor contacts.
4-54 FI SYSTEM DIAGNOSIS "C46" EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION The operation signal does not reach the EXCV actuator. EXCVA position sensor voltage low or high. 0.1 ;;;;; Sensor voltage ;;;;; 4.9 V (without the above range.) POSSIBLE CAUSE • • • • EXCVA EXCVA EXCVA EXCVA INSPECTION Step 1 1) Lift and support the fuel tank with its prop stay. (c::::T'S-S) 2) Turn the ignition switch OFF. 3) Check the EXCVA lead wire coupler for loose or poor contacts. 4) Turn the ignition switch ON.
FI SYSTEM DIAGNOSIS Step 2 1) Check the installation of EXCV cables. (CTS-14) If it is necessary, adjust the EXCV cables. (CTS-B) 2) Turn the ignition switch OFF. 3) Disconnect the EXCVA position sensor lead wire coupler. 4) Turn the ignition switch ON. 5) Measure the voltage between the Red wire terminal and ground. S) If OK, then measure the voltage between the Red wire terminal and B/Br wire terminal. _ Position sensor input voltage: 4.5 - 5.
4·56 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Yellow wire and ground. _ Position sensor continuity: 00 0 (Infinity) 3) If OK, then measure the position sensor resistance. 4) Connect the position sensor coupler. 5) Set the EXCVA to adjustment position. (CT'6-4) 6) Disconnect the position sensor coupler and measure the resistance. (between Yellow and White wires) _ Position sensor resistance at adjustment position: Approx. 3.
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 position and fully open position. 4) Insert the needle pointed probes to the back side of the position sensor lead wire coupler. (0 Yellow - 8 White) 5) Disconnect the EXCVA motor lead wire coupler~. 6) To set the EXCV to fully close position, apply 12 volts to ® and @ terminals.
4·58 FI SYSTEM DIAGNOSIS 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 turning out the NO.1 cable adjuster CD. 2) Repeat the above procedure (Step 4) until the out put voltage becomes specified value. (If C46 code is indicated after adjusting the voltage, increase the voltage to 0.4 V.) ICAUTION I * Adjusting the cable with the EXCV fully opened or fully closed can damage the EXCVA.
FI SYSTEM DIAGNOSIS Step 6 1) Turn the ignition switch OFF. 2) Disconnect the motor lead wire coupler of the EXCVA. 3) Apply 12 volts to the terminal and check the operation of EXCVA. 4) Then, swap the wires supplied 12 volts and check the operation of EXCVA. (Check the operation of EXCVA both way) Is the operation OK? YES Loose or poor contacts on the EXCVA or ECM coupler. NO Replace the EXCVA with a new one.
4-60 FI SYSTEM DIAGNOSIS SENSORS CMP SENSOR INSPECTION The camshaft position sensor is installed on the cylinder head cover. (c:::::r4-26) CMP SENSOR REMOVAL AND INSTALLATION • Remove the CMP sensor. (c:::::r3-28) • Install the CMP sensor in the reverse order of removal. CKP SENSOR INSPECTION The crankshaft position sensor is installed on the right side of middle crankcase cover. (c:::::r4-28) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover.
FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the cylinder head. (c:::::r4-36) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor. (c:::::r7-8) • Install the ECT sensor in the reverse order of removal. Pay attention to the following points: ~ EeT sensor: 18 N·m (1.8 kgf-m, 13 Ib-ft) IAT SENSOR INSPECTION The intake air temperature sensor is installed on the right side of the air cleaner box.
4·62 FI SYSTEM DIAGNOSIS STP SENSOR INSPECTION STP SENSOR REMOVAL AND INSTALLATION The secondary throttle position sensor is installed at the right side of the No.4 throttle body. • Remove the STP sensor. (c:::::rS-17) • Install the STP sensor in the reverse order of removal. STP SENSOR ADJUSTMENT • Adjust the STP sensor.
FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM 5- 2 INTAKE AIR SYSTEM ....•........•.•...................................................................5- 3 SECONDARY THROTTLE CONTROL SYSTEM ..........................••.......5- 3 5- 4 OPERA TION FUEL SYSTEM FUEL FUEL FUEL FUEL FUEL FUEL FUEL FUEL FUEL 5- 5 TANK LIFT-UP.••......•........•...............................•...........................
5·2 FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe. Fuel pressure is regulated by the fuel pressure regulator.
FUEL SYSTEM AND THROTTLE BODY 5-3 INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM The secondary throttle control system (STCS) consists of the secondary throttle valve (STV), secondary throttle valve actuator (STVA) and secondary throttle position sensor (STPS). STV is installed in each throttle body. STVA and STPS are installed on the right side of the throttle body assembly. The STV is turned by the STVA.
5·4 FUEL SYSTEM AND THROTILE BODY OPERATION The secondary throttle control system (STCS) is operated by the signal supplied from the ECM. The open/close operation of the secondary throttle valve (STV) is performed by the secondary throttle valve actuator (STVA) which is controlled by the ECM. The STPS detects the STVA movement by measuring the voltage and then the ECM determines the STV angle based on the operation map.
FUEL SYSTEM AND THROTILE BODY FUEL SYSTEM FUEL TANK LIFT-UP • Remove the front seat. • Remove the frame cover. (CTa-G) • Remove the fuel tank mounting bolts. • Lift and support the fuel tank with the fuel tank prop stay CD. FUEL TANK REMOVAL • Lift and support the fuel tank with the fuel tank prop stay. • Disconnect the fuel pump coupler CD. • Place a rag under the fuel feed hose and remove the fuel feed hose (2).
5-6 FUEL SYSTEM AND THROTILE BODY FUEL PRESSURE INSPECTION • Lift and support the fuel tank with its prop stay. (c:::.:rS-S) • Place a rag under the fuel feed hose. (c:::.:rS-S) • Remove the fuel feed hose and install the special tools between the fuel tank and fuel delivery pipe. lrUt! 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.
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION ~ Turn the ignition switch ON and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor. FUEL DISCHARGE AMOUNT INSPECTION A WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Lift and support the fuel tank with its prop stay.
5-8 FUEL SYSTEM AND THROTTLE BODY • Place the measuring cylinder and insert the fuel hose end into the measuring cylinder. • Apply 12 volts to the fuel pump for 30 seconds and measure the amount of fuel discharged. Battery (±) terminal - - Power source lead wire CD (Yellow with red tracer) If the pump does not discharge the amount specified, it means that the fuel pump is defective or that the fuel filter is clogged. ~ Fuel discharge amount: Approx. 1 200 ml/30 sec. (1.3/1.1 US/Imp oz)/30 sec.
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP RELAY INSPECTION Fuel pump relay is located in front of the battery. • Remove the front and rear seats. • Lift and support the fuel tank with its prop stay. (c::::FS-S) • Remove the fuel pump relay. First, check the insulation between CD and (2) terminals with pocket tester. Then apply 12 volts to @ and @ terminals, CB to @ and 8 to @, and check the continuity between CD and (2). If there is no continuity, replace it with a new one.
5·10 FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the fuel tank. (c:::::rS-S) • Remove the fuel pump assembly by removing its mounting bolts diagonally. A WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the nuts. • Remove the screws. • Remove the fuel pump assy from the fuel pump plate. • Remove the fuel pump holder CD.
FUEL SYSTEM AND THROTTLE BODY • Remove the fuel mesh filter. • Remove the fuel pressure regulator holder G) and the fuel pressure regulator CZl. 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. Blow the fuel mesh filter with compressed air. NOTE: If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one.
5·12 FUEL SYSTEM AND THROTTLE BODY • Pass through the wires behind the thermistor CD. • Be sure to connect the wires to the proper terminals. ® CB terminal for fuel pump @ Thermistor Pass through the wires behind the thermistors.
FUEL SYSTEM AND THROTILE BODY • Install the O-ring and apply SUZUKI SUPER GREASE to it. JifJl99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) A WARNING The O-ring must be replaced with a new one to prevent fuel leakage. • When installing the fuel pump assembly, lightly tighten all the fuel pump assembly mounting bolts in the ascending order of numbers, and then tighten them to the specified torque in the above manner. ~ Fuel pump mounting bolt: 10 N·m (1.
5·14 FUELSYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION Except E-33
FUEL SYSTEM AND THROTILE BODY AIR CLEANER BOX AND THROTTLE BODY REMOVAL AIR CLEANER BOX • Lift and support the fuel tank with its prop stay. (c::::T5-5) • Disconnect the IAT sensor coupler CD and PAIR hose (2). • Disconnect the lAP sensor coupler @ and vacuum hose @. • Disconnect the crankcase breather hose @. • Loosen the throttle body clamp screws. • Remove the air cleaner box mounting bolt. • Remove the air cleaner box.
5-16 FUEL SYSTEM AND THROTILE BODY THROTTLE BODY • Disconnect the throttle cables from their drum. I CAUTION I 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. • Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank. • Disconnect the vacuum hose CD from the PAIR valve. • Disconnect the fuel injector coupler (2).
FUEL SYSTEM AND THROTILE BODY THROTTLE BODY DISASSEMBLY • Disconnect the respective vacuum hoses from each throttle body. (Except E-33) • Disconnect the respective vacuum hoses CD and EVAP purge hoses (2) from each throttle body. (For E-33) • Remove the lead wire clamps. • Disconnect the TP sensor coupler @, STP sensor coupler @, STVA motor lead wire coupler @ and fuel injector couplers @. • Remove the fuel delivery pipe assembly (f) by removing its mounting screws. • Remove the fuel injectors.
5·18 FUEL SYSTEM AND THROTTLE BODY • Remove the STP sensor ® with the special tool. ,roob 09930-11950: Torx wrench NOTE: Prior to disassembly, mark the STP sensor's original position with a paint or scribe for accurate reinstallation. I CAUTION I Never remove the STVA from the throttle body. I CAUTION I Never remove the secondary throttle valve and throttle valve. THROTTLE BODY CLEANING A.
FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points: • With the STV fully opened, install the STP sensor CD. NOTE: * Align the secondary throttle shaft end ® with the groove @ of the STP sensor. * Apply SUZUKI SUPER GREASE to the secondary throttle shaft end ® if necessary. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) iT%l..
5·20 FUEL SYSTEM AND THROTTLE BODY • Apply thin coat of the engine oil to the new O-rings ell. CAUTION I I I Replace the O-ring with a new one. • Assemble the fuel delivery pipes. • Install the fuel delivery pipe assembly to the throttle body assembly. ! CAUTION I Never turn the fuel injectors while installing them. • Tighten the fuel delivery pipe mounting screws. ~ Fuel delivery pipe mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 Ib-ft) • Connect the fuel injector couplers to each fuel injector.
FUEL SYSTEM AND THROTILE BODY THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the throttle pulling cable CD and throttle returning cable (2) to the throttle cable drum. • Adjust the throttle cable play with the cable adjusters @ and @. Refer to page 5-29 for details. [t I p1W ~ II ~ 3.5N·m (0.35 kgf-m, 2.5 Ib-ft) !CAUTIONj When installing the TPS the illustration.
5·22 FUEL SYSTEM AND THROTTLE BODY STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor position as follows: • Disconnect the STVA coupler. • Turn the ignition switch ON. • Close the secondary throttle valve by finger, and measure the STP sensor output voltage. _ STP sensor output voltage ST valve is fully closed: 0.48 - 0.
FUEL SYSTEM AND THROTTLE BODY FUEL INJECTOR INSPECTION The fuel injector can be checked without removing it from the throttle body. Refer to page 4-S1 for details. FUEL INJECTOR REMOVAL • Lift and support the fuel tank with its prop stay. (c::::T'S-S) • Remove the air cleaner box. (c::::T'S-1S) • With battery negative cable disconnected, disconnect the injector couplers. • Remove the fuel delivery pipe assembly. (c::::T'S-17) • Remove the fuel injectors No.1, No.2, NO.3 and No.4.
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 temperature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.
FUEL SYSTEM AND THROTTLE BODY THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH VACUUM GAUGE • Lift and support the fuel tank. (c::::rS-S) • Start up the engine and run it in idling condition for warming up. • Stop the warmed-up engine. • Disconnect the IAT sensor coupler CD and remove the IAT sensor from the air cleaner box. • Connect the removed IAT sensor to its coupler and place it on the frame.
5·26 FUEL SYSTEM AND THROTTLE BODY • Connect a tachometer. • Start up the engine and keep it running at 1 150 rpm by turning throttle stop screw @. ! CAUTION I Avoid drawing dirt into the throttle body while running the engine without air cleaner box. Dirt drawn into the engine will damage the internal engine parts. • Turn the air screw @ of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball (j) in the tube to the center line @.
FUEL SYSTEM AND THROTILE BODY THROTTLE VALVE SYNCHRONIZATION Step 1 • Disconnect the lAP sensor coupler CD. • To synchronize throttle valves, remove the vacuum hoses (2) from each vacuum nipple and connect the vacuum balancer gauge hoses to the vacuum nipples respectively. ,root. 09913-13121: Vacuum balancer gauge Step 2 • Connect a tachometer and start up the engine. • Bring the engine rpm to 1 150 rpm by the throttle stop screw.
5-28 FUEL SYSTEM AND THROTTLE BODY Step 3 • Turn in all the idle air screws to the complete close position. • Check for difference of vacuum between No.1 and NO.2. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower. Similarly perform the same procedures between NO.3 and NO.4. • Check for the synchronization adjustment.
FUEL SYSTEM AND THROTTLE BODY THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS setting condition. (Refer to page 4-18 for TPS setting procedure.) THROTTLE CABLE ADJUSTMENT NOTE: Minor adjustment can be made by the throttle grip side adjuster. (c:::::r2- 17) MAJOR ADJUSTMENT • Loosen the lock-nuts CD of the throttle returning cable ~. • Turn the returning cable adjuster @ to obtain proper cable play.
EXHAUST SYSTEM 6·1 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM ••..•••...............•..•..•.••.••...............•..•..•...........••................6- 2 EXHAUST CONTROL SYSTEM ................................•..•.•..................•....6- 2 OPERA TION•..................••..•..••.................•...•..••........•..................•..•..•.... 6- 3 EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VAL VEl .....................•..•................••.........................6- 4 EXCVA REMOVAL....
6-2 EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exhaust control system (EXeS) consists of the exhaust control valve (EXeV), exhaust control valve actuator (EXeVA) and exhaust control valve cables (EXeV cables). EXeV is installed between the exhaust pipes and joint pipe. EXeVA is mounted on the right side of the seat rail. The EXeV is operated by the EXeVA via the cables. This system is designed to improve the engine torque at low engine rpm and to reduce the exhaust noise.
EXHAUST SYSTEM 6·3 OPERATION The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then the ECM determines the EXCV opening angle based on the engine rpm and gear positions.
6-4 EXHAUST SYSTEM EXCVA(EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA REMOVAL • • • • Turn the ignition switch OFF. Remove the front and rear seats. Remove the fuel tank. (c::::rS-S) Connect the special tool (Mode select switch) to the dealer mode coupler. (c::::r4-16) • After turning the special tool's switch ON, turn the ignition switch ON. 'TImt, 09930-82720: Mode select switch • Check the cable slots ® of the EXCVA pulley face upward (adjustment position) as shown.
EXHAUST SYSTEM • Remove the clamp CD. • Disconnect the NO.2 cable (2) and then NO.1 cable @ from the pulley. • Disconnect the EXCVA lead wire couplers @. • Remove the EXCVA. EXCVA can also be removed in the following procedures. • Remove the front footrest @. • Disconnect the EXCV cable. (L7"6-12) • Remove the EXCVA mounting bolt. (L7"6-4) • Remove EXCVA, cable and EXCV together as a unit. EXCVA INSTALLATION Install the EXCVA in the reverse order of removal.
6·6 EXHAUST SYSTEM • Check the EXCVA to adjustment position. (c:::?6-4) I CAUTION I Do not use the adjustable wrench to turn EXCVA pulley so as not to cause damage to the internal gear of EXCVA. • Install the pulley @ to the shaft @. NOTE: Make sure that the shaft's line @ and cable slots upward as shown. © facing • Hold the pulley with an adjustable wrench, and then tighten the pulley mounting bolt to the specified torque. ~ EXCVA pulley mounting bolt: 5 N·m (0.5 kgf-m, 3.
EXHAUST SYSTEM 6-7 NOTE: The EXCV cables are identified by the plated chrome color and shape. Black chrome plated adjuster: NO.1 cable G) Silver chrome plated adjuster: NO.2 cable ~ • Connect the EXCV cables (No.1 and No.2) temporarily to the EXCVA pulley, • Check or adjust the clearance ® becomes the adjuster end and EXCVA pulley to provide 3 mm (0.12 in) and more. • Install the muffler joint pipe together with the muffler body. (c:::::r6-13) • Make the NO.1 cable straight and turn the NO.
6·8 EXHAUST SYSTEM • Connect the NO.1 cable and NO.2 cable to the EXCVA pulley. (t:76-5) • After connecting the NO.2 cable @, loosen the lock-nut ® and turn the adjuster @ in or out until 11 - 12 mm (0.43 - 0.47 in) of the thread length CQl on the cable adjuster cam be provided and tighten the lock-nut ®. bCbo :;===1 1 @ • Check the EXCVA to adjustment position. (t:76-4) I CAUTION I Do not use the adjustable wrench to turn EXCVA pulley so as not to cause damage to the internal gear of EXCVA.
EXHAUST SYSTEM EXCVA ADJUSTMENT 1st step: • Set the EXCVA to adjustment position. (c:::::r6-4) • Make sure that the NO.2 cable and NO.1 cable are fixed into the clamp. 2nd step: • Turn the mode select switch OFF. • Turn the ignition switch ON to check the EXCVA operation. • Turn the mode select switch ON. • If C46 is not indicated on the LCD (DISPLAY), the adjustment is correctly completed. In this case, it is unnecessary to proceed to 3rd step.
6·10 EXHAUST SYSTEM • To set the EXCV to fully close position, apply 12 volts to and @ terminals. Positive wire - ® (Pink wire) terminal Negative wire - @ (Gray wire) terminal ® I CAUTION I To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully close position. • Turn the ignition switch ON. • Measure the position sensor output voltage at fully close position. g Position sensor output voltage EXCV is fully close: 0.5 ;;;;; output voltage ;;;;; 1.
EXHAUST SYSTEM 4th step: To set the EXCV to fully open position, apply 12 volts to @ terminals. Positive wire - @ (Gray wire) terminal Negative wire - ® (Pink wire) terminal ® and !CAUTION! To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully open position. Measure the position sensor output voltage at fully open position. _ Position sensor output voltage EXCV is fully open: 3.7 ;;;;; output voltage;;;;; 4.
6·12 EXHAUST SYSTEM EXCV REMOVAL • Disconnect the two cables from the EXCVA pulley. (Refer to the EXCVA REMOVAL procedures.) ( CT"6-4) • Remove the muffler joint pipe CD together with the muffler body ~ by removing the mounting bolts and loosen the connector bolt. • Remove the EXCV cover @ and disconnect the two cables from the EXCV pulley. 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 muffler joint pipe.
EXHAUST SYSTEM EXCV INSTALLATION • Connect the EXCV cables temporarily to the EXCV pulley. • Adjust the clearance ® between the adjuster end and EXCV pulley to provide 3 mm (0.12 in) and more. • Adjust the inner cable length of the NO.2 cable. (c::::T6-7) • Install the EXCV cover. • Install the muffler joint pipe CD together with the muffler body ~. ~ Exhaust pipe connector bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5Ib-ft) • Connect the NO.1 and NO.
6-14 EXHAUST SYSTEM ICAUTION! * When adjusting the No.1 and No.2 cables, the cable slots of EXCVA pUlley must be located to adjustment position. * Do not use the adjustable wrench to turn EXCVA pulley so as not to cause damage to the internal gear of EXCVA. 58-59 mm (2.28 - 2.32 in) NO.2 3 mm (0.12 in) -No.1 Replace the gasket with a new one. ~/'\ .. ~ Cable guide /~--ft1J-q\l- ~23N.m (2.3 kgf-m, 16.5 Ib-ft) DO _ ~ 23N·m (2.3 kgf-m, 16.
COOLING AND LUBRICATION SYSTEM 7·1 COOLING AND LUBRICA TION SYSTEM CONTENTS ENGINE COOLANT.........................................••..•......................................... 7- 2 COOLING CIRCUIT COOLING CIRCUIT INSPECTION 7- 3 7- 3 RADIATOR AND WATER HOSES ........................................•....................... 7- 4 RADIATOR REMOVAL ..................••....................................................... 7RADIA TOR CAP INSPECTION ..................•......................•...•.••........
7-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection Anti-freeze density Freezing point 50% 55% 60% -30°C (-24 OF) -40 °C (-44 OF) -55°C (-67 OF) and excellent heat protection, and will protect the cooling system from freezing at temperatures above -31°C (-24 OF).
COOLING AND LUBRICATION SYSTEM 7·3 COOLING CIRCUIT THERMOSTAT CYLINDER HEAD CYLINDER COOLING FAN THERMO SWITCH RADIATOR WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the under cowling. (L7S-3) • Remove the radiator cap CD and connect the tester (2) to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • Give a pressure of about 120 kPa (1.
7-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowling. (CT8-3) • Drain the engine coolant. (CT2-19) • Remove the radiator. (CT3-4) RADIATOR CAP INSPECTION • Fit the cap CD to the radiator cap tester ~. • Build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 95 - 125 kPa (0.95 - 12.5 kgf/cm2 , 13.5 - 17.
COOLING AND LUBRICATION SYSTEM RADIATOR REMOUNTING • • • • • Install the radiator. Route the radiator hoses. (L::r10-19) Pour engine coolant. (L::r2-19) Bleed air from the cooling circuit. (L::r2-20) Install the under cowling. WATER HOSE INSPECTION • Remove the under cowling. (L::r8-3) • Any water hose found in a cracked condition or flattened must be replaced. • Any leakage from the connecting section should be corrected by proper tightening.
7·6 COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • • • • Remove the under cowling. ([78-3) Drain the engine coolant. ([72-19) Remove the radiator. ([73-4) Remove the cooling fan. INSPECTION • Remove the under cowling. ([78-3) • Disconnect the cooling fan coupler CD. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • The voltmeter is for making sure that the battery applies 12 volts to the motor.
COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH REMOVAL • • • • Remove the under cowling. (L7a-3) Drain the engine coolant. (L72-19) Disconnect the cooling fan thermo-switch coupler Remove the cooling fan thermo-switch (2). CD. INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure. Connect the thermo-switch to a circuit tester and place it in the oil contained in a pan, which is placed on a stove.
7·8 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SENSOR REMOVAL • Remove the front seat. (0=8-6) • Lift and support the fuel tank. (0=5-5) • Disconnect the engine coolant temperature sensor coupler. • Keep the motorcycle upright. • Place a rag under the sensor and remove the engine coolant temperature sensor CD. INSPECTION (2) • Check the engine coolant temperature sensor by testing it at the bench as shown in the figure.
COOLING AND LUBRICATION SYSTEM INSTALLATION • Tighten the engine coolant temperature sensor to the specified torque. (!J Engine coolant temperature sensor: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) I CAUTION I Take special care when handling the temperature sensor. It may cause damage if it gets a sharp impact. • Install the fuel tank. (L7'5-5) • Install the front seat. THERMOSTAT REMOVAL • • • • Remove the front seat. (L7'8-6) Lift and support the fuel tank. (L7'5-5) Place a rag under the thermostat cover.
7·10 COOLING AND LUBRICATION SYSTEM INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the following manner. • Pass a string CD between flange of thermostat (2), as shown. • Immerse the thermostat in the water contained in a beaker, as shown in the illustration. Note that the immersed thermostat is in suspension. Heat the water @ by placing the beaker on a stove @ and observe the rising temperature on a thermometer@.
COOLING AND LUBRICATION SYSTEM • Install the thermostat case. NOTE: Fit the clamp to the thermostat case bolt@. • Tighten the thermostat cover bolt to the specified torque. ~ Thermostat cover bolt: 10 N·m (1.0 kgf-m 7.0 Ib-ft) • Install the fuel tank. (c::::TS-S) • Install the front seat. WATER PUMP REMOVAL AND DISASSEMBLY • Remove the under cowling. (c::::TS-3) • Drain the engine coolant. (c::::T2-19) • Drain the engine oil.
7·12 COOLING AND LUBRICATION SYSTEM • Remove the gearshift lever. • Remove the engine sprocket cover (1). • Disconnect the water hoses. • Remove the water pump. • Remove the water pump cover. • Remove the impeller securing bolt (2) by holding the impeller shaft with a water pump pliers.
COOLING AND LUBRICATION SYSTEM • Remove the mechanical seal ring @ and the rubber seal @ from the impeller. • Remove the impeller shaft @. • Remove the bearings with the special tool. ,-root. 09921·20240: Bearing remover set NOTE: If there is no abnormal noise condition, bearing removal is not necessary. I CAUTION I The removed bearing must be replaced with a new one. • Remove the mechanical seal with the special tool.
7-14 COOLING AND LUBRICATION SYSTEM INSPECTION BEARING • Inspect the play of the bearing by hand while it is in the water pump case. • Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • Replace the bearing if there is anything unusual. MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with particular attention given to the sealing face. • Replace the mechanical seal that shows indications of leakage. Also replace the seal ring if necessary.
r COOLING AND LUBRICATION SYSTEM I REASSEMBLY AND INSTALLATION • Install the oil seal with the special tool. ,gOt, 09913·70210: Bearing installer set NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE to the oil seal lip. .JifJf 99000·25030: SUZUKI SUPER GREASE "A" (USA) 99000·25010: SUZUKI SUPER GREASE "A" (Others) • Install the new mechanical seal using a suitable size socket wrench.
7·16 COOLING AND LUBRICATION SYSTEM • Apply SUZUKI SUPER GREASE to the impeller shaft. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the impeller shaft to the water pump body. • Install the rubber seal CD into the impeller. • After wiping off the oily or greasy matter from the mechanical seal ring, install it into the impeller. NOTE: The marked side ler.
COOLING AND LUBRICATION SYSTEM • Install the new O-rings, @ and @. I CAUTION I Use the new O-rings to prevent engine coolant leakage. NOTE: * Apply engine coolant to the O-ring@. * Apply SUZUKI SUPER GREASE to the a-ring @. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Tighten the water pump cover screws to the specified torque. ~ Water pump cover screw: 5 N·m (0.5 kgf-m, 3.7Ib-ft) NOTE: Fit the clamp to the water pump cover screw ©.
7·18 • • • • • • COOLING AND LUBRICATION SYSTEM Connect the water hoses. (c::?10-19) Install the engine sprocket cover. Install the gearshift lever. Pour engine coolant. (c::?2-19) Pour engine oil. (c::?2-14) Install the under cowling.
COOLING AND LUBRICATION SYSTEM OIL COOLER REMOVAL • Remove the under cowling. (c::Ta-3) • Drain the engine oil. (c::T2-13) • Remove the oil cooler. (c::T3-4) INSPECTION AND CLEANING • Road dirt or trash stuck to the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. INSTALLATION • Install a new O-ring 0). I CAUTION I Use the new O-rings to prevent engine oil leakage.
7·20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART _---,---1 INTAKE CAMSHAFT ___ __ ____ ~ ...• INTAKE CAMSHAFT 1 - - - - - - - - - - - - - - - - - - , JOURNAL HOLDER 1 . . - - - - - - - , " CAM CHAIN TENSION ADJUSTER CAMSHAFT JOURNALS, CAMFACES AND TAPPETS '-- ~ EXHAUST CAMSHAFT ~EXHAUSTCAMSHAFTI..--------~ ...J JOURNAL HOLDER '-------, .,• .,• .... ~ ~ ICAM DRIVE CHAIN I CAMSHAFT JOURNALS, CAMFACES AND TAPPETS .....• ...,•. .
COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM 7-21
7-22 COOLING AND LUBRICATION SYSTEM I To transmission
CHASSIS CONTENTS EXTERIOR PARTS .........................................................................•............. 8- 2 FASTENER REMOVAL AND REINSTALLATION 8- 2 SCREEN 8- 3 BODY COWLING COVER AND LOWER BRACKET COVER 8- 3 RIGHT AND LEFT UNDER COWLINGS .............•.................................. 8- 3 BODY COWLING 8- 4 RIGHT AND LEFT AIR INTAKE PIPES 8- 5 COWLING BRACE ...............•.................................................................
CHASSIS REMOVAL 8-42 INSPECTION.................................•..............................•..........................8-42 REAR SHOCK ABSORBER DISPOSAL .............................................•..8-43 REMOUNTING 8-44 SUSPENSION SETTING.....................................................................•...8-44 REAR SUSPENSION 8-45 CONSTRUCTION 8-45 REMOVAL ..................................................•................................•...........8-46 INSPECTION AND DISASSEMBL Y ...............
8-2 CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND REINSTALLATION FASTENER Removal • Depress the head of fastener center piece • Pull out the fastener @. CD. Installation • Let the center piece stick out toward the head so that the pawls (2) close. • 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 until it becomes flush with the fastener outside face.
[ CHASSIS SCREEN • Remove the bolts and nuts. • Remove the screen. BODY COWLING COVER AND LOWER BRACKET COVER • Remove the body cowling cover CD by removing the fasteners. • Remove the lower bracket cover ~ by removing the bolts. RIGHT AND LEFT UNDER COWLINGS • Remove the fastener. • Remove the fastener. • Remove the right under cowling. • Disconnect the turn signal light lead wire coupler.
8·4 CHASSIS • Remove the left under cowling. • Disconnect the turn signal light lead wire coupler. BODY COWLING REMOVAL • Remove the rear view mirrors and bolts. • Remove the fasteners. • Remove the bolts.
CHASSIS • Remove the screws. • Disconnect the coupler and clamp. • Remove the body cowling. REMOUNTING NOTE: When remounting the body cowling, install the hooks cowling brace holes. RIGHT AND LEFT AIR INTAKE PIPES • Remove the body cowling. (c::::7'8-4) • Remove the fastener. • Remove the air intake pipes CD. COWLING BRACE REMOVAL • Remove the body cowling. (c::::7'8-4) • Remove the cowling brace CD. REMOUNTING • Tighten the cowling brace bolt. ~ Cowling brace bolt: 23 N·m (2.3 kgf-m, 16.
8-6 CHASSIS FRONT SEAT • Remove the front seat by removing the bolts. REAR SEAT AND SEAT TAIL COVER • Remove the rear seat (seat tail cover) with the ignition key. FRAME COVER • • • • Remove the seats. Remove the bolts. Disconnect the seat lock cable CD. Disconnect the rear combination light lead wire coupler ~. • Remove the fasteners. • Remove the frame cover.
CHASSIS FRONT WHEEL CONSTRUCTION ® .: CD Brake disc ~ Dust seal @ @ @ @ ® Bearing Spacer Spacer nut Front wheel Front axle @ Brake disc bolt (Front) ITEM N·m kgf-m Ib-ft ® 100 10.0 72.5 @ 23 2.3 16.
8-8 CHASSIS REMOVAL • Remove the brake calipers. I CAUTION I Do not operate the brake lever while removing the calipers. • Loosen two axle pinch bolts CD on the right front fork leg. • Slightly loosen the front axle C2l with the special tool. ,-Pooh 09900-1S740: Hexagon socket (24 mm) • Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block. I CAUTION I Do not work by using side stand. Do not support the motorcycle with exhaust pipe.
CHASSIS • Remove both side dust seals with the special tool. mm 09913-50121: Oil seal remover I CAUTION I The removed dust seals must be replaced with new ones. AXLE SHAFT Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit. jgot, 09900-20607: Dial gauge (11100) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) LiW Axle shaft runout: Service Limit: 0.25 mm (0.
8·10 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left <::=J c:::> Right ~ 23N·m ~ 23N·m (2.3 kgf-m, 16.5 Ib-ft) (2.3 kgf-m, 16.5 Ib-ft) ~ 100N·m ~~~d~~~~~~~~~~~~IV (10.0 kgf-m, 72.5Ib-ft) WHEEL BEARING • Apply SUZUKI SUPER GREASE to the wheel bearings.
CHASSIS • Install the wheel bearings as follows with the special tools. ,foOt, 09941-34513: Bearing/Steering race installer set 09924-84510: Bearing installer set I CAUTION I First install the left wheel bearing, then install the right wheel bearing. The sealed cover of the bearing must face outside. • Install the dust seal with the special tool. ,@, 09913-70210: Bearing installer set (52 mm) • Apply SUZUKI SUPER GREASE to the dust seal lip.
8·12 CHASSIS SPACER NUT With the flange of spacer nut CD contacting the left front fork leg, tighten the two axle pinch bolts (2) on the left front fork leg to the specified torque. ~ Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) WHEEL Install the front wheel with the front axle and hand-tighten the front axle temporarily. A WARNING The directional arrow on the tire should point to the wheel rotation, when remounting the wheel.
CHASSIS FRONT FORK CONSTRUCTION CD O-ring C2J Spring retainer Spacer Spring Adjuster rod Inner rod/damper rod (cartridge) Outer tube Oil seal retainer Oil seal ®J Oil seal stopper ring ® Dust seal @ Inner tube @ @ @ @ (J) @ @ ® Front fork cap bolt @ Lock-nut © Front axle pinch bolt (Ql Damper rod bolt ~J ITEM N·m kgf-m Ib-ft ® 23 2.3 16.5 @ 29 2.9 21.0 © © 23 2.3 16.5 23 2.3 16.5 r (§) \ l--------.
8·14 CHASSIS REMOVAL AND DISASSEMBLY • Remove the front wheel. (c:::rS-S) • Disconnect the brake hose from the brake hose guides on the front fender. • Remove the front fender. • Loosen the front fork upper clamp bolts CD, left and right. • Loosen the handlebar clamp bolts (2), left and right. NOTE: * Slightly loosen the front fork cap bolts @ before loosening the lower clamp bolts to facilitate later disassembly.
CHASSIS • Separate the front fork cap bolt from the front fork. • Compress the front fork spring with the special tool ® and insert the special tool @ between the lock-nut and the spacer. jrUh 09940-94930: Front fork spacer holder 09940-94922: Stopper plate @ ® • 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.
8·16 CHASSIS • Remove the inner rod/damper rod (cartridge) @. I CAUTION I Do not disassemble the inner rod/damper rod (cartridge). • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the "ANTI-FRICTION" metals. • Remove the following parts. OJ) Dust seal @ Oil seal stopper ring ® Oil seal ® Oil seal retainer I CAUTION I The removed oil seal must be replaced with a new one.
CHASSIS FORK SPRING Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one. _ Front fork spring free length: Service Limit: 225 mm (8.86 in) -~~ i Upper side I i i -~~ DAMPER ROD Move the inner rod by hand to examine it for smoothness. If any defects are found, replace inner rod/damper rod (cartridge) with a new one.
8·18 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. CD Dust seal 11) Oil seal stopper ring @ Oil seal @ Oil seal retainer I CAUTION I * When installing the oil seal to outer tube, be careful not to damage the oil seal lip.
CHASSIS ,root. 09940-30221: Front fork assembling tool ~ Damper rod bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) I CAUTION I Use a new damper rod bolt gasket to prevent oil leakage. I 'Mb FORK OIL • 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): 509 ml (17.2117.
8·20 CHASSIS FRONT FORK INNER ROD LOCKNUT • Adjust the height (8) of the inner rod threads by turning the lock-nut CD as shown in illustration. (8): 11 mm (0.43 in) FORK SPRING • Install the fork spring as shown in the illustration. ~ Upper side I I I ~ • Install the adjuster rod spacer@. CD, Lower side spring (2), spring retainer @ and FRONT FORK CAP BOLT • Pull up the inner rod with the special tool ®.
CHASSIS • Hold the cap bolt (2) and tighten the lock-nut @ to the specified torque. ~ Inner rod lock-nut: 29 N·m (2.9 kgf-m, 21.0 Ib-ft) • Remove the special tools. • Install the front fork cap bolt to the outer tube temporarily. • Set the upper surface of the outer tube height ® at 4.5 mm (0.18 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts to the specified torque. ~ Front fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.
8·22 CHASSIS SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT There are five grooved lines on the side of the spring adjuster. Position 1 provides the maximum spring pre-load and position 5 provides the minimum spring pre-load. STD POSITION: 4.5 DAMPING FORCE ADJUSTMENT Compression damping force Fully turn the damping force adjuster G) clockwise. It is at stiffest position and turn it out to standard setting position.
CHASSIS 8·23 STEERING DAMPER CONSTRUCTION G) Steering damper ~ Dust seal ® Damper rod bolt @ Damper rod nut ~ ITEM ® @ N·m kgf-m 23 2.3 16.5 23 2.3 16.5 REMOVAL • Remove the body cowling cover and lower bracket cover. (CT'8-3) • Remove the nut G) by holding the nut (2). • Remove the bolt @ and remove the steering damper. INSPECTION Inspect the steering damper body, bearing and oil seal for damage and oil leaking. Move the steering damper rod by hand to inspect for a smooth movement.
8·24 CHASSIS STEERING CONSTRUCTION G) (1) @ @ @ @ Steering stem upper bracket Handlebar Handlebar balancer Steering stem nut Dust seal Bearing (f) Steering stem lower bracket ® Steering stem head nut @ Steering stem lock-nut © Front fork upper clamp bolt © Handlebar clamp bolt eEl Front fork lower clamp bolt REMOVAL AND DISASSEMBLY • Remove the front wheel. (eTa-a) • Remove the front fork. (eTa-14) ITEM N·m kgf-m Ib-ft ® 90 9.0 65.0 @ 80 8.0 58.0 © © ® 23 2.3 2.3 16.5 23 23 2.3 16.
CHASSIS • Remove the right handlebar switch lead wires from the guide. • Remove the steering stem upper bracket by removing its head nut. NOTE: It is not necessary to remove the ignition switch, only when replacing the steering stem lower bracket and bearings. (Ignition switch removal: c=T9-31) • Remove the brake hose clamp bolt. • Remove the steering damper. (c=Ta-23) • Remove the steering stem lock-nut, washer and steering stem nut with the special tools.
8·26 CHASSIS INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal noise of bearing If any abnormal points are found, replace defective parts with the new ones. • Remove the steering stem lower bearing inner race with a chisel. I CAUTION I The removed bearing outer race must be replaced with a new one.
CHASSIS BEARING • Apply SUZUKI SUPER GREASE to the bearings and bearing races. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race. STEM NUT • Install the dust seal. • Tighten the steering stem nut to the specified torque with the special tools.
8·28 CHASSIS FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem upper bracket in the following steps: 1) Install the upper bracket, washer CD and steering stem head nut (2) temporarily. NOTE: Pay attention to the direction of the washer. 2) Position the handlebars on the front forks and tighten the steering stem head nut (2). ~ Steering stem head nut: 90 N·m (9.0 kgf-m, 65 Ib-ft) 3) Tighten the front fork upper and lower clamp bolts and brake hose clamp bolt.
CHASSIS 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 (O.S - 1.2 in). • Remove the steering damper. (c:::::rS-23) • Check to make sure that the cables and wire harnesses are properly routed.
8·30 CHASSIS HANDLEBAR CONSTRUCTION CD Left handle grip ~ Right handle grip @ @ @ @ Right handle switch Left handle switch handlebar Handle balancer ® Handlebar clamp bolt REMOVAL AND DISASSEMBLY RIGHT HANDLEBAR • Remove the brake master cylinder G). (c::78-61) • Remove the right handle switch CZl. • Remove the handle balancer @. • Remove the right handle grip @. LEFT HANDLEBAR • Remove the left handle switch G). • Remove the handle balancer CZl. • Remove the left handle grip @.
CHASSIS • Loosen the handlebar clamp bolts. • Loosen the front fork upper clamp bolt. • Remove the steering stem upper bracket by removing the steering stem head nut. NOTE: Place the rags under the steering stem upper bracket to prevent scratching the body cowling and the air intake pipes. • Draw out the handlebars to upward. REASSEMBLY AND REMOUNTING Reassemble and remount the handlebar in the reverse order of removal and disassembly.
8·32 CHASSIS • Tighten the handlebar clamp bolts. ~ Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) • When remounting the clutch lever holder, align the holder's mating surface ® with punch mark @ on the handlebar. • Install the front brake master cylinder. (L7'8-62) • When remounting the brake master cylinder, align the holders mating surface with punch mark © on the handlebar. • Apply the SUZUKI SUPER GREASE to the throttle cables and their holder.
CHASSIS REAR WHEEL CONSTRUCTIIOO~N~ ~__ .: CD CD Rear axle ~ Caliper bracket @ Brake disc @Collar @ Bearing @ Rear wheel (J) Spacer @ Bearing ® Cushion ® Spacer ® Sprocket drum @ Sprocket © Bearing @ Dust seal @Collar .
8·34 CHASSIS REMOVAL • Remove the cotter pin. (For E-03, 28, 33) • Loosen the axle nut. • Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. • Remove the rear wheel by disengaging the drive chain. I CAUTION I Do not operate the brake pedal while removing the rear wheel. • Remove the collar CD. • Remove the brake disc (2). • Remove the collar @.
CHASSIS • Remove the dust seal with the special tool. S 09913-50121: Oil seal remover I CAUTION I The removed dust seal must be replaced with a new one. INSPECTION AND DISASSEMBLY TIRE INSPECTION (c::::r2-2S, S-70) WHEEL INSPECTION (c::::rS-70) REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. _ Axle shaft runout: Service Limit: 0.25 mm (0.010 in) .
8·36 CHASSIS BEARINGS Inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. • Remove the sprocket mounting drum bearing and wheel bearings with the special tool. EI 09921·20240: Bearing remover set I CAUTION I The removed bearings must be replaced with new ones.
CHASSIS 8·37 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left¢J c::::> Right ~100N.m (10.0 kgf-m, 72.5 Ib-ft) ~60N.m (6.0 kgf-m, 43.5 Ib-ft) ~35N.m (3.5 kgf-m, 25.5 Ib-ft) i.===b".------i~~ '/--~'iJtil===;=J~8 ~100N.m (10.0 kgf-m, 72.5 Ib-ft) E-03, 28, 33 ~25N.m (2.5 kgf-m, 18.
8-38 CHASSIS BEARINGS • Apply SUZUKI SUPER GREASE to the bearings before installing. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the new bearing to the sprocket mounting drum with the special tool. jgot. 09924-84510: Bearing installer set • First install the right wheel bearing, then install the left wheel bearing with the special tools.
CHASSIS DUST SEALS • Install the new dust seal with the special tool. nut. 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE to the dust seal lip before assembling rear wheel. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) REAR SPROCKET AND SPROCKET MOUNTING DRUM • Install the rear sprocket mounting drum retainer • Install the rear sprocket mounting drum to the rear wheel. w. • Tighten the sprocket mounting nuts to the specified torque.
8·40 CHASSIS REAR AXLE • Remount the rear wheel and rear axle shaft and, install the washer CD and rear axle nut (2). • Adjust the chain slack after rear wheel installation. (c::::7'2-22) • Tighten both chain adjuster lock-nuts ® securely. • Tighten the rear axle nut (2) to the specified torque. ~ Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 Ib-ft) • Install the new cotter pin.
CHASSIS 8·41 REAR SHOCK ABSORBER CONSTRUCTION CD Rear shock absorber ~ Rear shock absorber bracket ® Rear shock absorber mounting bolt/nut @ Rear shock absorber bracket nut ITEM N·m kgf-m Ib-ft ® 50 5.0 36.0 @ 115 11.5 83.
8-42 CHASSIS REMOVAL • Support the motorcycle with a jack relieve no load on the rear shock absorber. • Remove the rear shock absorber upper and lower mounting bolts and nuts. • Take out the rear shock absorber. 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. I CAUTION I Do not attempt to disassemble the rear shock absorber unit. It is unserviceable.
CHASSIS REAR SHOCK ABSORBER DISPOSAL A. WARNING * The rear shock absorber unit contains high-pressure nitrogen gas. * Mishandling can cause explosion. * Keep away from fire and heat. High gas pressure caused by heat can cause an explosion. * Release gas pressure before disposing. GAS PRESSURE RELEASE The rear cushion damper unit contains high-pressure nitrogen gas. Make sure to observe the following precautions. A.
8-44 CHASSIS REMOUNTING Remount the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber upper/lower mounting bolts and nuts. ~ Rear shock absorber mounting nut: 50 N·m (5.0 kgf-m, 36.0 Ib-ft) SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The set length 184.6 mm (7.
CHASSIS 8-45 REAR SUSPENSION CONSTRUCTION G) (2) @ @ @ @ (j) @ Rear shock absorber Rear cushion rod Rear cushion lever Spacer Bearing Dust seal Chain cover Chain buffer ® Chain adjuster (j]) Chain adjuster lock-nut ® Swinqarrn pivot boss ® Rear shock absorber mounting bolt/nut @ Rear cushion lever bolt/nut © Rear cushion rod bolt/nut © Swingarm pivot shaft CEl Swingarm pivot lock nut ® Swlnqarrn pivot nut © SWingarm pivot boss nut ITEM N·m kgf-m Ib-ft ® 50 5.0 36.0 @ 78 7.8 56.
8-46 CHASSIS REMOVAL • Cut the drive chain. (c::::::;=a-74) NOTE: It is necessary to cut the drive chain, only when replacing drive chain or swingarm. • Raise the rear wheel off the ground and support the motorcycle with a jack or a wooden block. • Remove the rear wheel. (c::::::;=a-34) • Remove the side stand. NOTE: It is necessary to remove the side-stand, only when replacing the cushion lever. • Remove the rear brake hose union bolt.
CHASSIS • Remove the swingarm pivot shaft lock-nut with the special tool. IT'foti 09940-14940: Swingarm pivot thrust adjuster socket wrench • Hold the swingarm pivot shaft pivot nut (2). IKiOh 09900-18740: CD and remove the swingarm Hexagon socket (24 mm) • Draw out the swingarm pivot shaft. • Remove the rear suspension assembly. • Remove the cushion rod. • Remove the chain case @ and chain buffer @. • Remove the dust covers @ and washers @.
8-48 CHASSIS • Remove the swingarm pivot boss by removing its set screws. • Set the swingarm pivot boss by its set screws. • Tighten the swingarm boss nut to the specified torque. ~ Swingarm pivot boss nut: 65 N·m (6.5 kgf-m, 47.0 Ib-ft) INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm. • Remove the spacers from the cushion lever. • Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones.
CHASSIS SWINGARM BEARING Insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Draw out the swingarm pivot bearings CD and the swingarm cushion rod upper bearings ~ with the special tool. 1m 09921-20240: Bearing remover set I CAUTION I The removed bearings must be replaced with new ones. CUSHION LEVER BEARING Insert the spacer into bearing and check the play when moving the spacer up and down.
8·50 CHASSIS CUSHION LEVER AND CUSHION LEVER RODS Inspect the cushion lever and cushion lever rods for damage. 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) n13KI 09900-20607: Dial gauge (11100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) CHAIN BUFFER Inspect the chain buffer for wear and damage.
CHASSIS 8·51 REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: c:::> Right Left ¢:::l ..-:-----~ 115 Nrn 11.5 kgt-m) ( 83.0Ib-ft @--+-flI-------..1H-++--f1+- ©+-f---+=:::m-----+J+\.-='f#H-------, ~ 78 N·m .0 I 7.8 kgt-m) ( 56.5 Ib-ft LL I V VVasher ~ 15N·m 1.5 kgt-m) ( 11.0 Ib-ft ~~~~~~~~/ ®--+-,rr--TA------"....-rr-----------------rrf---'rr-----.'r'-r--,,f------- ~ ~ 100N·m 10.0 kgt-m) ( 72.5Ib-ft ~ 65N·m 6.
8-52 CHASSIS SWINGARM BEARING • Press the bearing into the swingarm pivot with the special tool. jr'OOt! 09941-34513: Steering race installer • Press the swingarm cushion rod upper side bearing with the special tool. j-FoR, 09941-34513: Steering race installer NOTE: When reinstalling the bearing, stamped mark on bearing must face outside. CUSHION LEVER BEARING • Press the bearings into the cushion lever with the special tool.
CHASSIS • Assemble the cushion rod onto the swingarm temporarily. • Remount the chain case CD and chain buffer~. REMOUNTING Remount the swingarm in the reverse order of disassembly and removal, and pay attention to the following points. SWINGARM PIVOT THRUST CLEARANCE ADJUSTMENT Adjust swingarm pivot thrust clearance in the following procedure. • Insert the swingarm pivot shaft and tighten to the specified torque . •@t. 09900-18740: Hexagon socket (24 mm) ~ Swingarm pivot shaft: 15 N·m (1.5 kgf-m, 11.
8·54 CHASSIS SHOCK ABSORBER AND CUSHION LEVER MOUNTING NUT • Install the washers ® and cushion lever. (c:::::rS-51) • Tighten the cushion lever mounting nut CD to the specified torque. ~ Cushion lever mounting nut: 78 N·m (7.8 kgf-m, 56.5 Ib-ft) • Assemble the cushion lever, cushion rod and rear shock absorber. (c:::::rS-44) ~ Rear shock absorber mounting nut ~: 50 N·m (5.0 kgf-m, 36.0 Ib-ft) Cushion rod nut @: 78 N·m (7.8 kgf-m, 56.5 Ib-ft) • Route the brake hose and install the brake hose guides.
CHASSIS 8·55 FRONT BRAKE CONSTRUCTION CD Front brake lever ~ Dust boot Q) Piston set @ Piston seal @ Dust seal @ Brake caliper piston (l) Brake pad @ Brake pad spring @ Brake hose ®J Brake hose ®Tape ® Front master cylinder mounting bolt @ Brake hose union bolt © Caliper mounting bolt (Ql Caliper air bleeder valve ~ Caliper housing bolt ® Brake pad mounting pin ITEM N·m kgf-m Ib-ft ® 10 1.0 7.0 @ 23 2.3 16.5 © 25 2.5 18.0 (Ql 8 0.8 6.0 ~ 22 2.2 16.0 ® 16 1.6 11.
8·56 CHASSIS BRAKE PAD REPLACEMENT • Remove the pad mounting pins • Remove the brake pads. CD and springs. ~® I CAUTION I * Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected. • Install the new brake pads. ~ Pad mounting pin: 16 N·m (1.6 kgf-m, 11.5Ib-ft) NOTE: * Before installing the pad, clean the piston and peel the backing sheet ~ from the pad.
CHASSIS CALIPER REMOVAL AND DISASSEMBLY • Remove the brake pads. (c:::::ra-S6) • Remove the brake hose from the caliper by removing the union bolt CD and catch the brake fluid in a suitable receptacle. NOTE: * Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. * When reusing the pad, put a reference mark on the pad so that the original position can be restored during reassembly. After cleaning the pad, attach a new tape on it.
8·58 CHASSIS • Remove the dust seals and piston seals. I CAUTION I Do not reuse the dust seals and piston seals to prevent fluid leakage. CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches or other damage. Clean and degrease the contact portions ® of pad and piston.
CHASSIS PISTON SEAL • Install the piston seals as shown in the illustration. Piston seal O-RING • Install the new O-ring and reassemble caliper halves. I CAUTION I I Replace the O-ring with a new one. • Tighten each bolt to the specified torque. ~ Front brake caliper housing bolt: 22 N·m (2.2 kgf-m, 16.0 Ib-ft) Front brake caliper mounting bolt CD: 39 N·m (3.9 kgf-m, 28.0 Ib-ft) Front brake hose union bolt ~: 23 N·m (2.3 kgf-m, 16.
8·60 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. _ Front disc thickness: Service Limit: 5.0 mm (0.197 in) j@t. 09900-20205: Micrometer (0 - 25 mm) • Remove the brake calipers. (c:::::ra-57) Measure the runout with a dial gauge. Replace the disc if the runout exceeds the service limit. _ Front disc runout: Service Limit: 0.30 mm (0.
CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY • Disconnect the front brake light switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch any split brake fluid. Remove the union bolt and disconnect the brake hose. I CAUTION I Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The fluid reacts chemically with paint, plastics and rubber materials, etc. and will damage them severely.
8·62 CHASSIS • Pull out the dust boot CD and remove the snap ring (2), • Remove the piston/secondary cup, primary cup and return spring. @ Secondary cup @ Piston @ Primary cup @ Return spring • Remove the snap ring (f), connector @ and O-ring @. MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage.
CHASSIS • When remounting the brake master cylinder onto the handlebar, align the master cylinder holders mating surface with punched mark ® on the handlebar and tighten the upper clamp bolt first as shown. ~ Front brake master cylinder mounting bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) • Tighten the union bolt. (Brake hose routing: CT1 0-20) ~ Brake hose union bolt: 23 N·m (2.3 kgf.m, 16.5Ib-ft) • Bleed air from the brake system.
8·64 CHASSIS REAR BRAKE CONSTRUCTION ITEM N·m kgf-m Ib-ft ® 8 0.8 6.0 @ 23 2.3 16.5 © © eEl ® © 25 2.5 18.0 10 1.0 7.0 18 1.8 13.0 37 3.7 27.0 17 1.7 12.
CHASSIS BRAKE PAD REPLACEMENT • Remove the brake pad mounting pin CD and spring ~. • Remove the brake pads. ICAUTION! * Do not operate the brake pedal while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected. • Install the new brake pads and shims. ~ Pad mounting pin: 17 N·m (1.7 kgf-m, 12.5Ib-ft) NOTE: After replacing the brake pads, pump the brake pedal a few times to set the brake parts correctly and then check the brake fluid level.
8·66 CHASSIS CALIPER REMOVAL AND DISASSEMBLY • Remove the brake pads. (c:::::Ta-65) • Remove the union bolt G) and catch the brake fluid in a suitable receptacle. NOTE: Slightly loosen the caliper housing bolts CZ) to facilitate later disassembly before removing the caliper mounting bolts. I CAUTION I Never reuse the brake fluid left over from previous servicing and stored for long periods. A WARNING Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.
CHASSIS CALIPER INSPECTION CALIPER INSPECTION (L78-58) BRAKE DISC INSPECTION (L78-60) _ Service Limit Rear disc thickness: 4.5 mm (0.177 in) Rear disc runout: 0.30 mm (0.012 in) CALIPER REASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of removal and disassembly. Pay attention to the following points: • Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves.
8·68 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY • Remove the frame cover. (CT8-6) • Remove the brake fluid reservoir tank mounting bolt W. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt (Z) and disconnect the brake hose. • Loosen the lock-nut @. • Remove the mounting bolts @. !CAUTION! Immediately and completely wipe off any brake fluid contacting any parts of the motorcycle.
CHASSIS MASTER CYLINDER INSPECTION CYLINDER, PISTON AND CUP SET Inspect the cylinder bore wall for any scratches or other damage. Inspect the cup set and each rubber part for damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: !CAUTIONI * Clean the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them.
8·70 CHASSIS 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. For operating procedures, refer to the instructions supplied by the tire changer manufacturer.
CHASSIS VALVE INSPECTION Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal ® rubber is peeling or has damage. NOTE: If the external appearance of the valve shows no abnormal condition, removing of the valve is not necessary. If the seal has abnormal deformation, replace the valve with a new one. ® lr-.---... Any dust or rust around the valve hole @ must be cleaned off. Then install the valve © in the rim.
8·72 CHASSIS TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points. I CAUTION I * 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. • When installing the tire, the arrow ® on the side wall should point to the direction of wheel rotation. • Align the chalk mark put on the tire at the time of removal with the valve position.
CHASSIS • In this condition, check the "rim line" @ cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides. Coat the bead with lubricant and fit the tire again. • When the bead has been fitted properly, adjust the pressure to specification. • As necessary, adjust the tire balance.
8·74 CHASSIS DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain. ,ggt! 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. DRIVE CHAIN CUTTING • Set up the special tool as shown in the illustration.
CHASSIS • Place the drive chain link being disjointed on the holder part @ of the tool. • Turn in both the adjuster bolt @ and pressure bolt "A" @ so that each of their end hole fits over the chain joint pin properly. • Tighten the pressure bolt "A" @ with the bar. • Turn in the pressure bolt "B" @ with the bar @ and force out the drive chain joint pin ®. [CAUTION I Continue turning in the pressure bolt "8" @ until the joint pin has been completely pushed out of the chain.
8·76 CHASSIS • Apply grease on the recessed portion of the joint plate holder @ and set the joint plate @. NOTE: When positioning the joint plate @ on the tool, its stamp mark must face the joint plate holder@ side. • Set the drive chain on the tool as illustrated and turn in the adjuster bolt @ to secure the wedge holder & wedge pin @.
CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt "A" @ with the bar until the pin end diameter becomes the specified dimension. _ Pin end diameter specification DID © 5.50 - 5.75 mm (0.217 - 0.226 in) I CAUTION I * After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found. * Should any abnormal condition be found, reassemble the chain link using the new joint parts.
ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING .•......................••......................•......................... 9- 2 CONNECTOR ...............................................•.................................•....... 9COUPLER •..••...........•.....•.•....................•.......................••....•........•..••......9CLAMP....•.••............................................••....•..............•.............•......••.... 9FUSE...................................................•..............
ELECTRICAL SYSTEM FUEL PUMP RELAy 9·1 9-31 SWITCHES 9-31 BATTERY 9-33 SPECIFICA TIONS.••........................•..••...................•....................•..•..•....
9·2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and breakage in its cover. COUPLER • With a lock type coupler, be sure to release the lock before disconnecting and push it in fully till the lock works when connecting. • When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.
ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with semi-conductor built in such as ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY • The MF battery used in this vehicle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment). • During normal charging, no hydrogen gas is produced.
9·4 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester c±l and 8 probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin measuring in the highest range. • When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged. • After using the tester, be sure to turn the switch to the OFF position.
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS CD Ignition coil (No.
9-6 ELECTRICAL SYSTEM CD Fuel pump (CT5-7) 12) Fuel level switch @ Battery @ ECM (Engine Control Module) @ Starter relay/Main fuse @ Fuel pump relay (CT5-9) ([) Tip over sensor (CT4-61) @ Regulator/Rectifier @ Mode selection switch coupler (CT4-23) @ Cooling fan (CT7-6) ® Speedometer sensor @ Gear position switch ® Side-stand switch ® Generator
ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/rectifier Generator r------------, Ie L TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Ii: IRemove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (erg-8) Is the battery for current leaks OK? YES Go to Step 3. NO • • Short circuit of wire harness. Faulty electrical equipment.
9-8 ELECTRICAL SYSTEM StepS 1) Measure the generator no-load voltage. (c:::79-9) Is the generator no-load voltage OK? YES I NO I_G_o_to_S_te...:-p_6_.- - - - - - - - - - - - - - - - - - - - - - _F_a_ul....:ty;,-.g:::,.e_n_e_ra_t_o_r. _ Step 6 1) Inspect the regulator/rectifier. (c:::79-10) Is the regulator/rectifier OK? YES Go to Step 7. NO Faulty regulator/rectifier. Step 7 1) Inspect wirings. Is the wirings OK? YES Faulty battery NO • Short circuit of wire harness. • Poor contact of couplers.
ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. (c::::ra-6) • Start the engine and keep it running at 5 000 r/rnin. with lighting switch turned ON and dimmer switch turned HI position. Measure the DC voltage between the @ and 8 battery terminals using the multi circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/rectifier. (c::::r9-10 and 9-11) NOTE: When making this test, be sure fully-charged condition.
9·10 ELECTRICAL SYSTEM REGULATOR/RECTIFIER • Remove the frame cover. (c:::::ra-6) • Disconnect the regulator/rectifier coupler. Measure the voltage between the lead wires using the multi circuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulatorlrectifier with a new one. ,gob 09900-25008: Multi circuit tester set ~ Tester knob indication: Diode test (-1+) Unit: V ' .8' ' <, CB Probe of tester to: B/R CD U5 B/R 2 B1 '0 Q) B2 .
ELECTRICAL SYSTEM 9·11 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop switch To Ignition coil Ignition switch £7R Fuse (30 A) A-It---t--- Y/G Gear position i : (])2:switch (Neutral) : 'iii ~ Starter relay BIY ~ Clutch lever Starter button ~ position switch , B/W I ~ TROUBLESHOOTING Starter motor will not run Step 1 1) Shift the transmission to neutral.
9·12 ELECTRICAL SYSTEM Step 4 1) Check the starter relay. (c:::7'9-14) Is the starter relay OK? YES NO Poor contact of the starter relay. Faulty starter relay. Starter motor runs but does not crank the engine Step 1 1) The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up. 2) Check the side-stand switch. (c:::7'9-15) Is the side-stand switch OK? YES NO Go to Step 2. Faulty side-stand switch.
ELECTRICAL SYSTEM 9·13 STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut ®. If abnormal wear is found, replace the armature with a new one. If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth.
9·14 ELECTRICAL SYSTEM • Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft. ~ 99000-25140: SUZUKI MOLY PASTE • Fit the projection of the starter motor case to the depression of the housing end. • Apply SUZUKI SUPER GREASE to the a-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Tighten the starter motor lead wire mounting nut to the specified torque. ~ Lead wire mounting nut: 3 N·m (0.3 kgf-m, 2.
ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. ITUt! 09900-25008: Multi circuit tester set _ Starter relay resistance: 3 - 5 n 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.
9·16 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Lift the fuel tank. (c::::TS-S) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmission in "NEUTRAL".
ELECTRICAL SYSTEM 9·17 TURN SIGNAUSIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between © and ® terminals with the tester. Then apply 12 V to terminals © and © (CB to © and 8 to ©) and check the continuity between © and ®. If there is no continuity, replace the turn signal/side-stand relay with a new one.
9·18 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch bS;de- ECM I P.owersource circuit CKP sensor O I #1 -;;l stand relay Fuse r-----,-Ern..~ Waveform ~ ~ arrangement '-P--4---1 circuit -- r:v";»..-----t------t---------JI -= CPU #3 1 Ignition switch .,., Waveform ~ arrangement '--+--+-1-+-...-------. '-P--4---1 circuit Cam position L::.::.:.~---l----' sensor 6 : Battery b Throttle position sensor Engine coolant temp.
ELECTRICAL SYSTEM 9·19 Step 2 1) Measure the battery voltage between input lead wires at the ECM with the ignition switch in the "ON" position. (E-02, 19: O/G and BIW, E-03, 24, 28, 33: OIW and BIW) Is the voltage OK? YES NO Go to Step 3. • Faulty ignition switch. • Faulty turn signal/side-stand relay. • Faulty engine stop switch. • Broken wire harness or poor connection of related circuit couplers. Step 3 1) Measure the ignition coil primary peak voltage.
9·20 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. (c::::75-15) • 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. I CAUTION I * Do not remove the ignition coil/plug cap before disconnecting the lead wire coupler, or the lead wire will be damaged. * Do not pry up the ignition coil/plug cap with a screwdriver or a bar to avoid damage.
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. • Repeat the above inspection a few times and measure the highest peak voltage.
9·22 ELECTRICAL SYSTEM CKP SENSOR PEAK VOLTAGE • Remove the front seat. (eTa-6) NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Disconnect the both couplers CD. • Connect the multi circuit tester with peak volt adaptor as follows. • Measure the CKP sensor peak voltage between Green/Blue and GreenlWhite lead wires at the ECM coupler (2). GreenlWhite (CB Probe) - Green/Blue (8 Probe) .roK.
ELECTRICAL SYSTEM 9·23 If the peak voltage is lower than the standard range, check the peak voltage at the CKP sensor lead wire coupler. • Lift up the fuel tank. (c::::.rS-S) • Disconnect the CKP sensor lead wire coupler and connect the multi circuit tester with the peak volt adaptor. Green (@ Probe) - Black (8 Probe) • Measure the CKP sensor peak voltage at the CKP sensor lead wire coupler. ~ Tester knob indication: Voltage (=-=-:) B CKP sensor peak voltage: 0.
9·24 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition. The rpm pointer is driven by the stepping motor. The LCDs indicate speed, OdofTrip1fTrip2/Clock and engine coolant temp.lFI respectively.
ELECTRICAL SYSTEM REMOVAL AND DISASSEMBLY • Remove the screws W, • Draw out the hook ~ from the head lamp housing. • Disconnect the lead wire coupler. • Remove the combination meter. ICAUTION I When disconnecting and reconnecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Disassemble the combination meter as follows. ICAUTION I Do not attempt to disassemble the combination meter unit ~.
9-26 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights immediately after turning the ignition switch on. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire harness/coupler. STEPPING MOTOR Check that the pointer calibrates itself immediately after turning the ignition switch on and stops at zero point.
ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR Engine coolant temperature sensor inspection. (c::::77-8) • Lift up the fuel tank. (c::::75-5) • Disconnect the engine coolant temperature sensor coupler CD. I CAUTION I When connecting and disconnecting the engine coolant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Connect the variable resistor ® between the terminals. • Turn the ignition switch ON.
9·28 ELECTRICAL SYSTEM FUEL LEVEL INDICATOR SWITCH INSPECTION • Remove and disassemble the fuel pump assembly. (c::::rS-10, 11) • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel level indicator switch as shown in the right illustrations. The bulb should come on after one minutes if the switch is in good condition. • When the switch is immersed in water under the above condition, the bulb should go out. If the bulb remains lit, replace the unit with a new one. ON ~rt)r----
ELECTRICAL SYSTEM 9-29 SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of couplers. If the speedometer sensor and connection are functioning properly, replace the meter with a new one. SPEEDOMETER SENSOR • Lift and support the fuel tank with its prop stay. (c::::rS-S) • Disconnect speedometer sensor coupler. • Remove the speedometer sensor CD by removing its mounting bolt.
9·30 ELECTRICAL SYSTEM LAMPS HEADLIGHT, BRAKE LlGHTrrAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12V55WH7(1) 12 V 60/55 W H4 ~ I I I I I I I l \ POSITION LIGHT 12 V 5 W @ (Except for E-03, 24, 28, 33) BRAKE L1GHTrrAILLIGHT: LED \ LICENCE PLATE LIGHT @ ~ 12 V 5 W ~ ~=~- ~ \ 'fJ> (fJJ ~.
ELECTRICAL SYSTEM RELAYS TURN SIGNAUSIDE-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. If the bulb, turn signal switch and circuit connection are OK, the turn signal relay may be faulty.
9·32 ELECTRICAL SYSTEM Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. STARTER BUnON ~ O/w Y/G PUSH 0 -0 ~ OIG G PUSH 0 -0 Position • HAZARD SWITCH ~r Position Lbl B • (OFF) ItA (ON) Lg Position r-.. C • -0 '-./ IGNITION SWITCH ~r Position ON OFF LOCK P R 0 0 'J r-..
,~ ELECTRICAL SYSTEM 9-33 BATTERY SPECIFICATIONS Type designation Capacity FTX12-BS 12 V, 36 kC (10 Ah)/10 HR INITIAL CHARGING Filling electrolyte • Remove the aluminum tape G) sealing the battery electrolyte filler holes. • Remove the caps (2). NOTE: * After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes. * Do not remove or pierce the sealed areas @ of the electrolyte container.
9·34 ELECTRICAL SYSTEM 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 battery. Wait for about more than 20 minutes. *~ ~ .lj{ l * Never use anything except the specified battery. * Once the caps have been installed to the battery, do not remove the caps.
ELECTRICAL SYSTEM RECHARGING OPERATION • Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0 V (DC), recharge the battery with a battery charger. I CAUTION I * When recharging the battery, remove the battery from the motorcycle. * Do not remove the caps on the battery top while recharging. Charging period (V) 18 17 16 15 14 13 12 ..L __ Stop charging ~ 1\ """'" o 10 20 30 Time (V) Recharging time: 5 A for 1 hour or 1.
SERVICING INFORMATION 10-1 SERVICING INFORMA TION CONTENTS TROUBLESHOOTING .........................................••..•...................................10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION...............................•..................•..••....•...........................•...10- 2 ENGINE ....................................................•............................................10- 4 RADIATOR (COOLING SYSTEM) 10- 9 CHASSIS ...............••.•...••..••.••.....•...••........
10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED ITEM CODE NO FAULT COO Camshaft position sensor C11 C12 C13 C14 Crankshaft position sensor Intake air pressure sensor Throttle position sensor Engine coolant temperature sensor C15 C21 C22 Intake air temperature sensor Atmospheric pressure sensor Tip over sensor C23 Ignition signal C24/C25 C26/C27 DETECTED FAILURE CONDITION CHECK FOR The signal does not reach ECM for 4 sec.
SERVICING INFORMATION MALFUNCTION CODE DETECTED ITEM Secondary throttle valve actuator C28 Secondary throttle position sensor C29 Gear position signal C31 Fuel injector C32/C33 C34/C35 Fuel pump relay C41 C42 Ignition switch Exhaust control valve actuator C46 10·3 DETECTED FAILURE CONDITION CHECK FOR When no actuator control signal is supplied from the ECM or communication signal does not reach ECM or operation voltage does not reach STVA motor, C28 is indicated. STVA can not operate.
10-4 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Engine will not start Compression too low or is hard to start. 1. Out of adjustment tappet clearance. 2. Worn valve guides or poor seating of valves. 3. Mistiming valves. 4. Excessively worn piston rings. 5. Worn-down cylinder bores. 6. Too slowly starter motor cranks. 7. Poor seating of spark plugs. Plug not sparking 1. Fouled spark plugs. 2. Wet spark plugs. 3. Defective ignition coil. 4. Defective CKP sensor. 5. Defective ECM. 6.
SERVICING INFORMATION Complaint Engine idles poorly. Symptom and possible causes 1. Out of adjustment tappet clearance. 2. Poor seating of valves. 3. Defective valve guides. 4. Worn down camshafts. 5. Too wide spark plug gaps. 6. Defective ignition coil/plug caps. 7. Defective CKP sensor. 8. Defective ECM. 9. Defective TP sensor. 10. Defective fuel pump. 11. Imbalanced throttle valve. 12. Damaged or cracked vacuum hose. Engine stalls easily. Incorrect fuel/air mixture 1. Defective lAP sensor or circuit.
10-6 SERVICING INFORMATION Complaint Noisy engine. Symptom and possible causes Excessive valve chatter 1. Too large tappet clearance. 2. Weakened or broken valve springs. 3. Worn tappet or cam surface. 4. Worn and burnt camshaft journal. Noise seems to come from piston 1. Worn down pistons or cylinders. 2. Fouled with carbon combustion chambers. 3. Worn piston pins or piston pin bore. 4. Worn piston rings or ring grooves. Noise seems to come from timing chain 1. Stretched chain. 2. Worn sprockets. 3.
SERVICING INFORMATION Symptom and possible causes Complaint Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs. 2. Worn camshafts. 3. Valve timing out of adjustment. 4. Too narrow spark plug gaps. 5. Ignition not advanced sufficiently due to poorly working timing advance circuit. 6. Defective ignition coils. 7. Defective CKP sensor. 8. Defective ECM. 9. Clogged air cleaner element. 10.
10·8 SERVICING INFORMATION Symptom and possible causes Complaint Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance. 2. Weakened valve springs. 3. Out of adjustment valve timing. 4. Worn piston rings or cylinders. 5. Poor seating of valves. 6. Fouled spark plugs. 7. Incorrect spark plugs. 8. Clogged injectors. 9. Out of adjustment TP sensor. 10. Clogged air cleaner element. 11. Imbalancing throttle valve synchronization. 12.
SERVICING INFORMATION Complaint Dirty or heavy exhaust smoke. Symptom and possible causes 1. Too much engine oil in the engine. Scored or scuffed cylinder walls. Worn valves stems. Defective stem seal. Worn oil ring side rails. Weakened clutch springs. 2. Worn or distorted pressure plates. 3. Distorted clutch plates or pressure plates. Check with inspection window drain out excess oil. Replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace. 1.
10·10 SERVICING INFORMATION CHASSIS Complaint Heavy steering. 1. 2. 3. 4. Wobbly handlebars. 6. 1. 2. 3. 4. 5. Front suspension too soft. Front suspension too stiff. Noisy front suspension. Wobbly rear wheel. 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. Rear suspension too stiff. Noisy rear suspension. Distorted front fork. Distorted front axle or crooked tire. Loose steering stem nut. Worn or incorrect tire or wrong tire pressure. Worn bearing/race in steering stem. Distorted wheel rim.
SERVICING INFORMATION 10-11 BRAKES Complaint Insufficient brake power. 2. Brake squeaking. 3. 4. 5. 6. 1. Carbon adhesion on pad surface. 1. Symptom and possible causes Leakage of brake fluid from hydraulic system. Worn pads. Oil adhesion of engaging surface of pads/shoe. Worn disc. Air in hydraulic system. Not enough brake fluid in the reservoir. 2. Tilted pad. 3. Damaged wheel bearing. 4. Loosen front-wheel axle or rear-wheel axle. 5. Worn pads. 6. Foreign material in brake fluid. 7.
10·12 SERVICING INFORMATION ELECTRICAL Complaint No sparking or poor sparking. Spark plug soon become fouled with carbon. Symptom and possible causes 1. Defective ignition coils or CKP sensor. 2. 3. 4. 5. Defective spark plugs. Defective sensor. Defective ECM. Defective tip over sensor. 6. Open-circuited wiring connections. 1. Mixture too rich. 2. Idling speed set too high. 3. Incorrect gasoline. 4. Dirty element in air cleaner. 5. Too cold spark plugs. Spark plug become fouled too soon.
SERVICING INFORMATION 10·13 BATTERY Complaint "Sulfation", acidic white powdery substance or spots on surface of cell plates. Symptom and possible causes 1. Cracked battery case. 2. Battery has been left in a run-down condition for a long time. Battery runs down quickly. 1. Not correct the charging system. I 2. Cell plates have lost much of their active material as a result of overcharging. 3. Internal short-circuit in the battery. 4. Too low battery voltage. 5. Too old battery. Battery "sulfation".
10-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Position light Headlight lead wire is made to slacken. Wiring harness Clamp Clamp Handlebar switch (R) Ignition switch Clamp IBa".
SERVICING INFORMATION Clamp Wiring harness Oil pressure SWI'tc h Side-stand switch Battery 8 CKP sensor Speed sensor EXCV actuator Clamp Handlebar switch (L) Clutch cable Clamp Wiring harness Clamp Clamp the wiring harness to the frame, ~~~~=~;:;I Clamp Wiring harn~';.._~._.".
....... er ....... en en ( ) , \ / Gear position sensor lead wire m :::a \:I1CI~mp Clamp Gear position sensor Water bypass hose Water hose (Cylinder inlet) CKP sensor < o z C) Z "T1 o:::a s:: ~ z o Clamp Generator '\ . f Gear position sensor ~6N.m r:">. (0.6 kgf-m, 4.5 Ib-ft) ~ ~ 11 Nrn (1.1 k9f- m, 8.0 Ib-ft) ) ~ 1.5 N·m J , Let direction of a clamp be a clutch cover mating surface at parallel. Oil pressure switch ~ 14N·m (1.4 kgf-m, 10.0 Ib-ft) (0.15 kgf-m, 1.
SERVICING INFORMATION CABLE ROUTING Throttle cable NO.1 ~ Throttle cable No.2 ~ .",. .... Throttle cable NO.2 ---.;'----"~'" Throttle cable NO.2 ~ Clutch cable Guide Clutch cable Pass through the clutch cable under the engine mounting bracket. Pass through the throttle cable NO.1 over the throttle cable No.2.
." c: m r- ---~';Tf;Oc~--,~l7'-,::) , -).~Ul :" /' ---' ,/;::,/ I I I I " -3- ,, ,, ,, ,, ,, -'\ r /~-_-=- ,, ,,, ,, ,,, , : , I :, Fuel tank drain hose » Z .: /:--/ ,,,-;:,"", " , " ,/:;", -I ,, - r- /----'~-------~_/ ~ \ ~ 0 en m ::D z G) Marking (White) z 0:z c: :::! Face the clamp to down side. < Z ::I: 0 Pay attention to the direction of the clamp. :JJ ('; " » - L ':. 1,- ' , : ) -, ...
®: The ®: The ~ ends of the clamp face . clamp bolt head face . ® " ": 1// ~V ® Down side -Z ~PR::; side t!J Clamp bolt 2 Nrn (0.2 'gl-m, 1.5 Ib-ft) .@Rightside t!J Clamp bolt 2 Nrn (0.2 kgf-m, 1.5 Ib-ft) "(USA) . . (Others) ® o o or- Right side C) (J) -< (J) -t m s: :J: o(J) m t!J Clamp bolt 2 Nrn ® (0.2 kgf-m, 1.5 Ib-ft) Marking (Red) ::D Left side o c: t!J 6 N·m ::j z (0.6 kgf-m, 4.3 Ib-ft) C) Jiggle valve ~og ~ (While) \ Marking (Red) .
"T1 :D o . ~ \ 1$f \ Z -I OJ Face the clamp ends down :D ~ . " m ::J: oen m '~-lln~ ·~OOUll r I ~ :D o Pass through the brake hose behind the throttle cables. c: ~' . ~~=J L _ ~~ I 1/ ~ /1 .r. . \ :::! z C) After positioning the clamp with the stopper, tighten the clamp bolt. I, Clamp the brake hose firmly. Insert the clamp to the hole of the front fender fully. After touching the brake hose unions to the stopper, tighten the union bolts. ....
X \~: ~ Face the clamp ends forward . :D m ~~ » :D \--tm ~(WJx~ Frame 'toppe~ ~/ After touchinq the brake tighten the union hose union fa the bolt. ' D:J :D » "m / Stopper :::I: oCJ) m :D oc: ~' \ --tZ C) ~ Pass thorough the brake hose inside of the guide. Face the clamp ends backward. en m ;:Q < ('; z C> Z "T1 o;:Q s:: ~ <5 :z: ......
10·22 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR valve vacuum hose - - - - f (530 mm) ! '\ To throttle body (NO.~ cylinder) \, PAIR valve hose R (50 mm) PAIR valve ~ mil 10 Nrn (1.0 kgf-m, 7.5Ib-ft) ~ ~ ~ ~ PAIR cleaner hose! \ ~"""'.. ~) I II It .
"T1 C m r- -t » Z "emn -t I C "0 Adh~ r-: en m < :XJ (") z C) Z ~ "'TI o :XJ 3: » --I zs :z .
o o ....=E Right al~ intake pipe ~/ ~ Lower bracket cover -Z en C> m -I • c: "'tJ ~ /'41 ~~eftUnder ~ mner cowl I,g ~ ~ U) G') Left air intake pipe ......
SERVICING INFORMATION FRAME COVER SET-UP HEAT SHIELD SET-UP >< Right under cowling Right under cowling heat shield Under cowling molding 10·25
10·26 SERVICING INFORMATION SIDE-STAND SET-UP • I (USA) : ::t~e:) / <,1 (5.0 ~ 40N·m (4.0 kgf-m, 29.0 Ib-ft) kgf-m, 36.0 Ib-ft) GEARSHIFT PEDAL SET-UP /'" / 60-70 mm (2.4 - 2.
SERVICING INFORMATION SEAT LOCK CABLE ROUTING Seat lock cable Seat lock 10·27
10·28 SERVICING INFORMATION HANDLEBAR BALANCER Handle balancer expander Throttle grip Har"' ~.- Screw ~ 5.5N·m (0.5 kgf-m, 4.
SERVICING INFORMATION 10-29 SPECIAL TOOLS r 09900-06108 Snap ring pliers 09900-18740 Hexagon socket (24 mm) 09900-20205 Micrometer (0-25 mm) 09900-20602 09900-20605 09900-20607 09900-20508 Dial gauge Dial calipers Dial gauge Cylinder gauge set (111000 mm, 1 mm) (1/100 mm, 10-34 mm) (1/100 mm, 10 mm) 09900-20701 Magnetic stand 09900-20803 09900-20806 Thickness gauge 09900-20101 09900-20102 Vernier calipers 09900-20805 Tire depth gauge 09900-20202 Micrometer (25 - 50 mm) 09900-20203 Micrometer (50
10·30 SERVICING INFORMATION 09913-13121 Vacuum balancer gauge 09913-50121 Oil seal remover 09913-70210 09915-40610 Bearing installer set Oil filter wrench 09915-64510 Compression gauge set 09915-74521 09915-74540 09915-77331 Oil pressure gauge Oil pressure gauge Meter 09916-10911 hose attachment (for high pressure) Valve lapper set 09916-14510 Valve lifter 09916-14910 Valve lifter attachment 09916-20650 Solid pilot (N-100 - 4.
SERVICING INFORMATION 09917-47010 Vacuum pump gauge 09920-34830 Starter clutch holder 09920-53740 Clutch sleeve hub 09921-20210 holder Bearing remover 09922-22711 09925-18011 Steering bearing Drive chain cutting 09924-84510 Bearing installer set installer and joining tool '- 10·31 09921-20240 Bearing remover set 09930-11920 Torx bit JT40H 09930-11940 Bit holder 09930-44520 Rotor holder 09930-82720 Mode selection switch 09930-11950 Torx wrench 09930-30102 Sliding shaft 09930-34980 Rotor remover
10-32 SERVICING INFORMATION ~:: ;:::: ~ ~ e 09940-40220 09940-50120 09940-40211 Fuel pressure gauge Fuel pressure gauge Front fork inner adaptor hose attachment rod holder 09940-52861 Front fork oil seal installer 09940-92720 Spring scale £fJ 09940-94922 Front fork spring stopper plate 09940-94930 Front fork spacer holder 09941-34513 Steering race installer 09943-74111 Fork oil level gauge NOTE: When order the special tool, please confirm whether it is available or not.
SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM Exhaust pipe bolt Muffler connecting nut Muffler mounting nut Speed sensor rotor bolt Engine sprocket nut Engine mounting bolt and nut (M:12) (M:10) Engine mounting thrust adjuster Engine mounting thrust adjuster lock-nut Engine mounting pinch bolt Cylinder head cover bolt Spark plug Cam chain guide bolt Camshaft journal holder bolt Cam chain tension adjuster cap bolt Cam chain tension adjuster mounting bolt Cam chain tensioner bolt Cylinder head bolt
10·34 SERVICING INFORMATION ITEM Ib-ft 7.0 13.0 13.0 26.5 16.5 7.0 7.0 15.1 10 10 10 10 10 10 14 10 10 kgf-m 1.0 1.8 1.8 3.5 2.3 1.0 1.0 2.1 90 0 (1/4 turn) 1.0 1.0 1.0 1.0 1.0 1.0 1.4 1.0 1.0 N·m kgf-m Ib-ft CKP sensor mounting bolt IAT sensor 8 18 0.8 1.8 6.0 13.0 Fuel delivery pipe mounting screw 3.5 0.35 2.5 Fuel pump mounting bolt 10 1.0 7.0 TPS and STPS mounting screw 3.5 0.35 2.
SERVICING INFORMATION CHASSIS ITEM Steering stem head nut Steering stem lock-nut Steering damper bolt and nut Front fork upper clamp bolt Front fork lower clamp bolt Front fork cap bolt Front fork inner rod lock-nut Front fork damper rod bolt Front axle Front axle pinch bolt Handlebar clamp bolt Front brake master cylinder mounting bolt Front brake caliper mounting bolt Front brake caliper housing bolt Front brake pad mounting pin Brake hose union bolt Clutch lever holder mounting bolt Air bleeder valve
10·36 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter ®(mm) Conventional or "4" marked bolt kgf-m Ib-ft N·m N·m "7" marked bolt kgf-m 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 1.0 7.0 Ib-ft 8 13 1.3 9.5 23 2.3 16.5 10 29 2.9 21.0 50 5.0 36.0 12 45 4.5 32.5 85 8.5 61.5 14 65 6.5 47.0 135 13.5 97.5 16 105 10.5 76.0 210 21.0 152.
SERVICING INFORMATION 10·37 SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD Valve diam. IN. EX. Tappet clearance (when cold) IN. EX. Valve guide to valve stem clearance IN. EX. Valve guide 1.0. IN. &EX. Valve stem 0.0. IN. EX. Valve stem deflection Valve stem runout Valve head thickness Valve seat width Valve head radial runout Valve spring free length LIMIT 29 (1.14) 24 (0.94) 0.10 - 0.20 (0.004 - 0.008) 0.20 - 0.30 (0.008 - 0.012) 0.010- 0.037 (0.0004 - 0.0015) 0.030 (0.
10-38 SERVICING INFORMATION ITEM Camshaft journal holder I.D. Camshaft journal O.D. IN. & EX. IN. & EX. Camshaft runout Cam chain pin (at arrow "3") Cylinder head distortion STANDARD 24.012 (0.9454 23.959 (0.9433 - LIMIT 24.025 0.9459) - 23.980 0.9441) - - 0.10 (0.004) 14th pin - - 0.20 (0.
SERVICING INFORMATION ITEM Piston ring thickness STANDARD 1st 2nd Piston pin bore 1.0. Piston pin 0.0. 10·39 LIMIT 0.97 - 0.99 (0.0382 - 0.0390) 0.77 - 0.79 (0.0303 - 0.0311) 16.002 - 16.008 (0.6300 - 0.6302) 16.030 (0.6311 ) 15.995 - 16.000 (0.6297 - 0.6299) 15.980 (0.6291) CONROD + CRANKSHAFT - Unit: mm (in) STANDARD LIMIT 16.010 -16.018 (0.6303 - 0.6306) 16.040 (0.6315) 0.10 - 0.20 (0.004 - 0.008) 0.30 (0.012) Conrod big end width 19.95 - 20.00 (0.7854 - 0.
10·40 SERVICING INFORMATION OIL PUMP STANDARD 100 - 400 kPa (1.0 - 4.0 kgf/cm 2 , 14 - 57 psi) at 3 000 r/min. ITEM Oil pressure (at 60°C, 140 OF) CLUTCH LIMIT - Unit: mm (in) ITEM Clutch lever play Clutch release screw Drive plate thickness Drive plate claw width STANDARD LIMIT 10 -15 (0.4 - 0.6) - 1/4 turn back - No.1, 2 and 3 2.45 - 2.95 (0.096 - 0.116) No.1, 2 and 3 13.85 - 13.96 (0.5453 - 0.5496) Driven plate distortion - Clutch spring free height 77.77 (3.
SERVICING INFORMATION THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Approx. 82°C (180 OF) - 8 mm (0.31 in) and over at 95°C (203 OF) - Thermostat valve opening temperature Thermostat valve lift ECT sensor resistance Radiator cap valve opening pressure Cooling fan thermo-switch operating temperature Engine coolant type Engine coolant 20°C (68 OF) Approx. 2.45 kQ - 50°C (122 OF) Approx. 0.811 kQ - 80°C (176 OF) Approx. 0.318 kQ - 110°C (230 OF) Approx. 0.
10-42 SERVICING INFORMATION FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM CMP sensor resistance CMP sensor peak voltage SPECIFICATION 0.9 -1.
SERVICING INFORMATION 10·43 THROTTLE BODY SPECIFICATION 42mm 40F5 (For E-33), 40F4 (For the others) 1150±100r/min. 2200 r/min. (After warming up) 2.0-4.0 mm (0.08 - 0.16 in) ITEM Bore size 1.0. No. Idle r/min. Fast idle r/min. Throttle cable play ELECTRICAL Unit: mm (in) ITEM SPECIFICATION Firing order Spark plug 1.2.4.3 NGK: CR9E DENSO: U27ESR-N 0.7- 0.8 (0.028 - 0.031) Over 8 (0.3) at 1 atm.
10-44 SERVICING INFORMATION WATTAGE Unit: W STANDARD/SPECIFICATION E-03, -24, -28, -33 Others ITEM Headlight HI 60/55 W 55/55 W LO Position/Parking light Brake lightlTaillight f- 55W 5W LED 18 W x 4 5W LED LED Turn signal light License plate light Combination meter light Turn signal indicator light fffff- High beam indicator light LED f- Neutral indicator light LED f- FI indicator light/Oil pressure indicator light/Engine coolant temp.
SERVICING INFORMATION ITEM Brake caliper piston diam STANDARD Wheel rim runout Wheel rim size Wheel axle runout LIMIT Front 30.150 - 30.200 (1.1870-1.1890) - Rear 38.110 - 38.130 (1.5004 - 1.5012) - DOT 4 - Brake fluid type Axial - 2.0 (0.08) Radial - 2.0 (0.08) Front Rear 17 MIG x MT 3.50 17 MIG x MT 6.00 Front - 0.25 (0.010) Rear - 0.25 (0.010) STANDARD LIMIT - TIRE ITEM Gold inflation tire pressure (Solo riding) Tire size Front Tire type Front Rear 250 kPa (2.
10·46 SERVICING INFORMATION SUSPENSION Unit: mm (in) STANDARD 120 (4.92) 230.0 (9.06) 101 (3.98) ITEM Front fork stroke Front fork spring free length Front fork oil level (without spring, outer tube fully compressed) Front fork oil type Front fork oil capacity (each leg) Rear wheel travel Swingarm pivot shaft runout 225 (8.86) - 509 ml (17.2/17.9 US/Imp oz) - 4.5 th groove from top Rebound 6 clicks out from stiffest position Compression 11 clicks out from stiffest position 179.6 (7.
SERVICING INFORMATION 10·47 FUEL + OIL ITEM Fuel type SPECIFICATION Use only unleaded gasoline of at least 90 pump octane ( R:2 M ). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended. Fuel tank capacity Including reserve 18 L (4.8/4.0 US/Imp gal) Fuel level indicator light lighting Approx.
EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMA TION CONTENTS 11FUEL INJECTION SySTEM 11CRANKCASE EMISSION CONTROL SYSTEM.................................•. 11EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) 11NOISE EMISSION CONTROL SYSTEM 11EVAPORA TIVE EMISSION CONTROL SYSTEM (Only for E-33) 11PAIR (AIRSUPPLY) SYSTEM INSPECTION 11- EMISSION CONTROL SySTEMS 2 2 3 4 5 5 6 HOSES .•................................................................................................
11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM G8X-R1000 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. Fuel tank Fuel mesh filter (For\low pressure) "". \ \ ? v~) .~ " \ ~ Before-pressurized fuel . . . Pressurized fuel .<------, Relieved fuel ~~: .
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 crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body. t <::::=:J FRESH AIR ~ VACUUM ¢:s FUEUAIR MIXTURE . . .
11-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and exhaust control system. The fresh air is drawn into the exhaust port with the PAIR valve and PAIR reed valve. The PAIR valve is operated by the engine vacuum, and the exhaust gas flow is controlled by the ECM by changing the exhaust control valve angle. ECM <::=J FRESH AIR ~VACUUM . .
EMISSION CONTROL INFORMATION 11-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: 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.
11·6 EMISSION CONTROL INFORMATION PAIR (AIRSUPPLY) SYSTEM INSPECTION HOSES • Inspect the hoses for wear or damage. • Inspect that the hoses and pipes are securely connected. PAIR REED VALVE • Remove the PAIR reed valve cover. • 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. PAIR CONTROL VALVE • Check that air flows through the PAIR control valve air inlet port to the air outlet ports.
EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM DIAGRAM To #4 throttle body (Vacuum inlet) From air cleaner SECTION A-A E FRESH AIR ~-------- EXHAUST GAS 11-7
11-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR valve vacuum hose (530 mm) • \ -----f ~ To throttle body (No.4 cylinder) PAIRvalve~ .. ~ ~ 10 Nrn 1.0 kgf-m 7.
EMISSION CONTROL INFORMATION ~ EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the seat and frame cover. (c:::J"a-6) • Lift and support the fuel tank with its prop stay. (c:::J"S-S) HOSES Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. EVAP CANISTER Inspect the canister for damage to the body. TANK PRESSURE CONTROL VALVE Inspect the tank pressure contorol valve body for damage.
11·10 EMISSION CONTROL INFORMATION EVAP CANISTER HOSE ROUTING (Only for E-33) --- Surge hose (Red tracer) -
WIRING DIAGRAM E-03, 24, 28, 33 Wiring diagrams wire color, refer to section "WIRE COLOR". HANDLEBAR SWITCH (R) HAZARD ENGINESTOP STARTER FRONT BRAKE SWITCH SWITCH BUTTON SWITCH T TURN SIGNAL INDICATOR LIGHT HI BEAM INDICATOR LIGHT B N NEUTRAL INDICATOR LIGHT FUEL WARNNING LIGHT F OIL OIL INDICATOR LIGHT ~ {.:..=iT ~ .. I rr -------l I IGNITIDNSWITCH RO Br SPEED ON T B __--'u;-;N F SPEEDOMETER . • ~ '""V" 1"""1::: "!'TI ** -rr-H-,---,...,.
E-02,19 HANDLEBAR SWITCH (Rl HAZARD ENGINESTDP STARTER FRONT BRAKE SWITCH SWITCH BUTTON SWITCH ~~ OFF T TURN SIGNAL INDICATOR LIGHT HI BEAM INDICATOR LIGHT B N NEUTRAL INDICATOR LIGHT F FUEL WARNNING LIGHT OIL OIL INDICATOR LIGHT N lit. ~ il "@~f!;,,,r m= ,:"~~~:~~.," 1~1I',;i1l~ I~~III~~ II~~ llillJ.il IH~I H ~:~lHLlGHT1 1 1 1I TJ1TITIT ~ ~ #0 ~ T ",:E B",,-_U'l''I' il IGNITION IGNITION IGNITION IGNIT10l OIL SPEEDOMETER . . . . SENSOR ........
G,