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Suzuki GSX-R1000 2007, Service Manual

The Suzuki GSX-R1000 2007 Service Manual is available for free download from manualshive.com. This comprehensive manual provides essential maintenance, repair, and troubleshooting information for owners of this powerful sport bike. Get your hands on this essential manual today to ensure the optimal performance of your ride.

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FUEL SYSTEM AND THROTTLE BODY     5-11

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:

• Replace the O-rings with new ones.

• Apply thin coat of engine oil to the O-ring 

.

• Set the fuel outlet joint 

 as shown.

• Be sure to connect the wires to the proper terminals.

"

 (B).........  

 terminal for fuel pump

#

 (R).........  

 terminal for fuel level gauge

Use new O-rings to prevent fuel leakage.

Summary of Contents for GSX-R1000 2007

Page 1: ...9 9 5 0 0 3 9 3 1 0 0 1 E GSX R1000 PDF processed with CutePDF evaluation edition www CutePDF com...

Page 2: ...customers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2007 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have...

Page 3: ...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 CHASS...

Page 4: ...t use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper...

Page 5: ...nd 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...

Page 6: ...markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number is stamped on the right side of the steering head pipe The engine serial number is located on the rear si...

Page 7: ...AE 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...

Page 8: ...mperature 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...

Page 9: ...ing its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 6 500 r min Up to 1 600 km 1 000 miles Below 10 000 r min Over to 1 600 km...

Page 10: ...or E 03 28 33 Vacuum hose routing label A For E 33 Fuel caution label A For E 02 24 Fuel information label A A Manual notice label A For E 03 33 Screen label A A Warning steering label A A Tire inform...

Page 11: ...s 4 Bore 73 4 mm 2 900 in Stroke 59 0 mm 2 323 in Displacement 999 cm 61 0 cu in Compression ratio 12 5 1 Fuel system Fuel injection Air cleaner Paper element Starter system Electric Lubrication syste...

Page 12: ...generator Main fuse 30 A Fuse 15 15 10 10 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 Speedometer light LED Tachomete...

Page 13: ...UST CONTROL VALVE 2 13 FUEL LINE 2 14 THROTTLE VALVE SYNCHRONIZATION 2 14 EVAPORATIVE EMISSION CONTROL SYSTEM E 33 ONLY 2 14 PAIR AIR SUPPLY SYSTEM 2 14 THROTTLE CABLE PLAY 2 15 CLUTCH 2 16 COOLING SY...

Page 14: ...500 Item months 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Exhaust control valve I I I Valve clearance I Spark plugs I R I R Fuel line I I I I Evaporative emi...

Page 15: ...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...

Page 16: ...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...

Page 17: ...ug is wet appearing or dark color replace the spark plug with hotter type one If it is white or glazed appearing replace the spark plug with colder type one Inspect every 6 000 km 4 000 miles 12 month...

Page 18: ...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 To prevent the damage of iridium center electrode use a wire gauge to check the gap Neve...

Page 19: ...ted 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...

Page 20: ...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 one rotation to bring the TOP line on the starter clutc...

Page 21: ...ze 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...

Page 22: ...2 05 2 10 2 15 2 20 0 44 0 48 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 49 0 53 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 54 0 58 1 60...

Page 23: ...5 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 29 0 38 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 39 0 43 1 45 1 5...

Page 24: ...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 Hold the motor cycle vertically and check...

Page 25: ...l replacement procedure NECESSARY AMOUNT OF ENGINE OIL Oil change 3 0 L 3 2 2 6 US Imp qt Oil and filter change 3 3 L 3 5 2 9 US Imp qt Engine overhaul 3 6 L 3 8 3 2 US Imp qt EXHAUST CONTROL VALVE Ch...

Page 26: ...N Inspect the throttle valve synchronization periodically 5 27 EVAPORATIVE EMISSION CONTROL SYSTEM E 33 ONLY Inspect the evaporative emission control system periodically PAIR AIR SUPPLY SYSTEM Inspect...

Page 27: ...rottle grip is between 2 0 4 0 mm 0 08 0 16 in Tighten the lock nut while holding the adjuster Throttle cable play 2 0 4 0 mm 0 08 0 16 in Inspect initially at 1 000 km 600 miles 2 months and every 6...

Page 28: ...ct every 6 000 km 4 000 miles 6 months Replace hose every 4 years Replace fluid every 2 years The clutch system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different...

Page 29: ...e and release the clutch lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the fluid runs into...

Page 30: ...with fresh water if necessary Connect the radiator hose securely Pour the specified engine coolant up to the radiator inlet Engine coolant capacity excluding reservoir 2 250 ml 2 4 2 0 US lmp qt Blee...

Page 31: ...ve procedure until no air bleeds from the radi ator inlet Lift and support the fuel tank 5 3 Loosen the air bleeder bolt and check that the engine cool ant flows out Tighten the air bleeder bolt secur...

Page 32: ...HOSES Remove the under cowlings 8 5 Lift and support the fuel tank 5 3 Remove the sprocket cover bolts Check the radiator hoses for crack damage or engine coolant leakage If any defect is found repla...

Page 33: ...hen replacing the drive chain replace the drive chain and sprockets as a set CHECKING Loosen the axle nut Loosen the chain adjuster lock nuts LH and RH Give tension to the drive chain fully by turning...

Page 34: ...specified torque Tighten chain adjuster lock nuts LH and RH securely Rear axle nut 100 N m 10 0 kgf m 72 5 lb ft Recheck the drive chain slack after tightening the axle nut CLEANING AND LUBRICATING C...

Page 35: ...hs 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 glyco...

Page 36: ...e pads with the new ones 8 66 Rear brake The extent of brake pad wear can be checked by observing the grooved limit line on the pads When the wear exceeds the grooved limit line replace the pads with...

Page 37: ...t when the brake pedal is depressed AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the maste...

Page 38: ...cle contains no air bubbles NOTE While bleeding the brake system replenish the brake fluid in the reservoir as necessary Make sure that there is always some fluid visible in the reservoir Close the ai...

Page 39: ...fected and tire wear will increase Therefore main tain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows Cold inflation tire pressure Sol...

Page 40: ...er fork tubes near the axle and pull forward If play is found read just the steering 8 35 FRONT FORK Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tube...

Page 41: ...ecting bolts to the specified torque HO2 sensor removal and installation 4 113 Tighten initially at 1 000 km 600 miles 2 months and every 12 000 km 7 500 miles 24 months thereafter Gasket Gasket Conne...

Page 42: ...2 16 0 Brake hose union bolt Front Rear 23 2 3 16 5 Clutch hose union bolt 23 2 3 16 5 Air bleeder valve Front Rear brake caliper 7 5 0 75 5 5 Air bleeder valve Front master cylinder 6 0 0 6 4 5 Air...

Page 43: ...PERIODIC MAINTENANCE 2 31...

Page 44: ...sion 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 pre...

Page 45: ...nd 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 Remo...

Page 46: ...ne failure to be determined Also in the case of a customer vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condit...

Page 47: ...acing Approx 3 000 r min Check the manifold absolute pressure XX kPa Check the engine coolant temperature XX C PAIR control solenoid valve ON OFF in accordance with the throttle valve opens closes Sec...

Page 48: ...gative pressure during idling 100 C Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure XX kPa Check the engine coolant temperature Approx 100 C C...

Page 49: ...me condition then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring With DTC not output if the value of engine coolant temperature is f...

Page 50: ...CHAIN TENSION ADJUSTER 3 32 CAM CHAIN TENSIONER 3 33 CAM CHAIN GUIDE 3 33 CYLINDER HEAD AND VALVE 3 33 CLUTCH 3 41 CLUTCH LIFTER 3 43 OIL PUMP 3 44 STARTER CLUTCH 3 45 GENERATOR 3 45 WATER PUMP 3 46...

Page 51: ...Oil cooler 7 17 7 18 7 18 Oil pan 3 26 3 82 ITEM REMOVAL INSPECTION INSTALLATION Exhaust pipe and muffler 6 12 6 16 Cam chain tension adjuster 3 16 3 32 3 102 Clutch cover 3 18 3 96 Clutch plates 3 19...

Page 52: ...is sequentially explained in the following steps Reinstall the engine by reversing the removal procedure Remove the under cowlings 8 5 Remove the side cowlings 8 6 Drain engine oil 2 12 Drain engine...

Page 53: ...Remove the oil cooler RADIATOR Remove the regulator rectifier bracket Disconnect the water air bleed hose and radiator inlet hose Disconnect the reservoir inlet hose Disconnect the cooling fan lead w...

Page 54: ...the front engine cover MUFFLER CHAMBER AND EXHAUST PIPE Remove the EXCV cables along with the bracket Disconnect the HO2 sensor coupler lead wire 6 13 Remove the mufflers muffler chamber and exhaust...

Page 55: ...CKP sensor lead wire coupler Disconnect the ECT sensor lead wire coupler Disconnect the GP switch lead wire coupler Disconnect the speed sensor lead wire coupler Disconnect the generator lead wire co...

Page 56: ...from the gearshift shaft Remove the engine sprocket cover Remove the clutch push rod Remove the speed sensor rotor Remove the engine sprocket nut and the washer Do not pry up the ignition coil plug c...

Page 57: ...osen the chain adjusters LH and RH Push the rear wheel forward and make sure that the drive chain has enough slack Disengage the drive chain from the rear sprocket Remove the engine sprocket ENGINE MO...

Page 58: ...nd Remove the engine mounting bolts and Remove the engine mounting nut Remove the engine mounting thrust adjuster lock nut with the special tool Loosen the engine mounting thrust adjuster fully 09940...

Page 59: ...emove the engine mounting bolts and gradually lower the front side of the engine Then take off the drive chain from the driveshaft Remove the engine assembly ENGINE INSTALLATION Install the engine in...

Page 60: ...mounting thrust adjuster lock nuts to the specified torque with the special tool Engine mounting thrust adjuster lock nut 45 N m 4 5 kgf m 32 5 lb ft 09940 14980 Engine mounting thrust adjuster socke...

Page 61: ...3 12 ENGINE B LH C RH LENGTH ITEM N m kgf m lb ft ITEM mm in 55 5 5 40 0 Bolt 45 1 77 75 7 5 54 0 55 2 17 23 2 3 16 5 215 8 46 23 2 3 16 5 Spacer 30 5 1 20 45 4 5 32 5 Adjuster 40 1 57...

Page 62: ...the specified torque Engine sprocket nut 115 N m 11 5 kgf m 83 0 lb ft Install the speed sensor rotor Tighten the speed sensor rotor bolt to the specified torque Speed sensor rotor bolt 25 N m 2 5 kg...

Page 63: ...lts install the oil cooler hose H 99000 32110 THREAD LOCK SUPER 1322 or equivalent Oil cooler bolt 10 N m 1 0 kgf m 7 0 lb ft Perform service and adjustment in the following items Gearshift lever posi...

Page 64: ...TARTER MOTOR Remove the starter motor CYLINDER HEAD COVER Remove the cylinder head cover and its gaskets Remove the dowel pins and O rings Identify the position of each removed part Organize the parts...

Page 65: ...aft to bring the line on the starter clutch to the index mark of the valve timing inspection hole and also to bring the cams to the position as shown below Remove the cam chain tension adjuster cap bo...

Page 66: ...ass hose Remove the thermostat cover and thermostat Thermostat inspection 7 9 Remove the ECT sensor ECT sensor inspection 7 8 Remove the cylinder head bolts M6 Remove the cylinder head bolts and washe...

Page 67: ...lutch cover Remove the gasket and dowel pins Hold the clutch housing with the special tool 09920 53740 Clutch sleeve hub holder Remove the clutch springs NOTE Loosen the clutch spring set bolts little...

Page 68: ...plates and driven plates Remove the clutch push piece bearing and the thrust washer Remove the spring washer and its seat Remove the clutch push rod NOTE If it is difficult to pull out the push rod u...

Page 69: ...the conical spring washer washer and spring washer seat from the clutch sleeve hub Remove the spring washers and clutch lifter driven cam Remove the clutch lifter drive cam and washer Remove the space...

Page 70: ...the conical spring washer washer and spring washer seat from the clutch sleeve hub Remove the spring washers and clutch lifter driven cam Remove the clutch lifter drive cam and washer Remove the space...

Page 71: ...ump driven gear NOTE Do not drop the snap ring into the crankcase Remove the pin and washer Remove the oil pump NOTE Do not drop the pin and washer into the crankcase GEARSHIFT SYSTEM With the snap ri...

Page 72: ...TER IDLE GEAR Remove the starter idle gear cover Remove the dowel pins and gasket Remove the spring washer washer and starter idle gear No 1 Remove the shaft bearing and thrust washer Remove the start...

Page 73: ...special tool 09920 34830 Starter clutch holder Remove the starter clutch bolt and washer Remove the starter clutch assembly and washer CAM CHAIN CAM CHAIN TENSIONER CAM CHAIN GUIDE No 1 Remove the cam...

Page 74: ...old the generator rotor with the special tool 09930 44520 Rotor holder Remove the generator rotor bolt Install a bolt of suitable size to the left end of crankshaft SUITABLE BOLT M12 length 28 38 mm 1...

Page 75: ...PUMP Remove the water inlet cover Remove the water pump Water pump servicing 7 13 GEAR POSITION SWITCH Remove the gear position switch CRANKCASE BREATHER PCV COVER Remove the crankcase breather cover...

Page 76: ...ench OIL PAN Remove the oil pan Remove the gasket Remove the oil pipe OIL PRESSURE SWITCH Remove the oil pressure switch OIL STRAINER Remove the oil strainer and O ring LOWER CRANKCASE Remove the lowe...

Page 77: ...s and bearing pins MIDDLE CRANKCASE Remove the crankcase bolts M6 Remove the crankcase bolts M6 Remove the crankcase bolts M8 Remove the crankshaft journal bolts M9 NOTE Loosen the crankcase bolts dia...

Page 78: ...ve the bearing cap Remove the crankshaft and thrust washers PISTON AND CONROD Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase Remove the piston pin circ...

Page 79: ...ove the CMP sensor from the cylinder head cover INSPECTION Inspect the CMP sensor 4 36 INSTALLATION Install the CMP sensor NOTE When installing clean the CMP sensor s face CMP sensor mounting bolt 10...

Page 80: ...specified torque 99000 32110 THREAD LOCK SUPER 1322 or equivalent PAIR reed valve cover bolt 10 N m 1 0 kgf m 7 0 lb ft CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from...

Page 81: ...t IN EX 0 150 mm 0 0059 in 09900 22301 Plastigauge 09900 22302 Plastigauge NOTE Install camshaft journal holders to their original positions 3 101 Tighten the camshaft journal holder bolts evenly and...

Page 82: ...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 runout Service Limit IN EX 0 10...

Page 83: ...ove the tappet and shim by fingers or magnetic hand Insert the special tool between the valve spring and cylin der head Using the special tools compress the valve spring and remove the two cotter halv...

Page 84: ...ading at any position of the straightedge exceeds the limit replace the cylinder head Cylinder head distortion Service Limit 0 20 mm 09900 20803 Thickness gauge VALVE STEM RUNOUT Support the valve usi...

Page 85: ...t each valve stem and valve face for wear and pitting If it is worn or damaged replace the valve with a new one VALVE STEM DEFLECTION Lift the valve about 10 mm from the valve seat Measure the valve s...

Page 86: ...cement 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 intake or exhaus...

Page 87: ...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 INSPEC...

Page 88: ...inspect the valve seat and face for burrs or other things that could prevent the valve from sealing IN EX Valve seat angles 30 45 55 15 45 60 Valve seat width 0 9 1 1mm 0 035 0 043 in Valve diameter...

Page 89: ...ring free length Service limit IN EX 38 0 mm 1 50 in 09900 20102 Vernier calipers Valve spring tension IN EX Standard Approx 163 N 16 6 kgf 33 55 mm 36 6 lbs 1 32 in VALVE AND VALVE SPRING REASSEMBLY...

Page 90: ...the cotter fits snugly into the groove in the stem end Install the other valves and springs in the same manner as described previously Valve spring retainer Cotter Install the tappet shims and the ta...

Page 91: ...UTCH CLUTCH DRIVE PLATE INSPECTION NOTE Wipe off engine oil from the clutch drive plates with a clean rag Clutch drive plate No 1 I D 111 mm 4 4 in Friction piece 36 pcs Clutch drive plate No 2 I D 11...

Page 92: ...imit Driven plate distortion No 1 No 2 and No 3 Service Limit 0 10 mm 0 004 in 09900 20803 Thickness gauge CLUTCH SPRING INSPECTION Measure the free length of each coil spring with a vernier cali pers...

Page 93: ...If any defects are found replace the clutch lifter drive cam and driven cam as a set CLUTCH LIFTER PIN ADJUSTMENT NOTE When adjusting the clutch lifter it is not necessary to install the clutch onto t...

Page 94: ...nce is felt Tighten the lock nut Clutch lifter adjusting pin screw height Standard 0 2 0 4 mm 0 008 0 016 in 09900 20803 Thickness gauge Clutch lifter pin lock nut 23 N m 2 3 kgf m 16 5 lb ft WAVE SPR...

Page 95: ...e is felt for rotation inspect the starter clutch bearing or the starter clutch contacting surface on the starter driven gear for wear and damage If they are found to be damaged replace them with the...

Page 96: ...hift 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 Install the f...

Page 97: ...piston with a proper bar If the piston does not operate replace the oil pressure regula tor with a new one INSTALLATION Apply grease to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent Press...

Page 98: ...ards the 3rd 4th drive gears Slide the 6th and 2nd drive gears toward the 3rd 4th drive gears then remove the 2nd drive gear circlip Countershaft 1st drive gear 6th driven gear 5th drive gear 3rd driv...

Page 99: ...snap rings The cross sectional view shows the correct position of the gears bushings washers and snap rings 3 50 When installing a new snap ring pay attention to its direction Fit it to the side wher...

Page 100: ...3 50 ENGINE TRANSMISSION PARTS LOCATION Countershaft Driveshaft...

Page 101: ...s 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 CYLIND...

Page 102: ...clearance 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 di...

Page 103: ...s gauge 09900 20205 Micrometer 0 25 mm Piston ring to groove clearance Service Limit 1st 0 180 mm 0 0071 in 2nd 0 150 mm 0 0059 in Piston ring groove width Standard 1st B 0 83 0 85 mm 0 0327 0 0335 in...

Page 104: ...linder and measure the piston ring end gap using the thickness gauge If any of the measurements exceeds the service limit replace the piston ring with a new one Piston ring free end gap Service Limit...

Page 105: ...ck the gearshift fork clearance in the groove of its gear The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action Shift fork to groove c...

Page 106: ...rotation Replace the bearings if there is anything unusual Inspect the gearshift cam bearing gearshift shaft bearings and for abnormal noise and smooth rotation while they are in the crankcase Replace...

Page 107: ...70210 Bearing installer set 20 22 32 NOTE The stamped mark side of the gearshift shaft bearing faces out side Install the oil seal with the special tool 09913 70210 Bearing installer set 22 Apply gre...

Page 108: ...Apply a small quantity of thread lock to the bearing retainer screws Tighten the bearing retainer screws and gearshift fork shaft retainer bolt to the specified torque H 99000 32110 THREAD LOCK SUPER...

Page 109: ...om the lower crank case Remove the oil jet for cam chain tension adjuster from the cylinder head Inspection and cleaning Check the oil jets for clogging If they are clogged clean their oil passage wit...

Page 110: ...nd tighten them to the specified torque H 99000 32110 THREAD LOCK SUPER 1322 or equivalent Piston cooling oil jet bolt 10 N m 1 0 kgf m 7 0 lb ft Install the oil jet for transmission Apply engine oil...

Page 111: ...READ LOCK SUPER 1322 or equivalent NOTE It is not required to apply thread lock when installing the other removed oil gallery plugs Tighten each plug to the specified torque Water jacket plug 9 5 N m...

Page 112: ...shaft with the punch 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 th...

Page 113: ...haft journal O D code number 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 B...

Page 114: ...e runout is greater than the limit Crankshaft runout Service Limit 0 05 mm 0 002 in 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 21303 V block set 75 mm 09900 21304 V block s...

Page 115: ...n 09900 20205 Micrometer 0 25 mm Crank pin width Standard 20 10 20 15 mm 0 7913 0 7933 in 09900 20605 Dial calipers 1 100 mm 10 34 mm CONROD BIG END BEARING INSPECTION Inspect the bearing surfaces for...

Page 116: ...0 0013 0 0022 in Service Limit 0 080 mm 0 0031 in If the oil clearance exceeds the service limit select the speci fied bearings from the bearing selection table Check the corresponding conrod I D cod...

Page 117: ...34 992 mm 1 3773 1 3776 in 3 34 976 34 984 mm 1 3770 1 3773 in Color Part No Thickness Green 12164 41G01 0A0 1 480 1 484 mm 0 0583 0 0584 in Black 12164 41G01 0B0 1 484 1 488 mm 0 0584 0 0586 in Brow...

Page 118: ...900 22301 Plastigauge Mate the middle crankcase with the upper crankcase Tighten the crankshaft journal bolts M9 in ascending order of numbers assigned to these bolts Tighten each bolt a little at a t...

Page 119: ...speci fied bearings from the bearing selection table Check the corresponding crankcase journal I D code number A B or C which is stamped on the rear of upper crankcase Check the corresponding cranksh...

Page 120: ...ther end Code O D specification A 34 994 35 000 mm 1 3777 1 3780 in B 34 988 34 994 mm 1 3775 1 3777 in C 34 982 34 988 mm 1 3772 1 3775 in Color Part No Thickness Green 12229 41G00 0A0 1 492 1 495 mm...

Page 121: ...T 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 n...

Page 122: ...mm 0 0028 0 0043 in 2 550 2 570 mm 0 1004 0 1012 in Red 12228 48B00 0C0 2 460 2 480 mm 0 0969 0 0976 in 0 070 0 110 mm 0 0028 0 0043 in 2 530 2 550 mm 0 0996 0 1004 in Yellow 12228 48B00 0D0 2 440 2 4...

Page 123: ...earing 3 57 Gearshift cam bearing 3 57 Gearshift cam 3 57 Bearing retainer 3 58 Oil jets 3 60 PISTON RING Install the piston rings in the order of oil ring 2nd ring and 1st ring The first member to go...

Page 124: ...d lower side rail Upper side rail 1st ring and spacer PISTON AND CONROD Apply a small quantity of MOLYBDENUM OIL SOLUTION onto each piston pin P MOLYBDENUM OIL SOLUTION Assemble the piston and conrod...

Page 125: ...stall the pistons with conrods into the cylinders from topside using the special tool NOTE When installing the pistons the indent of each piston head must be brought to the exhaust side 09916 77310 Pi...

Page 126: ...surface P MOLYBDENUM OIL SOLUTION When fitting the conrod cap make sure that I D code on each conrod faces intake side Apply engine oil to the bearing cap bolts Tighten the bearing cap bolt by using...

Page 127: ...ight thrust bearing has green painting BALANCER SHAFT Install the thrust washers and oil seal Apply a MOLYBDENUM OIL SOLUTION to each balancer shaft journal and bearing lightly P MOLYBDENUM OIL SOLUTI...

Page 128: ...d 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 Tighten t...

Page 129: ...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 NOTE Fit a new gasket washer to the crankcase bolt NOTE After the crankshaft journal...

Page 130: ...g with the groove of bearing and the bearing pin with the indent on the bearing Install the driveshaft assembly to the middle crankcase NOTE Align the C ring with the groove of bearing and the bearing...

Page 131: ...gn materials Apply to both mating surfaces of crankcases at hatched parts Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply...

Page 132: ...Initial 15 N m 1 5 kgf m 11 0 lb ft Final 26 N m 2 6 kgf m 19 0 lb ft Check that the countershaft and driveshaft rotate smoothly OIL STRAINER Install the O ring Apply grease to the O ring X 99000 250...

Page 133: ...ecified torque D 99000 31140 SUZUKI BOND 1207B or equivalent Oil pressure switch 14 N m 1 4 kgf m 10 0 lb ft NOTE Be careful not to apply bond to the hole of thread end OIL PAN Install a new gasket In...

Page 134: ...ket Install the breather cover Breather cover bolt 10 N m 1 0 kgf m 7 0 lb ft GEAR POSITION SWITCH Apply grease to the O ring NOTE Align the gear position switch pin with the gearshift cam hole X 9900...

Page 135: ...rib and clamp the gear position switch lead wire Apply engine coolant to the O ring Install the water inlet cover Water inlet cover bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Fit the clamp to the bolt GENER...

Page 136: ...line between the upper and middle crankcases as shown D 99000 31140 SUZUKI BOND 1207B or equivalent Install the dowel pins and new gasket Install the generator cover and tighten the generator cover bo...

Page 137: ...en installing the cam chain drive sprocket align the wide spline teeth and CAM CHAIN TENSIONER CAM CHAIN GUIDE Install the cam chain Apply a small quantity of thread lock to the cam chain ten sioner b...

Page 138: ...ial tool and tighten its bolt to the specified torque 09920 34830 Starter clutch holder Starter clutch bolt 55 N m 5 5 kgf m 40 0 lb ft STARTER IDLE GEAR Install the starter idle gear No 2 shaft and s...

Page 139: ...sher bearing starter idle gear No 1 washer and spring washer Install the dowel pins and new gasket Install the starter idle gear cover and tighten its bolts to the specified torque Starter idle gear c...

Page 140: ...pper Check the gearshift cam stopper moves smoothly Locate the gearshift cam in the neutral position Install the gearshift cam stopper plate NOTE Align the gearshift cam pin with the gearshift cam sto...

Page 141: ...g bolts and then tighten them to the specified torque Oil pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Install the washer and pin NOTE Be careful not to drop the washer and pin into the crank case In...

Page 142: ...rive gear and the primary driven gear with the drive gear Install the bearing and spacer and apply engine oil to them Install the thrust washer Install the spring washer seat to the clutch sleeve hub...

Page 143: ...replace it with a new one The conical curve side of spring washer faces outside Hold the clutch sleeve hub with the special tool 09920 53740 Clutch sleeve hub holder Tighten the clutch sleeve hub nut...

Page 144: ...rust washer to the countershaft NOTE Thrust washer is located between the pressure plate and bearing Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the presc...

Page 145: ...he clutch system they can be distinguished by the inside diameter I D clutch friction piece and painted color DRIVEN PLATE E F G Total 9 pcs E No 2 Driven plate Thickness 2 3 mm 0 091 in 1 pc Dark col...

Page 146: ...pring set bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Tighten the clutch spring set bolts diagonally CLUTCH COVER Apply bond lightly to the mating surfaces at the parting line between the upper middle and lo...

Page 147: ...linder head bolts to the specified torque with a torque wrench sequentially and diagonally Step 2 Loosen all the cylinder head bolts diagonally Step 3 Retighten the cylinder head bolts to the specifie...

Page 148: ...que Cylinder head bolt M6 10 N m 1 0 kgf m 7 0 lb ft Fit the gasket and tighten the ECT sensor ECT sensor 18 N m 1 8 kgf m 13 0 lb ft Install the thermostat NOTE The jiggle valve of thermostat faces u...

Page 149: ...s on cylinder head apply MOLYBDENUM OIL SOLUTION to their journals and cam faces Apply a MOLYBDENUM OIL SOLUTION to the camshaft jour nal holders P MOLYBDENUM OIL SOLUTION NOTE Before installing the c...

Page 150: ...d 2 should now be pointing straight up Starting from the roller pin that is directly above the arrow marked 2 count out 14 roller pins from the exhaust cam shaft side going towards the intake camshaft...

Page 151: ...rawn down evenly Each camshaft journal holder is identified with a cast on letter The ascending order of numbers are indicated on the cam shaft journal holders Tighten the camshaft journal holder bolt...

Page 152: ...when the cam chain tension adjuster cap bolt is installed Tighten the cam chain tension adjuster cap bolt to the speci fied torque Cam chain tension adjuster cap bolt 23 N m 2 3 kgf m 16 5 lb ft Remov...

Page 153: ...ENGINE 3 103 10 N m 1 0 kgf m 7 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft...

Page 154: ...s Install the O rings Install new gaskets to the cylinder head cover Apply bond to the cam end caps of the gaskets as shown D 99000 31140 SUZUKI BOND 1207B or equivalent Place the cylinder head cover...

Page 155: ...O ring X 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the starter motor Starter motor mounting bolt 10 N m 1 0 kgf m 7 0 lb ft ENGINE COOLANT RESERVOIR BRACKET Install the engine coolant re...

Page 156: ...27 USE OF SDS DIAGNOSIS RESET PROCEDURE 4 28 SHOW DATA WHEN TROUBLE DISPLAING DATA AT THE TIME OF DTC 4 29 MALFUNCTION CODE AND DEFECTIVE CONDITION 4 30 C11 P0340 CMP SENSOR CIRCUIT MALFUNCTION 4 36 C...

Page 157: ...ID VALVE CIRCUIT MALFUNCTION 4 108 SENSORS 4 111 CMP SENSOR INSPECTION 4 111 CMP SENSOR REMOVAL AND INSTALLATION 4 111 CKP SENSOR INSPECTION 4 111 CKP SENSOR REMOVAL AND INSTALLATION 4 111 IAP SENSOR...

Page 158: ...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 contaminati...

Page 159: ...check the coupler for locking loose ness corrosion dust etc Coupler Probe Where male terminal fits FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not us...

Page 160: ...otive 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 wit...

Page 161: ...on Also check for condition of the coupler lock if equipped Sensor ECM 1 Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tensi...

Page 162: ...t 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...

Page 163: ...rs of those parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit terminal in figure and body ground If continuity is indicated there is a short circuit to...

Page 164: ...d 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 c...

Page 165: ...nd various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air...

Page 166: ...e 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 v...

Page 167: ...tion sensor TPS Secondary throttle position sensor STPS Secondary throttle valve actuator STVA Exhaust control valve actuator EXCVA Fuel pump relay FP relay Fuel pump FP Crankshaft position sensor CKP...

Page 168: ...shaft position sensor CMPS Gear position switch GP switch Speed sensor Cooling fan relay Cooling fan Primary fuel injector Secondary fuel injector Idle speed control valve ISC valve Ignition coil IG c...

Page 169: ...on switch Neutral indicator light Starter switch Gear position switch ECM Secondary throttle position sensor STPS EXCVA EXCVA position sensor Secondary fuel injector Cooling fan motor 15 A 1 For E 02...

Page 170: ...peedometer TP sensor signal TPS Power source for fuel injectors VM Power source for sensors VCC 0 Steering damper solenoid SSO CMP sensor CMPS 1 Steering damper solenoid SSO CKP sensor CKPS 2 STVA sig...

Page 171: ...or 4 41 V EVAP system purge control solenoid For E 33 E Primary injector 3 31 W Serial data for self diagnosis F Primary injector 2 21 X Driving mode switch 1 DMS1 G Primary injector 1 11 Y Immobilize...

Page 172: ...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 sig...

Page 173: ...se 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 dis...

Page 174: ...injector signal 1 FI 1 Primary injector signal 2 FI 2 Primary injector signal 3 FI 3 Primary injector signal 4 FI 4 Secondary injector signal 1 Secondary injector signal 2 Secondary injector signal 3...

Page 175: ...se 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 dis...

Page 176: ...ssary loosen the screw and turn the throttle position sensor and bring the line to the middle 3 Then tighten the screw to fix the throttle position sensor 09930 11950 Torx wrench 09930 82720 Mode sele...

Page 177: ...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...

Page 178: ...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 Gear position signal Gear position signal is fix...

Page 179: ...condition LED Always ON Sometimes ON Always OFF Good condition Malfunction display code LCD User mode No display Malfunction display Dealer mode No code Malfunction code PROBLEM SYMPTOMS Difficult St...

Page 180: ...n Broken fuse FI indicator light operation 4 17 and 9 30 Each warning light operation 9 30 Speedometer operation 9 33 Exhaust gas leakage and noise 2 29 Each coupler disconnection Clogged radiator fin...

Page 181: ...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...

Page 182: ...RVICING 4 3 before inspection and observe what is written there Remove the front seat 8 8 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code...

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 wh...

Page 184: ...ng 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...

Page 185: ...ed value IAP sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value IAP sensor circuit open or shorted to ground or VCC circuit open C14 TP sensor The sens...

Page 186: ...ircuit open 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 indic...

Page 187: ...coil signal is pro duced but fuel injector signal is inter rupted 4 times or more continuously In this case the code C32 P0201 C33 P0202 C34 P0203 or C35 P0204 is indicated Primary fuel injector wiri...

Page 188: ...tage is applied to the ECM although the ignition switch is turned ON No voltage is applied to the speedom eter when turning the ignition switch ON Lead wire coupler connection of ECM terminal to fuel...

Page 189: ...operation voltage does not reach EXCVA motor C46 P1658 is indi cated EXCVA motor can not operate EXCVA EXCVA motor lead wire coupler C49 PAIR control solenoid valve PAIR control solenoid valve voltag...

Page 190: ...ring damper solenoid valve circuit interrupter element shorted feedback current con vergence failure low battery voltage P1769 H Steering damper control current is higher than specified value An abnor...

Page 191: ...lti circuit tester as shown in the illustration 09900 25008 Multi circuit tester set W Tester knob indication Voltage DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec or more...

Page 192: ...d to ground Loose or poor contacts on the CKP sensor cou pler or ECM coupler terminal or If wires and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for op...

Page 193: ...e CKP sensor resistance 142 194 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...

Page 194: ...Peak volt adaptor 09900 25008 Multi circuit tester set W Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 4 28 YES Go to Step 2 NO Replace t...

Page 195: ...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...

Page 196: ...pointed probe set W Tester knob indication Voltage 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 f...

Page 197: ...ble clear the DTC using SDS tool 4 28 Step 1 When indicating P0105 L 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...

Page 198: ...d wire coupler 3 Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler between G B and B Br wires IAP sensor output voltage Approx 2 6 V at idle speed G B B...

Page 199: ...tage OK 5 After repairing the trouble clear the DTC using SDS tool 4 28 Output voltage VCC voltage 4 5 5 0 V ambient temp 20 30 C 68 86 F YES G B R or B Br wire open or shorted to ground or poor or co...

Page 200: ...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 s...

Page 201: ...und is not heard from the tester the circuit condition is OK 6 Disconnect the ECM coupler 7 Check the continuity between P B wire and terminal 8 Also check the continuity between B Br wire and termina...

Page 202: ...the sound is not heard from the tester the circuit condi tion is OK 7 Disconnect the ECM coupler 8 Check the continuity between P B wire and terminal 9 Also check the continuity between R wire and te...

Page 203: ...set 09900 28630 TPS test wire harness W Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool 4 28 2 V TPS ECM P B R B Br 2 YES P B R or B Br wir...

Page 204: ...he voltage between B Bl wire terminal and B Br wire terminal 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...

Page 205: ...sensor coupler and ECM coupler 5 Check the continuity between B Bl wire and terminal 7 6 Also check the continuity between B Br wire and terminal ECTS lead wire continuity Continuity 09900 25008 Multi...

Page 206: ...rom 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 and ground EC...

Page 207: ...uble clear the DTC using SDS tool 4 28 ECT sensor specification YES B Bl or B Br wire open or shorted to ground or poor 7 or connection If wire and connection are OK intermittent trou ble or faulty EC...

Page 208: ...ONDITION 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...

Page 209: ...OK then check the IAT sensor lead wire continuity 4 Disconnect the IAT sensor coupler and ECM coupler 5 Check the continuity between Dg wire and terminal 8 6 Also check the continuity between B Br wir...

Page 210: ...t 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 and gr...

Page 211: ...ame way as that of the ECT sensor Refer to page 7 7 for details 2 YES Dg or B Br wire open or shorted to ground or poor 8 or connection If wire and connection are OK intermittent trou ble or faulty EC...

Page 212: ...g 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 mal...

Page 213: ...oltage Is the voltage OK Step 1 When indicating P1450 H 1 Turn the ignition switch OFF 2 Remove the front seat 8 8 3 Check the AP sensor coupler for loose or poor contacts If OK then check the AP sens...

Page 214: ...trouble clear the DTC using SDS tool 4 28 Step 1 When indicating P1450 L 1 Turn the ignition switch OFF 2 Remove the front seat 8 8 3 Check the AP sensor coupler for loose or poor contacts If OK then...

Page 215: ...he needle pointed probes to the lead wire coupler Turn the ignition switch ON 3 Measure the AP sensor output voltage at the wire side cou pler between G Y and B Br wires AP sensor output voltage Appro...

Page 216: ...repairing the trouble clear the DTC using SDS tool 4 28 Output voltage VCC voltage 4 5 5 0 V ambient temp 20 30 C 68 86 F YES R G Y or B Br wire open or shorted to ground or poor or connection If wir...

Page 217: ...w 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 speci...

Page 218: ...oupler 5 Check the continuity between R wire and B wire If the sound is not heard from the tester the circuit condition is OK 6 Disconnect the ECM coupler 7 Check the continuity between B wire and ter...

Page 219: ...Br wire If the sound is not heard from the tester the circuit condi tion is OK 7 Disconnect the ECM coupler 8 Check the continuity between R wire and terminal 9 Also then check the continuity between...

Page 220: ...5008 Multi circuit tester set 09900 25009 Needle pointed probe set W Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 4 28 C24 P0351 C25 P035...

Page 221: ...ED 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...

Page 222: ...8 Multi circuit tester set V Tester knob indication Resistance Is the resistance OK 5 After repairing the trouble clear the DTC using SDS tool 4 28 2 2 YES W B P W G and B Lg wire open or shorted to g...

Page 223: ...1 Set up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 4 Click each button At this time if an operation...

Page 224: ...s 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...

Page 225: ...ound is not heard from the tester the circuit condition is OK 6 Disconnect the ECM coupler 7 Check the continuity between Y W wire and terminal 8 Also check the continuity between B Br wire and termin...

Page 226: ...e If the sound is not heard from the tester the circuit condi tion is OK 7 Disconnect the ECM coupler 8 Check the continuity between Y W wire and terminal 9 Also check the continuity between R wire an...

Page 227: ...Approx 0 5 V Secondary throttle valve is opened Approx 3 9 V 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set W Tester knob indication Voltage Is the voltage OK After repairin...

Page 228: ...nd 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 W Tester knob indication...

Page 229: ...termittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO P or B W wire open or P wire...

Page 230: ...resistance between terminals Primary injector resistance 11 13 at 20 C 68 F Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is interrupted by 4 tim...

Page 231: ...cuit tester set W Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 4 28 YES Go to Step 2 NO Replace the primary injector with a new one 5 24...

Page 232: ...the resistance between terminals Secondary injector resistance 11 13 at 20 C 68 F Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE Some failure exists in the fuel injector signal in a high load hi...

Page 233: ...ircuit tester set W Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 4 28 YES Go to Step 2 NO Replace the secondary injector with a new one 5...

Page 234: ...lve pre set position is incorrect C40 P0507 Idle speed is higher than the desired idle speed Disconnected ISC valve hose ISC valve is fixed ISC valve pre set position is incorrect ECM ISC 1A ISC 1B IS...

Page 235: ...nuity test Is the continuity OK 6 After repairing the trouble clear the DTC using SDS tool 4 28 Step 2 1 Measure the resistance between terminals and termi nals and ISC valve resistance Approx 80 at 2...

Page 236: ...50 100 rpm 6 Check that the Desired idle speed is within the specified idle rpm Check 2 1 Click the button and decrease the Spec to 1 050 rpm slowly 2 Check that the Desired idle speed is nearly equal...

Page 237: ...in the ISC valve position increases Check 4 1 Increase the Spec to 1 900 rpm 2 Check that the Desired idle speed is approx 1 900 rpm 3 Check that the Engine speed is close to 1 900 rpm NOTE Be careful...

Page 238: ...ircuit open or short FP relay malfunction ECM malfunction P0230 H Voltage is applied to fuel pump although FP relay is turned OFF FP relay switch circuit shorted to power source Faulty FP relay switch...

Page 239: ...re 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 R...

Page 240: ...le clear the DTC using SDS tool 4 28 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 connection If wire and connection are...

Page 241: ...the ignition switch is turned ON No voltage is applied to the speedome ter when turning the ignition switch ON Lead wire coupler connection of ECM terminal to fuel fuse Fuel fuse Power source of spee...

Page 242: ...l wire open or shorted or poor terminal connection Power source of speedometer shorted to ground or open If the wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and...

Page 243: ...er 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 1 0 V In other...

Page 244: ...ler 2 Warm up the engine enough 3 Measure the HO2 sensor output voltage between W G wire and B Br wire when idling condition HO2 sensor output voltage at idle speed 0 3 V and less W G B Br 4 If OK the...

Page 245: ...or affects resistance value largely Make sure that the sensor heater is at correct temperature 09900 25008 Multi circuit tester set V Tester knob indication Resistance Is the voltage OK 5 After repair...

Page 246: ...09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set W Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 4 28 YES O W or...

Page 247: ...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...

Page 248: ...pler 5 Check the continuity between R wire and Y wire If the sound is not heard from the tester the circuit condition is OK 6 Disconnect the ECM coupler 7 Check the continuity between Y wire and termi...

Page 249: ...Y wire and B Br wire If the sound is not heard from the tester the circuit condi tion is OK 7 Disconnect the ECM coupler 8 Check the continuity between Y wire and terminal 9 Also check the continuity...

Page 250: ...isconnect the EXCVA position sensor coupler 5 Turn the ignition switch ON 6 Measure the voltage between the R wire terminal and ground 7 If OK then measure the voltage between the R wire terminal and...

Page 251: ...e 4 Connect the EXCVA position sensor coupler 5 Set the EXCVA to adjustment position 6 4 6 Disconnect the EXCVA position sensor coupler and measure the resistance between Y and W wires EXCVA position...

Page 252: ...tch ON 8 Measure the EXCVA position sensor output voltage at EXCV fully closed position 9 Then to set the EXCV to fully opened position apply 12 V to and terminals Positive wire Gr wire terminal Negat...

Page 253: ...ust the output voltage to the specified value by turning out the No 2 cable adjuster Repeat the above procedure Step 4 until the output voltage is within the specified value EXCVA position sensor outp...

Page 254: ...OK 5 After repairing the trouble clear the DTC using SDS tool 4 28 6 6 12 V 6 12 V YES Loose or poor contacts on the EXCVA or ECM coupler terminal or Open or short circuit in the B R wire or R B wire...

Page 255: ...N 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 4 Click each button At this time if an operation sou...

Page 256: ...resistance 18 22 at 20 30 C 68 86 F Terminal Terminal 09900 25008 Multi circuit tester set V Tester knob indication Resistance Is the resistance OK 6 After repairing the trouble clear the DTC using SD...

Page 257: ...peration manual for further details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control 4 Click each button At this time if an operation sound is heard from the PAIR control solenoid valv...

Page 258: ...USE Cooling fan relay signal is not input to ECM Cooling fan relay circuit open or short ECM malfunction ECM Side stand relay Ignition switch Engine stop switch FAR G R O W Cooling fan motor Cooling f...

Page 259: ...heard from the cooling fan relay and cooling fan motor is operated the function is normal NOTE The cooling fan relay and cooling fan motor inspection is operational at any engine coolant temperature...

Page 260: ...ature is below 50 C 122 F Check that the cooling fan relay operates for a few seconds as the engine coolant temperature arrives each at 50 C 122 F 70 C 158 F and 90 C 194 F above 4 000 r min It is coo...

Page 261: ...es not recieve signal from the vehi cle speed sensor for more than 6 sec when the motorcycle is running ECM does not receive signal from the vehicle speed sensor for more than 6 sec when the motorcycl...

Page 262: ...28 Battery voltage YES P wire open or shorted to ground Loose or poor contacts on the speed sensor coupler or ECM coupler terminal If wires and connection are OK intermittent trouble or faulty ECM Re...

Page 263: ...or below with the engine running Steering damper solenoid valve circuit interrupter element shorted Feedback current convergence failure Low battery voltage ECM malfunction P1769 H Steering damper con...

Page 264: ...age Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 4 28 YES Go to Step 2 NO Replace the steering damper with a new one 1 V 2 YES W wire shorted to VCC or poor 1 connectio...

Page 265: ...details 2 Raise the front wheel off the ground 3 Turn the ignition switch ON 4 Click Steering damper solenoid operating control 5 Click each button ON OFF while turning the handlebars left and right...

Page 266: ...over 3 18 Install the starter 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 40 IAP SENSOR REM...

Page 267: ...4 Remove the IAT sensor from the air cleaner box Install the IAT sensor in the reverse order of removal IAT sensor 3 N m 0 3 kgf m 2 0 lb ft AP SENSOR INSPECTION The AP sensor is located under the fro...

Page 268: ...ler chamber 4 88 HO2 SENSOR REMOVAL AND INSTALLATION Remove the left under cowling 8 5 Disconnect the HO2 sensor coupler Remove the muffler chamber 6 13 Remove the HO2 sensor Installation is in the re...

Page 269: ...FUEL MESH FILTER INSTALLATION 5 11 THROTTLE BODY 5 13 CONSTRUCTION 5 13 AIR CLEANER BOX REMOVAL 5 14 THROTTLE BODY REMOVAL 5 15 THROTTLE BODY DISASSEMBLY 5 16 THROTTLE BODY CLEANING 5 19 INSPECTION 5...

Page 270: ...fuel pressure regulator As the fuel pressure applied to the fuel injectors the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgf cm2 43 psi the fuel...

Page 271: ...E BODY 5 3 FUEL SYSTEM FUEL TANK LIFT UP Remove the seats 8 8 and 9 Remove the fuel tank side covers 8 8 Take out the fuel tank prop stay Remove the fuel tank bolt Lift and support the fuel tank with...

Page 272: ...hose Except for E 33 Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank Remove the fuel tank by removing the mounting bolt FUEL TANK INSTALLATION Installation is...

Page 273: ...the ignition switch ON and check the fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm2 43 psi If the fuel pressure is lower than the specification inspect the following items Fuel hose leakage Cl...

Page 274: ...tip over sensor and fuel pump circuit con nections are OK the fuel pump may be faulty replace the fuel pump with a new one FUEL DISCHARGE AMOUNT INSPECTION Lift and support the fuel tank 5 3 Place a r...

Page 275: ...p is defective or that the fuel filter is clogged Fuel discharge amount 220 ml 7 4 7 7 US Imp oz and more 10 sec NOTE The battery must be in fully charged condition FUEL PUMP RELAY INSPECTION Fuel pum...

Page 276: ...BODY FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION Fuel level gauge Fuel pump case Fuel filter cartridge Fuel mesh filter ITEM N m kgf m lb ft Fuel outlet joint O ring 10 1 0 7 0 O ring O ring Fuel...

Page 277: ...its mounting bolts diagonally Disconnect the lead wires R and B Remove the fuel level gauge Remove the fuel filter cartridge Remove the fuel outlet joint Remove the O rings Gasoline is highly flammab...

Page 278: ...mp from the case FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result Blow the fuel mesh fi...

Page 279: ...e reverse order of removal Pay attention to the following points Replace the O rings with new ones Apply thin coat of engine oil to the O ring Set the fuel outlet joint as shown Be sure to connect the...

Page 280: ...y first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending order of numbers Fuel pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Apply a small quanti...

Page 281: ...ion seal STP sensor ISC valve STVA EVAP purge control solenoid valve Fuel delivery pipe Vacuum hose ITEM N m kgf m lb ft Fuel delivery pipe joint Fuel delivery pipe mounting screw 3 5 0 35 2 5 O ring...

Page 282: ...he fuel tank 5 3 Disconnect the PAIR hose IAT sensor lead wire coupler and IAP sensor Loosen the throttle body clamp screw RH Disconnect the PCV hose and ISC valve hose Loosen the throttle body clamp...

Page 283: ...se from the fuel pump Disconnect the STVA lead wire coupler STP sensor lead wire coupler TP sensor lead wire coupler and IAP sen sor hose Remove the wire clamp Disconnect all the fuel injector lead wi...

Page 284: ...om each throt tle body Disconnect the ISC valve hose Remove the fuel delivery pipe joint assembly Remove the primary fuel injectors and secondary injectors from the fuel delivery pipe Identify the pos...

Page 285: ...ry pipe assembly Remove the ISC valve hoses Remove the ISC valve Remove the TP sensor and STP sensor with the special tool 09930 11950 Torx wrench NOTE Prior to disassembly mark the each sensor s orig...

Page 286: ...AND THROTTLE BODY Never remove the secondary throttle valves and throttle valves These adjusting screws are fac tory adjusted at the time of delivery and do not turn or remove them Do not separate th...

Page 287: ...arburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical manufacturer s instructions on proper use handling and st...

Page 288: ...11950 Torx wrench STP sensor mounting screw 3 5 N m 0 35 kgf m 2 5lb ft NOTE Make sure the secondary throttle valves smoothly open and close If the STP sensor adjustment is necessary refer to page 5 2...

Page 289: ...fuel delivery pipe assembly to the throttle body Tighten the fuel delivery pipe mounting screws to the speci fied torque Fuel delivery pipe mounting screw 3 5 N m 0 35 kgf m 2 5lb ft Replace the O ri...

Page 290: ...refers to the appropriate fuel injector Connect the throttle pulling cable and throttle returning cable to the throttle cable drum Loosen each throttle cable lock nut Turn in each throttle cable adjus...

Page 291: ...ignition switch ON Close the secondary throttle valve by finger and measure the STP sensor output voltage STP sensor output voltage ST valve is fully closed 0 48 0 52 V Y B 09900 25008 Multi circuit...

Page 292: ...blies 5 16 Remove the primary and secondary fuel injectors 1 2 3 and 4 5 16 FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination If present clean and check for pr...

Page 293: ...tall the ISC valve in the reverse order of removal NOTE When removing or replacing the ISC valve must be set to the PRE SET position 5 26 Be careful not to disconnect the ISC valve coupler at least 5...

Page 294: ...n 2 Set up the SDS tool 4 27 3 Click Active control 4 Click ISC learned value reset 5 Click Reset button to clear the ISC learned value NOTE The learned value of the ISC valve is set at PRE SET positi...

Page 295: ...ylinders Step 1 Lift and support the fuel tank 5 3 Disconnect the respective vacuum hoses from each vac uum nipple Disconnect the IAP sensor coupler Connect the respective vacuum tester hoses to each...

Page 296: ...from 1 to 4 cylin ders Equalize the vacuum of the cylinders by turning each air screw and keep it running at idling speed NOTE Always set the engine rpm at idle rpm If the adjustment is not yet correc...

Page 297: ...dure discribes only defference between use of SDS tool and use of mode select switch Step 1 Step 1 is the same as the use of SDS tool Step 2 Connect the special tool mode select swich and turn it ON S...

Page 298: ...LVE ACTUATOR AND EXCV EXHAUST CONTROL VALVE 6 4 EXCVA REMOVAL 6 4 EXCVA PULLEY INSPECTION 6 5 EXCVA INSTALLATION 6 6 EXCVA INSPECTION 6 7 EXCV CABLE REPLACEMENT 6 7 EXCVA ADJUSTMENT 6 10 MUFFLER MUFFL...

Page 299: ...control valve actuator EXCVA and exhaust control valve cables EXCV cables EXCV is installed in the exhaust pipe EXCVA is mounted inside of the right frame The EXCV is operated by the EXCVA via the ca...

Page 300: ...ction 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...

Page 301: ...witch ON 09930 82720 Mode select switch Check the cable slots of the EXCVA pulley facing upward adjustment position as shown Turn the ignition switch OFF Disconnect the EXCVA lead wire couplers Measur...

Page 302: ...ulley from the EXCVA body EXCVA PULLEY INSPECTION Inspect the EXCVA pulley groove for wear and damage If any defects are found replace the EXCVA pulley with a new one When loosening or tightening the...

Page 303: ...ified torque EXCVA pulley mounting bolt 5 N m 0 5 kgf m 3 5 lb ft Connect the No 1 cable 21H0CL and No 2 cable 21H0OP to the EXCVA pulley Tighten the EXCVA mounting bolts to the specified torque EXCVA...

Page 304: ...nut Connect the EXCVA lead wire couplers EXCVA INSPECTION 4 66 EXCV CABLE REPLACEMENT Turn the ignition switch OFF Lift and support the fuel tank 5 3 Remove the right under cowling 8 5 Disconnect the...

Page 305: ...ster fully Loosen the lock nuts and turn the No 2 cable adjuster in or out until the inner cable length becomes 60 61 mm 2 36 2 40 in After adjusting the inner cable length tighten the lock nuts Conne...

Page 306: ...1 No 2 11 12 mm 0 43 0 47 in 5 N m 0 5 kgf m 3 5 lb ft When adjusting the No 1 and No 2 cables the cable slots of EXCVA pulley must be located to adjustment position Do not use the adjustable wrench t...

Page 307: ...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 ignition switch OFF Insert the needle poin...

Page 308: ...edure until the output voltage becomes specified value Go to 4th 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 opened p...

Page 309: ...rform 2nd step to confirm C46 is not indicated MUFFLER MUFFLER CHAMBER AND EXCV EXHAUST PIPE REMOVAL Remove the No 2 muffler joint cover RH only Loosen the muffler chamber connecting bolt LH RH NOTE T...

Page 310: ...muffler and muffler joint Remove the gasket and O rings from the muffler Remove the under cowlings 8 5 Disconnect the HO2 sensor lead wire coupler Loosen the muffler chamber connecting bolt Remove the...

Page 311: ...om the EXCV pulley Remove the side cowlings 8 6 Move the radiator and oil cooler forward Disconnect one of the oil cooler hose from the oil cooler Remove the exhaust pipe bolts Remove the exhaust pipe...

Page 312: ...hand and check that it moves smoothly If it does not move smoothly replace the EXCV together with the exhaust pipe assembly Decarbonize the EXCV if necessary Do not attempt to disassemble the EXCV The...

Page 313: ...Replace the O rings and gasket with new ones 23 N m 2 3 kgf m 16 5 lb ft Replace the connector with a new one Chamber side faces backward Replace the connector with a new one Chamfer side faces backwa...

Page 314: ...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 WATE...

Page 315: ...more anti freeze or 50 and less Refer to below figure Do not use a radiator anti leak additive Anti freeze 1 250 ml 2 6 2 2 US lmp pt Water 1 250 ml 2 6 2 2 US lmp pt 20 40 60 80 100 Density 0 10 20...

Page 316: ...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 pon...

Page 317: ...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 satis...

Page 318: ...perly 10 20 Pour engine coolant 2 18 Bleed air from the cooling circuit 2 19 Install the under cowlings 8 5 WATER HOSE INSPECTION Remove the under cowlings 8 5 Lift and support the fuel tank 5 3 Remov...

Page 319: ...d as shown in the illustration The voltmeter is for making sure that the battery applies 12 V to the cooling fan motor With the cooling fan motor with electric motor fan running at full speed the amme...

Page 320: ...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 couple...

Page 321: ...194 F 4 000 r min and more If the resistance is noted to show infinity or too much different resistance value replace the ECT sensor with a new one INSTALLATION Tighten the ECT sensor to the specifie...

Page 322: ...ng manner Pass a string between flange 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...

Page 323: ...t 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 NOTE The jiggle valve of the thermo...

Page 324: ...ngine 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 cool...

Page 325: ...ing bolt Remove the mechanical seal ring and rubber seal from the impeller Remove the impeller shaft and washer Remove the mechanical seal with the special tool 09921 20240 Bearing remover set 12 mm N...

Page 326: ...Also replace the seal 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 S...

Page 327: ...echanical seal side Apply a small quantity of the grease to the oil seal lip X 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the new mechanical seal using a suitable size socket wrench NOTE...

Page 328: ...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 s...

Page 329: ...g bolts to the specified torque Water pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Pass the gear position switch lead wire under the water pump lib Connect the water hoses 10 20 Install the engi...

Page 330: ...ION SYSTEM OIL PRESSURE 2 33 OIL FILTER 2 13 OIL PRESSURE REGULATOR 3 47 OIL STRAINER 3 47 OIL JET 3 59 OIL PUMP 3 44 OIL PRESSURE SWITCH 9 34 OIL COOLER REMOVAL Remove the under cowlings 8 5 Drain th...

Page 331: ...ed for this cleaning Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver INSTALLATION Install a new O ring NOTE Apply engine oil to the O ring Tighten...

Page 332: ...ING OIL JET 14 OIL FILTER OIL COOLER OIL PUMP ORIFICE OIL STRAINER OIL PRESSUER REGULATOR COUNTERSHAFT LEFT SIDE BEARING COUNTERSHAFT GEARS AND BUSHINGS DRIVESHAFT GEARS AND BUSHINGS CLUTCH PUSH PIECE...

Page 333: ...7 20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM MAIN GALLERY To sub gallery To sub gallery...

Page 334: ...COOLING AND LUBRICATION SYSTEM 7 21 To transmission SUB GALLERY MAIN GALLERY VIEW OF A A...

Page 335: ...18 REMOVAL AND DISASSEMBLY 8 19 INSPECTION 8 22 REASSEMBLY 8 23 INSTALLATION 8 27 FRONT SUSPENSION SETTING 8 28 STEERING DAMPER 8 29 CONSTRUCTION 8 29 REMOVAL 8 30 INSPECTION 8 30 INSTALLATION 8 31 ST...

Page 336: ...PER REMOVAL AND DISASSEMBLY 8 78 CALIPER INSPECTION 8 80 CALIPER REASSEMBLY 8 81 CALIPER INSTALLATION 8 82 MASTER CYLINDER REMOVAL 8 82 MASTER CYLINDER DISASSEMBLY 8 83 MASTER CYLINDER INSPECTION 8 83...

Page 337: ...ick out toward the head so that the pawls close Insert the fastener into the installation hole NOTE To prevent the pawl from damage insert the fastener all the way into the installation hole Push in t...

Page 338: ...8 4 CHASSIS Installation Insert the fastener into the installation hole NOTE To prevent the pawl from damage insert the fastener all the way into the installation hole Push in the head of center piece...

Page 339: ...tall the lower bracket cover in the reverse order of removal UNDER COWLING REMOVAL Remove the fasteners and bolts Remove the under cowlings LH RH Remove the under cowling Center NOTE indicates hook lo...

Page 340: ...owling 8 5 Remove the body cowling cover fasteners and Bend the body cowling cover and remove the side cowling fastener Remove the side cowling LH RH INSTALLATION Install the side cowling in the rever...

Page 341: ...order of removal Refer to the rear view mirrors turn signals cable routing 10 37 BODY COWLING REMOVAL Remove the under cowlings 8 5 Remove the screen Above Remove the screws Disconnect the steering d...

Page 342: ...Install 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...

Page 343: ...il cover firmly until the seat seat tail cover snaps into the locked position FRAME COVER REMOVAL Remove the front and rear seats 8 8 and above Remove the fasteners and bolts Disconnect the seat lock...

Page 344: ...8 10 CHASSIS FRONT WHEEL CONSTRUCTION Brake disc Front axle Collar Front wheel ITEM N m kgf m lb ft Dust seal Front axle bolt 100 10 0 72 5 Bearing Brake disc bolt 23 23 0 16 5 Spacer...

Page 345: ...e motorcy cle with a jack or a wooden block 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 col...

Page 346: ...mm 0 010 in WHEEL Make sure that the wheel 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 replac...

Page 347: ...CHASSIS 8 13 Remove the wheel bearings with the special tool 09921 20240 Bearing remover set Remove the spacer The removed bearings must be replaced with new ones...

Page 348: ...the following points WHEEL BEARING Apply grease to the wheel bearings 99000 25010 SUZUKI SUPER GREASE A or equivalent 100 N m 10 0 kgf m 72 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 39 N m 3 9 kgf m 28 0 l...

Page 349: ...99000 25010 SUZUKI SUPER GREASE A or equivalent 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 spe...

Page 350: ...28 0 lb ft FRONT AXLE Hold the front axle with the special tool and tighten the front axle bolt to the specified torque 09900 18740 Heaxagon socket 24 mm Front axle bolt 100 N m 10 0 kgf m 72 5 lb ft...

Page 351: ...CHASSIS 8 17 Move the front fork up and down 4 or 5 times 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 352: ...l seal stopper ring Spacer Dust seal Washer Inner tube Spring Front fork cap bolt ITEM N m kgf m lb ft Adjuster rod Lock nut 23 2 3 16 5 Inner rod Damper rod cartridge Front axle pinch bolt 15 1 5 11...

Page 353: ...ront fork upper clamp bolt Loosen the handlebar clamp bolt NOTE Slightly loosen the front fork cap bolt before loosening the lower clamp bolts to facilitate later disassembly Be sure to adjust the reb...

Page 354: ...ont 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 Re...

Page 355: ...NOTE Be careful not to damage the ANTI FRICTION metals Remove the dust seal and oil seal stopper ring Remove the oil seal with the special tool 09913 50121 Oil seal remover Remove the oil seal retaine...

Page 356: ...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 Service Limit 233...

Page 357: ...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...

Page 358: ...L 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 512 ml 17 3 18 0 US lmp oz 99000 99044 L01 SUZU...

Page 359: ...are 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 for...

Page 360: ...rod threads is as fol lows 11 mm 0 43 in Slowly turn the cap bolt completely by hand until the end of the cap bolt seats on the lock nut Apply fork oil to the O ring Insert the adjuster rod in to the...

Page 361: ...m 2 3 kgf m 16 5 lb ft Tighten the front fork cap bolt to the specified torque and recheck the front fork outer tube upper surface height from the upper surface of the steering stem upper bracket Fro...

Page 362: ...ion Compression damping force High speed Fully turn the compression damping force High speed adjuster clockwise From that position stiffest turn it out to the stan dard setting position STD position 3...

Page 363: ...8 29 STEERING DAMPER CONSTRUCTION Steering damper Convex curve side of the washer faces down side Dust seal ITEM N m kgf m lb ft Steering stem head nut Damper rod bolt 23 2 3 16 5 Damper rod nut 90 9...

Page 364: ...the nut Remove the bolt Remove the steering damper INSPECTION Inspect the steering damper body bearing and oil seal for damage and oil leaking Move the steering damper rod by hand to inspect for a sm...

Page 365: ...al Pay attention to the following points Apply grease to the bearings and dust seals 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the steering damper and tighten the bolt and nut Steering d...

Page 366: ...wer bracket handlebars Steering stem head nut ITEM N m kgf m lb ft Steering stem nut Steering stem lock nut 90 9 0 65 0 Dust seal cover Front fork upper clamp bolt 90 9 0 65 0 Dust seal Handlebar clam...

Page 367: ...ot necessary to remove the ignition switch when replac ing only the steering stem lower bracket and bearings Ignition switch removal 9 38 Remove the brake hose clamp bolt Remove the steering stem lock...

Page 368: ...ear and brinelling Bearing wear or damage Abnormal noise of bearing If any abnormal points are found replace defective parts with new ones Remove the steering stem lower bearing inner race with a chis...

Page 369: ...ing installer INSTALLATION Install the steering stem in the reverse order of removal Pay attention to the following points BEARING Apply grease to the bearings and bearing races 99000 25010 SUZUKI SUP...

Page 370: ...ring stem nut wrench 09940 14960 Steering stem nut wrench socket Steering stem lock nut 90 N m 9 0 kgf m 65 0 lb ft FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem...

Page 371: ...20 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 up...

Page 372: ...ont brake master cylinder Remove the right handle switch Remove the handle balancer Remove the throttle grip Left handle grip Handlebar RH Throttle grip Handlebar LH Left handle switch Handlebar clamp...

Page 373: ...tem head nut Remove the steering stem upper bracket along with the ignition switch NOTE Place a rag under the steering stem upper bracket to prevent scratching the fuel tank and under cowlings It is n...

Page 374: ...er clamp bolts and handlebar clamp bolts to the specified torque LH and RH 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 handle grip bo...

Page 375: ...valent Apply grease to the throttle cables and cable drum 99000 25010 SUZUKI SUPER GREASE A or equivalent When remounting the right and left handle switches engage the stopper with the handlebar hole...

Page 376: ...NSTRUCTION Rear axle Wheel damper Brake disc Sprocket mounting drum Collar Sprocket Dust seal Brake disc bolt ITEM N m kgf m lb ft Rear wheel Rear sprocket nut 35 3 5 25 5 Spacer Rear axle nut 60 6 0...

Page 377: ...axle Remove the rear wheel by disengaging the drive chain Remove the collar Remove the brake disc Remove the collar Loosen the rear sprocket mounting bolt and separate the rear sprocket from its mount...

Page 378: ...ial gauge check the rear axle for runout If the runout exceeds the limit replace the rear axle with a new one Axle shaft runout Service Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 1 100 mm 09900 207...

Page 379: ...heel bearing and sprocket mounting drum bearing by hand while they are installed in place Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there i...

Page 380: ...rear wheel in the reverse order of removal and disassembly Pay attention to the following points LH RH b c d e a 100 N m 10 0 kgf m 72 5 lb ft 33 N m 3 3 kgf m 24 0 lb ft 60 N m 6 0 kgf m 43 5 lb ft...

Page 381: ...ew bearing to the sprocket mounting drum with the special tool 09924 84510 Bearing installer set First install the right wheel bearing then install the left one with the special tools 09941 34513 Stee...

Page 382: ...ing installer set Apply grease to the dust seal lip before assembling rear wheel 99000 25010 SUZUKI SUPER GREASE A or equivalent REAR SPROCKET AND SPROCKET MOUNTING DRUM Install the rear sprocket moun...

Page 383: ...E DISC Apply THREAD LOCK to the disc bolts and tighten them to the specified torque NOTE Make sure that the brake disc is clean and free of any greasy matter 99000 32130 THREAD LOCK SUPER 1360 or equi...

Page 384: ...S REAR SHOCK ABSORBER CONSTRUCTION Left Right Rear shock absorber Rear shock absorber mount ing bolt nut ITEM N m kgf m lb ft Rear shock absorber bracket Rear shock absorber bracket nut 50 5 0 36 0 11...

Page 385: ...uffler chamber brackets Remove the rear shock absorber upper and lower mounting bolts and nuts Take out the rear shock absorber INSPECTION Inspect the shock absorber body and bushing for damage and oi...

Page 386: ...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 b...

Page 387: ...ING PRE LOAD ADJUSTMENT The set length 156 0 mm 6 14 in provides the maximum spring pre load The set length 166 0 mm 6 54 in provides the minimum spring pre load STD length 161 0 mm 6 34 in DAMPING FO...

Page 388: ...t position E 02 19 13 clicks out from stiffest position E 03 24 28 33 STANDARD REAR SUSPENSION SETTING E 02 19 STANDARD REAR SUSPENSION SETTING E 03 24 28 33 C O M P H S REAR Spring set length Damping...

Page 389: ...gf m lb ft Spacer Rear cushion lever bolt nut 50 5 0 36 0 Bearing Rear cushion rod bolt nut 98 9 8 71 0 Chain case Swingarm pivot shaft 78 7 8 56 5 Chain buffer Swingarm pivot lock nut 15 1 5 11 0 Cha...

Page 390: ...e caliper from the swingarm Remove the rear shock absorber 8 51 Remove the cushion lever and washers Remove the cushion rod and washers Remove the swingarm pivot shaft lock nut with the special tool 0...

Page 391: ...N Remove the swingarm 8 56 Remove the swingarm pivot boss nut NOTE Remove the swingarm pivot boss when only replacing it Remove the swingarm pivot boss by removing its set screws Set the swingarm pivo...

Page 392: ...ny defects are found replace the spacers with new ones SWINGARM BEARING Insert the spacer into bearing and check the play when mov ing the spacer up and down If excessive play is noted replace the bea...

Page 393: ...mov ing the spacer up and down If excessive play is noted replace the bearing with a new one Remove the cushion rod bearings with the special tool 09921 20240 Bearing remover set 17 mm SWINGARM PIVOT...

Page 394: ...8 60 CHASSIS 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...

Page 395: ...seals 50 N m 5 0 kgf m 36 0 lb ft 65 N m 6 5 kgf m 47 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft 65 N m 6 5 kgf m 47 0 lb ft 98 N m 9 8 kgf m 71 0 lb ft 90 N m 9 0 kgf m 65 0 lb ft NOTE When installing the b...

Page 396: ...pth from the cushion lever surface with the special tool and suitable size socket wrench 8 61 09924 84521 Bearing installer set NOTE When installing the bearing stamped mark on the bearing must face o...

Page 397: ...ocedure Insert the swingarm pivot shaft and tighten it 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 tight...

Page 398: ...hion rod mounting nut Front side 98 N m 9 8 kgf m 71 0 lb ft Rear side 78 N m 7 8 kgf m 56 5 lb ft Install the rear shock absorber 8 53 Route the rear brake hose properly 10 22 and install the brake h...

Page 399: ...iston set Brake hose union bolt 10 1 0 7 0 Piston seal Caliper mounting bolt 23 2 3 16 5 Dust seal Caliper air bleeder valve 39 3 9 28 0 Brake caliper piston Caliper housing bolt 7 5 0 75 5 5 Brake pa...

Page 400: ...s 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 stor...

Page 401: ...PLACEMENT Place the motorcycle on a level surface and keep the handle bars straight Remove the brake fluid reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoi...

Page 402: ...luid in a suitable recepta cle Remove the brake pads and spring 8 66 CALIPER DISASSEMBLY Remove the caliper air bleeder valve Separate the caliper halves by removing the caliper housing bolts with the...

Page 403: ...nd piston seals CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks scratches or other damage BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scrat...

Page 404: ...w O ring and reassemble caliper halves 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...

Page 405: ...INSPECTION Visually check the brake disc for damage or cracks Measure the thickness with a micrometer Replace the disc if the thickness is less than the service limit or if damage is found Front disc...

Page 406: ...luid Remove the union bolt and disconnect the brake hose Remove the master cylinder by removing the master cylinder bolts Remove the reservoir cap insulator diaphragm and reservoir tank Remove the bra...

Page 407: ...e following parts Secondary cup Piston Primary cup Return spring Return spring guide Air bleeder valve Remove the dust rubber and snap ring Remove the connector and O ring MASTER CYLINDER INSPECTION I...

Page 408: ...cification 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 or equivalent Clean the master cylind...

Page 409: ...n the reverse order of removal Pay attention to the following points When installing the brake master cylinder onto the handle bar align the master cylinder holder s mating surface with punch mark on...

Page 410: ...ITEM N m kgf m lb ft Reservoir hose Brake caliper mounting bolt 7 5 0 75 5 5 Brake hose Brake master cylinder mounting bolt 23 2 3 16 5 Brake pad Brake master cylinder rod lock nut 18 1 8 13 0 Piston...

Page 411: ...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 c...

Page 412: ...e brake hose from the caliper by removing the union bolt 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 fl...

Page 413: ...bber boot 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 and piston seal Avoid using high pressure...

Page 414: ...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...

Page 415: ...boot 99000 25100 SUZUKI SILICONE GREASE or equivalent Install the spacer Install the caliper air bleeder valve Install the brake pad spring Clean the caliper components with fresh brake fluid before...

Page 416: ...ke fluid reservoir to catch any split brake fluid Remove the brake fluid reservoir cap Drain the brake fluid Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brak...

Page 417: ...move the O ring Pull out the dust boot then remove the snap ring 09900 06108 Snap ring pliers Remove the push rod piston primary cup and spring MASTER CYLINDER INSPECTION CYLINDER PISTON AND CUP SET I...

Page 418: ...R 1322 or equivalent Tighten each bolt to the specified torque Brake hose routing 10 22 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Maste...

Page 419: ...rod Clutch release cylinder ITEM N m kgf m lb ft Dust boot Clutch master cylinder mounting bolt 10 1 0 7 0 Piston cup set Clutch hose union bolt 23 2 3 16 5 Clutch hose Air bleeder valve 6 0 0 6 4 5 C...

Page 420: ...hose Fill the reservoir with fresh brake fluid to the upper level Air bleeder valve 6 0 N m 0 6 kgf m 4 5 lb ft This clutch system is filled with an ethylene glycol based DOT 4 brake fluid Do not use...

Page 421: ...ton by using compressed air CLUTCH RELEASE CYLINDER INSPECTION Inspect the clutch release cylinder bore wall for nicks scratches or other damage Inspect the oil seal for damage and wear Inspect the pi...

Page 422: ...valent Remove the clutch release cylinder Tighten each bolt to the specified torque Clutch hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Air bleeder valve 6 0 N m 0 6 kgf m 4 5 lb ft Wash the clutch cyl...

Page 423: ...d Remove the union bolt and disconnect the clutch hose from the master cylinder Remove the clutch master cylinder Remove the reservoir cap insulator and diaphragm Remove the clutch lever and clutch le...

Page 424: ...emove the piston cup set Secondary cup Piston Primary cup Spring CLUTCH MASTER CYLINDER INSPECTION Inspect the piston surface for any scratches or other damage Inspect the primary cup secondary cup an...

Page 425: ...condary cup Snap ring Install O rings to the master cylinder and reservoir tank Install the reservoir tank Apply SUZUKI SILICONE GREASE to the push rod Install the push rod and dust boot 99500 25100 S...

Page 426: ...master cylinder onto the handle bar align the master cylinder holder s mating surface with punch mark on the handlebar and tighten the upper clamp bolt first Clutch master cylinder mounting bolt 10 N...

Page 427: ...he 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 ag...

Page 428: ...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 must be cleaned...

Page 429: ...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 r...

Page 430: ...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 installi...

Page 431: ...the threaded parts of the special tool DRIVE CHAIN CUTTING Set up the special tool as shown in the illustration Tool body Grip handle Pressure bolt A Pressure bolt B Bar Adjuster bolt with through ho...

Page 432: ...djuster bolt Grip handle without hole Joint plate holder Pressure bolt A engraved mark F50 Bar Wedge holder wedge pin Connect both ends of the drive chain with the joint pin inserted from the wheel si...

Page 433: ...r using the bar 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 specificat...

Page 434: ...cified dimension Pin end diameter specification Adjust the drive chain after connecting it 2 22 DID 5 50 5 80 mm 0 217 0 228 in After joining of the chain has been completed check to make sure that th...

Page 435: ...RTER SYSTEM 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 STA...

Page 436: ...Y 9 37 STARTER RELAY 9 37 FUEL PUMP RELAY 9 37 COOLING FAN RELAY 9 37 SWITCH 9 38 IGNITION SWITCH REMOVAL 9 38 IGNITION SWITCH INSTALLATION 9 38 DRIVING MODE SWITCH 9 39 SWITCH INSPECTION 9 41 BATTERY...

Page 437: ...er 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 14 to 16 Bend the clamp proper...

Page 438: ...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...

Page 439: ...sure to turn the switch OFF 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 pr...

Page 440: ...actuator 4 66 STP sensor 4 69 TP sensor 4 45 IAT sensor 4 53 Driving mode switch TO sensor 4 62 PAIR control solenoid valve 11 6 CMP sensor 4 36 Ignition coil ISC valve 4 79 EVAP system purge control...

Page 441: ...tor 4 75 Fuel pump Fuel level gauge Regulator Rectifier Horn Battery Cooling fan relay 7 7 Fuel pump relay 5 7 AP sensor 4 57 Mode select switch coupler ECM Starter relay Main fuse Generator Fuse box...

Page 442: ...e 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 accessor...

Page 443: ...itch OFF 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 ev...

Page 444: ...condition 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...

Page 445: ...e 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 10 4...

Page 446: ...hed 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...

Page 447: ...9 17 Is the side stand switch OK Step 2 1 Check the starter clutch Is the starter clutch OK STARTER MOTOR REMOVAL Disconnect the battery lead wire Lift and support the fuel tank Disconnect the starter...

Page 448: ...h brush found to have worn down to the limit Starter motor brush length Service Limit 3 5 mm 0 14 in COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut If abnormal wear is f...

Page 449: ...L INSPECTION 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...

Page 450: ...e starter relay Apply 12 V to and 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...

Page 451: ...e SIDE STAND SWITCH The side stand switch coupler is located above the crankcase Remove the left under cowling 8 5 Disconnect the side stand switch coupler and measure the voltage between G and B W le...

Page 452: ...easure the voltage between P and B W lead wires using the multi circuit tester when shifting the gearshift lever from low to top 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe s...

Page 453: ...ontinuity 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...

Page 454: ...neutral this circuit cuts off fuel when engine speed reaches 12 900 r min Under no load the engine can run over 12 900 r min though the ignition cut off circuit is effec tive which may possibly cause...

Page 455: ...system is installed as a standard equipment The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna When the ID agreement is verifie...

Page 456: ...in successful communica tion If the indicator light LED flashes fast it notifies of communica tion error or disagreement of ID NOTE If the indicator light flashes fast turn the ignition switch OFF th...

Page 457: ...ECM with the ignition switch in 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...

Page 458: ...r peak voltage 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...

Page 459: ...terminal Probe Ground Probe terminal No 2 ignition coil plug cap B wire terminal Probe Ground Probe terminal No 3 ignition coil plug cap Y wire terminal Probe Ground Probe terminal No 4 ignition coil...

Page 460: ...gnition 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 coi...

Page 461: ...r Repeat the above test procedure a few times and measure the highest peak voltage Measure the CKP sensor peak voltage at the ECM coupler and terminals 4 39 Tester knob indication Voltage CKP sensor p...

Page 462: ...intenance free LED is less electric power consuming and stronger to vibration resistance com pared to the bulb Engine revolution indicator lamp This speedometer is equipped the engine revolution indic...

Page 463: ...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...

Page 464: ...lace 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...

Page 465: ...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 im...

Page 466: ...Multi circuit tester set Tester knob indication Resistance FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly check the fuel level gauge and its lead wi...

Page 467: ...ounting bolt Connect 12 V battery 10 k resistor and the multi circuit tester as shown in the right illustration 09900 25008 Multi circuit tester set Tester knob indication Voltage Under above conditio...

Page 468: ...e the right under cowling 8 5 Disconnect the oil pressure switch lead wire from the oil pres sure switch Turn the ignition switch ON Check if the oil pressure indicator will light and LCD will flicker...

Page 469: ...NAL LIGHT HEADLIGHT 12 V 55 W H7 12 V 65 W H9 POSITION LIGHT 12 V 5 W BRAKE LIGHT TAILLIGHT LED LICENCE PLATE LIGHT 12 V 5 W TURN SIGNAL LIGHT 12 V 21 W 4 If you have touched and the bulb with your ba...

Page 470: ...EM HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam NOTE Use a screw driver for adjuster and To adjust the headlight beam adjust the beam horizontally first then adjust vertically Horizontal adjust...

Page 471: ...nal 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 r...

Page 472: ...a center punch remove the ignition switch mounting bolts Remove the ignition switch IGNITION SWITCH INSTALLATION Install the ignition switch in the reverse order of removal Pay attention to the follo...

Page 473: ...to C to B to A Pushing the lower part can change from A to B to C to A The driving mode indicator indicates actual driving mode NOTE Operating the driving mode while riding may cause unex pected engin...

Page 474: ...on manual for further details 2 Turn the ignition switch ON 3 Click Data monitor 4 Make sure each of Driving mode selection on the monitor is indicated Open 5 Push each of driving mode switch and UP a...

Page 475: ...G O R Y W PUSH FRONT BRAKE SWITCH REAR BRAKE SWITCH CLUTCH SWITCH OIL PRESSURE SWITCH Color Position G Y Ground ON engine is at stop OFF engine is running Color Position B W B Y OFF ON Color Position...

Page 476: ...Remove the caps NOTE After filling the electrolyte completely use the removed cap as sealing caps of battery filler holes Do not remove or pierce the sealed areas of the electrolyte container Insert...

Page 477: ...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...

Page 478: ...period 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 vo...

Page 479: ...ROUTING 10 23 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 24 FUEL TANK INSTALLATION 10 25 FUEL TANK LOWER SIDE COVER CUSHION RUBBER FASTENER INSTALLATION 10 26 AIR INTAKE COVER CUSHION RUBBER INSTALLATION...

Page 480: ...TION LIGHT INSTALLATION 10 38 REAR COMBINATION LIGHT CUSHION FASTENER INSTALLATION 10 39 REGULATOR RECTIFIER INSTALLATION 10 40 SPECIAL TOOLS 10 41 TIGHTENING TORQUE 10 45 ENGINE 10 45 FI SYSTEM AND I...

Page 481: ...manifold 1 Clogged fuel filter or fuel hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective ECM 7 Open circuited wiring con...

Page 482: ...ective thermostat 7 Defective IAT sensor 8 Damaged or cracked vacuum hose 9 Damaged or clogged ISC valve Fuel injector improperly operating 1 Defective fuel injectors 2 No injection signal from ECM 3...

Page 483: ...kened clutch dampers 6 Worn clutch lifter related parts 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 la...

Page 484: ...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 7 Defect...

Page 485: ...uum hose 14 Too much engine oil 15 Defective fuel pump or ECM 16 Defective CKP sensor and ignition coils 17 Defective STP sensor or STVA Defective control circuit or sensor 1 Low fuel pressure 2 Defec...

Page 486: ...earned value Dirty or heavy exhaust smoke 1 Too much engine 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 st...

Page 487: ...Faulty cooling fan 4 Defective cooling fan relay or open or short circuited 5 Defective ECM 6 Defective ECT sensor 7 Clogged water passage 8 Air trapped in the cooling circuit 9 Defective water pump 1...

Page 488: ...mping force adjuster 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 fo...

Page 489: ...gn 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 Disasse...

Page 490: ...rcuited 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 Generat...

Page 491: ...lt 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...

Page 492: ...l solenoid valve Clamp Fixed clamp Fixed clamp Clamp Clamp ECM Clamp Fixed clamp Fixed clamp Fixed clamp Secondary fuel injector Primary fuel injector Regulator Rectifier Fixed clamp Fixed clamp ECM h...

Page 493: ...SERVICING INFORMATION 10 15 ECM cushion Clamp Clamp Backside of the headlight Guide Fixed clamp Clamp Guide Clutch hose Side stand switch HO2 sensor lead wire...

Page 494: ...lb ft Oil pressure switch 14 N m 1 4 kgf m 10 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 1 5 N m 0 15 kgf m 1 0 lb ft 5 N m 0 5 kgf m 3 5 lb ft Engine ground lead wire When tightening the starter motor mount...

Page 495: ...SERVICING INFORMATION 10 17 THROTTLE CABLE ROUTING Throttle cable No 1 Brake hose Throttle cable No 2 1 Pass the throttle cables along the air cleaner box 0 mm 0 in 0 mm 0 in 1...

Page 496: ...se EVAP purge hose E 33 only PCV breather hose EVAP system purge control solenoid valve E 33 only ISC valve hose EVAP system purge control solenoid valve hose EVAP surge hose E 33 only To IAP sensor E...

Page 497: ...he breather hose and drain hose through over the wiring harness Breather hose Except for E 33 Bend the hose clamp at the white painted mark on the breather hose Drain hose Set the breather hose and dr...

Page 498: ...hite Backward A Marking Green Right side Right side A B Left side A Backward Top side A B Left side A Backward B Left side B Align the marking with the rib of pipe Marking 45 Be careful not to contact...

Page 499: ...the brake hose union has contacted the stopper tighten the union bolt 23 N m 2 3 kgf m 16 5 lb ft Clamp the brake hose firmly 7 5 N m 0 75 kgf m 5 5 lb ft After positioning the clamp with stopper tig...

Page 500: ...3 N m 2 3 kgf m 16 5 lb ft Clamp ends should face inside 33 N m 3 3 kgf m 24 0 lb ft White paint faces outside 7 5 N m 0 75 kgf m 5 5 lb ft After the brake hose union has contacted the stopper tighten...

Page 501: ...6 N m 0 6 kgf m 4 3 lb ft Stopper After the clutch hose union has con tacted the stopper tighten the union bolt 23 N m 2 3 kgf m 16 5 lb ft Grommet Install the grommet of the clutch hose to the clutch...

Page 502: ...10 24 SERVICING INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING 0 1 0 Approx 45 Approx 25 1 1 PAIR control solenoid valve Air cleaner box PAIR reed valve 1 To air cleaner box...

Page 503: ...ION 10 25 FUEL TANK INSTALLATION Fuel tank cover Apply adhesive agent Velcro fastening View from bottom Frame cover cushion Align the fuel tank cushion with the dent mark Fuel tank cushion Dent mark A...

Page 504: ...ER INSTALLATION NOTE Clean the adhesive surface before adhering the cushion rubber Cushion Protective tape Cushion Align the velcro fastening to the aligned mark Clean an adhesive surface before adher...

Page 505: ...he adhesive surface before adhering the cushion rubber UNDER COWLING HEAT SHIELD INSTALLATION NOTE Clean an adhesive surface before adhering the heat shield Heat shield RH Clean the adhesive surface b...

Page 506: ...INFORMATION FUEL TANK HEAT SHIELD AND FUEL TANK BRACKET CUSHION INSTALLATION FUEL TANK COVER CUSHION VELCRO FASTENING INSTALLATION The ends of the clamp should face forward Fuel tank cover cushion Ve...

Page 507: ...SERVICING INFORMATION 10 29 COWLING INSTALLATION B A1 To A To A1 A To B To Radiator heat shield...

Page 508: ...10 30 SERVICING INFORMATION FRAME COVER INSTALLATION SEAT LOCK CABLE ROUTING...

Page 509: ...SERVICING INFORMATION 10 31 FRONT FENDER INSTALLATION 1 Reflex reflector 1 8 N m 0 18 kgf m 1 3 lb ft 4 5 N m 0 45 kgf m 3 25 lb ft For E 03 24 28 33 a b 1 a b...

Page 510: ...10 32 SERVICING INFORMATION REAR FENDER INSTALLATION Rear fender front Rear fender lower Rear fender cover front Swingarm Rear fender rear...

Page 511: ...SERVICING INFORMATION 10 33 SIDE STAND INSTALLATION 50 N m 5 0 kgf m 36 0 lb ft 95 N m 9 5 kgf m 68 5 lb ft 40 N m 4 0 kgf m 29 0 lb ft X Apply grease to sliding surface b c a a c b...

Page 512: ...ional gearshift rod must be used A STD footrest top position A 195 65 mm 7 70 in b Adjust the thread of each rod end b to equal length B Lower footrest top position B 198 26 mm 7 81 in H 70 mm 2 76 in...

Page 513: ...MATION 10 35 FRONT FOOTREST INSTALLATION 39 N m 3 9 kgf m 28 0 lb ft 18 N m 1 8 kgf m 13 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft Align the cutaway when installing 10 N m 1 0 kgf m 9 0 lb ft d c b a b b c...

Page 514: ...10 36 SERVICING INFORMATION PILLION FOOTREST INSTALLATION Footrest X Apply grease to sliding surface...

Page 515: ...R INSTALLATION Body cowling Mirror cover Cowling brace Mirror body Cushion 10 N m 1 0 kgf m 7 0 lb ft Turn signal lead wire Locate the turn signal lead wire coupler between the mirror cover and mirror...

Page 516: ...10 38 SERVICING INFORMATION REAR COMBINATION LIGHT INSTALLATION 5 N m 0 5 kgf m 3 5 lb ft 2 75 N m 0 275 kgf m 2 0 lb ft 2 75 N m 0 275 kgf m 2 0 lb ft a b b c a b c...

Page 517: ...COMBINATION LIGHT CUSHION FASTENER INSTALLATION Rear combination light Align the corner of cushions and fasteners with the root of the rib 30 mm 1 18 in 40 mm 1 58 in 4 mm 0 16 in or more 33 mm 1 30 i...

Page 518: ...ING INFORMATION REGULATOR RECTIFIER INSTALLATION NOTE To remove or install the regulator rectifier easily hold its bolt head with an open end wrench 1 Regulator Rectifier 3 Clamp 2 Bracket 4 Radiator...

Page 519: ...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 T...

Page 520: ...77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14530 Valve lifter attach ment 09916 33210 Valve guide reamer 4 5 mm 09916 33320 Valve guide reamer 9 8 mm 09...

Page 521: ...ler set 09925 18011 Steering bearing installer 09930 11920 Torx bit JT40H 09930 11940 Bit holder 09930 11950 Torx wrench 09930 30104 Sliding shaft 09930 34980 Rotor remover 09930 44520 Rotor holder 09...

Page 522: ...ssure 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 for...

Page 523: ...am 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 Cylinder head bolt M 10 Step 1 step 3 31 3 1 22 5 Final step 60...

Page 524: ...l strainer bolt 11 1 1 8 0 Oil pan bolt 10 1 0 7 0 Oil cooler mounting bolt 10 1 0 7 0 Oil cooler union bolt 10 1 0 7 0 Water bypass union 12 1 2 8 5 Starter motor mounting bolt 6 0 6 4 3 ITEM N m kgf...

Page 525: ...nt master cylinder 6 0 0 6 4 5 Air breeder valve Clutch release 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 18 1 8 13 0 Rea...

Page 526: ...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...

Page 527: ...ion 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 38 0 1 50 Valve spring tensi...

Page 528: ...73 280 2 8850 Cylinder distortion 0 02 0 008 Piston ring free end gap 1st Approx 6 5 0 26 5 2 0 20 2nd T Approx 8 0 0 31 6 4 0 25 Piston ring end gap 1st 0 06 0 18 0 002 0 007 0 50 0 020 2nd T 0 06 0...

Page 529: ...O D 34 976 35 000 1 3770 1 3780 Crankshaft journal oil clearance 0 010 0 028 0 0004 0 0011 0 080 0 0031 Crankshaft journal O D 34 982 35 000 1 3772 1 3780 Crankshaft thrust bearing thickness Right si...

Page 530: ...lutch master cylinder piston diam 12 657 12 684 0 4983 0 4994 Clutch release cylinder bore 35 700 35 762 1 4055 1 4079 Clutch release cylinder piston diam 35 650 35 675 1 4035 1 4045 Clutch fluid type...

Page 531: ...re 93 123 kPa 0 93 1 23 kgf cm 13 2 17 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 n...

Page 532: ...stance 16 5 22 3 k 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 vol...

Page 533: ...age 0 5 V and more Ignition coil resistance Primary 1 1 1 9 Terminal Terminal Secondary 10 8 16 2 k Plug cap Terminal Ignition coil primary peak voltage 80 V and more Generator coil resistance 0 2 0 9...

Page 534: ...obilizer indicator light LED ITEM STANDARD LIMIT Rear brake pedal height 65 75 2 6 3 0 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...

Page 535: ...ANDARD 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 29...

Page 536: ...mping force adjuster Rebound 6 clicks out from stiffest position Compression Hi 3 turns out from stiffest position Lo 14 clicks out from stiffest position Rear shock absorber spring set length 161 6 3...

Page 537: ...ibitor is permissible E 03 28 33 Gasoline used should be graded 95 octane or higher An unleaded gasoline is recommended Others Fuel tank capacity Including reserve 16 5 L 4 4 3 6 US lmp gal E 33 17 5...

Page 538: ...3 EXHAUST EMISSION CONTROL SYSTEM 11 4 HO2 SENSOR INSPECTION 11 5 HO2 SENSOR REMOVAL AND INSTALLATION 11 5 NOISE EMISSION CONTROL SYSTEM 11 5 PAIR AIR SUPPLY SYSTEM AND EMISSION CONTROL SYSTEM INSPECT...

Page 539: ...l injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO NOX and HC Adjusting interfering with improper replacement or resetting of any of the fuel injecti...

Page 540: ...ent discharging crankcase emissions into the atomo sphere Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combus tion chamber through the PCV breather hose ai...

Page 541: ...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 ISC valve adjusts the bypass air...

Page 542: ...ry to the ultimate purchaser or while 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 T...

Page 543: ...ew one PCV HOSE Remove the PCV hose from the crankcase breather cover Inspect the PCV hose for wear and damage If it is worn or damaged replace the PCV hose with a new one PAIR CONTROL SOLENOID VALVE...

Page 544: ...en the terminals of the PAIR con trol solenoid valve Resistance 18 22 at 20 30 C 68 86 F 09900 25008 Multi circuit tester set V Tester knob indication Resistance INSTALLATION If the resistance is not...

Page 545: ...FORMATION PAIR AIR SUPPLY SYSTEM DIAGRAM PAIR AIR SUPPLY SYSTEM HOSE ROUTING 10 24 PAIR control solenoid valve 1 From air cleaner PAIR reed valve 2 To 1 and 2 cylinders FRESH AIR 3 To 3 and 4 cylinder...

Page 546: ...B Bl G Y B Bl O G Y R B W B Lg B Br Bl W Bl B Bl G Bl Y R O G W R Gr B W Y Bl Br G W Gr B W B B B B B B O Bl O R B W O B O W B R B Bl Y G O R Y W O W B Br W G W B Y R B W R B M HEADLIGHT LO HEADLIGHT...

Page 547: ...Lg Y R B W R B B Br Bl W Bl B Bl G Bl Y R O W W R Gr B W Y Bl Br G O W Dbr W Gr B W O W B Br W G W B B B B B B B HEADLIGHT LO HEADLIGHT HI POSITION LIGHT STEERING DAMPER SOLENOID FRONT TURN SIGNAL LI...

Page 548: ...Prepared by January 2007 Part No 99500 39310 01E Printed in Japan 556...

Page 549: ...Printed in Japan K7...

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