Suzuki 2006 GSR600 Service Manual Download Page 57

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ENGINE 3-5

• Remove the front engine cover

EXHAUST PIPE AND MUFFLER JOINT

• Remove the exhaust pipe and muffler joint. (



6-3)

• Remove the O2 sensor. (



6-3)

• Remove the radiator mounting bracket

ELECTRIC PARTS AND PAIR HOSE

• Remove the regulator/rectifier

• Disconnect the oil pressure switch lead wire

Summary of Contents for 2006 GSR600

Page 1: ...GSR600 9 9 5 0 0 3 6 1 6 0 0 1 E...

Page 2: ...stomers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2005 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have b...

Page 3: ...ts are listed on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instruct...

Page 4: ...e oil and SUZUKI MOLY PASTE in a ratio of 1 1 Use fork oil 99000 99044 10G Apply SUZUKI SUPER GREASE A or equivalent grease 99000 25010 Apply or use brake fluid Apply SUZUKI MOLY PASTE 99000 25140 Mea...

Page 5: ...O Carbon Monoxide CPU Central Processing Unit D DC Direct Current DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light DTC Diagnostic Trouble Code E ECM Engine Control Modu...

Page 6: ...e Ventilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System STC System Secondary Throttle Control System STCS STP Sensor Sec...

Page 7: ...Yellow tracer Gr B Gray with Black tracer Gr R Gray with Red tracer Gr W Gray with White tracer Gr Y Gray with Yellow tracer Lg BI Light green with Blue tracer Lg G Light green with Green tracer Lg W...

Page 8: ...1B9111300 100001 GSR600UE E 19 EU JS1B9121100 100001 WARNING CAUTION NOTE 1 2 GENERAL PRECAUTIONS 1 2 SUZUKI GSR600K6 06 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION...

Page 9: ...t use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper...

Page 10: ...nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O...

Page 11: ...kets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number 1 is stamped on the right side of the steering head pipe The engine serial number 2 is located on the rear si...

Page 12: ...s not available select an alternative accord ing to the right chart BRAKE FLUID Specification and classification DOT 4 FRONT FORK OIL Use fork oil G 10 or an equivalent fork oil Since the brake system...

Page 13: ...area does not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator...

Page 14: ...restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km Below 7 000 r min Up to 1 600 km Below 10 500 r min Over to 1 600...

Page 15: ...ORMATION LABELS A Attached GSR600 GSR600U E 02 E 19 E 24 E 19 1 Noise label A 2 Fuel caution label A A 3 Tire information label A A A A 4 General information label A A 5 General warning label A A 6 ID...

Page 16: ...5 mm Displacement 599 cm Compression ratio 12 5 1 Fuel system Fuel injection Air cleaner Paper element Starter system Electric Lubrication system Wet sump Idle speed 1 300 100 r min DRIVE TRAIN Clutch...

Page 17: ...k plug NGK CR9E or DENSO U27ESR N Battery 12 V 28 8 kC 8 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 15 15 10 10 A Headlight 12 V 60 55 W H4 Turn signal light 12 V 10 W Brak...

Page 18: ...CLEARANCE 2 7 ENGINE OIL AND OIL FILTER 2 13 FUEL LINE 2 14 ENGINE IDLE SPEED 2 15 PAIR AIR SUPPLY SYSTEM 2 15 THROTTLE CABLE PLAY 2 15 CLUTCH 2 16 COOLING SYSTEM 2 17 DRIVE CHAIN 2 19 BRAKE 2 22 TIR...

Page 19: ...ghten Interval km 1 000 6 000 12 000 18 000 24 000 Item months 2 12 24 36 48 Air cleaner element I I R I Spark plugs I R I R Valve clearance I Engine oil R R R R R Engine oil filter R R Fuel line I I...

Page 20: ...cating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been o...

Page 21: ...ir cleaner element is clogged with dust replace the air cleaner element with a new one NOTE If driving under dusty conditions replace the air cleaner element more frequently Make sure that the air cle...

Page 22: ...zed appearing replace the spark plug with colder type one NOTE R type spark plug has a resistor built into at the center elec trode to prevent radio noise CARBON DEPOSITS Check carbon deposits on the...

Page 23: ...ad with fingers and then tighten them to the specified torque Spark plug 11 N m 1 1 kgf m Install the ignition coil plug caps and connect their lead wire couplers Confirm the thread size and reach whe...

Page 24: ...ve clearance must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mecha nism is serviced and 3 when the camshafts are removed for servicing Valve clearance when cold Stan...

Page 25: ...h to the index mark and also to bring the notches A on the left ends of both camshafts Ex and In to the positions as shown In this condition read the valve clearance at the valves B In and Ex of No 4...

Page 26: ...5 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 provi...

Page 27: ...and camshafts rotate the engine so that the tappet is depressed fully This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement Then check the cleara...

Page 28: ...2 05 2 10 2 15 2 20 0 41 0 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 46 0 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 51 0 55 1 60...

Page 29: ...5 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 31 0 35 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 36 0 40 1 45 1 5...

Page 30: ...SH SJ with JASO MA Oil drain plug 23 N m 2 3 kgf m Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about three minutes then check the oil leve...

Page 31: ...tighten the oil filter by hand only Oil filter 20 N m 2 0 kgf m Add new engine oil and check the oil level is as described in the engine oil replacement procedure NECESSARY AMOUNT OF ENGINE OIL Oil c...

Page 32: ...he lock nut 2 of the throttle pulling cable 1 Turn the adjuster 3 in or out until the throttle cable play at the throttle grip A is between 2 0 4 0 mm Tighten the lock nut 2 while holding the adjuster...

Page 33: ...move the clutch release adjuster cap 5 Loosen the lock nut 6 and turn in the adjusting screw 7 until it stop From this position turn out the adjusting screw 7 1 2 rotation and tighten the lock nut 6 w...

Page 34: ...e pump Flush the radiator with fresh water if necessary Connect the radiator hose 2 securely Pour the specified engine coolant up to the radiator inlet Engine coolant capacity total 2 800 ml Bleed the...

Page 35: ...e procedure until no air bleeds from the radi ator inlet Loosen the air bleeding bolt 1 and check that the engine coolant flows out Air bleeder bolt 0 5 N m 0 05 kgf m Close the radiator cap securely...

Page 36: ...adjustment Dry or rusted links Missing O ring seals Kinked or binding links If any defect is found the drive chain must be replaced NOTE When replacing the drive chain replace the drive chain and spro...

Page 37: ...een the engine and rear sprockets as shown The chain adjuster posi tion relative to the reference marks A on both sides of the swingarm must be equal to ensure that the front and rear wheels are corre...

Page 38: ...the chain oil it with a heavyweight motor oil Do not use trichloroethylene gasoline or any similar solvent These fluids will damage the O rings Use only kerosine to clean the drive chain Do not use a...

Page 39: ...6 000 km 12 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 12 months Replace hoses every 4 years Replace fluid every 2 years The brake system of this motorcycle is filled with a g...

Page 40: ...8 65 BRAKE PEDAL HEIGHT Remove the front footrest bracket bolts 1 Loosen the lock nut 2 Turn the push rod 3 until the brake pedal height A becomes 45 55 mm below the top of the footrest Tighten the lo...

Page 41: ...large proportion of the pressure developed by the master cyl inder and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brak...

Page 42: ...sary Make sure that there is always some fluid visible in the reservoir Close the air bleeder valve and disconnect the hose Fill the reservoir with brake fluid to the top of the inspection window Spec...

Page 43: ...al riding Front 250 kPa 2 50 kgf cm2 Rear 290 kPa 2 90 kgf cm2 TIRE TYPE BRIDGESTONE Front BT014F SN Rear BT014R N STEERING The steering should be adjusted properly for smooth turning of the handlebar...

Page 44: ...outer surface of the inner tubes Replace any defective parts if necessary 8 14 REAR SUSPENSION Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm Replace...

Page 45: ...en initially at 1 000 km 2 months and every 12 000 km 24 months thereafter Set chamfer side to muffler side Set chamfer side to muffler joint side Muffler joint Muffler Apply PERMATEX 1372 1 Gasket B...

Page 46: ...aster cylinder mounting bolt 10 1 0 0 Front brake caliper mounting bolt 25 2 5 A Front brake caliper housing bolt 22 2 2 B Front brake pad mounting pin 16 1 6 C Brake hose union bolt 23 2 3 D Air blee...

Page 47: ...2 30 PERIODIC MAINTENANCE...

Page 48: ...e All compression pressure readings are below 1 100 kPa 11 kgf cm2 even when they measure 900 kPa 9 kgf cm2 and more COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure...

Page 49: ...PROCEDURE Start the engine and check if the oil pressure indicator light is turned on If the light stays on check the oil pressure indicator light circuit If the circuit is OK check the oil pressure i...

Page 50: ...e normal data that have been saved or filed can allow the specific engine failure to be determined Remove the left frame cover 8 4 Set up the SDS tools 4 46 09904 41010 SDS set tool 99565 01010 007 CD...

Page 51: ...t 3 000 r min under no load Data at the time of racing 3 000 r min Check the manifold absolute pressure XXX mmHg Throttle Quick wide open Throttle Slowly open Secondary throttle valve opens closes in...

Page 52: ...ENANCE 2 35 Data of intake negative pressure during idling 100 C Data of secondary throttle valve operation at the time of starting Check the manifold absolute pressure Approx XXX mmHg Closes fully in...

Page 53: ...D VALVE 3 27 PCV HOSE 3 28 CAMSHAFT 3 28 CAM CHAIN TENSION ADJUSTER 3 30 CAM CHAIN TENSIONER 3 31 CAM CHAIN GUIDE 3 31 CYLINDER HEAD AND VALVE 3 31 CLUTCH 3 40 OIL PUMP 3 41 STARTER CLUTCH 3 41 GENERA...

Page 54: ...23 3 78 Oil cooler 3 23 3 78 Oil pan 3 23 3 78 ITEM REMOVAL INSPECTION REINSTALLATION Exhaust pipe and muffler joint 3 5 6 2 3 13 Cam chain tension adjuster 3 15 3 30 3 97 Clutch cover 3 17 3 91 Clutc...

Page 55: ...ngine removal is sequentially explained in the following steps Reinstall the engine by reversing the removal procedure Remove the under covers 8 5 Lift and support the fuel tank 5 3 Drain engine oil 2...

Page 56: ...ct the oil cooler water hose 3 Open the hose clamp 4 Remove the radiator mounting bolts Move the radiator forward Disconnect the radiator hose 5 Disconnect the cooling fan coupler 6 Disconnect the hor...

Page 57: ...AUST PIPE AND MUFFLER JOINT Remove the exhaust pipe and muffler joint 6 3 Remove the O2 sensor 6 3 Remove the radiator mounting bracket 1 ELECTRIC PARTS AND PAIR HOSE Remove the regulator rectifier 1...

Page 58: ...nnect the ignition coil plug cap lead wire couplers 0 and CMP sensor lead wire coupler A Remove the ignition coil plug caps B Disconnect the PAIR hoses C Do not remove the ignition coil plug cap befor...

Page 59: ...ve the speed sensor rotor 5 Remove the engine sprocket nut 6 and its washer NOTE When loosening the engine sprocket nut 6 depress the brake pedal Loosen the rear axle nut 7 Loosen the chain adjuster l...

Page 60: ...8 ENGINE Remove the engine sprocket 9 ENGINE MOUNTING Support the engine using an engine jack Remove the engine mounting bolts 1 Remove the engine mounting bolt 2 Remove the engine mounting bolt nut...

Page 61: ...m the driveshaft Remove the engine assembly ENGINE INSTALLATION Install the engine in the reverse order of removal Pay attention to the following points NOTE Be careful not to damage the frame and eng...

Page 62: ...t adjuster 2 to the speci fied torque Engine mounting thrust adjuster 23 N m 2 3 kgf m Tighten the engine mounting thrust adjuster lock nut 3 to the specified torque with the special tool Engine mount...

Page 63: ...the specified torque NOTE The engine mounting nuts are self locking Once the nuts have been removed they are no longer of any use A Left B Right LENGTH ITEM N m kgf m ITEM mm abc 55 5 5 Bolt ac 55 12...

Page 64: ...stall the speed sensor rotor 2 Tighten the speed sensor rotor bolt 3 to the specified torque Speed sensor rotor bolt 23 N m 2 3 kgf m Apply SUZUKI SUPER GREASE A to the clutch push rod end 99000 25010...

Page 65: ...ting bolts to the specified torque Exhaust pipe bolt 23 N m 2 3 kgf m Muffler mounting bolt 23 N m 2 3 kgf m Muffler connecting bolt 23 N m 2 3 kgf m Install the HO2 sensor 2 HO2 sensor 48 N m 4 8 kgf...

Page 66: ...INDER HEAD COVER AND PAIR REED VALVE Remove the cylinder head cover 1 and its gaskets Remove the PAIR reed valves 2 and their gaskets Identify the position of each removed part Organize the parts in t...

Page 67: ...ing inspection hole and also to bring the cams to the position as shown Remove the cam chain tension adjuster cap bolt 2 Remove the cam chain tension adjuster 3 with the spring Remove the cam chain gu...

Page 68: ...ermostat THERMOSTAT INSPECTION 7 9 Remove the ECT sensor 3 ECT SENSOR INSPECTION 7 7 Remove the cylinder head bolts M6 4 and side face bolt 5 Remove the O rings 6 Remove the cylinder head bolts and wa...

Page 69: ...leeve hub holder Remove the clutch springs NOTE Loosen the clutch spring set bolts little by little and diagonally Remove the pressure plate 2 Remove the clutch drive plates and driven plates Remove t...

Page 70: ...d or a wire Unlock the clutch sleeve hub nut Hold the clutch sleeve hub with the special tool 09920 53740 Clutch sleeve hub holder Remove the clutch sleeve hub nut Remove the concaved washer 9 washer...

Page 71: ...e the snap ring 1 Remove the oil pump driven gear 2 NOTE Do not drop the snap ring 1 into the crankcase 09900 06107 Snap ring priers Remove the pin 3 and washer 4 Remove the oil pump 5 NOTE Do not dro...

Page 72: ...case Remove the gearshift cam plate bolt 5 and gearshift cam plate 6 Remove the gearshift cam stopper 7 STARTER IDLE GEAR Remove the starter idle gear cover 1 Remove the dowel pins and gasket Remove t...

Page 73: ...utch with the special tool 09920 34830 Starter clutch holder Remove the starter clutch bolt and washer Remove the starter clutch assembly and washer CAM CHAIN CAM CHAIN TENSIONER AND CAM CHAIN GUIDE R...

Page 74: ...l 09930 44520 Rotor holder Remove the generator rotor bolt Install a bolt A of suitable size to the left end of crankshaft SUITABLE BOLT A M12 length 28 38 mm Remove the generator rotor with the speci...

Page 75: ...he gear position switch 1 CRANKCASE BREATHER PCV COVER Remove the crankcase breather cover 1 OIL FILTER Remove the oil filter with the special tool 09915 40610 Oil filter wrench OIL COOLER Remove the...

Page 76: ...SWITCH Remove the oil pressure switch 1 Remove the oil pipe 2 OIL STRAINER Remove the oil strainer 3 and its O ring LOWER CRANK CASE Remove the lower crankcase bolts M6 Remove the lower crankcase bolt...

Page 77: ...izes first CRANKSHAFT Loosen the bearing cap bolts using a 10 mm 12 point socket wrench and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap Remove the dowel pins Remo...

Page 78: ...3 26 ENGINE Remove the piston pin circlip 1 Separate the piston and conrod by driving out the piston pin NOTE Scribe the cylinder number on the piston head...

Page 79: ...he CMP sensor 1 from the cylinder head cover INSPECTION Inspect the CMP sensor 4 32 INSTALLATION Install the oil seal 1 and CMP sensor NOTE When installing clean the CMP sensor s surface CMP sensor bo...

Page 80: ...ase breather cover Inspect the PCV hose for wear or damage If it is worn or damaged replace the PCV hose with a new one CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from...

Page 81: ...ervice Limit IN EX 0 150 mm 09900 22301 Plastigauge 09900 22302 Plastigauge NOTE Install camshaft journal holders to their original positions 3 96 Tighten the camshaft journal holder bolts evenly and...

Page 82: ...mm 09900 20205 Micrometer 0 25 mm CAMSHAFT RUNOUT Measure the runout using the dial gauge Replace the camshaft if the runout exceeds the limit Camshaft runout Service Limit IN EX 0 10 mm 09900 20607 D...

Page 83: ...eplace 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 V...

Page 84: ...oil seal 7 and spring seat 8 Remove the other valves in the same manner as described previously CYLINDER HEAD DISTORTION Decarbonize the combustion chambers Check the gasketed surface of the cylinder...

Page 85: ...more than the service limit replace the valve Valve head radial runout Service Limit 0 03 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm VALVE FACE WEAR...

Page 86: ...ing valve or guide be sure to recheck the deflec tion Valve stem O D Standard IN 3 975 3 990 mm EX 3 955 3 970 mm 09900 20205 Micrometer 0 25 mm NOTE If valve guides have to be removed for replacement...

Page 87: ...10 Valve guide reamer 4 mm 09916 34542 Reamer handle NOTE Be sure to cool down the cylinder head to ambient air temper ature Insert the reamer from the combustion chamber and always turn the reamer ha...

Page 88: ...alve seats be sure to check the valve clear ance after the cylinder head has been reinstalled 2 7 15 45 60 30 45 60 INTAKE EXHAUST Seat angle 30 45 60 15 45 60 Seat width 0 9 1 1 mm 0 9 1 1 mm Valve d...

Page 89: ...an the service limit or if the force required to compress the spring does not fall within the range specified replace the spring Valve spring free length Service limit IN 36 2 mm EX 36 0 mm 09900 2010...

Page 90: ...4511 Tweezers 09919 28610 Sleeve protector Be sure that the rounded lip E of the cotter fits snugly into the groove F in the stem end Install the other valves and springs in the same manner as describ...

Page 91: ...PER GREASE to the O rings Install the intake pipes WATER BYPASS UNION Remove the water bypass union 1 Apply SUZUKI BOND to the thread part of water bypass union and tighten it to the specified torque...

Page 92: ...ive plates found to have worn down to the limit Drive plate claw width Service Limit 12 90 mm 09900 20102 Vernier calipers CLUTCH DRIVEN PLATES INSPECTION NOTE Wipe off engine oil from the clutch driv...

Page 93: ...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 n...

Page 94: ...the starter driven gear for wear and damage If they are found to be damaged replace them with the new ones GENERATOR INSPECTION 9 10 REASSEMBLY When installing the generator stator set bolts tighten...

Page 95: ...the gearshift shaft gearshift arm for wear or bend Inspect the return springs for damage or fatigue Replace the arm or spring if there is anything unusual GEARSHIFT SHAFT GEARSHIFT ARM REASSEMBLY Ins...

Page 96: ...ation of the oil pressure regulator by pushing on the piston with a proper bar If the piston does not operate replace the oil pressure regula tor with a new one OIL STRAINER Inspect the oil strainer b...

Page 97: ...e gears 2 Slide the 6th 3 and 2nd 4 drive gears toward the 3rd 4th drive gears 2 then remove the 2nd drive gear circlip 5 1 Countershaft 1st drive gear 8 6th driven gear 2 5th drive gear 9 3rd driven...

Page 98: ...s and snap rings The cross sectional view shows the correct position of the gears bushings washers and snap rings 3 47 When installing a new snap ring pay attention to its direction Fit it to the side...

Page 99: ...ENGINE 3 47 TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft...

Page 100: ...eral places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the crankcase set Cylinder distortion Service Limit 0 02 mm 09900 20803 Thickness gauge CY...

Page 101: ...ance exceeds the service limit replace the crankcase set or the piston or both Piston to cylinder clearance Service Limit 0 120 mm PISTON PIN AND PIN BORE Measure the piston pin bore inside diameter u...

Page 102: ...2nd 0 81 0 83 mm Oil 1 51 1 53 mm Piston ring thickness Standard 1st 0 97 0 99 mm 2nd 0 77 0 79 mm PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using the vern...

Page 103: ...hickness gauge check the gearshift fork clearance in the groove of its gear The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action Shif...

Page 104: ...lace the bearings if there is anything unusual Inspect the gearshift cam bearing 1 gearshift shaft bearings 2 and 3 for abnormal noise and smooth rotation while they are in the crankcase Replace the b...

Page 105: ...ng installer set 1 2 22 3 32 NOTE The stamped mark side of the gearshift shaft bearing faces out side Install the oil seal with the special tool 09913 70210 Bearing installer set 22 Apply SUZUKI SUPER...

Page 106: ...E 8 For 5th driven gear 17E 1F Apply a small quantity of THREAD LOCK to the bearing retainer screws 9 Tighten the bearing retainer screws 9 and gearshift fork shaft retainer bolt 0 to the specified to...

Page 107: ...the lower crank case Remove the oil jet 3 for cam chain tension adjuster from the cylinder head Inspection and cleaning Check the oil jets for clogging If they are clogged clean their oil passage wit...

Page 108: ...OCK to the bolts and tighten them to the specified torque 99000 32050 THREAD LOCK 1342 Piston cooling oil jet bolt 10 N m 1 0 kgf m Install the oil jet for transmission Apply engine oil to the O ring...

Page 109: ...to the oil gallery plug 2 99000 32050 THREAD LOCK 1342 NOTE It is not required to apply THREAD LOCK when installing the other removed oil gallery plugs Tighten each plug to the specified torque 1 Wate...

Page 110: ...greater than the limit Crankshaft runout Service Limit 0 05 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm CONROD SMALL END I D Using a small bore...

Page 111: ...ter 0 25 mm Crank pin width Standard 20 10 20 15 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm CONROD BIG END BEARING INSPECTION Inspect the bearing surfaces for any sign of fusion pitting burn or fl...

Page 112: ...2 0 056 mm Service Limit 0 080 mm If the oil clearance exceeds the service limit select the speci fied bearings from the bearing selection table Check the corresponding conrod I D code number 1 or 2 A...

Page 113: ...specification 1 30 992 31 000 mm 2 30 984 30 992 mm 3 30 976 30 984 mm Color C Part No Thickness Yellow 12164 29G00 0D0 1 492 1 496 mm Brown 12164 29G00 0C0 1 488 1 492 mm Black 12164 29G00 0B0 1 484...

Page 114: ...ing two steps in the indicated order Crankshaft journal bolt 9 mm Initial 18 N m 1 8 kgf m Final 50 Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope s...

Page 115: ...nk case Check the corresponding crankshaft journal O D code num ber B A B or C which is stamped on the crankshaft Bearing selection table Crankcase I D specification Crankshaft journal O D B Code A B...

Page 116: ...the upper and middle crankcases be sure to fix the stopper part A first and press the other end Code O D specification A 29 992 30 000 mm B 29 984 29 992 mm C 29 976 29 984 mm Color Part No Thickness...

Page 117: ...res CRANKSHAFT THRUST CLEARANCE ADJUSTMENT Remove the right side thrust bearing and measure its thick ness with a micrometer If the thickness of the right side thrust bearing is below stan dard replac...

Page 118: ...bearing Clearance before inserting left side thrust bearing Color Part No Thrust bearing thickness Thrust clearance 2 560 2 585 mm White 12228 17E00 0F0 2 475 2 500 mm 0 060 0 110 mm 2 535 2 560 mm Ye...

Page 119: ...3 53 Gearshift cam bearing 3 53 Gearshift cam 3 53 Bearing retainer 3 54 Oil jets 3 55 PISTON RING Install the piston rings in the order of oil ring 2nd ring and 1st ring The first member to go into...

Page 120: ...UM OIL SOLUTION Assemble the piston and conrod NOTE When installing the pistons the indent A on the piston head must be brought to the other side of ID code B on the conrod big end Install the piston...

Page 121: ...ID code D on each conrod faces intake side Apply MOLYBDENUM OIL SOLUTION to the crank pin bear ings surface MOLYBDENUM OIL SOLUTION CRANKSHAFT Position the No 2 and No 3 conrod big ends on the same s...

Page 122: ...ide Apply engine oil to the bearing cap bolts Tighten the bearing cap bolt by using a 10 mm 12 point socket wrench in the following two steps Conrod bearing cap bolt Initial 15 N m 1 5 kgf m Final 90...

Page 123: ...t and left thrust bearings with oil groove B fac ing the crank web NOTE Right thrust bearing has green painting CRANKCASE Clean the mating surfaces of the crankcases Install the dowel pins 1 and O rin...

Page 124: ...ases within few minutes Take extreme care not to apply any BOND to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film Tighten the crankshaft journal...

Page 125: ...time to equalize the pressure Crankcase bolt M6 Initial 6 N m 0 6 kgf m Final 11 N m 1 1 kgf m NOTE Fit the clamp to the crankcase bolt A NOTE Fit a new gasket to the crankcase bolt B NOTE After the...

Page 126: ...earing and the bearing pin with the indent on the bearing Install the driveshaft assembly on the middle crankcase NOTE Align the C ring with the groove of bearing and the bearing pin with the indent o...

Page 127: ...pread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply any BOND to the oil hole oil groove and bearing Apply to distorted surfaces...

Page 128: ...sure Crankcase bolt M6 Initial 6 N m 0 6 kgf m Final 11 N m 1 1 kgf m M8 Initial 15 N m 1 5 kgf m Final 26 N m 2 6 kgf m NOTE Fit new copper washer to the crankcase bolts A Fit new gasket washer to th...

Page 129: ...PER GREASE A or equivalent grease Apply SUZUKI SUPER GREASE A to the O ring Press in the pipe 2 to the oil pan Install the oil pressure regulator case 3 and tighten the bolts 4 to the specified torque...

Page 130: ...f m OIL COOLER Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply THREAD LOCK to the oil cooler mounting bolts and install the oil cooler 99000 3205...

Page 131: ...ply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the gear position switch as shown Apply THREAD LOCK to the gear position switch bolts 99000 32110...

Page 132: ...ver bolt 10 N m 1 0 kgf m GENERATOR ROTOR Degrease the tapered portion A of generator rotor and also the crankshaft B Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these...

Page 133: ...d other foreign materials Spread on surfaces thinly to form an even layer and assemble the covers within few minutes Take extreme care not to apply any BOND to the oil hole oil groove and bearing Appl...

Page 134: ...Install the generator cover and tighten the generator cover bolts to the specified torque Generator cover bolt 10 N m 1 0 kgf m NOTE Fit the gasket washer to the bolts A Install the CKP sensor 3 Appl...

Page 135: ...eeth A and B 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 tensione...

Page 136: ...the special tool and tighten its bolt to the specified torque 09920 34830 Starter clutch holder Starter clutch bolt 54 N m 5 4 kgf m STARTER IDLE GEAR Install the starter idle gear No 2 1 its shaft 2...

Page 137: ...w gasket C Install the starter idle gear cover and tighten its bolts to the specified torque Starter idle gear cover bolt 10 N m 1 0 kgf m NOTE Fit the gasket washer to the bolt D GEARSHIFT SYSTEM Ins...

Page 138: ...rshift cam pin B with the gearshift cam stopper plate hole C Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque 99000 32050 THREAD LOC...

Page 139: ...ith the oil pump mounting bolts and then tighten them to the specified torque Oil pump mounting bolt 10 N m 1 0 kgf m Install the washer 1 and pin 2 NOTE Be careful not to drop the washer 1 and pin 2...

Page 140: ...Install the bearing 3 and spacer 4 and apply engine oil to them Install the thrust washer 5 Install the clutch sleeve hub 6 onto the countershaft Install the washer 7 and spring washer 8 NOTE The con...

Page 141: ...g washer seat 9 and spring washer 0 onto the clutch sleeve hub correctly Install the clutch push rod A into the countershaft Install the clutch push piece B bearing C and thrust washer D to the counte...

Page 142: ...wn 1 Direction of outside DRIVE PLATE a No 2 Drive plate 1 pc 48 friction pieces I D 101 mm b No 1 Drive plate 6 pcs 40 friction pieces I D 101 mm c No 3 Drive plate 1 pc 48 friction pieces I D 108 mm...

Page 143: ...onally CLUTCH COVER Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper middle and lower crankcases as shown 99000 31140 SUZUKI BOND 1207B Install the dowel pins and...

Page 144: ...er head bolts diagonally Step 3 Retighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagonally Step 4 Tighten the cylinder head bolts to the specified angle...

Page 145: ...kgf m Install the thermostat 3 NOTE The jiggle valve A of thermostat faces upside Install the thermostat cover 4 Thermostat cover bolt 10 N m 1 0 kgf m Install the water hose 5 10 23 CAMSHAFT Turn th...

Page 146: ...OIL SOLUTION to the camshaft jour nal holders MOLYBDENUM OIL SOLUTION NOTE Before installing the camshaft check that the tappets are installed correctly Pull the cam chain upward or the chain will be...

Page 147: ...2 D should now be pointing straight up Starting from the roller pin that is directly above the arrow marked 2 D count out 12 roller pins from the exhaust cam shaft side going towards the intake camsh...

Page 148: ...faces exhaust side Install the can chain guide 5 Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts lightly in the ascending order of numbers NOTE Fit the copp...

Page 149: ...nstall the cam chain tension adjuster 2 and tighten its mounting bolts Cam chain tension adjuster mounting bolt 10 N m 1 0 kgf m Install the spring 3 The camshaft journal holder bolts are made of a sp...

Page 150: ...ion adjuster cap bolt to the speci fied torque Cam chain tension adjuster cap bolt 23 N m 2 3 kgf m Cut the wire clamps 6 After installing the cam chain tension adjuster rotate the crankshaft some tur...

Page 151: ...ENGINE 3 99 A Cam chain tension adjuster mounting bolt B Cam chain tension adjuster cap bolt ITEM N m kgf m A 10 1 0 B 23 2 3...

Page 152: ...ure to check the valve clearance 2 7 Install the PAIR reed valves 1 along with the gaskets Install new gasket 2 to the cylinder head cover Apply SUZUKI BOND to the cam end caps of the gasket as shown...

Page 153: ...14 N m 1 4 kgf m STARTER MOTOR Install the new O ring 1 to the starter motor Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the starter motor...

Page 154: ...4 23 SELF DIAGNOSTIC PROCEDURES 4 24 SELF DIAGNOSIS RESET PROCEDURE 4 24 USE OF SDS DIAGNOSTIC PROCEDURES 4 25 USE OF SDS DIAGNOSIS RESET PROCEDURE 4 26 SHOW DATA WHEN TROUBLE DISPLAING DATA AT THE TI...

Page 155: ...ION 4 87 CMP SENSOR REMOVAL AND INSTALLATION 4 87 CKP SENSOR INSPECTION 4 87 CKP SENSOR REMOVAL AND INSTALLATION 4 87 IAP SENSOR INSPECTION 4 87 IAP SENSOR REMOVAL AND INSTALLATION 4 87 TP SENSOR INSP...

Page 156: ...he coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination...

Page 157: ...onnector for excessive opening Also check the coupler for locking loose ness corrosion dust etc 1 Coupler 2 Probe 3 Where male terminal fits FUSE When a fuse blows always investigate the cause to corr...

Page 158: ...motive force will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check wi...

Page 159: ...ection Also check for condition of the coupler lock if equipped 1 Sensor 2 ECM 1 Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for conta...

Page 160: ...circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body...

Page 161: ...se parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground...

Page 162: ...en measuring the resistance with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied...

Page 163: ...nd various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air...

Page 164: ...is lean and less fuel is supplied if it is rich BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time it monitors the voltage signal for compensation of the fuel injection t...

Page 165: ...ARTS LOCATION A Speedometer F Intake air pressure sensor IAPS B Engine coolant temperature sensor ECTS G Intake air temperature sensor IATS C Ignition coil H Fuel injector D Speed sensor I HO2 sensor...

Page 166: ...throttle valve actuator STVA N Fuel pump FP K Secondary throttle position sensor STPS O Fuel pump relay FP relay L Throttle position sensor TPS P Atmospheric pressure sensor APS M Crankshaft position...

Page 167: ...sure sensor APS Engine coolant temperature sensor ECTS Intake air temperature sensor IATS Tip over sensor TOS Secondary throttle valve actuator STVA Clutch lever position switch Starter motor Cooling...

Page 168: ...a Fuel injector 4 B HO2 sensor signal HO2 b Fuel injector 3 C CMP sensor signal CMP c Fuel injector 2 D CKP sensor signal CKP d Fuel injector 1 E Cooling fan relay FAR e Ignition coil 3 F Power source...

Page 169: ...not sent to ECM In this case FI is indicated in the LCD panel Motorcycle can not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 5 seconds For Example T...

Page 170: ...evices These affected devices are indicated in the code form 09930 82720 Mode select switch Before checking the malfunction code do not disconnect the ECM lead wire couplers If the couplers from the E...

Page 171: ...C12 C13 C14 C15 C21 C22 C23 C24 C25 C26 C27 C28 C29 C31 C32 C33 C34 C35 C41 C42 C44 C49 C60 None Camshaft position sensor CMPS Crankshaft position sensor CKPS Intake air pressure sensor IAPS Throttle...

Page 172: ...the air cleaner box 5 13 and follow the procedure below 4 Loosen the screw and turn the throttle position sensor 1 and bring the line to the middle 5 Then tighten the screw to fix the throttle positio...

Page 173: ...d to 760 mmHg YES YES TP sensor The throttle opening is fixed to half open position Ignition timing is also fixed YES YES ECT sensor Engine coolant temperature value is fixed to 80 C Cooling fan is fi...

Page 174: ...rcuit can not work and ignition or injection is stopped ITEM FAIL SAFE MODE STARTING ABILITY RUNNING ABILITY Secondary throttle valve actuator Secondary throttle valve is fixed to full close position...

Page 175: ...condition LED Always ON Sometimes ON Always OFF Good condition Malfunction display code LCD User mode No display Malfunction display Dealer mode No code Malfunction code PROBLEM SYMPTOMS Difficult St...

Page 176: ...onnection Burnt fuse FI light operation 4 16 9 29 and 31 Each warning light operation 9 31 Speedometer operation 9 34 Exhaust gas leakage and noise 2 28 Each coupler disconnection Clogged radiator fin...

Page 177: ...er 8 4 Connect the special tool to the dealer mode coupler at the wir ing harness and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch ON and check the malfu...

Page 178: ...TIONS IN SERVICING 4 3 before inspection and observe what is written there Remove the left frame cover 8 4 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagno...

Page 179: ...the ECM Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when...

Page 180: ...or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a...

Page 181: ...ed value IAP sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value IAP sensor circuit open or shorted to ground or VCC circuit open C14 TP sensor The sens...

Page 182: ...C23 TO sensor The sensor voltage should be the fol lowing for 2 sec and more after igni tion switch is turned ON 0 2 V sensor voltage 4 8 V In other than the above value C23 P1651 is indicated TO sen...

Page 183: ...pro duced but fuel injector signal is inter rupted 4 times or more continuously In this case the code C32 P0201 C33 P0202 C34 P0203 or C35 P0204 is indicated Fuel injector wiring coupler con nection p...

Page 184: ...ed to ground P0130 C44 The Heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit C44 P0135 is indicated HO2 sensor lead wire coupler connection Battery vol...

Page 185: ...rcuit tester set Tester knob indication Resistance 6 If OK then check the continuity between each terminal and ground CMP sensor continuity Infinity Terminal Ground Are the resistance and continuity O...

Page 186: ...g the trouble clear the DTC using SDS tool 4 26 YES G Y or Brown wire open or shorted to ground Loose or poor contacts on the CKP sensor cou pler or ECM coupler terminal C or T If wire and connection...

Page 187: ...he CKP sensor coupler and measure the resis tance CKP sensor resistance 142 194 Black Green 09900 25008 Multi circuit tester set Tester knob indication Resistance DETECTED CONDITION POSSIBLE CAUSE The...

Page 188: ...circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 4 26 YES Go to step 2 NO Replace the CKP sensor with a new one YES G W or...

Page 189: ...hat atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air...

Page 190: ...nted probe set Tester knob indication Voltage Is the voltage OK Step 1 When indicating P0105 H 1 Turn the ignition switch to OFF 2 Lift and support the fuel tank 5 3 3 Check the IAP sensor coupler for...

Page 191: ...trouble clear the DTC using SDS tool 4 26 Step 1 When indicating P0105 L 1 Turn the ignition switch to OFF 2 Lift and support the fuel tank 5 3 3 Check the IAP sensor coupler for loose or poor contac...

Page 192: ...es to the IAP sensor lead wire coupler as shown 3 Start the engine at idle speed and measure the IAP sensor output voltage between G B and B Br wires IAP sensor output voltage Approx 2 7 V at idle spe...

Page 193: ...d up to 400 mmHg by using vacuum pump gauge 4 41 09917 47011 Vacuum pump gauge 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear...

Page 194: ...VCC voltage 4 5 5 0 V ambient temp 20 30 C ALTITUDE Reference ATMOSPHERIC PRESSURE OUTPUT VOLTAGE m mmHg kPa V 0 610 760 708 100 95 3 1 3 6 611 1 524 707 635 94 86 2 8 3 4 1 525 2 438 634 568 85 77 2...

Page 195: ...B and ground 8 If OK then measure the voltage at the Red wire B and B Br wire C DETECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following range Difference between actual throttl...

Page 196: ...P B wire A and Red wire B If the sound is not heard from the tester the circuit condition is OK 7 Disconnect the ECM coupler 8 Check the continuity between P B wire A and terminal 8 9 Also check the c...

Page 197: ...tween P B wire A and B Br wire C If the sound is not heard from the tester the circuit condi tion is OK 8 Disconnect the ECM coupler 9 Check the continuity between P B wire A and terminal 8 10 Also ch...

Page 198: ...r knob indication Continuity test 5 If OK then measure the TP sensor resistance at the test har ness terminals between terminal A and terminal B 6 Turn the throttle grip and measure the resistance TP...

Page 199: ...t tester set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool 4 26 YES Go to Step 3 NO Reset the TP sensor position correctly Replace the TP...

Page 200: ...T sensor voltage 4 5 5 5 V B Bl Ground B Bl B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C15 Output voltage is not withi...

Page 201: ...ECM coupler 4 Check the continuity between B Bl wire A and terminal 0 5 Also check the continuity between B Br wire B and terminal S ECTS lead wire continuity Continuity 09900 25008 Multi circuit test...

Page 202: ...circuit condition is OK Tester knob indication Continuity test 5 Connect the ECT sensor coupler and turn the ignition switch to ON 6 Measure the voltage between B Bl wire A and ground ECT sensor outp...

Page 203: ...pairing the trouble clear the DTC using SDS tool 4 26 ECT sensor specification YES B Bl or B Br wire open or shorted to ground or poor 0 or S connection If wire and connection are OK intermittent trou...

Page 204: ...ire terminal B IAT sensor input voltage 4 5 5 5 V Dg Ground Dg B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C21 Output v...

Page 205: ...ensor coupler and ECM coupler 5 Check the continuity between Dg wire A and terminal Q 6 Also check the continuity between B Br wire B and terminal S IATS lead wire continuity Continuity 09900 25008 Mu...

Page 206: ...not heard from the tester the circuit condition is OK Tester knob indication Continuity test 6 Connect the IAT sensor coupler and turn the ignition switch ON 7 Measure the voltage between Dg wire A a...

Page 207: ...d is the same way as that of the ECT sensor Refer to page 7 7 for details 2 YES Dg or B Br wire open or shorted to ground or poor Q or S connection If wire and connection are OK intermittent trou ble...

Page 208: ...lowing range 0 5 V Sensor voltage 4 85 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged ai...

Page 209: ...Is the voltage OK Step 1 When indicating P1450 H 1 Turn the ignition switch to OFF 2 Lift and support the fuel tank 5 3 3 Check the AP sensor coupler for loose or poor contacts If OK then check the A...

Page 210: ...g the trouble clear the DTC using SDS tool 4 26 Step 1 When indicating P1450 L 1 Turn the ignition switch to OFF 2 Remove the front seat 8 3 3 Check the AP sensor coupler for loose or poor contacts If...

Page 211: ...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 cou pler between G Y and B Br wires AP sensor output volt...

Page 212: ...tage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool 4 26 Output voltage VCC voltage 4 5 5 0 V ambient temp 20 30 C YES R G Y or B Br wire open or shorted to ground or poo...

Page 213: ...25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE C23 The sensor voltage should be the follow ing for 2 sec and more after ignitio...

Page 214: ...d is not heard from the tester the circuit condition is OK 6 Disconnect the ECM coupler 7 Check the continuity between B wire B and terminal L 8 Also check the continuity between B Br wire C and termi...

Page 215: ...nd B Br wire C If the sound is not heard from the tester the circuit condi tion is OK 7 Disconnect the ECM coupler 8 Check the continuity between R wire A and terminal A 9 Also then check the continui...

Page 216: ...9900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 4 26 C24 P0351 C25...

Page 217: ...pen Is the operating OK 5 After repairing the trouble clear the DTC using SDS tool 4 26 DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA ECM does not receive communicati...

Page 218: ...inal C Terminal D 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 5 After repairing the trouble clear the DTC using SDS tool 4 26 2 2 YES W B P W G and B Lg...

Page 219: ...t up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch to ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operati...

Page 220: ...A and ground 8 Also measure the voltage at the R wire A and B Br wire C DETECTED CONDITION POSSIBLE CAUSE C29 Signal voltage is not within the following range Difference between actual throttle open i...

Page 221: ...Y W wire B and R wire A If the sound is not heard from the tester the circuit condition is OK 7 Disconnect the ECM coupler 8 Check the continuity between Y W wire B and terminal J 9 Also check the co...

Page 222: ...ty between Y W wire B and B Br wire C If the sound is not heard from the tester the circuit condi tion is OK 8 Disconnect the ECM coupler 9 Check the continuity between Y W wire B and terminal J 10 Al...

Page 223: ...Infinity Terminal Ground 09900 25008 Multi circuit tester set 09900 28630 TPS test wire harness 6 If OK then measure the STP sensor resistance at the wire terminals between terminal B and terminal C...

Page 224: ...l C by turning the secondary throttle valve close and open with a finger STP sensor output voltage Secondary throttle valve is closed Approx 0 5 V Secondary throttle valve is opened Approx 3 9 V Teste...

Page 225: ...sure the voltage at the wire side coupler between P wire and B W wire when shifting the gearshift lever from 1st to Top GP switch voltage 0 6 V and more P B W 09900 25008 Multi circuit tester set 0990...

Page 226: ...intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO P or B W wire open or P wi...

Page 227: ...ct the injector coupler and measure the resistance between terminals Injector resistance 11 13 at 20 C Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance DETECTED...

Page 228: ...n Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 4 26 YES Go to Step 2 NO Replace the injector with a new one 5 14 YES Gr W wire open or shorted to ground or poor...

Page 229: ...although fuel pump relay is turned OFF Fuel pump relay switch circuit shorted to power source Faulty fuel pump relay switch side L No voltage is applied to fuel pump although fuel pump relay is turned...

Page 230: ...SDS tool 4 26 1 YES Y R wire shorted to power source Y B wire shorted to ground If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circui...

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Suzuki 2006 GSR600, Service Manual

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