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Suzuki 2006 gsxr 600, Service Manual

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Suzuki 2006 gsxr 600 Service Manual Download Page 75

3-22     ENGINE

GEAR POSITION SWITCH

• Remove the gear position switch 

1

.

CRANKCASE BREATHER (PCV) COVER

• Remove the crankcase breather cover 

1

.

• Remove the gasket 

2

.

OIL PRESSURE SWITCH

• Remove the oil pressure switch 

1

.

OIL FILTER

• Remove the oil filter with the special tool.

09915-40610: Oil filter wrench

Summary of Contents for 2006 gsxr 600

Page 1: ...GSX R750 9 9 5 0 0 3 7 1 3 0 0 1 E ...

Page 2: ...you can assure your customers of fast and reliable service This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the con tent of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not r...

Page 3: ... 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 instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel 1 Brake disc 2 Collar 3 Dust seal 4 Bearing 5 Spacer 6 Front axle 7 Front ...

Page 4: ...f engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Use fork oil 99000 99001 SS5 Apply SUZUKI SUPER GREASE A or equivalent grease 99000 25010 Apply or use brake fluid Apply SUZUKI SILICONE GREASE 99000 25100 Measure in voltage range Apply SUZUKI MOLY PASTE 99000 25140 Measure in current range Apply SUZUKI BOND 1215 or equivalent bond 99000 31110 Measure in resistance range Apply SUZUKI BOND 1207B...

Page 5: ...HC Double Over Head Camshaft DRL Daytime Running Light DTC Diagnostic Trouble Code E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS EVAP Evaporative Emission EVAP Canister Evaporative Emission Canister Canister EXC System Exhaust Control System EXCS EXC Valve Exhaust Control Valve EXCV EXCV Actuator Exhaust ...

Page 6: ...se 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 Secondary Throttle Position Sensor STPS ST Valve Secondary Throttle Valve STV STV Actuator Secondary Throttle Valve Actuator STVA T TO Sensor Tip Over Sensor TOS TP Sensor Throttle Position Sensor TPS ...

Page 7: ...h 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 Light green with White tracer O B Orange with Black tracer O BI Orange with Blue tracer O G Orange with Green tracer O R Orange with Red tracer O W Orange with White tracer O Y Orange with Yellow tr...

Page 8: ... 1 6 LIQUID AMOUNT OF WATER ENGINE COOLANT 1 6 BREAK IN PROCEDURES 1 7 CYLINDER IDENTIFICATION 1 7 INFORMATION LABELS 1 8 SPECIFICATIONS 1 9 DIMENSIONS AND DRY MASS 1 9 ENGINE 1 9 DRIVE TRAIN 1 9 CHASSIS 1 10 ELECTRICAL 1 10 CAPACITIES 1 10 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA EFFECTIVE FRAME NO E 02 E 19 GSX R750 E 19 GSX ...

Page 9: ...st 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 service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle When 2 or more persons work together pay attention to the safety of...

Page 10: ...and 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 rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any...

Page 11: ...arkets 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 right side of the crankcase These num bers are required especially for registering the machine and ordering spare parts RIGHT SIDE LEFT SIDE ...

Page 12: ...SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the following chart ENGINE OIL FOR OTHER COUNTRIES Oil quality is a major contributor to your engine s performance and life Always select good quality engine oil Use of SF SG or SH SJ in API with MA in JASO Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available s...

Page 13: ...temperature in your 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 LIQUID AMOUNT OF WATER ENGINE COOLANT Solution capacity total Approx 2 700 ml 2 9 2 4 US Imp qt For engine coolant mixture information refer to cooling system section in page 7 2 M...

Page 14: ...ring its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 7 500 r min Up to 1 600 km 1 000 miles Below 11 000 r min Over to 1 600 km 1 000 miles Below 15 000 r min Upon reaching an odometer reading of 1 600 km 1 000 miles you can subject the motorcycle to full throt tle operation However do not exceed 15 000 r min at any time CYL...

Page 15: ... 03 33 7 Screen label A Except E 19 8 Screen label A For E 28 A 9 Screen label A For E 19 0 Warning steering label A For E 03 33 A Warning steering label A Except E 03 33 A B Tire information label A For E 03 33 C Tire information label A Except E 03 33 A D General warning label A Except E 19 28 E General warning label A F General warning label A For E 28 G General warning label A For E 19 H ICES ...

Page 16: ...rs 4 Bore 70 0 mm 2 756 in Stroke 48 7 mm 1 917 in Displacement 750 cm 45 8 cu in Compression ratio 12 5 1 Fuel system Fuel injection Air cleaner Paper element Starter system Electric Lubrication system Wet sump Idle speed 1 200 100 r min DRIVE TRAIN Clutch Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down 5 up Primary reduction ratio 1 761 74 42 Gear ratios Low 2 78...

Page 17: ...hase A C generator Main fuse 30 A Fuse 10 10 15 15 10 10 A Headlight 12 V 55 W H7 12 V 65 W H9 Turn signal light 12 V 21 W License plate light 12 V 5 W Brake light Taillight LED Position light 12 V 5 W 2 Speedometer light LED Tachometer light LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level indicator light LED Oil pressure Coolant temperature...

Page 18: ...NTROL VALVE 2 13 FUEL LINE 2 14 ENGINE IDLE SPEED 2 14 THROTTLE VALVE SYNCHRONIZATION 2 15 EVAPORATIVE EMISSION CONTROL SYSTEM E 33 ONLY 2 15 PAIR AIR SUPPLY SYSTEM 2 15 THROTTLE CABLE PLAY 2 15 CLUTCH 2 16 COOLING SYSTEM 2 17 DRIVE CHAIN 2 20 BRAKE 2 23 TIRES 2 27 STEERING 2 27 FRONT FORK 2 28 REAR SUSPENSION 2 28 EXHAUST PIPE BOLT AND NUT 2 29 CHASSIS BOLTS AND NUTS 2 30 COMPRESSION PRESSURE CHE...

Page 19: ... CHART NOTE I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Interval miles 600 4 000 7 500 11 000 14 500 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 Exhaust control valve I I I Engine oil R R R R R Engine oil filter R R Fuel line I I I I Idle speed I I I I I Throttle valve synchroni...

Page 20: ...e lubricating 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 operated under wet or rainy conditions Clutch lever holder Side stand pivot and spring hook Footrest pivot and gearshift lever pivot Drive chain Brake lever holder Brake pedal pivot and footrest...

Page 21: ...ner 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 cleaner is in good condi tion at all times The life of the engine depends largely on this component Install a new air cleaner element in the reverse order of removal Remove the drain plug from the air cleaner b...

Page 22: ...e 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 spark plug If carbon is deposited remove it using a spark plug cleaner machine or carefully use a tool with a pointed end Inspect every 6 000 km 4 000 miles 12 months Replace every 12 000 km 7 500 miles 24 months Disconnect ...

Page 23: ... head with fingers and then tighten them to the specified torque Spark plug 11 N m 1 1 kgf m 8 0 Ib ft Install the ignition coils plug caps and connect their lead wire couplers Confirm the thread size and reach when replacing the plug If the reach is too short carbon will be deposited on the screw portion of the plug hole and engine dam age may result Do not cross thread or over tighten the spark ...

Page 24: ...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 Standard IN 0 08 0 18 mm 0 003 0 007 in EX 0 18 0 28 mm 0 007 0 011 in NOTE The cam must be at positions A or B when checking or adjusting the valve clearance Clearance readings should not be taken with the ...

Page 25: ...nder Ex of No 3 and In of No 2 If the clearance is out of specification adjust the clearance 2 9 09900 20803 Thickness gauge Turn the crankshaft 360 degrees one rotation to bring the line on the CKP sensor rotor to the index mark of valve timing inspection hole and also to bring the notches A to the posi tion as shown Read the clearance at the rest of the valves C and adjust the clearance if neces...

Page 26: ...ck shim size with micrometer to ensure its size Refer to the tappet shim selection table 2 10 and 11 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating the tappet shim be sure the figure printed sur face faces the tappet NOTE Reinstall the camshafts in the specified manner 3 92 After replacing the tappet shim and camshafts rotate the engine so that the ta...

Page 27: ... 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 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 56 0 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 61 0 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 66 0 70 1 75 1...

Page 28: ...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 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 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 ...

Page 29: ...SF SG or SH SJ in API with MA in JASO Oil drain plug 23 N m 2 3 kgf m 16 5 lb ft 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 level through the inspection window If the level is below mark L add oil to F level If the level is above mark F drain oil to F level ENGINE OIL Replace initially at 1 000 km ...

Page 30: ...Oil change 2 2 L 2 3 1 9 US Imp qt Oil and filter change 2 5 L 2 6 2 2 US Imp qt Engine overhaul 2 9 L 3 1 2 6 US Imp qt EXHAUST CONTROL VALVE Exhaust control valve actuator is installed in the right hand side in tail cowl Check the exhaust control valve actuator 1 for its movement when the ignition switch is turned ON If the exhaust valve actu ator does not move check exhaust valve actuator elect...

Page 31: ... leakage If any defects are found the fuel feed hose must be replaced ENGINE IDLE SPEED NOTE Warm up the engine before adjusting the engine idle speed Start the engine turn the throttle stop screw and set the engine idle speed as follows Engine idle speed 1 200 100 r min Inspect initially 6 000 km 4 000 miles 12 months Inspect initially at 1 000 km 600 miles 2 months and every 6 000 km 4 000 miles...

Page 32: ...ottle cable play at the throttle grip A is between 2 0 4 0 mm 0 08 0 16 in Tighten the lock nut 2 while holding the adjuster 3 Throttle cable play A 2 0 4 0 mm 0 08 0 16 in Inspect initially at 1 000 km 600 miles 2 months E 33 only and every 12 000 km 7 500 miles 24 moths Inspect every 12 000 km 7 500 miles 24 months Replace vapor hose every 4 years Inspect every 12 000 km 7 500 miles 24 months In...

Page 33: ...sting screw 5 two or three rotations From that position slowly turn in the adjusting screw 5 until resistance is felt From this position turn out the adjusting screw 5 1 2 rotation and tighten the lock nut 4 while holding the screw 5 Turn the cable adjuster 3 to obtain 10 15 mm 0 4 0 6 in of free play A at the clutch lever end Tighten the lock nut 2 Clutch lever play A 10 15 mm 0 4 0 6 in Clutch r...

Page 34: ... with fresh water if necessary Connect the radiator hose 2 securely Pour the specified engine coolant up to the radiator inlet Engine coolant capacity excluding reservoir 2 400 ml 2 5 2 1 US lmp qt Bleed the air from the engine coolant circuit in the following procedure 2 18 ENGINE COOLANT INFORMATION 7 2 Inspect every 6 000 km 4 000 miles 12 months Replace engine coolant every 2 years Do not open...

Page 35: ...let Repeat the above procedure until no air bleeds from the radi ator inlet Loosen the air bleeding bolt 1 and check that the engine coolant flows out Close the air bleeding bolt securely Close the radiator cap securely After warming up and cooling down the engine several times add the engine coolant up to the full level of the reservoir Engine coolant capacity Engine side 2 400 ml 2 5 2 1 US Imp ...

Page 36: ...NCE 2 19 RADIATOR HOSES Remove the under cowlings 8 5 Lift and support the fuel tank 5 3 Check the radiator hoses for crack damage or engine coolant leakage If any defect is found replace the radiator hose with new one ...

Page 37: ...sing 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 sprockets as a set CHECKING Remove the axle cotter pin For E 03 28 33 Loosen the axle nut 1 Loosen the chain adjuster lock nuts 2 Give tension to the drive chain fully by turning both chain adjuster bolts 3 Inspect initially at 1 000 km 6...

Page 38: ...eference marks A on both sides of the swingarm must be equal to ensure that the front and rear wheels are correctly aligned Drive chain slack Standard 20 30 mm 0 8 1 2 in Place the motorcycle on its side stand for accurate adjust ment After adjusting the drive chain tighten the axle nut 2 to the specified torque Tighten both chain adjuster lock nuts 3 securely Rear axle nut 100 N m 10 0 kgf m 72 5...

Page 39: ...ng 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 any oil sold commercially as drive chain oil Such oil can damage the O rings The standard drive chain is RK525ROZ5Y Suzuki recommends to use this standard drive chain as a replacement ...

Page 40: ...nths thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 4 000 miles 12 months Replace hoses every 4 years Replace fluid every 2 years The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petro leum based fluids Do not use any brake fluid taken from old used or unsealed containers Never re use b...

Page 41: ...xceeds the grooved limit line replace the pads with the new ones 8 76 BRAKE PEDAL HEIGHT Loosen the lock nut 1 Turn the push rod 2 until the brake pedal height becomes 65 75 mm 2 6 3 0 in A below the top of the footrest Tighten the lock nut 1 securely Rear brake master cylinder rod lock nut 18 N m 1 8 kgf m 13 0 Ib ft Brake pedal height A Standard 65 75 mm 2 6 3 0 in Replace the brake pads as a se...

Page 42: ...dow Replace the reservoir cap to prevent dirt from enter ing Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle This will remov...

Page 43: ...0 N m 0 6 kgf m 4 3 Ib ft NOTE If air is trapped in the master cylinder bleed air from the master cylinder first REAR BRAKE Bleed air from the rear brake system in the same manner as front brake Air bleeder valve 7 5 N m 0 75 kgf m 5 5 Ib ft NOTE The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal ...

Page 44: ...ng Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi TIRE TYPE BRIDGESTONE Front BT014FSJ Rear BT014R W STEERING The steering should be adjusted properly for smooth turning of the handlebars and safe operation Overtighten steering pre vents smooth turning of the handlebars and too loose steering will cause poor stability Check that there is no play in the front fork Support the mo...

Page 45: ...ce of the inner tubes Replace any defective parts if necessary 8 18 REAR SUSPENSION Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm Replace any defective parts if necessary 8 49 Inspect every 12 000 km 7 500 miles 24 months Inspect every 12 000 km 7 500 miles 24 months ...

Page 46: ...ler mounting bolt and nut to the specified torque Tighten initially at 1 000 km 600 miles 2 months and every 12 000 km 7 500 miles 24 months thereafter 1 Gasket 2 Exhaust pipe connecter ITEM N m kgf m lb ft AB 23 2 3 16 5 CD Replace the gaskets and exhaust pipe connector with the new ones ...

Page 47: ...mounting bolt 35 3 5 25 5 A Front brake caliper housing bolt 22 2 2 16 0 B Brake hose union bolt Front Rear 23 2 3 16 5 C Air bleeder valve Front brake caliper Rear brake caliper 7 5 0 75 5 5 D Air bleeder valve Master cylinder 6 0 0 6 4 5 E Brake disc bolt Front 23 2 3 16 5 F Brake disc bolt Rear 35 3 5 25 5 G Rear brake caliper mounting bolt 17 1 7 12 5 H Rear brake master cylinder mounting bolt...

Page 48: ...PERIODIC MAINTENANCE 2 31 ...

Page 49: ...ssion pressure readings are below 1 300 kPa 13 kgf cm2 185 psi even when they measure 1 000 kPa 10 kgf cm2 148 psi and more COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted Have the engine warmed up before testing Make sure that the battery is fu...

Page 50: ...rt 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 in the fol lowing manner Remove the main oil gallery plug 1 Install the oil pressure gauge and adaptor into the main oil gallery Warm up the engine as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000 r m...

Page 51: ...th the normal data that have been saved or filed can allow the specific engine failure to be determined Remove the front seat 8 7 Set up the SDS tool 4 26 09904 41010 SDS set tool 99565 01010 007 CD ROM Ver 7 NOTE Before taking the sample of data check and clear the Past DTC 4 26 A number of different data under a fixed condition as shown below should be saved or filed as sample SAMPLE Data sample...

Page 52: ...at 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 according with the engine r min ...

Page 53: ... MAINTENANCE 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 approx XX sec ...

Page 54: ...SE 3 28 CAMSHAFT 3 29 CAM CHAIN TENSION ADJUSTER 3 31 CAM CHAIN TENSIONER 3 31 CAM CHAIN GUIDE 3 32 CYLINDER HEAD AND VALVE 3 32 CLUTCH 3 39 CLUTCH LIFTER 3 40 OIL PUMP 3 42 STARTER CLUTCH 3 42 GENERATOR 3 44 WATER PUMP 3 44 GEARSHIFT SYSTEM 3 44 OIL PRESSURE REGULATOR 3 45 OIL STRAINER 3 45 TRANSMISSION 3 46 CYLINDER 3 49 PISTON AND PISTON RING 3 50 CRANKCASE 3 52 BALANCER SHAFT 3 62 BALANCER SHA...

Page 55: ...ooler 3 23 7 17 3 83 Oil pan 3 23 3 83 Oil pump 3 23 3 42 3 82 ITEM REMOVAL INSPECTION INSTALLATION Exhaust pipe and muffler 3 5 3 12 Cam chain tension adjuster 3 15 3 32 3 99 Clutch cover 3 16 3 94 Clutch plates 3 17 3 39 3 92 Clutch lifter 3 18 3 40 3 90 Primary driven gear 3 18 3 40 3 90 Oil pump drive sprocket 3 19 3 89 Gearshift shaft 3 19 3 44 3 88 CKP sensor 3 16 4 35 3 94 Oil pump driven g...

Page 56: ... Engine removal is sequentially explained in the following steps Reinstall the engine by reversing the removal procedure Remove the under cowlings 8 5 Lift and support the fuel tank 5 3 Drain engine oil 2 12 Drain engine coolant 2 17 Disconnect the battery lead wire 1 Remove the air cleaner box 5 14 Remove the throttle body assembly 5 15 ...

Page 57: ...onnect the by pass hose 1 and radiator inlet hose 2 Disconnect the oil cooler outlet hose 3 Disconnect the cooling fan coupler 4 Remove the radiator mounting bolts Remove the radiator 5 Be careful not to bent the radiator fins ...

Page 58: ...olt Remove the HO2 sensor 2 For E 02 19 4 107 Remove the exhaust pipe bolts Remove the exhaust pipe Remove the exhaust pipe gaskets Remove the radiator mounting bracket 2 Remove the muffler body 6 11 ELECTRIC PARTS AND PAIR HOSE Disconnect the oil pressure switch lead wire 1 Remove the under cowling lower bracket 2 ...

Page 59: ...and regula tor rectifier couplers 0 Remove the ignition coils plug caps Disconnect the PAIR hoses A Disconnect the horn coupler B Remove the horn and regulator rectifier along with their bracket Remove the front engine cover C Do not remove the ignition coil plug cap before dis connecting its coupler Do not pry up the ignition coil plug cap with a screw driver or a bar to avoid its damage Be caref...

Page 60: ...3 Remove the speed sensor rotor 4 Remove the engine sprocket nut 5 and the washer 6 Remove the cotter pin For E 03 28 33 Loosen the rear axle nut 7 Loosen the chain adjuster lock nuts 8 Loosen the chain adjusters 9 Push the rear wheel forward and make sure that the drive chain has enough slack Disengage the drive chain from the rear sprocket ...

Page 61: ... 8 ENGINE Remove the engine sprocket 0 ENGINE MOUNTING Support the engine using an engine jack Remove the engine mounting bolt A Loosen the engine mounting pinch bolt 1 Remove the engine mounting bolt B ...

Page 62: ... Remove the engine mounting nut 5 Loosen the engine mounting thrust adjuster lock nut 6 with the special tool Loosen the engine mounting thrust adjuster 7 09940 14980 Engine mounting thrust adjuster socket wrench NOTE Do not remove the engine mounting bolts at this stage Remove the engine mounting bolts and gradually lower the front side of the engine Then take off the drive chain from the drivesh...

Page 63: ...ting thrust adjusters to the specified torque Engine mounting thrust adjuster 23 N m 2 3 kgf m 16 5 lb ft Tighten the engine mounting thrust adjuster lock nuts to the specified torque with the special tool 09940 14980 Engine mounting thrust adjuster socket wrench Engine mounting thrust adjuster lock nut 45 N m 4 5 kgf m 32 5 lb ft Tighten all engine mounting bolts and nuts to the specified torque ...

Page 64: ...11 a LH b RH LENGTH ITEM N m kgf m lb ft ITEM mm in AB 55 5 5 40 0 Bolt A 45 1 77 1 23 2 3 16 5 B 55 2 17 34 23 2 3 16 5 C 215 8 46 56 45 4 5 32 5 D 205 8 07 78 75 7 5 54 0 Spacer 2 30 5 1 20 Adjuster 34 40 1 57 ...

Page 65: ...nstall the speed sensor rotor 3 Tighten the speed sensor rotor bolt 4 to the specified torque Speed sensor rotor bolt 25 N m 2 5 kgf m 18 0 lb ft Apply SUZUKI SUPER GREASE A to the clutch push rod end 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the engine sprocket cover Replace the exhaust pipe gaskets and muffler connector with new ones NOTE Be sure to face the tabs 5 on the ex...

Page 66: ...Install the HO2 sensor 6 For E 02 19 HO2 sensor 48 N m 4 8 kgf m 34 5 lb ft Install the gearshift lever and adjust the lever height B Gearshift lever height B Standard 65 75 mm 2 56 2 95 in Perform service and adjustment in the following items Engine oil 2 12 Engine coolant 2 17 Throttle cable play 2 15 Clutch 2 16 Idling adjustment 2 14 Throttle valve synchronization 5 26 EXCV cable adjustment 6 ...

Page 67: ...R Remove the cylinder head cover 1 and its gaskets Remove the PAIR reed valves 2 with their gaskets CAMSHAFT Remove the valve timing inspection cap 1 Identify the position of each removed part Organize the parts in their respective groups e g intake exhaust so that they can be reinstalled in their origi nal positions ...

Page 68: ...ams to the position as shown Remove the cam chain tension adjuster 2 Remove the cam chain guide No 2 3 Remove the camshaft journal holders 4 Remove the intake camshaft 5 Remove the exhaust camshaft 6 Remove the dowel pins Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers ...

Page 69: ...ION 7 7 Remove the cylinder head bolts M6 5 Remove the O rings 6 Remove the cylinder head bolts and washers NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally Remove the cylinder head Remove the dowel pins and gasket CLUTCH Remove the clutch cover 1 along with the CKP sensor 2 Remove the dowel pins and gasket CKP SENSOR INSPECTION 4 35 ...

Page 70: ...gonally Remove the pressure plate 3 Remove the clutch drive plates 4 and driven plates 5 Remove the clutch push piece 6 thrust washer 7 and bear ing 8 Remove the spring washer 9 and its seat 0 Remove the clutch push rod A NOTE If it is difficult to pull out the push rod A use a magnetic hand or a wire Unlock the clutch sleeve hub nut Do not damage the clutch plates by the special tool ...

Page 71: ...nut Remove the washers C D and E from the clutch sleeve hub Remove the wave spring washers F and clutch lifter driven cam G Remove the clutch lifter drive cam H and washer I Remove the spacer J and bearing K Remove the primary driven gear assembly L NOTE If it is difficult to remove the primary driven gear rotate the crankshaft ...

Page 72: ... GEARSHIFT SYSTEM With the snap ring 1 and washer removed remove the gear shift shaft assembly 2 Remove the gearshift cam plate bolt 3 and gearshift cam plate 4 Remove the gearshift cam stopper 5 STARTER IDLE GEAR AND GENERATOR COVER Remove the starter idle gear cover Remove the spring washer 1 washer 2 and starter idle gear No 1 3 ...

Page 73: ...dle gear No 2 7 and shaft 8 CAM CHAIN CAM CHAIN TENSIONER CAM CHAIN GUIDE While holding the generator rotor with the special tool remove the CKP sensor rotor cam chain drive sprocket bolt 09930 44520 Rotor holder Remove the CKP sensor rotor cam chain drive sprocket 1 and cam chain 2 Remove the cam chain tensioner 3 and cam chain guide No 1 4 ...

Page 74: ... bolt Install a bolt A of suitable size to the left end of crankshaft SUITABLE BOLT A M12 length 28 38 mm 1 1 1 5 in Remove the generator rotor 1 and starter driven gear 2 with the special tool 09930 34980 Rotor remover WATER PUMP Remove the water hoses and water inlet connector 1 Remove the water pump 2 WATER PUMP SERVICING 7 11 28 38 mm 1 1 1 5 in ...

Page 75: ...ear position switch 1 CRANKCASE BREATHER PCV COVER Remove the crankcase breather cover 1 Remove the gasket 2 OIL PRESSURE SWITCH Remove the oil pressure switch 1 OIL FILTER Remove the oil filter with the special tool 09915 40610 Oil filter wrench ...

Page 76: ...e plate 1 and oil pan Remove the gasket OIL PRESSURE REGULATOR Remove the oil pressure regulator 1 OIL STRAINER Remove the oil strainer 2 OIL PUMP Remove the oil pump 1 Remove the dowel pins and O ring 2 LOWER CRANKCASE Remove the clutch push rod oil seal retainer 1 ...

Page 77: ...nkshaft journal bolts M9 Remove the lower crankcase assembly Remove the dowel pins and O ring 2 BALANCER SHAFT Remove the balancer shaft 1 and oil seal 2 COUNTERSHAFT Remove the dowel pin Remove the retainer 1 bushing 2 gearshift shaft and fork 3 Remove the oil seal 4 and countershaft assembly 5 ...

Page 78: ...ch and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap Remove the crankshaft and thrust bearings 1 PISTON AND CONROD Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase Remove the piston pin circlip 1 Be careful not to damage the cylinder wall by the con rod ...

Page 79: ...3 26 ENGINE Separate the piston and conrod by driving out the piston pin NOTE Scribe the cylinder number on the piston head ...

Page 80: ...the CMP sensor 1 from the cylinder head cover INSPECTION Inspect the CMP sensor 4 33 INSTALLATION Install the CMP sensor NOTE When installing clean the CMP sensor s face CMP sensor mounting bolt 10 N m 1 0 kgf m 7 0 lb ft PAIR REED VALVE REMOVAL Remove the PAIR reed valve 1 from the gasket Identify the position of each removed part Organize the parts in their respective groups i e intake exhaust N...

Page 81: ...spect the reed valve for the carbon deposit If the carbon deposit is found in the reed valve replace the crankcase breather reed valve with a new one INSTALLATION Install the reed valve to the breather cover Tighten the bolts to the specified torque Crankcase breather reed valve cover bolt 10 N m 1 0 kgf m 7 0 lb ft PCV HOSE Remove the PCV hose from the crankcase breather reed valve cover Inspect ...

Page 82: ...SHAFT 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 1 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 09900 22301 Plastigauge 09900 22302 Plastigauge NOTE Install camshaft journal holde...

Page 83: ...ne exceeds the specification Camshaft journal holder I D Standard IN EX 24 012 24 025 mm 0 9454 0 9459 in 09900 20602 Dial gauge 1 1000 1 mm 09900 22403 Small bore gauge 18 35 mm Camshaft journal O D Standard IN EX 23 959 23 980 mm 0 9433 0 9441 in 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 ru...

Page 84: ...ble the adjuster by releasing the inner circlip C and spill out the oil Check that the plunger is automatically out when tapping its head D If it does not work smoothly replace the cam chain tension adjuster with a new one 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 Do not turn the adjuster body until the...

Page 85: ...ools compress the valve spring and remove the two cotter halves from the valve stem 09916 14510 Valve lifter 09916 14530 Valve lifter attachment 09916 84511 Tweezers 09919 28610 Sleeve protector Remove the valve spring retainer 4 and valve spring 5 Pull out the valve 6 from the combustion chamber side Remove the oil seal 7 and spring seat 8 Remove the other valves in the same manner as described p...

Page 86: ... valve Valve stem runout Service Limit 0 05 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout If it measures more than the service limit replace the valve Valve head radial runout Service Limit 0 03 mm 09900 20607 Dial gauge 1 100...

Page 87: ...de be sure to recheck the deflec tion Valve stem O D Standard IN 4 475 4 490 mm 0 1762 0 1768 in EX 4 455 4 470 mm 0 1754 0 1760 in 09900 20205 Micrometer 0 25 mm NOTE If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in valve guide servicing below VALVE GUIDE SERVICING Using the valve guide remover drive the valve guide out toward the inta...

Page 88: ...0 Valve guide reamer 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 handle clockwise 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 v...

Page 89: ...eaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing INTAKE EXHAUST Seat angle 30 45 60 15 45 60 Seat width 0 9 1 1mm 0 035 0 043 in Valve diameter 29 0 mm 1 14 in 23 mm 0 91 in Valve guide I D 4 500 4 512 mm 0 177 0 178 in The valve seat contact area must be inspected after each cut Do not use lapping compound after the final cut is made T...

Page 90: ... free length Service limit IN EX 37 1 mm 1 460 in 09900 20102 Vernier calipers Valve spring tension IN EX Standard Approx 147 N 15 0 kgf 33 55 mm 33 1 lbs 1 32 in VALVE AND VALVE SPRING REASSEMBLY Install the valve spring seat Apply MOLYBDENUM OIL SOLUTION to the oil seal 1 and press fit it into position MOLYBDENUM OIL SOLUTION Insert the valve with its stem coated with MOLYBDENUM OIL SOLUTION all...

Page 91: ...f the cotter fits snugly into the groove F in the stem end Install the other valves and springs in the same manner as described previously 2 Valve spring retainer 4 Cotter Install the tappet shims and the tappets to their original posi tions NOTE Apply engine oil to the stem end shim and tappet before fitting them When seating the tappet shim be sure the figure printed sur face faces the tappet IN...

Page 92: ...r calipers If the drive plate thickness is found to have reached the limit replace it with a new one Drive plate thickness Service Limit 2 42 mm 0 095 in 09900 20102 Vernier calipers Measure the claw width of drive plates with a vernier calipers Replace the drive plates found to have worn down to the limit Drive plate claw width Service Limit 13 05 mm 0 5138 in 09900 20102 Vernier calipers CLUTCH ...

Page 93: ...artic ularly cracks to decide whether it can be reused or should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing CLUTCH SLEEVE HUB PRIMARY DRIVEN GEAR ASSEMBLY Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates If necessary replace it with a new one CLUTCH LIFTER CLUTCH LIF...

Page 94: ...ght H of clutch lifter adjusting pin screws at three positions using the thickness gauge If the measurement is out of the specification adjust the height H as shown in the following specification Clutch lifter adjusting pin screw height H Standard 0 2 0 4 mm 0 008 0 016 in 09900 20803 Thickness gauge NOTE Each clutch lifter adjusting pin screw height should be as closely as possible Loosen the loc...

Page 95: ...ot move smoothly replace the oil pump assembly STARTER CLUTCH INSPECTION Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement The gear turns one direction only If a large resistance is felt to rotation inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter ...

Page 96: ...tion flange side A of one way clutch to the rotor side When installing the starter clutch guide 2 to the rotor 3 make sure that the flange B side faces outside Degrease the securing bolts and bolt holes Apply THREAD LOCK SUPER 1303 to the bolts and tighten them to the specified torque while holding the rotor with the special tool 99000 32030 THREAD LOCK SUPER 1303 Starter clutch securing bolt 10 N...

Page 97: ...ift arm 1 Washer 5 Plate return spring 2 Snap ring 6 Washer 3 Gearshift shaft return spring 7 Screw 4 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 GEARSHIFT SHAFT GEARSHIFT ARM REASSEMBLY Apply THREAD LOCK to the ge...

Page 98: ... 3 Gearshift shaft return spring 7 Screw 4 Gearshift cam drive plate OIL PRESSURE REGULATOR Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar If the piston does not operate replace the oil pressure regula tor with a new one OIL STRAINER Inspect the oil strainer body for damage Clean the oil strainer if necessary ...

Page 99: ...the 3rd 4th drive gears 2 Slide the 6th 3 and 2nd 4 drive gears toward the 3rd 4th drive gears 2 then remove the 2nd drive gear circlip 5 1 Countershaft 1st drive gear 8 6th driven gear 2 5th drive gear 9 3rd driven gear 3 3rd 4th drive gears 0 4th driven gear 4 6th drive gear A 5th driven gear 5 2nd drive gear B 1st driven gear 6 Driveshaft A Engine sprocket nut ITEM N m kgf m lb ft 7 2nd driven ...

Page 100: ...rs and snap rings The cross sectional view shows the correct position of the gears bushings washers and snap rings 3 48 When installing a new snap ring pay attention to its direction Fit it to the side where the thrust is as shown in the illustration A Thrust B Sharp edge Never reuse a snap ring After a snap ring has been removed from a shaft it should be discarded and a new snap ring must be inst...

Page 101: ...3 48 ENGINE TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft ...

Page 102: ...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 0 008 in 09900 20803 Thickness gauge CYLINDER BORE Inspect the cylinder wall for any scratches nicks or other damage Measure the cylinder bore diameter at six places Cylinder bore Standard 70 000 70 015 mm 2 7559 2 7565 in 09900 20508 Cylinde...

Page 103: ...earance exceeds the service limit replace the crankcase set or the piston or both Piston to cylinder clearance Service Limit 0 120 mm 0 0047 in PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge If the measurement is out of specification replace the piston Piston pin bore I D Service Limit 15 030 mm 0 5917 in 09900 20602 Dial gauge 1 1000 mm 09900 22401 Small b...

Page 104: ...in Oil 1 51 1 53 mm 0 0594 0 0602 in Piston ring thickness Standard 1st 0 97 0 99 mm 0 0382 0 0390 in 2nd 0 77 0 79 mm 0 0303 0 0311 in PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using the vernier cali pers Next fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge If any of the measurements exceeds t...

Page 105: ...t forks 3 Remove the spacer 4 Remove the driveshaft left bearing dust seal 5 Remove the driveshaft left bearing case bolts By using suitable size bolts A remove the driveshaft left bearing case 6 Remove the dowel pin Remove the driveshaft right bearing case bolts By using suitable size bolts A remove the driveshaft right bearing assembly 7 ...

Page 106: ... Service Limit 0 5 mm 0 02 in 09900 20803 Thickness gauge If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both GEARSHIFT FORK GROOVE WIDTH Measure the gearshift fork groove width using the vernier cali pers Shift fork groove width Standard 5 0 5 1 mm 0 197 0 201 in 09900 20102 Vernier calipers GEARSHIFT FORK THICKNESS Measure the gearshift fork thick...

Page 107: ...bearings 3 LH and 4 RH for abnormal noise and smooth rotation while they are in the crankcase Replace the bearing if there is anything unusual Inspect the driveshaft left bearing for abnormal noise and smooth rotation while it is in the case Replace the bearing if there is anything unusual Inspect the driveshaft right bearing for abnormal noise and smooth rotation If there is anything unusual repl...

Page 108: ...the gearshift cam bearing with the special tools 09923 74511 Bearing remover 09930 30104 Sliding shaft Remove the oil seal LH only Remove the gearshift shaft bearings with the special tool 09921 20240 Bearing remover set 15 mm Remove the bearing with the special tool 09913 70210 Bearing installer set 62 Be careful not to lean the bearing remover ...

Page 109: ...1 32 2 3 20 NOTE The stamped mark side of the gearshift shaft bearing faces out side Install new oil seal with the special tool 09913 70210 Bearing installer set 22 Apply SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the bearing with the special tool 09913 70210 Bearing installer set 68 NOTE The stamped mark side of the driveshaft left bea...

Page 110: ... case bolt 12 N m 1 2 kgf m 8 7 lb ft Install the gearshift forks 3 as shown Install the gearshift cam 4 with the bearing fitted With engaging each fork end to the cam groove insert the fork shaft 5 Apply THREAD LOCK to the screws and tighten them to the specified torque 99000 32050 THREAD LOCK 1342 Bearing retainer screw 10 N m 1 0 kgf m 7 0 lb ft Install the dowel pin Apply SUZUKI SUPER GREASE A...

Page 111: ...to the bolts and tighten them to the specified torque 99000 25010 SUZUKI SUPER GREASE A or equivalent grease 99000 32050 THREAD LOCK 1342 Driveshaft retainer bolt 12 N m 1 2 kgf m 8 7 lb ft Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the spacer 7 OIL JET Removal Remove the piston cooling oil jets 1 from the upper crank case Replace the O...

Page 112: ...compressed air 1 Piston cooling oil jet 2 Oil jet 14 For transmission 3 Oil jet 8 For cam chain tension adjuster Installation Fit new O ring 1 to each piston cooling oil jet as shown and apply engine oil to them Install each piston cooling oil jet 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 bol...

Page 113: ...pply engine oil to the O ring Install the oil jet for cam chain tension adjuster PLUG Removal Remove the oil gallery plugs 1 and 2 Remove the oil gallery plugs 3 and 4 Remove the water jacket plugs 5 and 6 Use new O ring to prevent oil pressure leakage ...

Page 114: ...urface Apply engine coolant to the O rings of the water jacket plugs 5 and 6 99000 99032 11X SUZUKI COOLANT Except USA Tighten each plug to the specified torque 1 Oil gallery plug 10 N m 1 0 kgf m 7 0 lb ft 2 Oil gallery plug 22 N m 2 2 kgf m 16 0 lb ft 3 Oil gallery plug 15 N m 1 5 kgf m 11 0 lb ft 4 Oil gallery plug 35 N m 3 5 kgf m 25 5 lb ft 5 Water jacket plug 9 5 N m 0 95 kgf m 6 9 lb ft 6 W...

Page 115: ... shaft with the punch B on the balancer gear BALANCER SHAFT JOURNAL BEARING INSPECTION Inspect each bearing of upper and middle crankcases for any damage SELECTION Place the plastigauge axially along the balancer shaft journal as shown 09900 22301 Plastigauge Mate the middle crankcase with the upper crankcase and tighten the crankcase bolts M8 and crankshaft journal bolts M9 to the specified torqu...

Page 116: ...aft journal O D code number B A or B which is stamped on the balancer shaft Bearing selection table Crankcase I D specification Balancer shaft journal O D specification 09900 20205 Micrometer 0 25 mm Bearing thickness specification NOTE The balancer shaft journal bearings on upper and middle crank cases are the same Balancer shaft journal O D B Code A B Crankcase I D A A Green Black B Black Brown ...

Page 117: ...fitting the balancer shaft journal bearings to the upper and middle crankcases be sure to fix the stopper part A first and press the other end Do not touch the bearing surfaces with your hands Grasp by the edge of the bearing shell ...

Page 118: ...nd I D Service Limit 15 040 mm 0 5921 in 09900 20602 Dial gauge 1 1000 mm 1 mm 09900 22401 Small bore gauge 10 18 mm If the inside diameter of the conrod small end exceeds the limit replace the conrod CONROD BIG END SIDE CLEARANCE Inspect the conrod side clearance by using a thickness gauge If the clearance exceeds the limit remove the conrod and inspect the conrod big end width and the crank pin ...

Page 119: ...wo stages 3 77 1 The number faces the intake side Remove the bearing caps and measure the width of the com pressed plastigauge using the envelope scale This measure ment should be taken at the widest part of the compressed plastigauge 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 spec...

Page 120: ...heck the corresponding crank pin O D code number 1 2 or 3 B Bearing selection table Conrod I D Crank pin O D B Code 1 2 3 Conrod I D A 1 Green Black Brown 2 Black Brown Yellow Code I D specification 1 36 000 36 008 mm 1 4173 1 4176 in 2 36 008 36 016 mm 1 4176 1 4179 in ...

Page 121: ... 32 992 mm 1 2986 1 2989 in 3 32 976 32 984 mm 1 2983 1 2986 in Color C Part No Thickness Yellow 12164 30G00 0D0 1 492 1 496 mm 0 0587 0 0589 in Brown 12164 30G00 0C0 1 488 1 492 mm 0 0586 0 0587 in Black 12164 30G00 0B0 1 484 1 488 mm 0 0584 0 0586 in Green 12164 30G00 0A0 1 480 1 484 mm 0 0583 0 0584 in The bearings must be replaced as a set ...

Page 122: ...ttle at a time to equalize the pressure Crankshaft journal bolt M9 Initial 18 N m 1 8 kgf m 13 0 lb ft Final 50 Remove the lower crankcase and measure the width of the compressed plastigauge using the envelope scale This mea surement should be taken at the widest part of the com pressed plastigauge Crankshaft journal oil clearance Standard 0 010 0 028 mm 0 0004 0 0011 in Service Limit 0 080 mm 0 0...

Page 123: ...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 C Crankcase I D A A Green Black Brown B Black Brown Yellow C Brown Yellow Blue Code I D specification A 35 000 35 006 mm 1 3780 1 3782 in B 35 006 35 012 mm 1 3782 1 3784 in C 35 012 35 018 mm 1 3784 1 3787 in ...

Page 124: ...other end Code O D specification A 31 994 32 000 mm 1 2596 1 2598 in B 31 988 31 994 mm 1 2594 1 2596 in C 31 982 31 988 mm 1 2591 1 2594 in Color Part No Thickness Blue 12229 02H00 0E0 1 504 1 507 mm 0 0592 0 0593 in Yellow 12229 02H00 0D0 1 501 1 504 mm 0 0591 0 0592 in Brown 12229 02H00 0C0 1 498 1 501 mm 0 0590 0 0591 in Black 12229 02H00 0B0 1 495 1 498 mm 0 0589 0 0590 in Green 12229 02H00 0...

Page 125: ...AFT 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 replace it with a new one and once again perform the thrust clearance measurement listed above checking to make sure it is within standard Right side thrust bearing thickness Standard 2 425 2 450 mm 0 0955 0 0964 in 0...

Page 126: ...e 12228 17E00 0F0 2 475 2 500 mm 0 0974 0 0984 in 0 060 0 110 mm 0 0024 0 0043 in 2 535 2 560 mm 0 0998 0 1008 in Yellow 12228 17E00 0E0 2 450 2 475 mm 0 0965 0 0974 in 0 060 0 110 mm 0 0024 0 0043 in 2 510 2 535 mm 0 0988 0 0998 in Green 12228 17E00 0D0 2 425 2 450 mm 0 0955 0 0965 in 0 060 0 110 mm 0 0024 0 0043 in 2 485 2 510 mm 0 0978 0 0988 in Blue 12228 17E00 0C0 2 400 2 425 mm 0 0945 0 0955...

Page 127: ... 56 Gearshift cam bearings 3 56 Gearshift cam 3 57 Driveshaft bearings 3 57 Oil jets 3 59 PISTON RING Install the piston rings in the order of oil ring 2nd ring and 1st ring The first member to go into the oil ring groove is a spacer 1 After placing the spacer fit the two side rails 2 NOTE Side designations top and bottom are not applied to the spacer and side rails you can position each either wa...

Page 128: ...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 pin circlips 1 NOTE End gap of the circlip should not be aligned with the cutaway in the piston pin bore Apply a small quantity of MOLYBDENUM OIL SOLUTION to the sliding surface of the pistons and cylinder walls MOLYBDENUM OIL SO...

Page 129: ...conrod faces intake side Apply a MOLYBDENUM OIL SOLUTION to each crank pin bearing surface and crankshaft journal bearing surface MOLYBDENUM OIL SOLUTION CRANKSHAFT Position the No 2 and No 3 conrod big ends on the same side and the No 1 and No 4 conrod big ends on the opposite side of No 2 and No 3 Be careful not to damage the cylinder wall and piston jet by the conrod Be sure to clean the conrod...

Page 130: ...ring cap bolts Tighten the conrod 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 11 0 lb ft Final 90 1 4 turn Apply engine oil to the conrod big end side surfaces Check the conrod movement for smooth turning Apply a MOLYBDENUM OIL SOLUTION to each crankshaft journal and bearing lightly MOLYBDENUM OIL SOLUTION Be ...

Page 131: ...UM OIL SOLUTION to each balancer shaft journal and bearing lightly MOLYBDENUM OIL SOLUTION Set the balancer shaft so that its punch mark A is aligned with the index B on the crankshaft COUNTERSHAFT Install the C ring 1 and bearing pin 2 to the upper crank case Install the countershaft assembly to the upper crankcase NOTE Align the C ring with the groove of bearing and the bearing pin with the inde...

Page 132: ...ENGINE 3 79 Turn the bearing to fit the bearing dowel pin in the position A Install the dowel pin and oil seal 3 Install the gearshift shaft and fork 4 bushing 5 and retainer 6 ...

Page 133: ...I BOND 1215 or equivalent bond 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 Apply to distorted surfaces as it forms a comparatively thick film Replace the O ring w...

Page 134: ... kgf m 4 5 lb ft Final 11 N m 1 1 kgf m 8 0 lb ft M8 Initial 15 N m 1 5 kgf m 11 0 lb ft Final 26 N m 2 6 kgf m 19 0 lb ft Crankcase bolt B M8 Initial 15 N m 1 5 kgf m 11 0 lb ft Final 22 N m 2 2 kgf m 16 0 lb ft After the crankshaft journal bolts and crankcase bolts have been tightened check that the crankshaft rotates smoothly Also check that the driveshaft and countershaft rotate smoothly Fit n...

Page 135: ...equivalent grease Install the dowel pins Install the oil pump 1 and tighten the oil pump bolts to the specified torque Oil pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft OIL STRAINER AND OIL PRESSURE REGULATOR Apply SUZUKI SUPER GREASE A to the O rings and press in the oil strainer and oil pressure regulator to the crankcase 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Use a new O ring to...

Page 136: ... BOND 1207B Oil pressure switch 14 N m 1 4 kgf m 10 0 lb ft NOTE Be careful not to apply SUZUKI BOND to the hole of thread end OIL COOLER Apply SUZUKI SUPER GREASE A to the O ring and install the oil cooler 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply THREAD LOCK to the bolts and tighten them to the specified torque 99000 32110 THREAD LOCK SUPER 1322 or equivalent thread lock Oil c...

Page 137: ...ket 1 Install the crankcase breather cover 2 Crankcase breather cover bolt 10 N m 1 0 kgf m 7 0 lb ft GEAR POSITION SWITCH Apply SUZUKI SUPER GREASE A to the O ring NOTE Align the gear position switch pin A with the gearshift cam hole B 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the gear position switch as shown Gear position switch bolt 7 N m 0 7 kgf m 5 0 lb ft ...

Page 138: ...ft end A to the oil pump shaft B as shown Tighten the water pump mounting bolts to the specified torque Water pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Apply engine coolant to the O ring Install the water inlet connector 1 Water inlet connector bolt 10 N m 1 0 kgf m 7 0 lb ft Use a new O ring to prevent oil leakage Use a new O ring to prevent engine coolant leakage ...

Page 139: ...older Generator rotor bolt 120 N m 12 0 kgf m 87 0 lb ft CAM CHAIN CAM CHAIN TENSIONER 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 1 Install the cam chain guide No 1 2 99000 32050 THREAD LOCK 1342 Cam chain tensioner bolt 23 N m 2 3 kgf m 16 5 lb ft Cam chain guide No 1 bolt 23 ...

Page 140: ...9 0 lb ft STARTER IDLE GEAR Install the starter idle gear No 2 1 and shaft 2 Apply SUZUKI BOND lightly to the mating surfaces A at the parting line between the upper and lower crankcases 99000 31140 SUZUKI BOND 1207B Install the dowel pin 3 and gasket 4 Install the generator cover NOTE Fit the clamp to the generator cover bolt B Generator cover bolt 10 N m 1 0 kgf m 7 0 lb ft Use a new gasket to p...

Page 141: ...fied torque Starter idle gear cover bolt 10 N m 1 0 kgf m 7 0 lb ft GEARSHIFT SYSTEM Install the gearshift cam stopper 1 bolt 2 collar 3 and return spring 4 NOTE Apply a small quantity of THREAD LOCK to the gearshift cam stopper bolt 2 and tighten it to the specified torque 99000 32050 THREAD LOCK 1342 Gearshift cam stopper bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Hook the return spring end A to the s...

Page 142: ...ighten it to the specified torque 99000 32050 THREAD LOCK 1342 Gearshift cam stopper plate bolt 13 N m 1 3 kgf m 9 5 lb ft Install the washer 6 and gearshift shaft assembly 7 NOTE Pinch the gearshift arm stopper 8 with return spring ends Install the washer 9 and snap ring 0 OIL PUMP DRIVE SPROCKET Install the thrust washer onto the countershaft NOTE The chamfer side A of thrust washer should face ...

Page 143: ...cult to install the primary driven gear rotate the crankshaft Be sure to engage the oil pump drive sprocket with the primary driven gear Install the bearing 2 and spacer 3 and apply engine oil to them Install the thrust washer 4 Install the washer 5 to the clutch sleeve hub Install the wave spring washers 6 clutch lifter driven cam 7 and clutch lifter drive cam 8 NOTE Apply a small quantity of MOL...

Page 144: ...y replace it with a new one The conical curve side of spring washer 0 faces outside Hold the clutch sleeve hub with the special tool 09920 53740 Clutch sleeve hub holder Tighten the clutch sleeve hub nut to the specified torque Clutch sleeve hub nut 95 N m 9 5 kgf m 68 7 lb ft Lock the clutch sleeve hub nut with a center punch Install the spring washer seat A and spring washer B onto the clutch sl...

Page 145: ...ust washer F to the countershaft NOTE Thrust washer F is located between the pressure plate and bearing E 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 2 drive plate claws B to the other slits C of clutch housing as shown ...

Page 146: ... Thickness 1 6 mm 0 091 in 2 0 pcs Install the pressure plate H NOTE When install the pressure plate fit the convex part D of the pressure plate onto the concave part E of the clutch sleeve hub Install the clutch springs Hold the clutch housing with the special tool 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 kg...

Page 147: ...ightly to the CKP sensor gromet 99000 31140 SUZUKI BOND 1207B Install the clutch cover and tighten its bolts to the specified torque Clutch cover bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Fit new gasket washer to the bolts A CYLINDER HEAD Fit the dowel pins and new cylinder head gasket 1 to the cyl inder Use a new gasket to prevent oil leakage Use a new gasket washer to prevent oil leakage Use a new ga...

Page 148: ...lts to the specified torque with a torque wrench sequentially and diagonally Step 4 Additionally tighten the cylinder head bolts with the specified angles diagonally using an angular torque gauge Cylinder head bolt M10 Step 1 Step 3 31 N m 3 1 kgf m 22 5 lb ft Final step 60 1 6 turn NOTE Apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts Tight...

Page 149: ... kgf m 7 0 lb ft CAMSHAFT Turn the crankshaft clockwise with the box wrench and align the line A on the CKP sensor rotor to the rib B behind the clutch cover while keeping the cam chain pulled upward Use a new O ring to prevent engine coolant leakage Pull the cam chain upward or the chain will be caught between crankcase and cam drive sprocket To adjust the camshaft timing correctly be sure to ali...

Page 150: ...ocket Bind the cam chain and sprocket with a proper clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders The other arrow marked 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 camshaft side Engage the 12th roller p...

Page 151: ...aces exhaust side Install the can chain guide No 2 4 Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts lightly in the ascending order of numbers NOTE Fit the copper washer to the camshaft journal holder bolts F The ascending order of numbers are indicated on the cam shaft journal holders Replace the O rings with new ones Damage to head or camshaft journal h...

Page 152: ...body until the outer circlip A fits the groove B 3 31 The camshaft journal holder bolts are made of a spe cial material and much superior in strength compared with other types of high strength bolts Take special care not to use other types of bolts 5 23 24 10 9 6 1 21 22 8 7 2 19 20 14 13 3 17 18 16 15 25 26 12 11 4 Do not turn the adjuster body until the outer circlip A passes over the groove B o...

Page 153: ...ke the push rod come out from the adjuster against the cam chain via chain tensioner NOTE When slight pushing force is applied to the push rod head the push rod is automatically out from the adjuster body Turn the crankshaft clockwise and recheck the cam position 3 101 Use a new gasket to prevent oil leakage 180 Make sure that the adjuster works properly by check ing no slack made at point A ...

Page 154: ...ENGINE 3 101 10 N m 1 0 kgf m 7 0 lb ft ...

Page 155: ...R reed valves 1 along with the gaskets NOTE Fit the projection of the gaskets to the depression of the cam shaft holders Install a new gasket to the cylinder head cover Apply SUZUKI BOND to the cam end cap points of the gasket as shown 99000 31140 SUZUKI BOND 1207B Place the cylinder head cover on the cylinder head Fit a new gasket 2 to each head cover bolt Replace the gaskets with new ones Use a ...

Page 156: ...e Head cover bolt 14 N m 1 4 kgf m 10 0 lb ft STARTER MOTOR Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the starter motor 1 Starter motor mounting bolt 6 N m 0 6 kgf m 4 5 lb ft Install the spark plugs 2 6 ...

Page 157: ... 4 24 SELF DIAGNOSTIC PROCEDURES 4 25 SELF DIAGNOSIS RESET PROCEDURE 4 25 USE OF SDS DIAGNOSTIC PROCEDURES 4 26 USE OF SDS DIAGNOSIS RESET PROCEDURE 4 27 SHOW DATA WHEN TROUBLE DISPLAING DATA AT THE TIME OF DTC 4 28 MALFUNCTION CODE AND DEFECTIVE CONDITION 4 29 C11 P0340 CMP SENSOR CIRCUIT MALFUNCTION 4 33 C12 P0335 CKP SENSOR CIRCUIT MALFUNCTION 4 35 C13 P0105 H L IAP SENSOR CIRCUIT MALFUNCTION 4...

Page 158: ...Y CIRCUIT MALFUNCTION 4 103 SENSORS 4 105 CMP SENSOR INSPECTION 4 105 CMP SENSOR REMOVAL AND INSTALLATION 4 105 CKP SENSOR INSPECTION 4 105 CKP SENSOR REMOVAL AND INSTALLATION 4 105 IAP SENSOR INSPECTION 4 105 IAP SENSOR REMOVAL AND INSTALLATION 4 105 TP SENSOR INSPECTION 4 105 TP SENSOR REMOVAL AND INSTALLATION 4 105 TPS ADJUSTMENT 4 105 ECT SENSOR INSPECTION 4 106 ECT SENSOR REMOVAL AND INSTALLA...

Page 159: ...the 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 The terminals must be clean and free of any foreign material which could impede proper terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnorm...

Page 160: ...connector 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 correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse ECM VARIOUS SENSORS Since each component is a high precision part great...

Page 161: ...omotive 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 with a low voltage battery will lead to erroneous diagno sis Never connect any tester voltmeter ohmmeter or whatever to the ECM when its coupler is disconnected Otherwise damage to ECM may result Never...

Page 162: ...lso 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 contact tension Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is fully inserted in the coup...

Page 163: ... 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 ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals A and B Voltage Between C and body ground App...

Page 164: ...ose 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 between terminals A and C 1 Other parts 1 To other parts Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal A and body ground If continuity is ind...

Page 165: ...hen measuring the resistance with the multi circuit tester 1 will be shown as 10 00 MΩ and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After using the tester turn the power off 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side o...

Page 166: ...and 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 pressure signal Engine speed signal Throttle opening signal Crankshaft Position Sensor CKP Sensor Throttle Position Sensor TP Sensor Various Sensors Various signals Injection signal Injectors ECM Ba...

Page 167: ... 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 time volume A longer injection time is needed to adjust injection volume in the case of low voltage ENGINE RPM SIGNAL At high speed the injection time volume is increased This is the compensation of the SRAD START...

Page 168: ...sensor TPS B Secondary throttle position sensor STPS C Secondary throttle valve actuator STVA D Intake air pressure sensor IAPS E Exhaust control valve actuator EXCVA F HO2 sensor For E 02 19 G Crankshaft position sensor CKPS H Fuel pump relay FP relay I Fuel pump FP ECM ...

Page 169: ...ure sensor IATS M PAIR control solenoid valve N Camshaft position sensor CMPS O Ignition coil IG COIL P Secondary fuel injector Q Primary fuel injector R Engine coolant temperature sensor ECTS S Speed sensor T Atmospheric pressure sensor APS U Tip over sensor TOS V Speedometer ECM ...

Page 170: ...stop switch Fuel pump relay Fuel pump Primary fuel injector Ignition coil IG COIL Ignition switch Neutral indicator light Starter switch Gear position switch N 6 1 5 4 2 3 ECM Secondary throttle position sensor STPS EXCVA Secondary fuel injector Cooling fan motor 15 A 1 For E 02 19 markets are equipped HO2 sensor 2 PAIR control solenoid valve HO2 sensor W B W G 1 Cooling fan relay O W 2 For E 02 1...

Page 171: ...for speedometer M GP switch signal GP 7 N 8 TP sensor signal TP O Blank 9 IAP sensor signal IAP P AP sensor signal AP 0 ECT sensor signal ECT Q IAT sensor signal IAT A Power source for sensors VCC R Blank B HO2 sensor signal OX For E 02 19 24 S Sensors ground E2 C CMP sensor signal CMP T HO2 sensor control selector For E 02 19 D CKP sensor signal CKP U CKP sensor signal CKP E V Serial data for sel...

Page 172: ...al switch c Cooling fan relay FAR t Clutch position switch d PAIR control solenoid valve PAIR u Secondary fuel injector 4 42 e Primary fuel injector 4 41 v Secondary fuel injector 3 32 f Primary fuel injector 3 31 w Secondary fuel injector 2 22 g Primary fuel injector 2 21 x Secondary fuel injector 1 12 h Primary fuel injector 1 11 y i Ignition coil 3 z General ground E01 j Ignition coil 2 Ground ...

Page 173: ...icated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 5 seconds For Example The ignition switch is turned ON and the engine stop switch is turned OFF In this case the speed ometer does not receive any signal from ECM and the panel indicates CHEC If CHEC is indicated the LCD does not indicate the trouble code It i...

Page 174: ...devices 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 ECM are disconnected the malfunction code memory is erased and the malfunction code can not be checked MALFUNCTION LCD DISPLAY INDICATION FI LIGHT INDICATION INDICATION MODE NO C00 FI light turns OFF ...

Page 175: ...position sensor TPS Engine coolant temperature sensor ECTS Intake air temperature sensor IATS Atmospheric pressure sensor APS Tip over sensor TOS Ignition signal 1 IG coil 1 Ignition signal 2 IG coil 2 Ignition signal 3 IG coil 3 Ignition signal 4 IG coil 4 Secondary throttle valve actuator STVA Secondary throttle position sensor STPS Gear position signal GP switch Primary injector signal 1 FI 1 P...

Page 176: ...e the aircleaner box and lift up the throttle body 5 14 4 Loosen the screw and slide the throttle position sensor 1 to bring the line to the middle 5 Then tighten the screw to fix the throttle position sensor 09930 11950 Torx wrench 09930 82720 Mode select switch The LCD displays the line for 0 4 sec at a time and when such a display repeats two times it indicates the current position where the se...

Page 177: ... throttle opening is fixed to full open position Ignition timing is also fixed YES YES ECT sensor Engine coolant temperature value is fixed to 80 C 176 F Cooling fan is fixed on position YES YES IAT sensor Intake air temperature value is fixed to 40 C 104 F YES YES AP sensor Atmospheric pressure is fixed to 101 kPa 760 mmHg YES YES Ignition signal 1 Ignition off YES YES 2 3 4 cylinders can run 2 I...

Page 178: ...el cut secondary side YES 1 3 4 cylinders can run 3 Fuel cut secondary side YES 1 2 4 cylinders can run 4 Fuel cut secondary side YES 1 2 3 cylinders can run Secondary throttle valve actuator Secondary throttle valve is fixed to full close position When motor dis connection or lock occurs power from ECM is shut off YES YES STP sensor Secondary throttle valve is fixed to full close position YES YES...

Page 179: ...p 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 Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at cold warm always Surging Abnormal knocking Othe...

Page 180: ...tion Broken fuse FI light operation 4 17 and 9 31 Each warning light operation 9 31 Speedometer operation 9 34 Exhaust gas leakage and noise 2 29 Each coupler disconnection Clogged radiator fins 7 4 and 5 MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Hot Warm Cool Cold C F Always Frequency Always Sometimes time...

Page 181: ...t 8 7 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 malfunction code to determine the malfunction part 09930 82720 Mode select switch SELF DIAGNOSIS RESET PROCEDURE After repairing the trouble turn OFF the ignition switch and turn ON again If the malfunction...

Page 182: ...CAUTIONS IN SERVICING 4 3 before inspection and observe what is written there Remove the front seat 8 7 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code and show data when trouble displaying data at the time of DTC according to instructions displayed on SDS Not only is SDS used for detecting Diagnostic Trouble Codes but also for reprodu...

Page 183: ...in 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 a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS Click Clear 2 to delete history code Past DTC Follow the displayed instructions Chec...

Page 184: ...g 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 function to store each show data when trouble for two different malfunctions in the order as the malfunction is detected Utilizing this function it is possible to know the order of malfunctions that...

Page 185: ...ied value IAP sensor circuit open or shorted to VCC or ground circuit open L Sensor voltage is lower than specified value IAP sensor circuit shorted to ground or VCC circuit open C14 TP sensor The sensor should produce following voltage 0 2 V sensor voltage 4 80 V In other than the above range C14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than speci...

Page 186: ...n 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 sensor lead wire coupler connection P1651 H Sensor voltage is higher than specified value TO sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value TO sensor...

Page 187: ... fuel injector wiring cou pler connection power supply to the injector P0201 P0202 P0203 P0204 C36 C37 C38 C39 Secondary fuel injector Some failure exists in the fuel injector signal in a high load high revolution condition In this case the code C36 P1764 C37 P1765 C38 P1766 or C39 P1767 is indicated Secondary fuel injector wir ing coupler connection power supply to the injector P1764 P1765 P1766 ...

Page 188: ... from the ECM communica tion signal does not reach ECM or operation voltage does not reach EXCVA motor C46 P1658 is indi cated EXCVA can not operate EXCVA EXCVA lead wire cou pler P1657 H EXCVA position sensor voltage is higher than specified value EXCVA position sensor circuit shorted to VCC or ground circuit open L EXCVA position sensor voltage is lower than specified value EXCVA position sensor...

Page 189: ... batteries in series 1 kΩ resistor and the multi circuit tester as shown in the illustration 09900 25008 Multi circuit tester set Tester knob indication Voltage DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec or more after receiving the starter signal Metal particles or foreign material being stuck on the CMP sensor and rotor tip CMP sensor circuit open or short CMP senso...

Page 190: ...S or A If wires and connection are OK intermittent trouble 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 Inspect that metal particles or foreign material stuck on the CMP sensor and rotor tip If there are no metal particles and foreign mate rial then replace the CMP sensor with a new one When ...

Page 191: ...e CKP sensor resistance 4 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 142 194 Ω B G DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec or more after receiving the starter signal Metal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction ECM CKP...

Page 192: ...fter repairing the trouble clear the DTC using SDS tool 4 27 Step 2 1 Crank the engine a few seconds with the starter motor and measure the CKP sensor peak voltage at the coupler 2 Repeat the above test procedure a few times and measure the highest peak voltage CKP sensor peak voltage 0 28 V and more B G 1 Peak volt adaptor 09900 25008 Multi circuit tester set Tester knob indication Voltage YES Go...

Page 193: ...minal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Inspect that metal particles or foreign material stuck on the CKP sensor and rotor tip If there are no metal particles and foreign mate rial then replace the CKP sensor with a new one When using the multi circuit tester do not storongly touch the terminal of the ECM coupler wit...

Page 194: ...at 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 being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECM malfunction P0105 H Sensor voltage is higher than specified...

Page 195: ...Is the voltage OK Step 1 When indicating P0105 H 1 Turn the ignition switch OFF 2 Lift and support the fuel tank 5 3 3 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between R wire A and G B wire C If the sound is not heard from the tester the circuit condition is OK YES Go to S...

Page 196: ...on switch OFF 2 Lift and support the fuel tank 5 3 3 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between G B wire C and ground 6 Also check the continuity between G B wire C and B Br wire B If the sound is not heard from the tester the circuit condi tion is OK When using the ...

Page 197: ...ut voltage at the wire side coupler between G B and B Br wires IAP sensor output voltage Approx 2 7 V at idle speed G B B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool 4 27 When using the multi circuit tester do not storongly touch the terminal of the ECM coupl...

Page 198: ...08 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 4 27 YES G B R or B Br wire open or shorted to ground or poor 9 A or S connection If wire and connection are OK 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 an...

Page 199: ...nt temp 20 30 C 68 86 F ALTITUDE Reference ATMOSPHERIC PRESSURE OUTPUT VOLTAGE ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 3 1 3 6 2 001 5 000 611 1 524 707 634 94 85 2 8 3 4 5 001 8 000 1 525 2 438 634 567 85 76 2 6 3 1 8 001 10 000 2 439 3 048 567 526 76 70 2 4 2 9 ...

Page 200: ...re the voltage at the R wire B and B Br wire C DETECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following range Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 2 V Sensor voltage 4 8 V TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction ECM malfunction P0120 H Sensor voltage is higher than spec...

Page 201: ...rom the tester the circuit condition is OK 6 Disconnect the ECM coupler 7 Check the continuity between P B wire A and terminal 8 8 Also check the continuity between B Br wire C and terminal S TPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test YES Go to Step 2 NO Loose or poor contacts on the ECM coupl...

Page 202: ...nnect the ECM coupler 8 Check the continuity between P B wire A and terminal 8 9 Also check the continuity between R wire B and terminal A TPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool 4 27 YES Go to Step 2 NO P B wi...

Page 203: ...nsor resistance Throttle valve is closed Approx 1 1 kΩ Throttle valve is opened Approx 4 3 kΩ 7 If OK then measure the TP sensor resistance at the test har ness terminals between terminal C and terminal D TP sensor resistance Approx 4 68 kΩ Terminal C Terminal D 09900 25008 Multi circuit tester set 09900 28630 TPS test wire harness Tester knob indication Resistance Ω Are the continuity and resista...

Page 204: ...trouble clear the DTC using SDS tool 4 27 3 V ECM TPS P B R B Br 3 YES P B R or B Br wire open or shorted to ground or poor 8 A or S connection If wire and connection are OK 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 If check result is not satisfactory replace TP sen s...

Page 205: ...wire terminal B ECT 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 within the following range 0 15 V Sensor voltage 4 85 V ECT sensor circuit open or short ECT sensor malfunction ECM malfunction P0115 H Sensor voltage is higher than specified value ECT s...

Page 206: ...so check the continuity between B Br wire B and terminal S ECTS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 7 After repairing the trouble clear the DTC using SDS tool 4 27 1 When using the multi circuit tester do not storongly touch the terminal of the ECM coupler with a needle...

Page 207: ... from the tester the circuit condition is OK Tester knob indication Continuity test 6 Connect the ECT sensor coupler and turn the ignition switch ON 7 Measure the voltage between B Bl wire A and ground ECT sensor output voltage 0 15 4 85 V B BI Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Are the continuity and voltage OK 8 After r...

Page 208: ...n or shorted to ground or poor 0 or S connection If wire and connection are OK 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 Replace the ECT sensor with a new one When using the multi circuit tester do not storongly touch the terminal of the ECM coupler with a needle poin...

Page 209: ...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 voltage is not within the following range 0 15 V Sensor voltage 4 85 V IAT sensor circuit open or short IAT sensor malfunction ECM malfunction P0110 H Sensor voltage is higher than specified value IAT ...

Page 210: ...check the continuity between B Br wire B and terminal S IATS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 7 After repairing the trouble clear the DTC using SDS tool 4 27 1 When using the multi circuit tester do not storongly touch the terminal of the ECM coupler with a needle po...

Page 211: ...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 and ground IAT sensor output voltage 0 15 4 85 V Dg Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Are the continuity and voltage OK 8 Af...

Page 212: ...r shorted to ground or poor Q or S connection If wire and connection are OK 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 Replace the IAT sensor with a new one When using the multi circuit tester do not storongly touch the terminal of the ECM coupler with a needle pointed...

Page 213: ...ng 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 air passage with dust AP sensor circuit open or shorted to ground AP sensor malfunction ECM malfunction P1450 H Sensor voltage is higher than specified value AP sensor circuit shorted to VCC or ground circui...

Page 214: ...tage Is the voltage OK Step 1 When indicating P1450 H 1 Turn the ignition switch OFF 2 Remove the front seat 8 7 3 Check the AP sensor coupler for loose or poor contacts If OK then check the AP sensor lead wire continuity 4 Disconnect the AP sensor coupler 5 Check the continuity between R wire A and G Y wire C If the sound is not heard from the tester the circuit condition is OK YES Go to Step 2 N...

Page 215: ...ignition switch OFF 2 Remove the front seat 8 7 3 Check the AP sensor coupler for loose or poor contacts If OK then check the AP sensor lead wire continuity 4 Disconnect the AP sensor coupler 5 Check the continuity between G Y wire C and ground 6 Also check the continuity between G Y wire C and B Br wire B If the sound is not heard from the tester the circuit condi tion is OK When using the multi ...

Page 216: ...asure the AP sensor output voltage at the wire side cou pler between G Y and B Br wires AP sensor output voltage Approx 3 6 V at 100 kPa 760 mmHg G Y B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage 4 After repairing the trouble clear the DTC using SDS tool 4 27 When using the multi circuit tester do not storongly touch the terminal of t...

Page 217: ...it tester set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool 4 27 YES G Y R or B Br wire open or shorted to ground or poor P A or S connection If wire and connection are OK 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 a...

Page 218: ...nt temp 20 30 C 68 86 F ALTITUDE Reference ATMOSPHERIC PRESSURE OUTPUT VOLTAGE ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 3 1 3 6 2 001 5 000 611 1 524 707 634 94 85 2 8 3 4 5 001 8 000 1 524 2 438 634 567 85 76 2 6 3 1 8 001 10 000 2 439 3 048 567 526 76 70 2 4 2 9 ...

Page 219: ... Multi circuit tester set Tester knob indication Resistance Ω Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE C23 The sensor voltage should be the follow ing for 2 sec and more after ignition switch is turned ON 0 2 V Sensor voltage 4 8 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor circuit shorted to V...

Page 220: ... the continuity between B wire B and terminal L 8 Also check the continuity between B Br wire C and terminal S TOS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool 4 27 1 1 When using the multi circuit tester do not storongl...

Page 221: ...t the ECM coupler 8 Check the continuity between R wire A and terminal A 9 Also then check the continuity between B wire B and termi nal L TOS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool 4 27 1 1 When using the multi c...

Page 222: ... the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 4 27 C24 P0351 C25 P0352 C26 P0353 or C27 P0354 IGNITION SYSTEM MALFUNCTION Refer to the IGNITION SYSTEM for details 9 20 2 V 2 V 65 YES R B or B Br wire open or shorted to ground or poor A L or S connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open cir...

Page 223: ...open Is the operating OK 5 After repairing the trouble clear the DTC using SDS tool 4 27 DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA ECM does not receive communication signal from the STVA STVA malfunction STVA circuit open or short STVA motor malfunction ECM STVA 2B STVA 1A STVA 1B STVA B Lg P W G W B STVA 2A 1 YES Go to Step 2 NO Loose or poor contacts on the ...

Page 224: ...s the resistance OK 5 After repairing the trouble clear the DTC using SDS tool 4 27 2 2 YES W B P W G and B Lg wire open or shorted to ground or poor 1 2 H and I connection If wire and connection are OK 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 Loose or poor contacts ...

Page 225: ... Set up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operation sound is heard from the STVA the function is normal ...

Page 226: ...b indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C29 Signal voltage is not within the following range Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 15 V Sensor voltage 4 85 V STP sensor maladjusted STP sensor circuit open or short STP sensor malfunction ECM malfunction P1654 H Sensor voltage is higher than specifi...

Page 227: ...heck the continuity between Y W wire B and terminal J 8 Also check the continuity between B Br wire C and terminal S STPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool 4 27 1 1 When using the multi circuit tester do not s...

Page 228: ...e ECM coupler 8 Check the continuity between Y W wire B and terminal J 9 Also check the continuity between R wire A and terminal A STPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool 4 27 1 1 When using the multi circuit ...

Page 229: ...easure the valve closing and opening resistance STP sensor resistance Secondary throttle valve is closed Approx 0 5 kΩ Secondary throttle valve is opened Approx 3 9 kΩ Y A B B 7 If OK then measure the STP sensor resistance at the wire terminals between Bl wire C and B wire B STP sensor resistance Approx 4 69 kΩ Bl c B B 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Are t...

Page 230: ...ster set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK After repairing the trouble clear the DTC using SDS tool 4 27 3 V 3 3 YES R Y W or B Br wire open or shorted to ground or poor A J or S connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM ...

Page 231: ...n switch ON 9 Measure 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 09900 25009 Needle pointed probe set Tester knob indication Voltage DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage Switch voltage is not within the following range Swit...

Page 232: ... and poor connection Replace the ECM with a known good one and inspect it again NO P or B W wire open or P wire shorted to ground Loose or poor contacts on the ECM coupler terminal M or X If wire and connection are OK replace the GP switch with a new one When using the multi circuit tester do not storongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the term...

Page 233: ... the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Injector resistance 11 13 Ω at 20 C 68 F Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is interrupted by 4 times or more continuously Injector circuit open or short Injector malfunction ECM malfunction ECM Fuel pump relay Primary fuel injecto...

Page 234: ...K 6 After repairing the trouble clear the DTC using SDS tool 4 27 Step 2 1 Turn the ignition switch ON 2 Measure the injector voltage between Y R wire and ground Injector voltage Battery voltage Y R Ground NOTE Injector voltage can be detected only 3 for seconds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage YES Go to Step 2 NO Replace the in...

Page 235: ...r side Gr R wire open or shorted to ground or poor e connection 4 cylinder side If wire and connection are OK 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 Open circuit in the Y R wire When using the multi circuit tester do not storongly touch the terminal of the ECM coup...

Page 236: ...sure the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Injector resistance 11 13 Ω at 20 C 68 F Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE Some failure exists in the fuel injector signal in a high load high revolution condition Injector circuit open or short Injector malfunction ECM malfunction ECM Fuel pump relay Secondary fuel injecto...

Page 237: ... OK 6 After repairing the trouble clear the DTC using SDS tool 4 27 Step 2 1 Turn the ignition switch ON 2 Measure the injector voltage between Y R wire and ground Injector voltage Battery voltage Y R Ground NOTE Injector voltage can be detected only 3 seconds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage YES Go to Step 2 NO Replace the inje...

Page 238: ...side Lg BI wire open or shorted to ground or poor u connection 4 cylinder side If wire and connection are OK 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 Open circuit in the Y R wire When using the multi circuit tester do not storongly touch the terminal of the ECM coupl...

Page 239: ...lied to fuel pump although fuel pump relay is turned OFF Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction P0230 H Voltage is applied to fuel pump 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 ON Fuel pump relay c...

Page 240: ...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 Replace the FP relay with a new one When using the multi circuit tester do not storongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend ECM couplers Harness side 1 Black Gray 1 ...

Page 241: ...rouble clear the DTC using SDS tool 4 27 1 YES Y B wire open or poor connection O W wire open or shorted to ground R BI or Y R wire open or shorted to ground or poor W connection If wire and connection are OK 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 Replace the FP re...

Page 242: ...or details 9 39 DETECTED CONDITION POSSIBLE CAUSE Ignition switch signal is not input to the ECM Ignition system circuit open or short ECM malfunction When the ID agreement is not verified ECM does not receive communication signal from the immobilizer antenna For E 02 19 24 Immobilizer system malfunction For E 02 19 24 ...

Page 243: ...he sound is not heard from the tester the circuit condi tion is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE C44 P0130 HO2 sensor output voltage is not input to ECM during engine operation and running condition Sensor voltage 0 55 V HO2 sensor circuit open or shorted to ground Fuel system malfunction ECM malfunction C44 P0135 The ...

Page 244: ...en W G wire and B Br wire when idling condition HO2 sensor output voltage at idle speed 0 4 V and less W G B Br 4 If OK then remove the air cleaner box 5 14 and pinch the PAIR hoses 1 with proper hose clamps 5 Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r min HO2 sensor output voltage at 5 000 r min 0 6 V and more W G B Br 09900 25008 Multi circuit tester set 0990...

Page 245: ...erature 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 4 27 YES W G wire or B Br wire open or shorted to ground or poor B or S connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM w...

Page 246: ...r knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 4 27 YES O W or W wire open or shorted to ground or poor a connection Recheck each terminal and wire harness for open circuit and poor connection If wire and connection are OK intermittent trou ble or faulty ECM Replace the ECM with a known good one and inspect it again NO Open or short circuit i...

Page 247: ...sor voltage low or high 0 1 V Sensor voltage 4 9 V without the above range EXCVA maladjusted EXCVA circuit open or short EXCVA motor malfunction EXCVA position sensor malfunction P1657 H Sensor voltage is higher than specified value EXCVA position sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value EXCVA position sensor circuit open or shorted to gro...

Page 248: ...M coupler 7 Check the continuity between Y wire A and terminal 5 8 Also check the continuity between B Br wire B and terminal S EXCVA lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool 4 27 1 1 When using the multi circuit tes...

Page 249: ... 7 Disconnect the ECM coupler 8 Check the continuity between Y wire A and terminal 5 9 Also check the continuity between R wire C and terminal A EXCVA lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool 4 27 1 1 When using the...

Page 250: ... sensor lead wire coupler 4 Turn the ignition switch ON 5 Measure the voltage between the R wire terminal 1 and ground 6 If OK then measure the voltage between the R wire terminal 1 and B Br wire terminal 2 Position sensor input voltage 4 5 5 5 V R Ground R B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 7 After repairing the trouble clear the DTC using S...

Page 251: ...tance 4 Connect the position sensor coupler 5 Set the EXCVA to adjustment position 6 4 6 Disconnect the position sensor coupler and measure the resistance between Y and W wires Position sensor resistance at adjustment position Approx 3 1 kΩ Y W 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Is the resistance OK 3 3 YES Go to Step 4 NO Replace the EXCVA with a new one 3 ...

Page 252: ...Turn the ignition switch ON 8 Measure the position sensor output voltage at fully close posi tion 9 Then to set the EXCV to fully open position apply 12 V to B and A terminals Positive wire B Gr wire terminal Negative wire A P wire terminal 10 Measure the position sensor output voltage at fully open position Position sensor output voltage EXCV is fully close 0 5 1 3 V EXCV is fully open 3 7 4 5 V ...

Page 253: ...e output voltage to specified by turning out the No 2 cable adjuster 2 Repeat the above procedure Step 4 until the output voltage is within the specified value Position sensor output voltage EXCV is fully close 0 5 Output Voltage 1 3 EXCV is fully open 3 7 Output Voltage 4 5 Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 4 27 Adjusting the cable with the EXCV fully op...

Page 254: ...ion OK 5 After repairing the trouble clear the DTC using SDS tool 4 27 6 6 12 V 6 12 V YES Loose or poor contacts on the EXCVA or ECM coupler terminal 3 or 4 Open or short circuit in the B R wire or R B wire If wire and connection are OK 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 ...

Page 255: ... 1 Set up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Exhaust valve operating control 1 4 Click each button 2 At this time if an operation sound is heard from the EXCVA the function is normal ...

Page 256: ...resistance 18 22 Ω at 20 30 C 68 86 F Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Is the resistance OK 6 After repairing the trouble clear the DTC using SDS tool 4 27 DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to ECM PAIR control solenoid valve circuit open or short PAIR control solenoid valve malfunction ECM ma...

Page 257: ...r details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control 1 2 V YES W G wire open or shorted to ground or poor t connection failure If wire and connection are OK 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 Open or short circuit in the O W wire When usin...

Page 258: ...4 102 FI SYSTEM DIAGNOSIS 4 Click each button 2 At this time if an operation sound is heard from the PAIR control solenoid valve the function is normal ...

Page 259: ... short ECM malfunction ECM Side stand relay Ignition switch Engine stop switch FAR O R O W Cooling fan motor Cooling fan relay To Side stand switch 1 YES O W and O R wire open or shorted to ground or poor c connection If wire and connection are OK 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 an...

Page 260: ...t temperature is less than 100 C 212 F after starting the engine 5 Click the stop button 3 to check the operation properly 6 Click the off button 4 to check the cooling fan relay and cooling fan motor operation NOTE This inspection should be begun from when the engine coolant temperature is below 50 C 122 F Check that the cooling fan relay operates for a few seconds as the engine coolant temperatu...

Page 261: ...6 Install the clutch cover in the reverse order of removal IAP SENSOR INSPECTION The intake air pressure sensor is installed at the rear side of the air cleaner box 4 38 IAP SENSOR REMOVAL AND INSTALLATION Lift and support the fuel tank 5 3 Remove the IAP sensor Install the IAP sensor in the reverse order of removal TP SENSOR INSPECTION The throttle position sensor is installed at the right side o...

Page 262: ...SOR INSPECTION The AP sensor is located under the front seat 4 57 AP SENSOR REMOVAL AND INSTALLATION Remove the AP sensor from the frame Install the AP sensor in the reverse order of removal TO SENSOR INSPECTION TO SENSOR REMOVAL AND INSTALLATION The tip over sensor is located at the rear of seat tail rail 4 63 Remove the TO sensor Install the TO sensor in the reverse order of removal NOTE When in...

Page 263: ...coupler 1 and remove the HO2 sensor Installation is in the reverse order of removal Tighten the sensor unit to the specified torque HO2 sensor 48 N m 4 8 kgf m 34 5 lb ft Route the HO2 sensor lead wire properly 10 20 Do not remove the HO2 sensor while it is hot Be careful not to expose it to excessive shock Do not use an impact wrench while removing or installing the HO2 sensor Be careful not to t...

Page 264: ... FUEL MESH FILTER INSTALLATION 5 10 THROTTLE BODY 5 13 CONSTRUCTION 5 13 AIR CLEANER BOX REMOVAL AND INSTALLATION 5 14 THROTTLE BODY REMOVAL 5 15 THROTTLE BODY DISASSEMBLY 5 16 THROTTLE BODY CLEANING 5 18 INSPECTION 5 18 THROTTLE BODY REASSEMBLY 5 19 THROTTLE BODY INSTALLATION 5 21 STP SENSOR ADJUSTMENT 5 22 FUEL INJECTOR REMOVAL 5 23 FUEL INJECTOR INSPECTION 5 23 FUEL INJECTOR INSTALLATION 5 23 F...

Page 265: ...s the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 3 0 kgf cm2 300 kPa 43 psi the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM The fuel relieved by the fuel pressure regulator flows back to the fuel tank 1 Fuel tank 7 Fuel feed ...

Page 266: ...SYSTEM AND THROTTLE BODY 5 3 FUEL SYSTEM FUEL TANK LIFT UP Remove the seats 8 7 and 8 Take out the fuel tank prop stay 1 Remove the fuel tank bolt Lift and support the fuel tank with the fuel tank prop stay ...

Page 267: ...sconnect the fuel feed hose Remove the fuel tank bracket mounting bolt Remove the fuel tank FUEL TANK INSTALLATION Installation is in the reverse order of removal FUEL PRESSURE INSPECTION Lift and support the fuel tank 5 3 Place a rag under the fuel feed hose 1 and remove the fuel feed hose When removing the fuel tank do not leave the fuel feed hose 4 on the fuel tank side Gasoline is highly flamm...

Page 268: ...el pressure is higher than the specification inspect the following items Fuel pump check valve Pressure regulator A To fuel tank B To fuel delivery pipe FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper ates for few seconds If the fuel pump motor does not make operating sound inspect the fuel pump circuit connections or inspect the fuel pump relay and to sensor If ...

Page 269: ...y lead wire Place a rag under the fuel feed hose and disconnect the fuel feed hose 1 from the fuel pump Connect a proper fuel hose 2 to the fuel pump Place the measuring cylinder and insert the fuel hose end into the measuring cylinder Disconnect the fuel pump lead wire coupler 3 Gasoline is highly flammable and explosive Keep heat spark and flame away ...

Page 270: ...that the fuel pump is defective or that the fuel filter is clogged Fuel discharge amount 168 ml 5 7 5 9 US Imp oz and more 10 sec NOTE The battery must be in fully charged condition FUEL PUMP RELAY INSPECTION Fuel pump relay is located on the air cleaner box right side one Lift and support the fuel tank 5 3 Remove the fuel pump relay 1 First check the insulation between A and B terminals with pock...

Page 271: ...DY FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION 1 Fuel level gauge 5 Holder 2 Fuel pump case Fuel filter cartridge 6 Fuel mesh filter ITEM N m kgf m lb ft 3 Fuel pump 7 O ring A 10 1 0 7 0 4 Rubber cushion A Fuel pump mounting bolt ...

Page 272: ...y removing its mounting bolts diagonally Remove the nuts Remove the lead wire 1 screws and fuel level gauge 2 Remove the screw Remove the fuel pump 3 from the fuel pump plate 4 Remove the fuel pump holder 5 and rubber cushion 6 Gasoline is highly flammable and explosive Keep heat spark and flame away ...

Page 273: ...uel 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 FUEL PUMP AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh filter in the reverse order of removal Pay attention to the following points Install new bushing 1 to the fuel pump Install new O ring to the fuel pipe Apply thin coat ...

Page 274: ...to the proper terminals A Bl terminal for fuel pump B R terminal for fuel level gauge Install a new O ring and apply SUZUKI SUPER GREASE A to it 99000 25010 SUZUKI SUPER GREASE A or equivalent grease The O ring must be replaced with a new one to prevent fuel leakage ...

Page 275: ...n all the fuel pump mounting bolts lightly and then to the specified torque in the ascending order of numbers Fuel pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Apply a small quantity of the THREAD LOCK to the thread por tion of fuel pump mounting bolts 99000 32050 THREAD LOCK 1342 ...

Page 276: ...t idle adjusting screw 2 STP sensor 9 Throttle stop screw 3 STVA 0 Vacuum hose 4 Fuel delivery pipe A Fuel delivery pipe mounting screw ITEM N m kgf m lb ft 5 O ring B STP sensor mounting screw A 5 0 0 5 3 7 6 Fuel injector C TP sensor mounting screw B 3 5 0 35 2 5 7 Cushion seal C 3 5 0 35 2 5 ...

Page 277: ... the fuel pump relay 1 cooling fan relay 2 and IAT sensor lead wire coupler 3 Disconnect the PCV hose 4 Remove the air cleaner mounting bolt 5 Disconnect the PAIR hose 6 Remove the rubber caps 7 LH RH Loosen the throttle body clamp screws LH RH Remove the air cleaner box INSTALLATION Installation is in the reverse order of removal ...

Page 278: ...TVA lead wire coupler 1 STP sensor lead wire coupler 2 TP sensor lead wire coupler 3 and IAP sen sor lead wire coupler 4 Remove the wire clamps 5 and disconnect the fuel injector lead wire couplers 6 Loosen the throttle body clamp screws at the intake pipe side After disconnecting the throttle cables do not snap the throttle valve from full open to full close It may cause damage to the throttle va...

Page 279: ...m each throttle body Remove the IAP sensor 2 Remove the fuel delivery pipe assembly 3 Remove the cushion seal 4 from the throttle body Remove the fuel injectors 5 from the fuel delivery pipe 6 Identify the position of each removed part Organize the parts in their respective groups so that they can be reinstalled in their original positions ...

Page 280: ...ly mark the each sensor s original position with a paint or scribe for accurate reinstallation Never remove the STVA 7 from the throttle body Never remove the secondary throttle valve 8 and throttle valve 9 The fast idle screw 0 is factory adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary ...

Page 281: ...ions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instructions on proper use handling and storage Do not use wire to clean passageways Wire can dam age passageways If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions...

Page 282: ... lb ft NOTE Make sure the STP valve open or close smoothly If the STP sensor adjustment is necessary refer to page 5 22 for STP sensor setting procedure With the throttle valve fully closed install the TP sensor 2 and tighten the TP sensor mounting screw to the specified torque NOTE Apply thin coat of the engine oil to the O ring Align the throttle shaft end C with the groove D of TP sensor Apply ...

Page 283: ...nstall the fuel delivery pipe assembly 7 to the throttle body assembly Tighten the fuel delivery pipe mounting screws to the specified torque Fuel delivery pipe mounting screw 5 0 N m 0 5 kgf m 3 7 lb ft Never turn the injector while pushing it Never turn the fuel injectors while installing them Replace the O rings with the new ones Never turn the fuel delivery pipes while pushing them ...

Page 284: ...propriate fuel injector Connect the throttle pulling cable 3 and throttle returning cable 4 to the throttle cable drum Loosen each throttle cable lock nut Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance is 0 mm 0 in Tighten each lock nut Adjust the throttle cable play Refer to page 2 15 for details 1 Primary injector 2 Secondary injector 1 Y R and Gr W ...

Page 285: ... coupler Insert the needle pointed probes to the STP sensor 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 57 0 67 V Yellow Black 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Loosen the STP sensor mounting screw...

Page 286: ...TOR INSPECTION Check fuel injector filter for evidence of dirt and contamination If present clean and check for presence of dirt in the fuel lines and fuel tank The fuel injector can be checked without removing it from the throttle body Refer to page 4 77 to 82 for details FUEL INJECTOR INSTALLATION Apply thin coat of the engine oil to new injector cushion seal and O rings Install the injector by ...

Page 287: ...adjust the TP sensor 4 20 Turn the ignition switch OFF Disconnect the TP sensor coupler and install the test harness Start up the engine Measure the TP sensor output voltage at the wire terminals between terminal Red and terminal Black TP sensor output voltage at idle position Approx 1 125 V 09900 28630 TPS test wire harness 09900 25008 Multi circuit tester set Tester knob indication Voltage Turn ...

Page 288: ... is out of specification turn in or out the fast idle adjust screw 3 to adjust the voltage to specification Cool down the engine to ambient air temperature and start the engine to check the fast idle rpm comes with in the specified rpm Standard Fast idle rpm 1 500 2 000 r min Cold engine Idle rpm 1 200 100 r min Warmed engine If it is not at the specified rpm the cause may possibly be short circui...

Page 289: ...t a tachometer and start up the engine Bring the engine r min to 1 200 r min by the throttle stop screw Check the vacuum of the four cylinders and balance the four throttle valves with the balance screw 4 NOTE During balancing the throttle valves always set the engine r min at 1 200 r min using throttle stop screw After balancing the four valves set the idle r min to 1 200 r min by the throttle st...

Page 290: ... is not yet correct remove each idle air screw and clean them with a spray type carburetor cleaner and blow dry with a com pressed air Also clean the idle air screw passageways NOTE Slowly turn the idle air screw in clockwise and count the num ber of turns until the screw is lightly seated Make a note of how many turns were made so the screw can be reset correctly after cleaning Step 4 Repeat the ...

Page 291: ...CVA EXHAUST CONTROL VALVE ACTUATOR AND EXCV EXHAUST CONTROL VALVE 6 4 EXCVA REMOVAL 6 4 EXCVA PULLEY INSPECTION 6 5 EXCVA INSTALLATION 6 5 EXCVA INSPECTION 6 6 EXCV CABLE REPLACEMENT 6 7 EXCVA ADJUSTMENT 6 8 EXCV EXHAUST PIPE MUFFLER REMOVAL 6 10 EXCV INSPECTION 6 12 EXCV EXHAUST PIPE MUFFLER INSTALLATION 6 12 ...

Page 292: ...rol valve actuator EXCVA and exhaust control valve cables EXCV cables EXCV is installed the exhaust pipes EXCVA is mounted on the right side of the seat rail The EXCV is oper ated by the EXCVA via the cables This system is designed to improve the engine torque at low engine rpm 1 Exhaust control valve actuator EXCVA 2 Exhaust control valve EXCV ...

Page 293: ...ection 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 Every time the ignition switch is turned ON the EXCVA automatically drives the EXCV and detects full close open position voltages and sets the EXCV to middle position FULL CLOSE F...

Page 294: ...ulley facing rearward adjustment position as shown Turn the ignition switch OFF Disconnect the EXCVA lead wire couplers 1 2 Measure the thread lengths A and B before disconnecting the No 1 and No 2 cables Loosen the lock nut 3 on the No 2 cable 5 and turn in the cable adjuster 4 fully Loosen the lock nut 6 on the No 1 cable 8 and turn in the cable adjuster 7 fully Disconnect the No 2 cable 5 and t...

Page 295: ...aft s line A and cable slots B as shown Hold the EXCVA pulley with an adjustable wrench and then tighten the EXCVA pulley mounting bolt to the specified torque EXCVA pulley mounting bolt 5 N m 0 5 kgf m 3 5 lb ft When loosening or tightening the pulley bolt be sure to fix the pulley with an adjustable wrench or EXCVA may get damaged Do not use the adjustable wrench to turn EXCVA pul ley so as not ...

Page 296: ... or out until the thread length C becomes the measured value before disconnecting the No 1 cable 1 Tighten the lock nut 3 After connecting the No 2 cable 2 loosen the lock nut 5 and turn the adjuster 6 in or out until the thread length D becomes the measured value before disconnecting the No 2 cable Tighten the lock nut 5 Connect the EXCVA lead wire couplers 7 8 EXCVA INSPECTION 4 91 The cable slo...

Page 297: ... EXCV pulley Turn the adjuster 5 in or out and adjust the thread length A becomes the measured value before dis connecting ther No 1 cable Tighten the lock nut 6 After adjusting the thread length A adjust the inner cable length B becomes 41 0 42 0 mm 1 61 1 65 in by turning the adjuster 8 Tighten the lock nut 7 Turn in the No 2 cable adjuster 0 fully Loosen the lock nuts A and turn the No 2 cable ...

Page 298: ... 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 pro ceed to 3rd step If C46 is indicated repeat the adjustment procedure from 3rd and 4th step 3rd step This procedure is only required when C46 is indicated Turn the igniti...

Page 299: ...urn out the No 1 cable adjuster 3 Repeat the above procedure until the output voltage becomes specified value Position sensor output voltage EXCV is fully close 0 5 output voltage 1 3 V To next step NOTE If C46 code is indicated after adjusting the voltage increase the voltage to 0 9 V 4th step To set the EXCV to fully open position apply 12 V to A and B terminals Battery terminal B Gray lead wire...

Page 300: ...en 3 7 output voltage 4 5 V After adjusting the EXCV cables perform 2nd step to confirm C46 is not indicated EXCV EXHAUST PIPE MUFFLER REMOVAL Remove the frame cover 8 8 Remove the under cowling 8 5 Lift and support the fuel tank 5 3 Disconnect the EXCV cables 1 and 2 from the EXCV pul ley Remove the EXCV cable bracket 3 Disconnect the HO2 sensor lead wire coupler For E 02 19 4 107 Remove the HO2 ...

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

Page 302: ...e Exhaust pipe bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the muffler mounting bolts and exhaust pipe connec tor bolt to the specified torque Exhaust pipe connector bolt 23 N m 2 3kgf m 16 5 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the EXCV cable bracket to the specified torque EXCV cable bracket 10 N m 1 0 kgf m 7 0 lb ft Tighten the HO2 sensor to the specified torque For E 0...

Page 303: ...EXHAUST SYSTEM 6 13 Tighten the radiator mounting bolts to the specified torque Radiator mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Install the EXCV cables 6 7 ...

Page 304: ...A pul ley so as not to cause damage to the internal gear of EXCVA 23 N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 48 N m 4 8 kgf m 35 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 5 N m 0 5 kgf m 3 5 lb ft Replace the exhaust pipe connector with a new one Replace the gaskets with the new ones No 1 No 2 No 1 No 2 41 42 mm 1 61 1 65 in 60 61 mm 2 36 2 40 in 11 12 mm 0 43 0 ...

Page 305: ... REMOVAL 7 6 INSPECTION 7 6 INSTALLATION 7 6 COOLING FAN RELAY INSPECTION 7 7 ECT SENSOR 7 7 REMOVAL 7 7 INSPECTION 7 7 INSTALLATION 7 8 THERMOSTAT 7 9 REMOVAL 7 9 INSPECTION 7 9 INSTALLATION 7 10 WATER PUMP 7 11 REMOVAL AND DISASSEMBLY 7 11 INSPECTION 7 13 REASSEMBLY AND INSTALLATION 7 14 LUBRICATION SYSTEM 7 17 OIL COOLER 7 17 OIL PRESSURE 7 18 OIL FILTER 7 18 OIL PRESSURE REGULATOR 7 18 OIL STR...

Page 306: ...d more anti freeze or 50 and less Refer to below figure Do not use a radiator anti leak additive Anti freeze 1 350 ml 2 9 2 4 US lmp pt Water 1 350 ml 2 9 2 4 US lmp pt 20 40 60 80 100 Density 0 10 20 30 40 50 60 70 32 14 4 22 40 58 76 94 Freezing point Fig 1 Engine coolant density freezing point curve C F 0 10 20 30 40 50 60 Density 150 140 130 120 110 100 Boiling point C F 302 284 266 248 230 21...

Page 307: ... pressure for 10 seconds If the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the leaking com ponent or part Do not remove the radiator cap when the engine is hot WATER PUMP RADIATOR ECT SENSOR THERMOSTAT CYLINDER HEAD CYLINDER RESERVOIR TANK Oil cooler When removing the radiator cap tes...

Page 308: ... operating the tester Make sure that the pressure build up stops at 93 123 kPa 0 93 1 23 kgf cm2 13 2 17 5 psi and that with the tester held stand still the cap is capable of holding that pressure for at least 10 seconds Replace the cap if it is found not to satisfy either of these two requirements Radiator cap valve opening pressure Standard 108 137 kPa 1 1 1 4 kgf cm2 15 4 19 5 psi RADIATOR INSP...

Page 309: ... 8 kgf m 6 0 lb ft Install the radiator Route the radiator hoses properly 10 24 Pour engine coolant 2 17 Bleed air from the cooling circuit 2 18 Install the under cowlings 8 5 WATER HOSE INSPECTION Remove the under cowlings 8 5 Lift and support the fuel tank 5 3 Any water hose found in a cracked condition or flattened must be replaced Any leakage from the connecting section should be corrected by ...

Page 310: ...d as shown in the illustration The voltmeter is for making sure that the battery 2 applies 12 V to the cooling fan motor 3 With the cooling fan motor with electric motor fan running at full speed the ammeter 4 should be indicating not 5 A and more If the fan motor does not turn replace the motor assembly with a new one NOTE When making above test it is not necessary to remove the cool ing fan INST...

Page 311: ...ty replace it with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test ECT SENSOR REMOVAL Keep the motorcycle upright Lift and support the fuel tank 5 3 Disconnect the ECT sensor coupler 1 Place a rag under the ECT sensor and remove the ECT sen sor INSPECTION Check the ECT sensor by testing it at the bench as shown in the figure Connect the ECT sensor 1 to a circu...

Page 312: ...o show infinity or too much different resistance value replace the ECT sensor with a new one INSTALLATION Tighten the ECT sensor to the specified torque ECT sensor 18 N m 1 8 kgf m 13 0 lb ft Install the fuel tank 5 4 Install the front seat Pour engine coolant 2 17 Temperature Standard resistance 20 C 68 F Approx 2 45 kΩ 50 C 122 F Approx 0 811 kΩ 80 C 176 F Approx 0 318 kΩ 110 C 230 F Approx 0 14...

Page 313: ...ner Pass a string 1 between flange 2 of thermostat 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 3 by placing the beaker on a stove 4 and observe the rising temperature on a thermome ter 5 Read the thermometer just when opening the thermostat This reading which is the temperature lev...

Page 314: ...t 95 C 0 31 in and over at 203 F A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced INSTALLATION Install the thermostat 1 NOTE The jiggle valve A of the thermostat faces upside Install the thermostat cover 2 Tighten the thermostat cover bolts to the specified torque Thermostat cover bolt 10 N m 1 0 kgf m 7 0 lb ft Install the fu...

Page 315: ...e If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the mechanical seal and seal washer 7 13 Remove the under cowlings 8 5 Drain the engine coolant 2 17 Drain the engine oil 2 12 Remove the water pump assembly 1 Remove the water pump cover 2 and air bleeder plug 3 Remove the impeller securing bolt by holding the impeller with a pliers ...

Page 316: ...with the special tool 09921 20240 Bearing remover set 12 mm NOTE If there is no abnormal condition the mechanical seal removal is not necessary Remove the oil seal using a suitable bar NOTE If there is no abnormal condition the oil seal removal is not nec essary The removed mechanical seal must be replaced with a new one The removed oil seal must be replaced with a new one ...

Page 317: ...l ring if necessary OIL SEAL Visually inspect the oil seal for damage with particular atten tion given to the lip Replace the oil seal that shows indications of leakage IMPELLER SHAFT JOURNAL Visually inspect the journal for damage or scratch Replace the water pump body if necessary SEAL WASHER Visually inspect the seal washer for damage with particular attention given to the sealing face Replace ...

Page 318: ...Apply a small quantity of the SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the new mechanical seal using a suitable size socket wrench NOTE On the new mechanical seal the sealer A has been applied Apply SUZUKI SUPER GREASE A to the impeller shaft 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the impeller shaft to the wate...

Page 319: ...ller 5 and its securing bolt onto the shaft Tighten the impeller securing bolt to the specified torque Impeller securing bolt 8 N m 0 8 kgf m 6 0 lb ft NOTE Before installing the impeller securing bolt apply a small quan tity of the THREAD LOCK to it 99000 32050 THREAD LOCK 1342 Install the new O rings 6 and 7 NOTE Apply engine coolant to the O ring 6 Apply SUZUKI SUPER GREASE A to the O ring 7 99...

Page 320: ...ater pump shaft end F to the oil pump shaft G as shown Tighten the water pump mounting bolts to the specified torque Water pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Connect the water hoses 10 24 Pour engine coolant 2 17 Pour engine oil 2 13 Install the under cowlings 8 5 ...

Page 321: ...oler in the reverse order of removal Pay atten tion to the following points Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply THREAD LOCK to the oil cooler mounting bolts and install the oil cooler 1 as shown 99000 32050 THREAD LOCK 1342 Tighten the oil cooler mounting bolts to the specified torque Oil cooler mounting bolt 10 N m 1 0 kgf m 7 0 l...

Page 322: ...7 18 COOLING AND LUBRICATION SYSTEM OIL PRESSURE 2 33 OIL FILTER 2 13 OIL PRESSURE REGULATOR 3 44 OIL STRAINER 3 44 OIL JET 3 58 OIL PUMP 3 41 OIL PRESSURE SWITCH 9 34 ...

Page 323: ... REGULATOR PRIMARY DRIVEN GEAR BEARING OIL JET 14 COUNTERSHAFT LEFT SIDE BEARING COUNTERSHAFT RIGHT SIDE BEARING CLUTCH PUSH PIECE CLUTCH PLATES DRIVESHAFT RIGHT SIDE BEARING 3 CRANK PIN BEARING 4 CRANK PIN BEARING 2 PISTON AND CYLINDER WALL 3 PISTON AND CYLINDER WALL 4 PISTON AND CYLINDER WALL 2 PISTON COOLING OIL JET 3 PISTON COOLING OIL JET 4 PISTON COOLING OIL JET EXHAUST CAMSHAFT CAMSHAFT JOU...

Page 324: ...7 20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ...

Page 325: ...COOLING AND LUBRICATION SYSTEM 7 21 ...

Page 326: ...ASSEMBLY AND INSTALLATION 8 13 FRONT FORK 8 17 CONSTRUCTION 8 17 REMOVAL AND DISASSEMBLY 8 18 INSPECTION 8 21 REASSEMBLY 8 22 INSTALLATION 8 26 SUSPENSION SETTING 8 27 STEERING DAMPER 8 28 CONSTRUCTION 8 28 REMOVAL 8 29 INSPECTION 8 29 INSTALLATION 8 29 STEERING 8 30 CONSTRUCTION 8 30 REMOVAL 8 31 INSPECTION AND DISASSEMBLY 8 32 REASSEMBLY 8 33 INSTALLATION 8 33 STEERING TENSION ADJUSTMENT 8 35 HA...

Page 327: ...AKE DISC INSPECTION 8 70 MASTER CYLINDER REMOVAL AND DISASSEMBLY 8 71 MASTER CYLINDER INSPECTION 8 72 MASTER CYLINDER REASSEMBLY 8 73 MASTER CYLINDER INSTALLATION 8 74 REAR BRAKE 8 75 CONSTRUCTION 8 75 BRAKE PAD REPLACEMENT 8 76 BRAKE FLUID REPLACEMENT 8 77 CALIPER REMOVAL AND DISASSEMBLY 8 77 CALIPER INSPECTION 8 79 CALIPER REASSEMBLY 8 80 CALIPER INSTALLATION 8 81 MASTER CYLINDER REMOVAL AND DIS...

Page 328: ...ck 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 FASTENER Type B Removal Pry up the head of fastener center piece 1 with a screw driver Pull out the fastener a ...

Page 329: ...8 4 CHASSIS Installation Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece ...

Page 330: ... cover in the reverse order of removal INNER UNDER COWLING REMOVAL Remove the body cowling cover Above Remove the inner under cowlings 1 LH RH INSTALLATION Install the inner under cowlings in the reverse order of removal UNDER COWLING Remove the body cowling cover and inner under cowlings Above Remove the fasteners Remove the under cowlings LH RH NOTE indicates hook location INSTALLATION Install t...

Page 331: ... under cowlings 8 5 Remove the screen Above Remove the combination meter 9 29 Disconnect the turn signal lead wire couplers 1 Remove the rear view mirror turn signal assemblies 2 Remove the screws Disconnect the lead wire coupler 3 and remove wire clamp 4 Remove the body cowling INSTALLATION Install the body cowling in the reverse order of removal Refer to the turn signal cable routing 10 32 ...

Page 332: ...stall the cowling brace in the reverse order of removal Tighten the cowling brace bolts Cowling brace bolt 23 N m 2 3 kgf m 16 5 lb ft FRONT SEAT REMOVAL Remove the front seat by removing the bolts INSTALLATION Install the front seat in the reverse order of removal FUEL TANK LOWER SIDE COVER REMOVAL Remove the front seat Above Remove the fuel tank lower side covers 1 LH RH NOTE indicates hook loca...

Page 333: ...il cover firmly until the seat seat tail cover snaps into the locked position FRAME COVER REMOVAL Remove the front and rear seats 8 7 and 8 Remove the fasteners and screws Disconnect the seat lock cable 1 Disconnect the rear combination light lead wire coupler 2 Remove the frame cover 3 NOTE indicates hook location INSTALLATION Install the frame cover in the reverse order of removal ...

Page 334: ...HASSIS 8 9 FRONT WHEEL CONSTRUCTION 1 Brake disc 6 Front axle 2 Collar 7 Front wheel ITEM N m kgf m lb ft 3 Dust seal A Front axle bolt A 100 10 0 72 5 4 Bearing B Brake disc bolt B 23 2 3 16 5 5 Spacer ...

Page 335: ...oden block Loosen two axle pinch bolts 3 on the left front fork leg Draw out the front axle and remove the front wheel NOTE After removing the front wheel fit the calipers temporarily to the original positions Remove the collar 4 Do not operate the brake lever while removing the cal ipers Do not carry out the work with the motorcycle resting on the side stand Do not support the motorcycle with the...

Page 336: ... on both sides with the special tool 09913 50121 Oil seal remover Remove the wheel bearings with the special tool 09921 20240 Bearing remover set Remove the spacer 5 The removed dust seals must be replaced with new ones The removed bearings should be replaced with new ones ...

Page 337: ...runout checked as shown does not exceed the service limit An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Wheel runout Service Limit Axial and Radial 2 0 mm 0 08 in WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel Rotate t...

Page 338: ...erse order of removal and disassembly Pay attention to the following points WHEEL BEARING Apply SUZUKI SUPER GREASE A to the wheel bearings 99000 25010 SUZUKI SUPER GREASE A or equivalent grease 23 N m 2 3 kgf m 16 5 lb ft Left Right 23 N m 2 3 kgf m 16 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft ...

Page 339: ...PER GREASE A or equivalent grease BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter Apply THREAD LOCK to the disc mounting bolts and tighten them to the specified torque Brake disc bolt Front 23 N m 2 3 kgf m 16 5 lb ft 99000 32130 THREAD LOCK SUPER 1360 First install the right wheel bearing then install the spacer and left wheel bearing The sealed cover of the bearin...

Page 340: ... kgf m 25 5 lb ft FRONT AXLE Hold the front axle with the special tool and tighten the front axle bolt 1 to the specified torque 09900 18740 Heaxagon socket 24 mm Front axle bolt 100 N m 10 0 kgf m 72 5 lb ft Tighten two axle pinch bolts 2 on the right fork leg to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lb ft Move the front fork up and down 4 or 5 times The directional arr...

Page 341: ...8 16 CHASSIS Tighten two axle pinch bolts on the left front fork leg to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lb ft ...

Page 342: ...ng retainer 0 Dust seal 3 Spacer A Inner tube 4 Spring A Front fork cap bolt ITEM N m kgf m lb ft 5 Inner rod Damper rod cartridge B Lock nut A 35 3 5 25 5 6 Outer tube C Front axle pinch bolt B 20 2 0 14 5 7 Oil seal retainer D Damper rod bolt C 23 2 3 16 5 8 Oil seal D 35 3 5 25 5 ...

Page 343: ...ning the lower clamp bolts to facilitate later disassembly Be sure to adjust the rebound damping force adjuster 4 to the softest position before removing the front fork Loosen the front fork lower clamp bolts left and right Remove the front forks left and right NOTE Hold the front fork by the hand to prevent sliding out of the steer ing stem Separate the front fork cap bolt from the front fork Com...

Page 344: ...g 9 Invert the front fork and stroke the inner rod several times to let out fork oil Under the inverted condition of front fork drain oil completely by holding the fork for a while Remove the front axle pinch bolts 0 Remove the compression damping force adjuster A Do not disassemble the front fork cap bolt 5 After removing the front fork cap bolt 5 avoid hold ing the outer tube vertically by hand ...

Page 345: ...30221 Front fork assembling tool Remove the inner rod damper rod cartridge B Slide the outer tube to remove it from the inner tube NOTE Be careful not to damage the ANTI FRICTION metals Remove the dust seal C and oil seal stopper ring D Do not disassemble the inner rod damper rod car tridge ...

Page 346: ...ur face for scratches Inspect the ANTI FRICTION metal surfaces for scratches If any defects are found replace them with the new ones 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 A Service Limit 259 5 mm 10 22 in The removed oil seal must be replaced with a new one Do not remove the ANTI FRICTION meta...

Page 347: ...iner onto the inner tube 1 Dust seal 2 Oil seal stopper ring 3 Oil seal 4 Oil seal retainer Insert the inner tube into the outer tube and fit the oil seal and dust seal with the special tool 09940 52861 Front fork oil seal installer NOTE Stamped mark on the oil seal should face outside When installing the oil seal to outer tube be careful not to damage the oil seal lip Avoid using solvents for was...

Page 348: ...b ft COMPRESSION DAMPING FORCE ADJUSTER Tighten the compression damping force adjuster to the speci fied torque Compression damping force adjuster 23 N m 2 3 kgf m 16 5 lb ft 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 408 ml 13 8 14 4 US lmp oz 99000 99001 SS5 SUZUKI FORK OIL SS 05 ...

Page 349: ...dge top end or air may enter the cartridge during this procedure Take extreme care so as to pump out air completely Hold the front fork vertically and adjust fork oil level with the special tool NOTE When adjusting the fork oil level compress the outer tube fully without the fork spring Fork oil level 112 mm 4 41 in 09943 74111 Front fork oil level gauge FORK SPRING Install the fork spring Install...

Page 350: ...bolt seats on the inner rod Apply fork oil to the O ring Hold the cap bolt 2 and tighten the lock nut 3 to the speci fied torque Inner rod lock nut 20 N m 2 0 kgf m 14 5 lb ft Remove the special tools Install the front fork cap bolt to the outer tube temporarily The removed O ring must be replaced with a new one The removed O ring must be replaced with a new one Make sure that the rebound damping ...

Page 351: ...3 kgf m 16 5 lb ft Tighten the front fork cap bolt 2 to the specified torque and recheck the front fork outer tube upper surface height A from the upper surface of the steering stem upper bracket Front fork cap bolt 35 N m 3 5 kgf m 25 5 lb ft Position the handlebars on the upper bracket 8 37 to 38 Tighten the front fork upper clamp bolts 3 and handlebar clamp bolts 4 Front fork upper clamp bolt 2...

Page 352: ...ffest position and turn it out to standard setting position STD position 1 3 4 turns out from stiffest position Rebound damping force Turn the damping force adjuster 2 clockwise fully It is at stiffest position and turn it out to standard setting position STD position 1 1 2 turns out from stiffest position STANDARD FRONT SUSPENSION SETTING FRONT Spring pre load adjuster Damping force adjuster Comp...

Page 353: ...EERING DAMPER CONSTRUCTION 1 Steering damper 4 Convex curve side of the washer faces down side 2 Dust seal ITEM N m kgf m lb ft 3 Steering stem head nut A Damper rod bolt AB 23 2 3 16 5 B Damper rod nut 3 90 9 0 65 0 ...

Page 354: ...nd to inspect for a smooth movement If any defects are found replace the steering damper with a new one INSTALLATION Install the steering damper in the reverse order of removal Pay attention to the following points Apply SUZUKI SUPER GREASE A to the bearings and dust seals 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the steering damper and tighten the bolt 1 and nut 2 Steering d...

Page 355: ...rs A Steering stem head nut ITEM N m kgf m lb ft 3 Handlebar balancer B Steering stem lock nut A 90 9 0 65 0 4 Steering stem nut C Front fork upper clamp bolt B 80 8 0 58 0 5 Dust seal cover D Handlebar clamp bolt C 23 2 3 16 5 6 Dust seal E Front fork lower clamp bolt D 23 2 3 16 5 7 Bearing E 23 2 3 16 5 ...

Page 356: ...n replacing only the steering stem lower bracket and bearings Ignition switch removal 9 38 Remove the brake hose clamp bolt Remove the steering stem lock nut washer and steering stem nut with the special tools 09940 14911 Steering stem nut wrench 09940 14960 Steering stem nut wrench socket Draw out the steering stem lower bracket NOTE Hold the steering stem lower bracket by hand to prevent it from...

Page 357: ...ce 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 Drive out the steering stem bearing outer races upper and lower using the steel rod The removed bearing inner race must be replaced with a new one The removed bearing outer race must be rep...

Page 358: ...ler INSTALLATION Install the steering stem in the reverse order of removal Pay attention to the following points BEARING Apply SUZUKI SUPER GREASE A to the bearings and bearing races 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the lower bearing to the steering stem lower bracket Install the upper bearing and bearing inner race STEM NUT Install the dust seal and dust seal cover T...

Page 359: ...tem nut wrench 09940 14960 Steering stem nut wrench socket Steering stem lock nut 80 N m 8 0 kgf m 58 0 lb ft FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem upper bracket in the fol lowing steps 1 Install the upper bracket washer 1 and steering stem head nut 2 temporarily NOTE Pay attention to the direction of the washer 2 Position the handlebars on the front f...

Page 360: ...720 Spring scale If the initial force read on the scale when the handlebar starts turning is either too heavy or too light adjust it till it satisfies the specification 1 First loosen the front fork upper clamp bolts handlebar clamp bolts steering stem head nut and steering stem lock nut and then adjust the steering stem nut by loosening or tightening it 2 Tighten the steering stem lock nut stem h...

Page 361: ...ight handle switch 2 Remove the handle balancer 3 Remove the right handle throttle grip 4 FWD FWD 1 Left handle grip 5 Handlebar RH 2 Right handle throttle grip 6 Handlebar LH 3 Right handle switch 7 Handle balancer ITEM N m kgf m lb ft 4 Left handle switch A Handlebar clamp bolt A 23 2 3 16 5 ...

Page 362: ...k upper clamp bolts Remove the steering stem upper bracket 0 by removing the steering stem head nut NOTE Place a rag under the steering stem upper bracket to prevent scratching the body cowling and the air intake pipes Remove the handlebars A by sliding them upward INSTALLATION Install the handlebars in the reverse order of removal Pay atten tion to the following points Install the handlebars temp...

Page 363: ... specified torque Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Handlebar clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Apply a handle grip bond onto the left handlebar before installing the handlebar grip Install the clutch lever holder align the holder s mating sur face C with punched mark D on the handlebar Install the front brake master cylinder 8 74 Handle grip bond Up side ...

Page 364: ...010 SUZUKI SUPER GREASE A or equivalent grease When remounting the right and left handle switches engage the stopper with the handlebar hole After installing the steering the following adjustments are required before driving Cable routing 10 17 Throttle cable play 2 15 Clutch lever play 2 16 ...

Page 365: ...rum 2 Brake disc A Sprocket 3 Collar B Bearing 4 Dust seal C Dust seal 5 Rear wheel D Collar 6 Spacer A Brake disc bolt ITEM N m kgf m lb ft 7 Bearing B Rear sprocket nut A 35 3 5 25 5 8 Cushion C Rear axle nut B 93 9 3 67 5 9 Spacer 1 Except for E 03 28 33 C 100 10 0 72 5 ...

Page 366: ...t the rear axle Remove the rear wheel by disengaging the drive chain Remove the collar 2 Remove the brake disc bolts 3 Remove the brake disc 4 Remove the collar 5 Loosen the rear sprocket mounting bolts 6 and separate the rear sprocket 7 from its mounting drum 8 Draw out the rear sprocket mounting drum 8 from the wheel hub Remove the rear sprocket mounting drum retainer 9 Do not operate the brake ...

Page 367: ...sing a dial gauge check the rear axle for runout If the runout exceeds the limit replace the rear axle Axle shaft runout Service Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm WHEEL DAMPER Inspect the damper for wear and damage Replace the damper if there is anything unusual The removed dust seal must be replaced with a new one The ...

Page 368: ... 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 with the special tool 09913 70210 Bearing installer set Remove the wheel bearings with the special tool 09921 20240 Bearing remover set The removed bearings must be...

Page 369: ...install the rear wheel in the reverse order of removal and disassembly Pay attention to the following points Left Right 100 N m 10 0 kgf m 72 5 lb ft E 02 19 24 E 03 28 33 93 N m 9 3 kgf m 67 5 lb ft 35 N m 3 5 kgf m 25 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft ...

Page 370: ...new bearing to the sprocket mounting drum with the special tool 09913 70210 Bearing installer set First install the right wheel bearing then install the left wheel bearing with the special tools 09941 34513 Steering race installer 09924 84510 Bearing installer set The sealed cover of the bearing must face outside Left Right Left Right Spacer Clearance ...

Page 371: ...sembling rear wheel 99000 25010 SUZUKI SUPER GREASE A or equivalent grease REAR SPROCKET AND SPROCKET MOUNTING DRUM Install the rear sprocket mounting drum spacer 1 Install the rear sprocket mounting drum to the rear wheel Tighten the sprocket mounting nuts 2 to the specified torque Rear sprocket nut 93 N m 9 3 kgf m 67 5 lb ft NOTE Stamped mark A on the sprocket should face outside Install the co...

Page 372: ...brake disc is clean and free of any greasy matter 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 35 N m 3 5 kgf m 25 5 lb ft Install the collar 1 REAR AXLE Remount the rear wheel and rear axle shaft and install the washer 1 Except for E 03 28 33 and rear axle nut 2 Adjust the chain slack after rear wheel installation 2 20 ...

Page 373: ...S REAR SHOCK ABSORBER CONSTRUCTION 1 Rear shock absorber A Rear shock absorber mount ing bolt nut ITEM N m kgf m lb ft 2 Rear shock absorber bracket B Rear shock absorber bracket nut A 50 5 0 36 0 B 115 11 5 83 0 ...

Page 374: ...owling 8 5 Remove the exhaust muffler 6 10 Loosen the axle nut Support the motorcycle with a jack relieve no load on the rear shock absorber Remove the rear wheel 8 41 Remove the rear brake hose clamp 1 Remove the rear brake hose guide 2 Remove the side stand switch 3 Remove the side stand bracket 4 Remove the exhaust muffler bracket left 5 ...

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

Page 376: ...RBER SCRAPPING PROCEDURE REAR SHOCK ABSORBER GAS RELEASE Remove the valve cap 1 Do not attempt to disassemble the rear shock absorber unit It is unserviceable 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 scrapping ...

Page 377: ...rber bracket nut to the specified torque Rear shock absorber bracket nut 115 N m 11 5 kgf m 83 0 lb ft Releasing high pressure gas from the rear shock absorber unit can be hazardous Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit When releasing the gas pressure place a rag over the gas valve and use the tip of a screwdriver to press t...

Page 378: ...until two punch marks align Low speed Compression side Turn the damping force adjuster 2 clockwise fully It is at stiffest position and turn it out to standard setting position STD position 1 3 4 turns out from stiffest position Fine tune the adjuster by turning it slightly until two punch marks align High speed Compression side Turn the damping force adjuster 2 clockwise fully It is at stiffest p...

Page 379: ...cushion lever ITEM N m kgf m lb ft 4 Spacer B Rear cushion lever bolt nut A 50 5 0 36 0 5 Bearing C Rear cushion rod bolt nut B 98 9 8 71 0 6 Chain cover D Swingarm pivot shaft C 78 7 8 56 5 7 Chain buffer E Swingarm pivot lock nut D 15 1 5 11 0 8 Chain adjuster F Swingarm pivot nut E 90 9 0 65 0 9 Chain adjuster lock nut F 100 10 0 72 5 ...

Page 380: ...hion lever 2 Remove the cushion rod mounting bolt nut 3 Remove the cushion rod 4 Remove the swingarm pivot shaft lock nut with the special tool 09940 14940 Swingarm pivot thrust adjuster socket wrench Hold the swingarm pivot shaft 5 and remove the swingarm pivot nut 6 09944 28320 Hexagon socket 19 mm Draw out the swingarm pivot shaft Remove the rear suspension assembly Remove the rear fender lower...

Page 381: ...t shaft runout Service limit 0 3 mm 0 01 in 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm CHAIN BUFFER Inspect the chain buffer for wear and damage If any defects are found replace the chain buffer with a new one PLATE Inspect the plate for damage and excessive bend If any defects are found replace the plate with a new one ...

Page 382: ... are found replace the cushion rod with a new one CUSHION LEVER Inspect the cushion lever for damage If any defects are found replace the cushion lever with a new one SPACER Remove the spacers from swingarm Remove the spacers from the cushion lever Remove the spacer from cushion rod Inspect the spacers for any flaws or other damage If any defects are found replace the spacers with new ones ...

Page 383: ...aring with a new one CUSHION ROD BEARING Insert the spacer into bearing and check the play when mov ing the spacer up and down If excessive play is noted replace the bearing with a new one CUSHION LEVER BEARING Insert the spacer into bearing and check the play when mov ing the spacer up and down If excessive play is noted replace the bearing with a new one ...

Page 384: ...EARING Draw out the cushion rod bearings with the special tool 09921 20240 Bearing remover set CUSHION LEVER BEARING Draw out the cushion lever bearings with the special tool 09921 20240 Bearing remover set 1 20 mm 2 17 mm The removed bearings must be replaced with new ones The removed bearings must be replaced with new ones The removed bearings must be replaced with new ones ...

Page 385: ...ght 115 N m 11 5 kgf m 83 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft 78 N m 7 8 kgf m 56 5 lb ft 78 N m 7 8 kgf m 56 5 lb ft 98 N m 9 8 kgf m 71 0 lb ft 1 mm 0 04 in 1 mm 0 04 in 1 mm 0 04 in 1 mm 0 04 in NOTE When installing the bearing stamped mark on the bearing must face outside Apply SUZUKI SUPER GREASE A to the bearings washers and dust seals ...

Page 386: ...earings into the cushion rod with the special tool 09924 84521 Bearing installer set NOTE When installing the bearing stamped mark on the bearing must face outside CUSHION LEVER BEARING Press the bearings into the cushion lever with the special tool 09924 84521 Bearing installer set NOTE When installing the bearing stamped mark on the bearing must face outside Apply SUZUKI SUPER GREASE A to the be...

Page 387: ...tighten to the specified torque 09944 28320 Hexagon socket 19 mm Swingarm pivot shaft 15 N m 1 5 kgf m 11 0 lb ft Hold the swingarm pivot shaft and tighten the swingarm pivot nut 1 to the specified torque Swingarm pivot nut 100 N m 10 0 kgf m 72 5 lb ft Tighten the swingarm pivot lock nut to the specified torque with the special tool 09940 14940 Swingarm pivot thrust adjuster socket wrench Swingar...

Page 388: ... 9 8 kgf m 71 0 lb ft Install the cushion rod Tighten the cushion rod mounting nut 2 to the specified torque Cushion rod mounting nut 78 N m 7 8 kgf m 56 5 lb ft Install the rear shock absorber 8 52 Connect the drive chain 8 90 to 92 FINAL INSPECTION AND ADJUSTMENT After installing the rear suspension and wheel the following adjustments are required before driving Drive chain 2 20 Tire pressure 2 ...

Page 389: ... A 10 1 0 7 0 4 Piston seal D Caliper air bleeder valve B 23 2 3 16 5 5 Dust seal E Caliper housing bolt C 35 3 5 25 5 6 Brake caliper piston F Brake pad mounting pin D 7 5 0 75 5 5 7 Brake pad G Master cylinder air bleeder valve E 22 2 2 16 0 8 Brake pad spring H Brake lever pivot bolt F 15 1 5 11 0 9 Brake hose I Brake lever lock nut G 6 0 0 6 4 5 H 1 0 0 1 0 7 I 6 0 0 6 4 5 ...

Page 390: ...ch as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When washing brake components use fresh brake fluid...

Page 391: ...D REPLACEMENT Place the motorcycle on a level surface and keep the handle bars straight Remove the brake fluid reservoir cap 1 and diaphragm Drain the old brake fluid as much as possible Fill the reservoir with new brake fluid Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle Loosen the air bleeder valve and pump the brake lever until old brak...

Page 392: ...ving the caliper housing bolts 2 with the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder Remove the O ring 3 Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air Never reuse the brake fluid left over from previous servicing and stored for long periods of time Brake fluid if it leaks will interfere with safe running and dis...

Page 393: ...uid especially the dust seal grooves and piston seal grooves Specification and classification DOT 4 Avoid reusing the dust seals and piston seals to pre vent fluid leakage Clean the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to clean them Do not wipe the brake fluid off after cleaning the components When cleaning the components use the specif...

Page 394: ...0H 09930 11940 Bit holder CALIPER INSTALLATION Install the caliper in the reverse order of removal Pay attention to the following points Install the spring and brake pads 8 66 Install the brake caliper 8 66 Tighten each bolt to the specified torque Front brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Dust seal Piston seal Caliper body Replace the O ring with a new one The seal washers should be...

Page 395: ...t or if damage is found Front disc thickness Service Limit 5 0 mm 0 20 in 09900 20205 Micrometer 0 25 mm Remove the brake calipers 8 65 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 0 012 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand Brake disc removal 8 11 Brake disc installation 8 14 ...

Page 396: ...d Remove the union bolt and disconnect the brake hose Remove the master cylinder by removing the master cylinder bolts Remove the reservoir cap 3 insulator 4 diaphragm 5 and reservoir tank 6 Remove the brake switch 7 and brake lever 8 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 an...

Page 397: ...owing parts B Secondary cup C Piston D Primary cup E Return spring F Return spring guide G Air bleeder valve Remove the dust rubber H and snap ring I Remove the connector J and O ring K MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage ...

Page 398: ...ints Specification and classification DOT 4 Install the O ring to the brake hose connector Apply SUZUKI SILICONE GREASE to the push rod 99500 25100 SUZUKI SILICONE GREASE Clean the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to clean them Do not wipe the components with a rag Apply brake fluid to the cylinder bore and all the component...

Page 399: ...e order of removal Pay attention to the following points When installing the brake master cylinder 1 onto the handle bars 2 align the master cylinder holder s mating surface with punched mark A on the handlebars and tighten the upper clamp bolt 3 first as shown Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Tighten the union bolt Brake hose routing 10 24 Brake hose union bolt...

Page 400: ...f m lb ft 3 Reservoir hose C Brake caliper mounting bolt A 7 5 0 75 5 5 4 Brake hose D Brake master cylinder mounting bolt B 23 2 3 16 5 5 Brake pad E Brake master cylinder rod lock nut C 17 1 7 12 5 6 Piston F Brake pad mounting pin D 10 1 0 7 0 7 Brake pad spring G Brake caliper pin bolt E 18 1 8 13 0 F 15 1 5 11 0 G 32 3 2 23 0 ...

Page 401: ...um based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When washing brake components use fresh brake fluid Never use cleaning solvent A c...

Page 402: ...e brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta cle NOTE Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid Remove the pad mounting pin 2 Remove the caliper mounting bolt 3 Remove the brake caliper Bleed air from the brake system 2 23 Never reuse the brake fluid left over from previous servicing and s...

Page 403: ...bber boot 6 from the caliper Place a rag over the piston to prevent it from popping out and then force out the pistons using compressed air Remove the dust seal 7 and piston seal 8 Avoid using high pressure air to prevent piston dam age Avoid reusing the dust seals and piston seals to pre vent fluid leakage ...

Page 404: ...e is found replace the caliper with a new one BRAKE PAD SPRING BOOTS AND SPACER Inspect the brake pad spring for damage and excessive bend If any damage is found replace the brake pad spring with a new one Inspect the boot and spacer for damage and wear If any damage is found replace boot and spacer with new ones BRAKE DISC INSPECTION Inspect the rear brake disc in the same manner as the front bra...

Page 405: ...e of the boot 99000 25100 SUZUKI SILICONE GREASE Install the spacer 2 Install the caliper air bleeder valve Install the brake pad spring Clean the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to clean them Do not wipe the brake fluid off after cleaning the components When cleaning the components use the specified brake fluid Never use different...

Page 406: ...the brake fluid reservoir to catch any split brake fluid Remove the brake fluid reservoir cap 2 Drain the brake fluid Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Remove the union bolt 3 and disconnect the brake hose Loosen the lock nut 4 Remove the mounting bolts 5 Disconnect the reservoir hose Remove the master cylinder by turning the master ...

Page 407: ...g A with the special tool 09900 06108 Snap ring pliers Remove the connector B Remove the O ring C Pull out the dust boot D then remove the snap ring E 09900 06108 Snap ring pliers Remove the following parts F Push rod G Secondary cup H Piston I Primary cup J Return spring Replace the O ring with a new one ...

Page 408: ...e reverse order of disas sembly Pay attention to the following points Specification and classification DOT 4 Apply SUZUKI SILICONE GREASE to the push rod end 99000 25100 SUZUKI SILICONE GREASE Clean the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to clean them Do not wipe the components with a rag Apply brake fluid to the cylinder bore...

Page 409: ...valent thread lock Tighten each bolt to the specified torque Brake hose routing 10 25 Brake hose union bolt 1 23 N m 2 3 kgf m 16 5 lb ft Master cylinder mounting bolt 2 10 N m 1 0 kgf m 7 0 lb ft Master cylinder rod lock nut 3 18 N m 1 8 kgf m 13 0 lb ft Adjust the brake pedal height 2 25 The seal washers should be replaced with the new ones to prevent fluid leakage Bleed air from the system afte...

Page 410: ...the tire with a chalk to indicate the tire position relative to the valve position Even though the tire is refitted to the original position after repairing puncture the tire may have to be balanced again since such a repair can cause imbalance INSPECTION WHEEL Wipe the wheel clean and check for the following Distortion and crack Any flaws and scratches at the bead seating area Wheel rim runout 8 ...

Page 411: ...valve shows no abnormal con dition removing of the valve is not necessary If the seal has abnormal deformation replace the valve with a new one Any dust or rust around the valve hole B must be cleaned off Then install the valve C in the rim NOTE To properly install the valve into the valve hole apply a special tire lubricant or neutral soapy liquid to the valve Be careful not to damage the lip C o...

Page 412: ...n by the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facili tating air inflation Inflate the tire 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 Do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi If inflated bey...

Page 413: ...t the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance Cold inflation tire pressure BALANCER WEIGHT INSTALLATION When installing the balancer weights to the wheel set the two balancer weights A on both sides of wheel rim Do not run with a repaired tire at a high speed Front Rear Solo riding 250 kPa 2 50 kgf cm 36 psi 290 kP...

Page 414: ...aded parts of the special tool DRIVE CHAIN CUTTING Set up the special tool as shown in the illustration 1 Tool body 2 Grip handle 3 Pressure bolt A 4 Pressure bolt B 5 Bar 6 Adjuster bolt with through hole 7 Pin remover 8 Chain holder engraved mark 500 with reamer bolt M5 10 NOTE The tip of pin remover 7 should be positioned inside approxi mately 5 mm 0 2 in from the end face of pressure bolt A 3 ...

Page 415: ... 5 Adjuster bolt 2 Grip handle without hole 3 Joint plate holder 6 Pressure bolt A engraved mark C520 7 Bar 4 Wedge holder wedge pin Connect both ends of the drive chain with the joint pin 8 inserted from the wheel side A as installed on the motorcycle 9 O ring 4 pcs 0 Joint plate Joint set part number RK 27620 33E40 Continue turning in the pressure bolt B 4 until the joint pin has been completely...

Page 416: ...rther using the bar 7 to press the joint plate over the joint pins Continue pressing the joint plate until the distance between the two joint plates come to the specification Joint plate distance specification W JOINT PIN STAKING Set up the special tool as shown in the illustration 1 Tool body 2 Grip handle 3 Pressure bolt A 4 Adjuster bolt without hole 5 Staking pin stowed inside grip handle behi...

Page 417: ...ecified dimension Pin end diameter specification D Adjust the drive chain after connecting it 2 20 RK 5 45 5 85 mm 0 215 0 230 in After joining of the chain has been completed check to make sure that the link is smooth and no abnormal condition is found Should any abnormal condition be found reassem ble the chain link using the new joint parts ...

Page 418: ... AND SIDE STAND IGNITION INTERLOCK SYSTEM 9 12 TROUBLESHOOTING 9 12 STARTER MOTOR REMOVAL 9 13 STARTER MOTOR DISASSEMBLY 9 14 STARTER MOTOR INSPECTION 9 14 STARTER MOTOR REASSEMBLY 9 15 STARTER RELAY INSPECTION 9 16 SIDE STAND IGNITION INTERLOCK SYSTEM PARTS INSPECTION 9 17 IGNITION SYSTEM 9 20 IMMOBILIZER Except for E 03 28 33 9 21 TROUBLESHOOTING 9 23 INSPECTION 9 25 COMBINATION METER 9 29 DESCR...

Page 419: ...E STAND RELAY 9 37 STARTER RELAY 9 37 FUEL PUMP RELAY 9 37 COOLING FAN RELAY 9 37 IGNITION SWITCH REMOVAL 9 38 IGNITION SWITCH INSTALLATION 9 38 SWITCHES INSPECTION 9 39 BATTERY 9 40 SPECIFICATIONS 9 40 INITIAL CHARGING 9 40 SERVICING 9 42 RECHARGING OPERATION 9 42 ...

Page 420: ... wires Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRING HARNESS ROUTING 10 17 to 20 Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for ...

Page 421: ...tery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disassem bly or servicing be sure to disconnect the battery lead wire first When connecting the bat...

Page 422: ...ied If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them Use the needle pointed probe to prevent the rubber of the water proof coupler from...

Page 423: ...IAT sensor 4 53 3 Cooling fan relay 7 7 4 PAIR control solenoid valve 11 7 5 CMP sensor 4 33 6 Ignition coil No 1 2 3 4 7 Horn 8 Fuel level gauge 9 Fuel pump 5 8 0 Regulator Rectifier A Oil pressure switch B Generator C Speed sensor D GP switch E Side stand switch F TO sensor 4 63 ...

Page 424: ... Engine Control Module 6 Secondary fuel injector 4 80 7 Primary fuel injector 4 77 8 ECT sensor 4 49 9 STV actuator 4 67 0 STP sensor 4 70 A TP sensor 4 44 B IAP sensor 4 38 C Starter relay Main fuse D Turn signal Side stand relay E EXCVA 6 4 F CKP sensor 4 35 G HO2 sensor E 02 19 4 87 H Cooling fan 7 6 ...

Page 425: ...he regulated voltage between the battery terminals 9 10 Is the regulated voltage OK Step 4 1 Measure the resistance of the generator coil 9 10 Is the resistance of generator coil OK YES Remove accessories NO Go to Step 2 YES Go to Step 3 NO Short circuit of wire harness Faulty electrical equipment YES Faulty battery Abnormal driving condition NO Go to Step 4 YES Go to Step 5 NO Faulty generator co...

Page 426: ... position Disconnect the battery lead wire Measure the current between battery terminal and the battery lead wire using the multi circuit tester If the reading exceeds the specified value leakage is evident 09900 25008 Multi circuit tester set Battery current leak Under 3 mA Tester knob indication Current 20 mA YES Go to Step 6 NO Faulty generator YES Go to Step 7 NO Faulty regulator rectifier YES...

Page 427: ... 09900 25008 Multi circuit tester set Tester knob indication Voltage Regulated voltage Charging output 14 0 15 5 V at 5 000 r min GENERATOR COIL RESISTANCE Lift and support the fuel tank 5 3 Disconnect the generator coupler Measure the resistance between the three lead wires If the resistance is out of specified value replace the stator with a new one Also check that the generator core is insu lat...

Page 428: ... cleaner box 5 14 Disconnect the regulator rectifier couplers 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 regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V 1 4 V and more tester s battery voltage NOTE If the tester...

Page 429: ...shed Is a click sound heard Step 2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter motor run YES Go to Step 2 NO Go to Step 3 YES Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal NO Faulty starter m...

Page 430: ... stand switch OK Step 2 1 Check the starter clutch Is the starter clutch OK STARTER MOTOR REMOVAL Remove the front seat 8 7 Disconnect the battery lead wire Lift and support the fuel tank 5 3 Disconnect the starter motor lead wire 1 Remove the starter motor 2 YES Go to Step 4 NO Faulty engine stop switch Faulty clutch switch Faulty GP switch Faulty turn signal side stand relay Faulty starter butto...

Page 431: ...less than 6 5 mm 0 26 in replace the brush Starter motor brush length Service Limit 6 5 mm 0 26 in COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut A 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 If there is no undercut scrape out the insulator with...

Page 432: ...Check the oil seal lip for damage or leakage If any damage is found replace the housing end STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem bly Pay attention to the following points Apply SUZUKI SUPER GREASE A to the lip of the oil seal 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply a small quantity of SUZUKI MOLY PASTE to the arma ture shaft 99...

Page 433: ...o A and B terminals and check for continuity between the positive and negative terminals using the multi circuit tester If the starter relay clicks and continuity is found the relay is ok 09900 25008 Multi circuit tester set Tester knob indication Continuity test Measure the relay coil resistance between the terminals using the multi circuit tester If the resistance is not within the specified val...

Page 434: ...er is located above the crankcase Remove the front seat Disconnect the battery lead wire from the battery Lift and support the fuel tank 5 3 Disconnect the side stand switch coupler and measure the voltage between Green and Black White lead wires 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester reads 1 4 V and below when the tester probes are not connected ...

Page 435: ...sition and side stand to upright position Measure the voltage between Pink and Black White lead wires using the multi circuit tester with needle pointed probe set when shifting the gearshift lever from low to top 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Gear position switch voltage 0 6 V and more Low to top gear position Pink B W Exce...

Page 436: ...nd check the continuity between D and E If there is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test DIODE INSPECTION Measure the voltage between the terminals using the multi cir cuit tester Refer to the following table 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the...

Page 437: ... neutral this circuit cuts off fuel when engine speed reaches 14 100 r min Under no load the engine can run over 14 100 r min though the ignition cut off circuit is effec tive which may possibly cause engine damage Do not run the engine without load over 15 100 r min at anytime ECM TP sensor CMP sensor ECT sensor GP switch Engine stop switch Side stand relay Fuse Fuse Ignition switch Battery Wavef...

Page 438: ...lled as a standard equipment The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna When the ID agreement is verified the system makes the engine ready to start Immobi antenna Indicator light ECM Indicator light Immobilizer antenna ID Transponder ...

Page 439: ...ED flashes fast it notifies of communica tion error or disagreement of ID NOTE If the indicator light flashes fast turn the ignition switch OFF then ON to make judgment again as there is possible misjudg ment due to environmental radio interference NOTE In the case that the LED flashes fast remains lit or unlit the probable cause of such a failure may be due to abnormal condition in the key key cy...

Page 440: ...ECM with the ignition switch in the ON position E 02 19 24 O G and B W E 03 28 33 O W and B W Is the voltage OK Step 3 1 Measure the ignition coil primary peak voltage 9 25 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK Step 4 1 Inspect the spark plugs 2 5 to 6 Is the spark plug OK YES Go to Step 2 NO Poor connection of...

Page 441: ...ge inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resistance OK YES Go to Step 6 NO Poor connection of the ignition coil plug cap s Faulty ignition coil plug cap s YES Faulty ECM Open or short circuit in wire harness Poor connection of ignition couplers NO Faulty CKP sensor Metal particles or foreign material being stuck on the CKP sensor ...

Page 442: ...inal Probe Ground Probe terminal No 2 ignition coil plug cap Black wire terminal Probe Ground Probe terminal No 3 ignition coil plug cap Yellow wire terminal Probe Ground Probe terminal No 4 ignition coil plug cap Green wire terminal Probe Ground Probe terminal 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Do not remove the ignition coil plug cap before dis connecting t...

Page 443: ...tion coil primary peak voltage 80 V and more If the peak voltage is lower than the standard range check the ignition coil plug cap as follow IGNITION COIL PLUG CAP RESISTANCE Check the ignition coil plug cap for resistance in both primary and secondary coils If the resistance is not within the stan dard range replace the ignition coil plug cap with a new one 09900 25008 Multi circuit tester set Te...

Page 444: ...pler Shift the transmission into the neutral and turn ignition switch ON Crank the engine a few seconds with the starter motor by depressing starter button and check the CKP sensor peak voltage Repeat the above test procedure a few times and measure the highest peak voltage Tester knob indication Voltage CKP sensor peak voltage 0 28 V and more Orange Blue Green White Before using the multi circuit...

Page 445: ...oltage 0 28 V and more Green Black If the peak voltage is lower than the standard range check each coupler connection or replace the CKP sensor and inspect it again If the peak voltage is within the specification check the continu ity between the CKP sensor coupler and ECM coupler CKP SENSOR RESISTANCE Measure the resistance between the lead wires and ground If the resistance is not as specified t...

Page 446: ...r light LED is maintenance free LED is less electric power consuming and stronger to vibration resistance com pared to the bulb Engine RPM indicator light This speedometer is equipped the engine RPM indicator light The engine RPM indicator light is adjustable from 7 000 15 000 r min from 7 000 r min to 10 000 r min every 500 r min and 10 000 r min to 15 000 r min every 250 r min initial setting 13...

Page 447: ...meter lead wire coupler Remove the combination meter Disassemble the combination meter as follows When disconnecting and reconnecting the combina tion meter coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Do not attempt to disassemble the combination meter unit 2 1 Combination meter cover 3 Combination meter case 2 Combination meter unit ...

Page 448: ...the combination meter unit with a new one after checking its wire har ness coupler NOTE The pointer may not return to the proper position even turning the ignition switch on under low temperature condition In that case you can reset the pointer to the proper position by following the instruction below 1 With the adjuster switch A pressed turn the ignition switch on 2 Release the adjuster switch A ...

Page 449: ...ter with a new one NOTE If the engine stop switch is turned OFF or side stand ignition inter lock system is not working while the ignition switch is ON the LCD displays CHEC But it is not a malfunction This condition implies that combination meter receives no signal from the ECM In that case they are restored to normal indication by turning the engine stop switch to RUN position When connecting an...

Page 450: ... Multi circuit tester set Tester knob indication Resistance Ω FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly check the fuel level gauge and its lead wire coupler If the fuel level gauge and its lead wire coupler are functioning properly replace the combination meter with a new one Float position Resistance 190 mm 7 48 in 182 3 Ω 56 4 mm 2 22 in 4...

Page 451: ... above condition if a suitable screwdriver touching the pick up surface of the speed sensor is moved the tester read ing voltage changes 0 V 12 V or 12 V 0 V If the tester reading voltage does not change replace the speedometer sensor with a new one NOTE The highest voltage reading in this test will be the same as that of battery 12 V OIL PRESSURE INDICATOR NOTE Before inspecting the oil pressure ...

Page 452: ...IGHT HEADLIGHT 12 V 55 W H7 1 12 V 65 W H9 2 POSITION LIGHT 3 12 V 5 W 2 BRAKE LIGHT TAILLIGHT LED LICENCE PLATE LIGHT 4 12 V 5 W TURN SIGNAL LIGHT 5 12 V 21 W 4 If you have touched and the bulb with your bare hands clean it with a cloth moistened with alcohol or soapy water to maintain lens clarity ...

Page 453: ...djuster A and B To adjust the headlight beam adjust the beam horizontally first then adjust vertically A Horizontal adjuster B Vertical adjuster To adjust the beam horizontally Turn the adjuster A clockwise or counterclockwise To adjust the beam vertically Turn the adjuster B clockwise or counterclockwise ...

Page 454: ...gnal 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 In this case replace the turn sig nal side stand relay with a new one NOTE Make sure that the battery is fully charged Refer to the page 9 17 for the side stand relay and diode inspection STARTER RELAY 9 16 FUEL P...

Page 455: ...3 Remove the ignition switch mounting bolts with the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder IGNITION SWITCH INSTALLATION Install the ignition switch in the reverse order of removal Pay attention to the following points Apply thread lock to the ignition switch bolts 99000 32110 THREAD LOCK SUPER 1322 or equivalent thread lock When reusing the ignition switch bolt clean thre...

Page 456: ... Y G O R Y W PUSH FRONT BRAKE SWITCH REAR BRAKE SWITCH CLUTCH SWITCH OIL PRESSURE SWITCH WIRE COLOR B Black Lbl Light blue R Red Br Brown Lg Light green W White Gr Gray O Orange Y Yellow B BI Black with Blue tracer B R Black with Red tracer B W Black with White tracer B Y Black with Yellow tracer G Y Green with Yellow tracer O B Orange with Black tracer O R Orange with Red tracer O W Orange with W...

Page 457: ...l ground 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 3 of the electrolyte container Insert the nozzles of the electrolyte container 4 into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the flui...

Page 458: ...e caps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once the caps have been installed to the battery do not remove the caps Do not tap the caps with a tool such as hammer when installing them CORRECT INCORRECT For charging the battery make sure to use the cha...

Page 459: ... period B Stop charging Recharging time 5 A for 1 hour or 1 2 A for 5 to 10 hours After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester If the battery voltage is the 12 5 V and less recharge the bat tery again If battery voltage is still 12 5 V and less after recharging replace the battery with a new one When the motorcycle is not used for a long p...

Page 460: ...OUTING 10 22 COOLING SYSTEM HOSE ROUTING 10 23 FRONT BRAKE HOSE ROUTING 10 24 REAR BRAKE HOSE ROUTING 10 25 FUEL TANK INSTALLATION 10 26 COWLING INSTALLATION 10 26 FRAME COVER INSTALLATION 10 27 SEAT LOCK CABLE ROUTING 10 28 REAR FENDER INSTALLATION 10 28 SIDE STAND INSTALLATION 10 30 UNDER COWLING CUSHION RUBBER HEAT SHIELD INSTALLATION 10 30 FRONT FOOTREST INSTALLATION 10 31 REAR VIEW MIRROR INS...

Page 461: ...er than specified value IAP sensor circuit open or shorted to VCC or ground circuit open L Sensor voltage is lower than specified value IAP sensor circuit shorted to ground or VCC circuit open C14 TP sensor The sensor should produce following voltage 0 2 V sensor voltage 4 80 V In other than the above range C14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is hig...

Page 462: ...en 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 sensor lead wire coupler connection P1651 H Sensor voltage is higher than specified value TO sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value TO senso...

Page 463: ...y fuel injector wiring cou pler connection power supply to the injector P0201 P0202 P0203 P0204 C36 C37 C38 C39 Secondary fuel injector Some failure exists in the fuel injector signal in a high load high revolution condition In this case the code C36 P1764 C37 P1765 C38 P1766 or C39 P1767 is indicated Secondary fuel injector wir ing coupler connection power supply to the injector P1764 P1765 P1766...

Page 464: ...lied from the ECM communica tion signal does not reach ECM or operation voltage does not reach EXCVA motor C46 P1658 is indi cated EXCVA can not operate EXCVA EXCVA lead wire cou pler P1657 H EXCVA position sensor voltage is higher than specified value EXCVA position sensor circuit shorted to VCC or ground circuit open L EXCVA position sensor voltage is lower than specified value EXCVA position se...

Page 465: ...d fuel filter or fuel hose 2 Defective fuel pump 3 Defective CMP sensor 4 Defective fuel pressure regulator 5 Defective fuel injector 6 Defective fuel pump relay 7 Defective ECM 8 Open circuited wiring connections Incorrect fuel air mixture 1 TP sensor out of adjustment 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective TP sensor 5 Defective CKP sensor 6 Defective IAP sensor 7 D...

Page 466: ...ECT sensor 6 Defective thermostat 7 Defective IAT sensor 8 Damaged or cracked vacuum hose Fuel injector improperly operating 1 Defective fuel injectors 2 No injection signal from ECM 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operating 1 Defective ECM 2 Defective fuel pressure regulator 3 Defective TP sensor 4 Defecti...

Page 467: ... Worn clutch release bearing 5 Weakened clutch dampers Noise seems to come from crankshaft 1 Rattling bearings due to wear 2 Worn and burnt big end bearings 3 Worn and burnt journal bearings 4 Too large thrust clearance Noise seems to come from balancer 1 Worn and burnt journal bearings Noise seems to come from transmission 1 Worn or rubbing gears 2 Worn splines 3 Worn or rubbing primary gears 4 W...

Page 468: ... STVA Defective air flow system 1 Clogged air cleaner element 2 Defective throttle valve 3 Defective secondary throttle valve 4 Sucking air from throttle body joint 5 Defective ECM 6 Imbalancing throttle valve synchronization Defective control circuit or sensor 1 Low fuel pressure 2 Defective TP sensor 3 Defective IAT sensor 4 Defective CMP sensor 5 Defective CKP sensor 6 Defective GP sensor 7 Def...

Page 469: ...throttle valve or vacuum hose 14 Too much engine oil 15 Defective fuel pump or ECM 16 Defective CKP sensor and ignition coils Defective control circuit or sensor 1 Low fuel pressure 2 Defective TP sensor 3 Defective IAT sensor 4 Defective CMP sensor 5 Defective CKP sensor 6 Defective GP sensor 7 Defective IAP sensor 8 Defective ECM 9 Defective AP sensor 10 TP sensor out of adjustment 11 Defective ...

Page 470: ...ne oil in the engine 2 Worn piston rings or cylinders 3 Worn valve guides 4 Scored or scuffed cylinder walls 5 Worn valves stems 6 Defective stem seal 7 Worn oil ring side rails Check with inspection window drain out excess oil Replace Replace Replace Replace Replace Replace Slipping clutch 1 Weakened clutch springs 2 Worn or distorted pressure plates 3 Distorted clutch plates or pressure plates R...

Page 471: ...tive ECT sensor 7 Clogged water passage 8 Air trapped in the cooling circuit 9 Defective water pump 10 Use incorrect coolant 11 Defective thermostat Add coolant Clean Repair or replace Repair or replace Replace Replace Clean Bleed air Replace Replace Replace Engine overcools 1 Defective ECT sensor 2 Extremely cold weather 3 Defective thermostat 4 Defective cooling fan relay or open or short circui...

Page 472: ...Replace Replenish Replace Adjust Adjust Front suspension too stiff 1 Too viscous fork oil 2 Too much fork oil 3 Improperly set front fork spring adjuster 4 Improperly set front fork damping force adjuster 5 Bent front axle Replace Drain excess oil Adjust Adjust Replace Noisy front suspen sion 1 Not enough fork oil 2 Loose bolts on suspension Replenish Retighten Wobbly rear wheel 1 Distorted wheel ...

Page 473: ...ign material in brake fluid 7 Clogged return port of master cylinder Repair surface with sandpaper Correct pad fitting or replace Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Excessive brake lever stroke 1 Air in hydraulic system 2 Insufficient brake fluid 3 Improper quality of brake fluid Bleed air Replenish fluid to specified level bleed a...

Page 474: ...Open or short circuited lead wires or loose lead connections 2 Short circuited grounded or open generator coil 3 Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Generator does charge but charg ing rate is below the specification 1 Lead wires tend to get shorted or open circuited or loosely connected at terminals 2 Grounded or open circuited generator...

Page 475: ...ult of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments to obtain specified charging operation Replace the battery and correct the charging sys tem Replace the battery Recharge the battery fully Replace the battery Battery sulfation 1 Incorrect charging r...

Page 476: ...arness Starter motor lead wire Clamp 2 1 1 Integrated clamp 8 Protector 2 Cooling fan relay 1 To ECT sensor 3 Fuel pump relay 2 Cut the tip after clamping 4 Horn 3 To IAT sensor 5 Cooling fan motor 4 To CMP sensor 6 Left handlebar switch lead wire 5 Pass the lead wire through behind the frame and set it between the engine and frame 7 Air intake Frame right inside ...

Page 477: ...4 1 Clamp Guide Iginition switch Handlebar switch RH 1 Rear combination light 8 Brake light switch 2 EXCVA 9 Horn 3 AP sensor 0 Regulator rectifier 4 Starter relay 1 Lock part of the clamp should face inside 5 Turn signal side stand relay 2 White marking 6 TO sensor 3 Pass the lead wire through under the frame bridge 7 Integrated clamp 4 To fan motor ...

Page 478: ...m 1 0 kgf m 7 0 lb ft 6 N m 0 6 kgf m 4 5 lb ft 5 N m 0 5 kgf m 3 5 lb ft 11 N m 1 1 kgf m 8 0 lb ft 7 N m 0 7 kgf m 5 0 lb ft 14 N m 1 4 kgf m 10 lb ft 1 Battery lead wire 1 Fix the clamp in parallel with the cover surface 2 White tape ...

Page 479: ... the HO2 sensor lead wire so as not to over lap the oil inspection window 2 Clutch cable 3 Oil pan 3 Pass the HO2 sensor lead wire through between the frame and engine 4 Under cowling 1 Clamp the HO2 sensor lead wire so as not to contact with the under cowling 4 Pass the HO2 sensor lead wire through behind the clutch cable ...

Page 480: ...LE ROUTING 1 2 0 mm 3 0 mm 0 mm 1 Clutch cable 1 Clutch cable must be clamped on the grommet 2 Throttle cable No 1 2 Pass the throttle cables above the clutch cable 3 Throttle cable No 2 3 Pass the throttle cable No 2 outer from No 1 ...

Page 481: ...G 2 1 3 1 Fuel tank water drain hose 1 Pass the fuel tank drain hose and breather hose through behind the PCV hose 2 Fuel tank breather hose 2 Set the fuel tank drain hose and breather hose with lengthwise backward 3 PCV breather hose 3 White marking ...

Page 482: ...ld face right side 3 Oil cooler outlet hose 3 Yellow marking 4 Clearance 4 White marking 5 Radiator inlet hose 5 Clamp should face backward 6 Oil cooler inlet hose 6 Clamp should face left side 7 Oil cooler 7 Clamp should face foreword 8 Bypass hose 8 Red marking 9 Radiator outlet hose 0 Cylinder inlet hose 90 90 90 2 2 1 2 3 4 4 5 5 6 3 3 3 6 7 7 8 6 4 6 ...

Page 483: ... the brake hose firmly 1 Clamp should face downward 5 After positioning the clamp with stopper tighten the clamp bolt 2 Clamp should face backward 6 Insert the clamp to the hole of the front fender fully 3 After the brake hose union has contacted the stopper tighten the union bolt 7 The green paint is right side and face upside ...

Page 484: ... 3 3 1 Rear brake hose 2 Pass the reservoir hose above the brake hose 2 Brake fluid reservoir hose 3 Position the brake union with the stopper before tightening 3 Stopper 4 Face the clamp end inside 4 Rear lower fender 5 White marking 1 Face the clamp end backward 6 Insert the reservoir hose into the hose connector to the root ...

Page 485: ...RVICING INFORMATION FUEL TANK INSTALLATION COWLING INSTALLATION 1 1 1 1 Velcro fastening 4 Fuel tank side cushion 2 Frame cover cushion 1 Apply adhesive agent equivalent to ARONALPHA 201 3 Fuel tank front cover ...

Page 486: ...der cowling cover RH Side cowling RH To frame To oil pan Under cowling RH Heat shield Heat shield Body cowling Under cowling LH Under cowling cover LH Wind screen Cowling brace Air intakepipe LH Intake cover LH To headlight To headlight Lower bracket cover Under inner cowling LH Under inner cowling RH Body cowling cover ...

Page 487: ...10 28 SERVICING INFORMATION SEAT LOCK CABLE ROUTING REAR FENDER INSTALLATION ...

Page 488: ...SERVICING INFORMATION 10 29 1 Seat rail 4 Rear fender rear 2 Rear fender front 5 Rear fender lower 3 Rear fender cover front 6 Swingarm ...

Page 489: ...SHION RUBBER HEAT SHIELD INSTALLATION 40 N m 4 0 kgf m 29 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft 1 Side stand spring No 1 2 Side stand spring No 2 Max 3 mm 0 12 in 2 mm 0 08 in 1 Under cowling LH 3 Under cowling RH 2 Cushion rubber 4 Head shield ...

Page 490: ...5 lb ft 18 N m 1 8 kgf m 13 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 2 23 N m 2 3 kgf m 16 5 lb ft 2 1 Footrest 7 Front footrest No 2 bracket RH 2 Bank sensor 8 Front footrest No 2 bracket LH 3 Holder 9 Front footrest No 1 bracket RH 4 Pin 0 Front footrest No 2 bracket LH 5 Spring 1 Align the cutaway 6 E ring 2 Set this to shown position ...

Page 491: ... MIRROR INSTALLATION 1 1 Body cowling 5 Turn signal lead wire coupler 2 Cowling brace 6 Mirror cover 3 Cushion 7 Mirror body 4 Turn signal lead wire 1 Locate the turn signal lead wire coupler 5 between the mirror cover 6 and mirror body 7 ...

Page 492: ... 20508 Cylinder gauge set 09900 20602 Dial gauge 1 1000 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block set 100 mm 09900 22301 09900 22302 Plastigauge 09900 22401 10 18 mm 09900 22403 18 35 mm Small bore gauge 09900 25008 Multi circuit tester...

Page 493: ...ose 09915 74540 Oil pressure gauge attachment 09915 77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14530 Valve lifter attachment 09916 20640 Solid pilot N 100 4 5 09916 33210 Valve guide reamer 4 5 mm 09916 33320 Valve guide reamer 9 8 mm 09916 34542 Reamer handle 09916 43211 Valve guide remover installer 09916 53310 Valve guide remover installer 09916 43...

Page 494: ...Drive chain cutting and joining tool 09923 74511 Bearing remover 09924 84510 Bearing installer set 09924 84521 Bearing installer set 09925 18011 Steering bearing installer 09930 11930 Torx bit JT30H 09930 11940 Bit holder 09930 11950 Torx wrench 09930 30104 Sliding shaft 09930 34980 Rotor remover 09930 44520 Rotor holder 09930 82720 Mode selection switch 09940 14911 Steering stem nut wrench 09940 ...

Page 495: ...k assem bling tool 09940 40211 Fuel pressure gauge adaptor 09940 40220 Fuel pressure gauge hose attachment 09940 52841 Front fork inner rod holder 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 09940 94922 Front fork spring stopper plate 09940 94930 Front fork spacer holder 09941 34513 Steering race installer 09943 74111 Fork oil level gauge 09944 28320 Hexagon socket 19 mm 099...

Page 496: ... 0 7 0 Cam chain tension adjuster cap bolt 23 2 3 16 5 Cam chain tension adjuster mounting bolt 10 1 0 7 0 Cam chain tensioner bolt 23 2 3 16 5 Cam chain drive sprocket bolt 54 5 4 39 0 Cylinder head bolt M 10 Step 1 step 3 31 3 1 22 5 Final step 60 M 6 10 1 0 7 0 Water jacket plug 9 5 0 95 6 9 Clutch cover bolt 10 1 0 7 0 Clutch sleeve hub nut 95 9 5 68 5 Clutch spring set bolt 10 1 0 7 0 Clutch ...

Page 497: ...r screw 10 1 0 7 0 Breather cover bolt 10 1 0 7 0 Oil pan bolt 10 1 0 7 0 Oil cooler mounting bolt 10 1 0 7 0 Driveshaft bearing case bolt LH and RH 12 1 2 8 7 Starter motor mounting bolt 6 0 6 4 5 ITEM N m kgf m lb ft CKP sensor mounting bolt 8 0 8 6 0 HO2 sensor For E 02 19 48 4 8 34 5 Fuel delivery pipe mounting screw 5 0 5 3 5 Fuel pump mounting bolt 10 1 0 7 0 TPS and STPS mounting screw 3 5 ...

Page 498: ...1 5 11 0 Brake hose union bolt 23 2 3 16 5 Clutch lever holder mounting bolt 10 1 0 7 0 Air bleeder valve Front and rear brake caliper 7 5 0 75 5 5 Air breeder valve Master cylinder 6 0 0 6 4 5 Brake disc bolt Front 23 2 3 16 5 Brake disc bolt Rear 35 3 5 25 5 Rear brake caliper mounting bolt 17 1 7 12 5 Rear brake caliper pin bolt 32 3 2 23 0 Rear brake pad mounting pin 15 1 5 11 0 Rear brake mas...

Page 499: ...0 1 0 7 0 Bolt Diameter A mm Conventional or 4 marked bolt 7 marked bolt N m kgf m lb ft N m kgf m lb ft 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 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 0 18 160 16 0 115 5 240 24 0 173 5 Conventional bolt 4 marked bolt 7 marked bo...

Page 500: ...flection IN EX 0 25 0 010 Valve stem runout IN EX 0 05 0 002 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 37 1 1 46 Valve spring tension IN EX Approx 147 N 15 0 kgf 33 1 lbs at length 33 55 mm 1 32 in ITEM STANDARD LIMIT Cam height IN 36 78 36 83 1 448 1 450 35 48 1 397 EX 35 38 35 43 1 393 1 395 35 08 1 381 Camshaft journal oi...

Page 501: ...6 in from the skirt end 69 880 2 7512 Cylinder distortion 0 02 0 008 Piston ring free end gap 1st R Approx 9 2 0 36 7 3 0 29 2nd R Approx 7 3 0 29 5 8 0 23 Piston ring end gap 1st R 0 06 0 21 0 002 0 008 0 50 0 020 2nd R 0 06 0 18 0 002 0 007 0 50 0 020 Piston ring to groove clearance 1st 0 180 0 0071 2nd 0 150 0 0059 Piston ring groove width 1st 1 01 1 03 0 0398 0 0406 2nd 0 81 0 83 0 0319 0 0327...

Page 502: ...n O D 32 976 33 000 1 2983 1 2992 Crankshaft journal oil clearance 0 010 0 028 0 0004 0 0011 0 080 0 0031 Crankshaft journal O D 31 982 32 000 1 2591 1 2598 Crankshaft thrust bearing thickness Right side 2 425 2 450 0 0955 0 0965 Left side 2 350 2 500 0 0925 0 0984 Crankshaft thrust clearance 0 055 0 110 0 0022 0 0043 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Balancer shaft journal oil clea...

Page 503: ...94 Clutch lifter adjusting pin screw height 0 2 0 4 0 008 0 016 Wave spring washer height 4 30 0 169 ITEM STANDARD LIMIT Primary reduction ratio 1 761 74 42 Final reduction ratio 2 647 45 17 Gear ratios Low 2 785 39 14 2nd 2 052 39 19 3rd 1 714 36 21 4th 1 500 36 24 5th 1 347 31 23 Top 1 208 29 24 Shift fork to groove clearance 0 10 0 30 0 004 0 012 0 50 0 020 Shift fork groove width 5 0 5 1 0 197...

Page 504: ...ure 108 137 kPa 1 1 1 4 kgf cm 15 4 19 5 psi Cooling fan operating temperature OFF ON Approx 105 C 221 F ON OFF Approx 100 C 212 F Engine coolant type Use an antifreeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant Reservoir tank side Approx 250 ml 0 3 0 2 US lmp qt Engine side Approx 2 400 ml 2 5 2 1 US lmp qt ITEM SPECIFICATION NO...

Page 505: ...ut voltage Approx 3 6 V at 760 mmHg 100 kPa TO sensor resistance 16 5 22 3 kΩ TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V and more From 1st to Top Injector voltage Battery voltage Ignition coil primary peak voltage 80 V and more When cranking STP sensor input voltage 4 5 5 5 V STP sensor resistance Approx 4 69 kΩ Closed Approx 0 5 kΩ Opened Approx 3...

Page 506: ... Ω CKP sensor peak voltage 0 28 V and more Ignition coil resistance Primary 1 1 1 9 Ω Terminal Terminal Secondary 10 8 16 2 kΩ Plug cap Terminal Ignition coil primary peak voltage 80 V and more Generator coil resistance 0 2 1 0 Ω Generator no load voltage When engine is cold 65 V AC and more at 5 000 r min Starter motor brush length 10 mm 0 39 in 6 5 0 26 Regulated voltage 14 0 15 5 V at 5 000 r m...

Page 507: ...LED Immobilizer indicator light LED ITEM STANDARD LIMIT Rear brake pedal height 65 75 2 56 2 95 Brake disc thickness Front 5 3 5 7 0 209 0 224 5 0 0 20 Rear 4 8 5 2 0 189 0 205 4 5 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 19 050 19 093 0 7500 0 7517 Rear 14 000 14 043 0 5512 0 5529 Master cylinder piston diam Front 19 018 19 034 0 7487 0 7494 Rear 13 957 13 984 0 5495 0 5506 Br...

Page 508: ...TANDARD LIMIT Cold inflation tire pressure Solo riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Cold inflation tire pressure Dual riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Tire size Front 120 70 ZR17 M C 58 W Rear 180 55 ZR17 M C 73 W Tire type Front BRIDGESTONE BT014F SJ Rear BRIDGESTONE BT014R W Tire tread depth Recommended depth Front 1 6 0 ...

Page 509: ... from stiffest position Compression Lo 1 3 4 turns from stiffest position Hi 3 turns from stiffest position Rear wheel travel 130 5 12 Swingarm pivot shaft runout 0 3 0 01 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane R 2 M 2 Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and co...

Page 510: ...EMISSION CONTROL SYSTEM 11 3 EXHAUST EMISSION CONTROL SYSTEM PAIR SYSTEM 11 4 NOISE EMISSION CONTROL SYSTEM 11 5 PAIR AIR SUPPLY SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION 11 6 PAIR HOSES 11 6 PAIR REED VALVE 11 6 PCV HOSE 11 6 PAIR CONTROL SOLENOID VALVE 11 7 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 11 8 HO2 SENSOR INSPECTION For E 02 19 11 9 ...

Page 511: ...e ECM by varying engine conditions Adjusting interfering with improper replacement or resetting of any of the fuel injection components may adversely affect injection performance and cause the motorcycle to exceed the exhaust emission level limits if unable to effect repairs contact the distributor s representative for further technical informaiton and assistance 1 Fuel tank 7 Fuel feed hose 2 Fue...

Page 512: ...h a PCV system Blow by gas in the engine is constantly drawn into the crank case which is returned to the combustion chamber through the PCV breather hose air cleaner and throttle body 1 PAIR control solenoid valve C EXHAUSTGAS 2 PCV hose D BLOW BY GAS A FRESH AIR E RETURN OIL B FUEL AIR MIXTURE ...

Page 513: ...l solenoid valve is operated by the ECM and the fresh air flow is controlled according to the TPS ECTS IATS IAPS and CKPS The exhaust gas flow is performed by the exhaust control valve actuator which is controlled by the ECM by changing the exhaust control valve angle 1 PAIR control solenoid valve 7 Exhaust control valve actuator 2 PAIR reed valve 8 Exhaust control valve 3 Air cleaner box 9 Three ...

Page 514: ...hile it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts exhaust gases Removing or puncturing the air cleane...

Page 515: ...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 Set new gasket to the PAIR reed valve Install the PAIR reed valve assembly on the cam shaft journal holder with facing the projection A exhaust side Install the cylinder head cover 3 102 PCV HOSE Remove the PCV hose between air cleaner box and crank case breather cover ...

Page 516: ...he 12 V battery to the PAIR control solenoid valve terminals and check the air flow If air does not flow out the solenoid valve is in normal condi tion Check the resistance between the terminals of the PAIR con trol solenoid valve Resistance 18 22 Ω at 20 C 68 F 30 C 86 F 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω If the resistance is not within the standard range rep...

Page 517: ...11 8 EMISSION CONTROL INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING Approx 0 Approx 0 Approx 0 2 1 1 1 PAIR control solenoid valve 1 White marking 2 PAIR reed valve 2 Yellow marking Opposite side ...

Page 518: ... 73 F W W 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω If the resistance is not within the standard range replace the HO2 sensor with a new one NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature Do not remove the HO2 sensor while it is hot Be careful not to expose it to excessive shock Do not use an...

Page 519: ... G Y O G B R B W B B R B W P R O O G Br G B W G B W R Y B W O Bl O W B Br Bl W Bl B Bl G Bl R Bl Y R O G W W R Dgr Gr B W Y B G R CMP SENSOR GP SWITCH TO SENSOR FUEL PUMP RELAY COOLING FAN RELAY HO2 SENSOR ECT SENSOR AP SENSOR EXCVA COOLING FAN MOTOR CKP SENSOR STVA IAP SENSOR PRIMARY INJECTOR 1 PRIMARY INJECTOR 2 PRIMARY INJECTOR 3 PRIMARY INJECTOR 4 SECONDARY INJECTOR 1 SECONDARY INJECTOR 2 SECO...

Page 520: ...Br G B W G B W B Br Bl W Bl B Bl G Bl R Bl Y R O W W W R Dgr Gr B W Y Y Y CMP SENSOR GP SWITCH TO SENSOR FUEL PUMP RELAY COOLING FAN RELAY ECT SENSOR AP SENSOR EXCVA COOLING FAN MOTOR CKP SENSOR STVA IAP SENSOR PRIMARY INJECTOR 1 PRIMARY INJECTOR 2 PRIMARY INJECTOR 3 PRIMARY INJECTOR 4 SECONDARY INJECTOR 1 SECONDARY INJECTOR 2 SECONDARY INJECTOR 3 SECONDARY INJECTOR 4 TP SENSOR IAT SENSOR STP SENS...

Page 521: ...Prepared by December 2005 Part No 99500 37130 01E Printed in Japan 524 ...

Page 522: ...Printed in Japan K6 ...

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