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Suzuki GSX-R750, Service Manual

The Suzuki GSX-R750 Service Manual is a comprehensive guide for motorcycle enthusiasts. This manual provides step-by-step instructions for maintenance and repairs, ensuring your bike stays in top condition. Download this essential manual for free from manualshive.com, your go-to source for motorcycle user manuals.

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FI SYSTEM AND INTAKE AIR SYSTEM    4-1

4

FUEL SYSTEM ................................................................................. 4-51

FUEL TANK  LIFT-UP .................................................................... 4-51
FUEL TANK  REMOVAL ................................................................ 4-51
FUEL TANK  INSTALLATION ........................................................ 4-51
FUEL PRESSURE INSPECTION ................................................. 4-52
FUEL PUMP INSPECTION ........................................................... 4-53
FUEL PUMP RELAY INSPECTION .............................................. 4-55
FUEL PUMP AND FUEL FILTER REMOVAL .............................. 4-55
FUEL FILTER INSPECTION AND CLEANING ............................ 4-57
FUEL PUMP AND FUEL FILTER INSTALLATION ...................... 4-57

THROTTLE BODY AND STV ACTUATOR ...................................... 4-60

CONSTRUCTION .......................................................................... 4-60
THROTTLE BODY AND STV ACTUATOR REMOVAL ................ 4-61
THROTTLE BODY DISASSEMBLY .............................................. 4-66
THROTTLE BODY CLEANING..................................................... 4-67
INSPECTION ................................................................................. 4-67
THROTTLE BODY REASSEMBLY .............................................. 4-68
THROTTLE BODY AND STV ACTUATOR INSTALLATION ........ 4-70
STV ACTUATOR ADJUSTMENT ................................................. 4-71
FUEL INJECTOR INSPECTION ................................................... 4-75
FUEL INJECTOR REMOVAL ........................................................ 4-75
FUEL INJECTOR INSTALLATION ............................................... 4-76
FAST IDLE ADJUSTMENT .......................................................... 4-76
THROTTLE VALVE  SYNCHRONIZATION ................................... 4-77
THROTTLE POSITION SENSOR (TPS) SETTING....................... 4-80
THROTTLE CABLE ADJUSTMENT ............................................ 4-80

SENSORS ........................................................................................ 4-81

IAP SENSOR INSPECTION ......................................................... 4-81
IAP SENSOR REMOVAL/INSTALLATION ................................... 4-81
TP SENSOR INSPECTION ........................................................... 4-81
TP SENSOR REMOVAL/INSTALLATION .................................... 4-81
CKP SENSOR INSPECTION ........................................................ 4-81
CKP SENSOR REMOVAL/INSTALLATION ................................. 4-81
CMP SENSOR INSPECTION ....................................................... 4-81
CMP SENSOR REMOVAL/INSTALLATION ................................. 4-81
IAT SENSOR INSPECTION .......................................................... 4-81
IAT SENSOR REMOVAL/INSTALLATION ................................... 4-81
ECT SENSOR INSPECTION ........................................................ 4-82
ECT SENSOR REMOVAL/INSTALLATION ................................. 4-82
AP SENSOR INSPECTION .......................................................... 4-82
AP SENSOR REMOVAL/INSTALLATION .................................... 4-82
TO SENSOR INSPECTION ........................................................... 4-82
TO SENSOR REMOVAL/INSTALLATION .................................... 4-82

Summary of Contents for GSX-R750

Page 1: ...GSX R750 SUZUKI MOTOR CORPORATION PRINTED IN JAPAN FEBRUARY 2000 99500 37112 03E...

Page 2: ...b lication If modifications have been made since then differences may exist between the content of this manual and the actual motor cycle Illustrations in this manual are used to show the basic princi...

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

Page 4: ...EAD LOCK SUPER 1360 99000 32130 Apply or use brake fluid Apply SUZUKI BOND 1207B 99104 31140 for USA 99000 31140 for the other coun tries Apply THREAD LOCK SUPER 1303 99000 32030 Measure in voltage ra...

Page 5: ...ission EVAP Canister Evaporative Emission Canister Canister F FI Fuel Injection Fuel Injector FP Fuel Pump FPR Fuel Pressure Regulator FP Relay Fuel Pump Relay G GEN Generator GND Ground GP Switch Gea...

Page 6: ...ol Unit ECU Engine Coolant Level ECL Coolant Level Engine Coolant Temperature ECT Coolant Temperature Engine Coolant Tem perature Water Temperature Engine Speed RPM Engine Speed RPM Evaporative Emissi...

Page 7: ...OL P Programmable Read Only Memory PROM Pulsed Secondary Air lnjection PAIR Pulse Air Control PAIR R Random Access Memory RAM Read Only Memory ROM ROM S Secondary Air Injection AIR Secondary Throttle...

Page 8: ...CATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION 1 5 FUEL 1 5 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 ENGINE COOLANT 1 6 WATER FOR MIXING 1 6 ANTI FREEZE ENGINE COOLANT 1 6 LIQUID AMOUN...

Page 9: ...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 ad vice GENERAL PRECAUTIONS Proper serv...

Page 10: ...the larger sizes first Always tighten the bolts and nuts diagonally from the inside working out and to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking wa...

Page 11: ...he right side of the steering head pipe The engine serial number B is located on the rear side of the crank case These numbers are required especially for registering the machine and ordering spare pa...

Page 12: ...lternative according to the right chart ENGINE OIL For the other models Use a premium quality 4 stroke motor oil to ensure longer ser vice life of your motorcycle Use only oils which are rated SF or S...

Page 13: ...ficiency If the anti freeze engine coolant mixing ratio is below 50 rust inhabiting performance is greatly reduced Be sure to mix it above 50 even though the atmospheric temperature does not go down t...

Page 14: ...3 Vacuum hose routing label For E 33 4 Fuel caution label For E 02 24 5 Manual notice label For E 03 33 6 Frame caution label 7 Screen warning label 8 Steering warning label 9 Tire pressure label 0 W...

Page 15: ...mber of cylinders 4 Bore 72 0 mm 2 834 in Stroke 46 0 mm 1 811 in Piston displacement 749 cm3 45 7 cu in Compression ratio 12 0 1 Fuel system Fuel injection Air cleaner Paper element Starter system El...

Page 16: ...1 200 rpm Engine coolant temp 80 C Spark plug NGK CR9E DENSO U27ESR N Battery 12V 36 0 kC 10 Ah 10HR Generator Three phase A C Generator Main fuse 30A Fuse 15 15 15 15 10 10A Headlight 12V 55 55 55W H...

Page 17: ...CODES The following codes stand for the applicable country ies and area s MODEL CODE COUNTRY or AREA E 02 U K E 03 USA Except for california GSX R750 E 19 EU E 24 Australia E 28 Canada E 33 California...

Page 18: ...G 2 5 VALVE CLEARANCE 2 8 ENGINE OIL AND OIL FILTER 2 13 FUEL HOSE 2 15 ENGINE IDLE SPEED 2 15 THROTTLE VALVE SYNCHRONIZATION 2 15 THROTTLE CABLE PLAY 2 16 CLUTCH 2 17 COOLING SYSTEM 2 18 DRIVE CHAIN...

Page 19: ...nve nience NOTES More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART Interval km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7...

Page 20: ...icating 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 especially whenever the motorcycl...

Page 21: ...essure on the outside of the air cleaner element If air pressure is used on the inside dirt will be forced into the pores of the air cleaner element thus re stricting air flow through the air cleaner...

Page 22: ...air cleaner box 1 4 61 Disconnect all of the lead wire couplers from each ignition coil plug cap Do not remove the ignition coil plug cap before discon necting its lead wire coupler Remove all of the...

Page 23: ...If carbon is deposited remove it using a spark plug cleaner ma chine or carefully use a tool with a pointed end SPARK PLUG GAP Measure the spark plug gap using a thickness gauge If out of specificati...

Page 24: ...damaging the cylinder head threads first finger tighten the spark plug and then tighten it to the proper torque using the spark plug wrench Install the ignition coils plug caps and connect their lead...

Page 25: ...ve mechanism is serviced and 3 when the camshafts are disturbed by removing them for servicing Valve clearance when cold Standard IN 0 10 0 20 mm 0 004 0 008 in EX 0 20 0 30 mm 0 008 0 012 in NOTE The...

Page 26: ...nd In of No 2 If the clearance is out of specification adjust the clearance 2 10 09900 20803 Thickness gauge Turn the crankshaft 360 degrees one rotation to bring the TOP line on the starter clutch to...

Page 27: ...s toward tappet Be sure to check shim size with micrometer to ensure its size Refer to the tappet shim selection table 2 11 2 12 for details NOTE Be sure to apply engine oil to tappet shim top and bot...

Page 28: ...1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 2 20 0 26 0 30 1 35 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 0 31 0 35 1 40 1 45 1 50 1 55 1 60...

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

Page 30: ...motorcycle upright Place an oil pan below the engine and drain oil by removing the oil drain plug 1 and filler cap 2 Tighten the drain plug 1 to the specified torque and pour fresh oil through the oil...

Page 31: ...o properly tighten the oil filter use the special tool Never tighten the oil filter by hand Add new engine oil and check the oil level as described in the engine oil replacement procedure NECESSARY AM...

Page 32: ...v ery 6 000 km 4 000 miles 6 months thereafter NOTE Make this adjustment when the engine is hot Start the engine turn the throttle stop screw and set the engine idle speed as follows Engine idle speed...

Page 33: ...le cable play at the throttle grip A is between 2 0 4 0 mm 0 08 0 16 in Tighten the locknut 4 while holding the adjuster 6 Throttle cable play A 2 0 4 0 mm 0 08 0 16 in 3rd step While holding the thro...

Page 34: ...e lock nuts 1 securely After the adjustment is completed check that handle bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automati cally CLUTCH Inspe...

Page 35: ...n engine coolant by disconnecting the radiator hose 2 from the pump Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engine coolant may be harm...

Page 36: ...en the air bleeding bolt 1 and check the engine coolant flow out Air bleeding bolt 5 5 N m 0 55 kgf m 4 0 lb ft Close the radiator cap securely After warming up and cooling down the engine several tim...

Page 37: ...ry or rusted links Missing O ring seals Kinked or binding links If any defects are found the drive chain must be replaced NOTE When replacing the drive chain replace the drive chain and sprockets as a...

Page 38: ...11 0 kgf m 79 6 lb ft For E 03 28 33 120 N m 12 0 kgf m 86 8 lb ft For the others Torque link nut Rear 34 N m 3 4 kgf m 24 6 lb ft Install a new cotter pin For E 03 28 33 Recheck the drive chain slack...

Page 39: ...DOT 4 The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based fluids Do not use any brake f...

Page 40: ...nce will be adversely affected BRAKE PEDAL HEIGHT Loosen the locknut 1 Turn the push rod 2 until the brake pedal is 50 60 mm 2 0 2 4 in A below the top of the footrest Tighten the locknut 1 securely R...

Page 41: ...ir bleeder valve and insert the free end of the hose into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the...

Page 42: ...pedal TIRES Inspect every 6 000 km 4 000 miles 6 months TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous sit...

Page 43: ...use of tires other than those specified may cause instability It is highly recommended to use the specified tires TIRE TYPE DUNLOP D207FU Front D207U Rear E 03 24 28 33 MICHELIN PILOT SPORT C Front an...

Page 44: ...12 months Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm Replace any defective parts if necessary 6 46 6 50 EXHAUST PIPE BOLT AND NUT Tighten initiall...

Page 45: ...B Front brake caliper housing bolt 21 2 2 15 2 C Brake hose union bolt Front Rear 23 2 3 16 5 D Caliper air bleeder valve Front Rear 8 0 8 6 0 E Brake disc bolt Front 23 2 3 16 5 F Brake disc bolt Re...

Page 46: ...PERIODIC MAINTENANCE 2 29...

Page 47: ...aptor in the spark plug hole Make sure that the connection is tight Keep the throttle grip in the fully opened position Press the starter button and crank the engine for a few sec onds Record the maxi...

Page 48: ...d oil passage Combination of the above items OIL PRESSURETEST PROCEDURE Start the engine and check if the oil pressure indicator light is turned on If the light stays on check the oil pressure indicat...

Page 49: ...HAFT 3 30 CAM CHAIN TENSION ADJUSTER 3 32 CAM CHAIN TENSIONER 3 32 CAM CHAIN GUIDE 3 32 CYLINDER HEAD AND VALVE 3 33 CLUTCH 3 43 OIL PUMP 3 44 STARTER CLUTCH 3 44 GENERATOR 3 44 WATER PUMP 3 44 GEARSH...

Page 50: ...pump 3 21 3 44 3 85 Gearshift shaft 3 21 3 45 3 85 C Starter idle gear cover 3 23 3 83 Starter idle gear 3 23 3 82 D Starter clutch cover 3 23 3 82 Starter clutch 3 24 3 44 3 82 CKP sensor 3 24 7 23...

Page 51: ...steam cleaner Engine removal is sequentially explained in the following steps Reinstall the engine by reversing the removal pro cedure Remove the under cowlings 6 5 Remove the front and rear seats sea...

Page 52: ...3 4 ENGINE Remove the air cleaner box 4 61 RADIATOR Disconnect the reserve tank hose Disconnect the radiator inlet hoses Remove the throttle body and STV actuator 4 61...

Page 53: ...2 Remove the radiator mounting bolt Remove the radiator Be careful not to bent the radiator fin Remove the front engine cover 1 EXHAUST PIPE AND MUFFLER Remove the exhaust pipe bolts Remove the muffl...

Page 54: ...rom the clamps Disconnect the starter motor lead wire 2 Disconnect the ground lead wire 3 Disconnect the crankshaft position sensor coupler 4 Disconnect the gear position switch coupler 5 Disconnect t...

Page 55: ...the ignition coils plug caps Do not pry up the ignition coil plug cap with a driver or a bar to avoid its damage Be careful not to drop the ignition coil plug cap to prevent its short or open circuit...

Page 56: ...ove the cotter pin For E 03 28 33 Loosen the rear axle nut 3 and the rear torque link nut 4 Loosen the left and right chain adjusters 5 Push the rear wheel forward and make sure that the drive chain h...

Page 57: ...n the engine mounting pinch bolts 3 Remove the engine mounting bolts 4 Remove the engine mounting nut 5 Remove the engine mounting thrust adjuster locknut 6 with the special tool Loosen the engine mou...

Page 58: ...djuster locknut 2 Loosen the engine mounting thrust adjuster 3 NOTE Do not remove the engine mounting bolts at this stage Remove the engine mounting bolts and gradually lower the front side of the eng...

Page 59: ...Install all engine mounting bolts spacers and tighten them temporarily 3 12 Be careful not to catch the wiring harness between the frame and the engine Tighten the engine mounting thrust adjusters to...

Page 60: ...NGINE ITEM N m kgf m lb ft ABC 55 5 5 39 8 36 75 7 5 54 0 1 23 2 3 16 5 47 10 1 0 7 3 58 45 4 5 32 5 LENGTH ITEM mm in AC 45 1 77 Bolt B 55 2 17 DE 215 8 46 Spacer 2 30 5 1 20 Adjuster 47 40 1 57 Left...

Page 61: ...l the speed sensor rotor Tighten the speed sensor rotor bolt to the specified torque Speed sensor rotor bolt 20 N m 2 0 kgf m 14 4 lb ft Apply grease to the clutch push rod and install it W W W W W 99...

Page 62: ...ounting bracket 1 Install the exhaust pipe muffler Replace the gaskets with new ones Install and adjust the following items Engine oil 2 13 Engine coolant 2 19 Throttle cable play 2 16 Clutch 2 17 Idl...

Page 63: ...ain guide No 1 and Cam chain tensioner Cam chain and sprocket CKP sensor Starter clutch Generator cover Generator rotor Piston conrod and upper crankcase Cylinder Crankshaft Middle crankcase Transmiss...

Page 64: ...respective groups e g intake exhaust so that they can be reinstalled in their original posi tions Remove the spark plugs 2 5 PAIR VALVE Remove the PAIR valve 1 STARTER MOTOR Remove the starter motor...

Page 65: ...nd also to bring the cams to the position as shown Remove the cam chain tension adjuster cap bolt 1 NOTE The spring 3 and ball 4 are in the cam chain tension adjuster Remove the oil hose union bolt 2...

Page 66: ...INE COOLANT TEMP GAUGE INSPECTION 5 8 Remove the cylinder head side bolt 4 and its gasket When removing the cylinder head side bolt pull the cam chain upward or the chain will be caught between the cy...

Page 67: ...740 Clutch sleeve hub holder Remove the clutch springs NOTE Loosen the clutch spring set bolts little by little and diagonally Remove the pressure plate and clutch plates Remove the clutch push piece...

Page 68: ...utch sleeve hub nut Remove the wave washer 1 washer 2 clutch sleeve hub 3 and washer 4 Remove the spacer 5 and bearing 6 Remove the primary driven gear assembly 7 NOTE If it is difficult to remove the...

Page 69: ...circlip 1 the pin 3 and the washer 4 into the crankcase Remove the pin 3 and the washer 4 Remove the oil pump 5 GEAR SHIFT SYSTEM With the circlip 1 removed remove the gearshift shaft as sembly 2 Rem...

Page 70: ...R Remove the starter idle gear cover Remove the shaft 1 wave washer 2 washer 3 starter idle gear No 1 4 bearing 5 and washer 6 Remove the starter clutch cover Remove the wave washer 1 the starter idle...

Page 71: ...holder Remove the starter clutch bolt and washer Remove the starter clutch assembly CAM CHAIN CAM CHAIN TENSIONER CAM CHAIN GUIDE Remove the cam chain tensioner 1 and cam chain guide 2 Remove the cam...

Page 72: ...0 44530 Rotor holder Loosen the generator rotor bolt NOTE Install the bolt M 12 length 28 38 mm to the left end of crankshaft as shown in illustration Remove the generator rotor with the special tool...

Page 73: ...emove the gear position switch Remove the switch contacts and springs BREATHER COVER Remove the breather cover OIL FILTER Remove the oil filter with the special tool 2 14 09915 40610 Oil filter wrench...

Page 74: ...il pressure regulator 1 OIL PRESSURE SWITCH Remove the oil pressure switch 2 OIL STRAINER Remove the oil strainer 3 and O ring LOWER CRANK CASE Remove the lower crankcase bolts 6 mm Remove the lower c...

Page 75: ...iagonally and the smaller sizes first Remove the crankcase bolts 8 mm CRANKSHAFT Remove the O ring 1 Loosen the bearing cap bolts by using 10 mm 12 point socket wrench and tap the bearing cap bolt lig...

Page 76: ...remove the piston and conrod from the upper crankcase Be careful not to damage the cylinder wall by the conrod Remove the piston pin circlip Separate the piston and conrod by driving out the piston pi...

Page 77: ...air flows through the PAIR control valve air inlet port to the air outlet ports If air does not flow out replace the PAIR valve with a new one Connect the vacuum pump gauge to the vacuum port of the c...

Page 78: ...N m 0 8 kgf m 5 8 lb ft CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the intake by the embossed letters EX for exhaust as against letters IN for intake CAM W...

Page 79: ...should be taken at the widest part If the camshaft journal oil clearance measured exceeds the limit measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft jou...

Page 80: ...ck that the push rod slides smoothly when releasing stop per If it does not slide smoothly replace the cam chain tension ad juster with a new one CAM SPROCKET Inspect the sprocket teeth for wear If th...

Page 81: ...pecial tools compress the valve springs and remove the two cotter halves 3 from valve stem 09916 14510 Valve lifter 09916 14521 Valve lifter attachment IN 09916 14530 Valve lifter attachment EX 09916...

Page 82: ...If the runout exceeds the service limit replace the valve 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Valve stem runout Service Limit 0 05 mm 0 002 in VA...

Page 83: ...01 Magnetic stand Valve stem deflection IN EX Service Limit 0 35 mm 0 014 in VALVE STEM WEAR If the valve stem is worn down to the limit as measured with a micrometer replace the valve If the stem is...

Page 84: ...hole always turn it clockwise Apply engine oil to the valve guide hole NOTE Install the valve guide until the attachment contacts with the cyl inder head 3 Failure to oil the valve guide hole before...

Page 85: ...ve seat width W Standard 0 9 1 1 mm 0 035 0 043 in If the valve seat is out of specification re cut the seat VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are machined to...

Page 86: ...um amount necessary from the seat to pre vent the possibility of the valve stem becoming too close to the camshaft TOP NARROWING CUT If the contact area W is too high on the valve or if it is too wide...

Page 87: ...ed valve seat should have a velvety smooth finish but not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur during the first few se...

Page 88: ...Check the valve springs for proper strength by measuring their free length and also by the force required to compress them If the spring length is less than the service limit or if the force required...

Page 89: ...g each valve take care not to damage the lip of the oil seal O O O O O MOLYBDENUM OIL SOLUTION Install the valve springs with the small pitch portion A facing cylinder head B Large pitch portion Put o...

Page 90: ...nted sur face faces the tappet INTAKE PIPE Install the intake pipe in the following procedure Apply THREAD LOCK 1342 to the screw and install the in take pipes I 99000 32050 THREAD LOCK 1342 WATER BYP...

Page 91: ...CLUTCH DRIVEN PLATES INSPECTION NOTE Wipe off engine oil from the clutch driven plates with a clean rag Measure each driven plate for distortion with a thickness gauge and surface plate Replace drive...

Page 92: ...nspect the starter clutch for a smooth movement Inspect that the gear turns one direction only If a large resistance is felt for rotation inspect the starter clutch bearing or the starter clutch conta...

Page 93: ...shift 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 following parts...

Page 94: ...ation of the oil pressure regulator by pushing on the piston with a proper bar If the piston does not operate replace the oil pressure regula tor with a new one OIL STRAINER Inspect the oil strainer b...

Page 95: ...lip from its groove and slide it towards the 3rd 4th drive gear Slide the 6th 1 and 2nd 2 drive gears toward the 3rd 4th drive gears then remove the 2nd drive gear circlip 3 1 Countershaft 1st drive g...

Page 96: ...w circlip must be installed When installing a new circlip do not expand the end gap larger than required to slip the circlip over the shaft After installing a circlip make sure that it is completely s...

Page 97: ...ENGINE 3 49 Driveshaft Countershaft TRANSMISSION PARTS LOCATION...

Page 98: ...as indicated If the largest reading at any position of the straightedge ex ceeds the limit replace the cylinder 09900 20803 Thickness gauge Cylinder distortion Service Limit 0 20 mm 0 008 in CYLINDER...

Page 99: ...arance exceeds the service limit replace the cylinder and the piston Piston to cylinder clearance Service Limit 0 120 mm 0 0047 in PISTON PINS AND PIN BORE Measure the piston pin bore inside diameter...

Page 100: ...in Oil 1 51 1 53 mm 0 0594 0 0602 in Piston ring thickness Standard 1st 0 97 0 99 mm 0 0382 0 0390 in 2nd 0 77 0 79 mm 0 0303 0 0311 in PISTON RING FREE END GAP AND PISTON RING END GAP Measure the pi...

Page 101: ...When installing the spacer be careful not to allow its two ends to overlap in the groove Install the 2nd ring 3 and the 1st ring 4 NOTE 1st ring and 2nd ring differ in shape 1st ring and 2nd ring have...

Page 102: ...arshift fork plays an important role in the smoothness and positiveness of the shifting action Shift fork to groove clearance Service Limit 0 50 mm 0 020 in 09900 20803 Thickness gauge If the clearanc...

Page 103: ...se Replace a bearing if there is anything unusual Bearing removal Remove the gearshift fork bearing using the special tool 09921 20210 Bearing remover 09930 30102 Sliding shaft Remove the gearshift ca...

Page 104: ...special tool 09913 70210 Bearing installer set NOTE The stamped mark side of the gearshift shaft bearing faces outside Install the oil seal Install the gearshift cam with the bearing NOTE The stamped...

Page 105: ...For 5th driven gear Apply a small quantity of THREAD LOCK 1342 to the bearing retainer screws and the shift fork shaft retainer bolt Tighten them to the specified torque I 99000 32050 THREAD LOCK 134...

Page 106: ...e upper crank case Remove the oil jet for transmission from the lower crankcase Inspection and cleaning Check the oil jets for clogging If they are clogged clean their oil passage with a proper wire a...

Page 107: ...em Install each piston cooling oil jet with the bolts NOTE Apply a small quantity of THREAD LOCK 1342 to the bolts and tighten them to the specified torque I 99000 32050 THREAD LOCK 1342 Piston coolin...

Page 108: ...auge 1 1000 mm 1 mm 09900 22401 Small bore gauge 10 18 mm Conrod small end I D Service Limit 15 040 mm 0 5921 in If the inside diameter of the conrod small end exceeds the limit replace the conrod CON...

Page 109: ...pecified torque in two stages 3 69 Apply engine oil to the conrod cap bolt Never rotate the crankshaft or conrod when a piece of plastigauge is installed Remove the bearing caps and measure the width...

Page 110: ...Code O D specification 1 32 992 33 000 mm 1 2989 1 2992 in 2 32 984 32 992 mm 1 2986 1 2989 in 3 32 976 32 984 mm 1 2983 1 2986 in 09900 20202 Micrometer 25 50 mm Bearing thickness Color Part No Thic...

Page 111: ...the crankcase bolts M9 with the specified torque value in the indicated order Crankcase bolt 9 mm Initial 18 N m 1 8 kgf m 13 0 lb ft Final 32 N m 3 2 kgf m 23 0 lb ft Remove the lower crankcase and m...

Page 112: ...1 984 31 992 mm 1 2592 1 2595 in C 31 976 31 984 mm 1 2589 1 2592 in 09900 20202 Micrometer 25 50 mm Bearing thickness specification Color Part No Thickness Green 1 488 1 492 mm 12229 35F00 0A0 0 0586...

Page 113: ...dures CRANKSHAFT THRUST CLEARANCE ADJUSTMENT Remove the right side thrust bearing and measure its thick ness with a micrometer If the thickness of the right side thrust bearing is below stan dard repl...

Page 114: ...0D0 0 0955 0 0965 in 0 0024 0 0043 in 2 485 2 510 mm Blue 2 400 2 425 mm 0 060 0 110 mm 0 0978 0 0988 in 12228 17E00 0C0 0 0945 0 0955 in 0 0024 0 0043 in 2 460 2 485 mm Black 2 375 2 400 mm 0 060 0...

Page 115: ...cylinder check that the gaps are so located Rub a small quantity of molybdenum oil solution onto each pis ton pin O O O O O MOLYBDENUM OIL Assemble the piston and conrod NOTE When installing the pist...

Page 116: ...be faced to each exhaust side Be carefull not to damage the cylinder wall by the conrod Check that ID code B on the each conrods faces toward intake side Be sure to clean the conrod big end Apply mol...

Page 117: ...NUM OIL SOLUTION Be sure to clean the conrod big end When fitting the conrod cap make sure that I D code B on each conrod faces toward intake valve side Apply engine oil to the bearing cap bolts Tight...

Page 118: ...left thrust bearings with oil groove B facing the crank web NOTE Right thrust bearing has green painting CRANKCASE Clean the mating surfaces of the crankcases Install the dowel pins 1 and O ring 2 to...

Page 119: ...and assemble the crankcases within few minutes Take extreme care not to apply any BOND to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film Align t...

Page 120: ...the pressure Crankcase bolt M6 initial 6 N m 0 6 kgf m 4 5 lb ft Final 11 N m 1 1 kgf m 8 0 lb ft NOTE Fit the clamp to the crankcase bolt A NOTE After the crankcase bolts have been tightened check if...

Page 121: ...e on the bearing and the bearing pin with the indent on the bearing Install the driveshaft assembly on the upper crankcase NOTE Align the bearing ring with the groove on the crankcase and the bearing...

Page 122: ...follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to a...

Page 123: ...M6 initial 6 N m 0 6 kgf m 4 5 lb ft Final 11 N m 1 1 kgf m 8 0 lb ft M8 initial 15 N m 1 5 kgf m 10 8 lb ft Final 26 N m 2 6 kgf m 19 0 lb ft NOTE Fit the copper washer to the crankcase bolts A Fit...

Page 124: ...t to prevent oil leakage Install the oil pan NOTE Fit the gasket washer to the oil pan bolt A Tighten the oil pan bolts diagonally to the specified torque Oil pan bolt 10 N m 1 0 kgf m 7 0 lb ft Insta...

Page 125: ...h 14 N m 1 4 kgf m 10 0 lb ft NOTE Be careful not to apply SUZUKI BOND 1207B to the hole of the thread end OIL COOLER Apply the grease to the O ring W 99000 25030 SUZUKI SUPER GREASE A Use the new O r...

Page 126: ...m 7 0 lb ft GEAR POSITION SWITCH Install the gear position switch contacts 1 and the springs 2 Apply the grease to the O ring W 99000 25030 SUZUKI SUPER GREASE A Apply the THREAD LOCK to the gear pos...

Page 127: ...en the water pump mounting bolts to the specified torque Water pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Pass through the gear position switch lead wire under the warter pump lib A Apply the...

Page 128: ...09930 44530 Rotor holder Generator rotor bolt 100 N m 10 0 kgf m 72 3 lb ft GENERATOR COVER Apply SUZUKI BOND 1207B lightly to the mating surfaces at the parting line between the upper and lower cran...

Page 129: ...punched mark A on the cam chain drive sprocket with the punched mark B on the crankshaft CAM CHAIN TENSIONER AND CAM CHAIN GUIDE Install the cam chain Apply a small quantity of THREAD LOCK 1342 to th...

Page 130: ...h the washer Hold the starter clutch with special tool and tighten its bolt to the specified torque 09920 34830 Starter clutch Starter clutch bolt 55 N m 5 5 kgf m 40 0 lb ft STARTER IDLE GEAR Install...

Page 131: ...he new gasket washer to prevent oil leakage Starter idle gear cover 10 N m 1 0 kgf m 7 0 lb ft Install the starter idle gear No 1 shaft 1 and the thrust washer 2 the bearing 3 and the starter idle gea...

Page 132: ...bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Hook the return spring end to the stopper 1 Confirm the gearshift cam stopper movement Check the neutral position Install the gearshift cam stopper plate after al...

Page 133: ...w O ring to prevent oil leakage W 99000 25030 SUZUKI SUPER GREASE A NOTE Set the oil pump shaft end to the water pump shaft Install the oil pump with the three bolts and then tighten them to the speci...

Page 134: ...1 to the primary driven gear assembly NOTE Rotate the crankshaft so as not to contact the primary driven gear and crankshaft balance weight Install the primary driven gear assembly NOTE Be sure to en...

Page 135: ...tside Install the clutch sleeve hub nut Hold the clutch sleeve hub using the special tool 09920 53740 Clutch sleeve hub holder Tighten the clutch sleeve hub nut to the specified torque Clutch sleeve h...

Page 136: ...the countershaft NOTE Thrust washer 4 is located between the pressure plate and the bearing 3 Install the clutch pressure plate Direction of outside A No 1 Drive Plate Thickness 3 0 mm 0 12 in 8 pcs...

Page 137: ...gonally CLUTCH COVER Apply SUZUKI BOND 1207B lightly to the mating surfaces at the parting line between the upper middle and lower crankcases as shown C 99104 31140 SUZUKI BOND 1207B Install the gaske...

Page 138: ...ally and diagonally Cylinder head bolt M10 Initial 25 N m 2 5 kgf m 18 0 lb ft Final 46 N m 4 6 kgf m 33 3 lb ft NOTE Install the washers to the cylinder head bolts M10 as shown Apply engine oil to th...

Page 139: ...ten the water temp gauge Water temp gauge 18 N m 1 8 kgf m 13 0 lb ft Install the thermostat 5 10 Install the thermostat cover Thermostat cover bolt 10 N m 1 0 kgf m 7 0 lb ft NOTE Fit the clamp to th...

Page 140: ...als and cam faces Apply engine oil to the camshaft journal holders O O O O O MOLYBDENUM OIL SOLUTION NOTE Before installing the camshaft check that the tappets are installed correctly Pull the cam cha...

Page 141: ...ocket with a proper wire clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders NOTE The cam chain should now be on all three sprockets Be careful not to move the...

Page 142: ...wn down evenly Each camshaft journal holder is identified with a cast on letters A Tighten the camshaft journal holder bolts in ascending order of numbers see below to the specified torque Camshaft jo...

Page 143: ...nd tighten the union bolt Oil hose union bolt 12 N m 1 2 kgf m 8 7 lb ft Install the gaskets 5 and the cam chain tension adjuster cap bolt NOTE Click sound is heard when the cam chain tension adjuster...

Page 144: ...lb ft Align the center of cam chain tension adjuster mounting bolt with the left side face of oil hose union pipe White mark Oil hose 20 12 N m 1 2 kgf m 8 7 lb ft 23 N m 2 3 kgf m 16 5 lb ft 90 90 1...

Page 145: ...the dowel pins Install the O rings Install the new gaskets to the cylinder head cover Apply SUZUKI BOND 1207B to the cam end caps of the gas kets as shown C 99104 31140 SUZUKI BOND 1207B Use the new g...

Page 146: ...e PAIR valve and hose 8 22 I 99000 32050 THREAD LOCK 1342 PAIR reed valve cover bolt 10 N m 1 0 kgf m 7 0 lb ft STARTER MOTOR Apply the grease to the O ring W 99000 25030 SUZUKI SUPER GREASE A Install...

Page 147: ...SAFE FUNCTION 4 29 FI SYSTEM TROUBLESHOOTING 4 30 CUSTOMER COMPLAINT ANALYSIS 4 30 SELF DIAGNOSTIC PROCEDURES 4 31 SELF DIAGNOSIS RESET PROCEDURE 4 31 MALFUNCTION CODE AND DEFECTIVE CONDITION 4 32 C1...

Page 148: ...ON 4 70 STV ACTUATOR ADJUSTMENT 4 71 FUEL INJECTOR INSPECTION 4 75 FUEL INJECTOR REMOVAL 4 75 FUEL INJECTOR INSTALLATION 4 76 FAST IDLE ADJUSTMENT 4 76 THROTTLE VALVE SYNCHRONIZATION 4 77 THROTTLE POS...

Page 149: ...nation The terminals must be clean and free of any foreign material which could impede proper terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any a...

Page 150: ...rt great care should be taken not to apply any sharp impacts during removal and installation Be careful not to touch the electrical terminals of the ECM The static electricity from your body may damag...

Page 151: ...CM with its coupler con nected If attempted damage to ECM or sensors may result Be sure to use a specified voltmeter ohmmeter Otherwise ac curate measurements may not be obtained and personal injury m...

Page 152: ...e that each terminal is fully inserted in the coupler and locked If contact tension is not enough rectify the contact to increase tension or replace The terminals must be clean and free of any foreign...

Page 153: ...0V Also if measured values are as listed below a resistance ab normality exists which causes the voltage drop in the circuit between terminals A and B Voltage Between C and body ground Approx 5V B and...

Page 154: ...fter changing the resistance range When measuring the resistance with the multi circuit tester also measure the resistance with no load Sub tract that resistance from the resistance measured under loa...

Page 155: ...ning angle and various compensations which are determined according to the signals from various sensors that detect the engine and driving conditions ECM Intake Air Pressure Intake air pressure Sensor...

Page 156: ...ry voltage and at the same time it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltag...

Page 157: ...by the fuel pressure regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept absolute fuel pressure of 300 kPa 3 0 kgf cm2 43 psi the fue...

Page 158: ...e many grooves around it Then the fuel is drawn through the inlet port and with its pressure increased it is discharged through the outlet port The fuel pump has a check valve to keep some pressure in...

Page 159: ...ter It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM When the solenoid coil of the injector is energized by the ECM it become...

Page 160: ...itch has been turned on Thereafter when the crankshaft is turned by the starter motor or the engine has been started the engine revolving signal is input to the ECM Then current flows to the fuel pump...

Page 161: ...nal information received CPU calculates the volume of fuel necessary for injection using maps programmed for varying engine conditions Then the operation signal of the fuel injection is sent from the...

Page 162: ...n sensor to identify the cylinder during operation and these information are sent to the ECM This makes it possible to inject the optimum volume of fuel in the best timing for the engine operating con...

Page 163: ...nd sent to the ECM The basic fuel injection time volume is determined according to the voltage signal output voltage The voltage signal increases when the intake air pressure is high THROTTLE POSITION...

Page 164: ...position sensor Pick up coil is installed on the cylinder head cover The sensor generates the pick up signal to be supplied to the ECM The ECM calculates and decides the cylinder identity and se quent...

Page 165: ...sensor is located beneath the left side of the seat rail The sensor detects the atmospheric pressure The detected pres sure is converted into voltage signal and sent to the ECM The injection time vol...

Page 166: ...located in ahead of the rear fender The sensor detects the leaning of the motorcycle When it leans more than 43 the mechanical switch turns ON and a signal is sent to the ECM At the same time this si...

Page 167: ...take air so as to improve engine output power The system produces more seamless and linear throttle response This is performed by opening or closing the throttle body intake port according to the gear...

Page 168: ...ECM to change the current direction into the motor of the STV actuator The motor and the position sensor are located inside the STV actuator The position sensor detects the STV actuator movement by me...

Page 169: ...Engine coolant temperature sensor ECTS C Ignition coil IG COIL D Speed sensor E Atmospheric pressure sensor APS F Camshaft position sensor CMPS ECM G Intake air pressure sensor IAPS H Fuel injector FI...

Page 170: ...DINTAKEAIRSYSTEM 4 23 ECM J Intake air temperature sensor IATS K Throttle position sensor TPS L Crankshaft position sensor CKPS M Secondary throttle valve actuator STVA N Fuel pump FP O Fuel pump rela...

Page 171: ...4 24 FISYSTEMANDINTAKEAIRSYSTEM FP RELAY FI 1 FI 2 FI 3 FI 4 1 2 3 4 IATS TPS STVA APS IAPS IG CMPS ECTS STARTER MOTOR SPEED SENSOR CKPS GPS ECM BATTERY TS TOS FP CLP SWITCH FI SYSTEM DIAGRAM...

Page 172: ...FISYSTEMANDINTAKEAIRSYSTEM 4 25 FI SYSTEM WIRING DIAGRAM...

Page 173: ...cycle can run 2 The injection signal is stopped when the camshaft position sensor signal crankshaft position sensor signal tip over sensor signal 1 2 3 and 4 ignition signals 1 2 3 and 4 injector sign...

Page 174: ...the devices These affected devices are indicated in the code form 09930 82710 Mode select switch Before checking the malfunction code do not disconnect the ECM lead wire couplers If the couplers from...

Page 175: ...witch signal Anti theft In the LCD DISPLAY panel the malfunction code is indicated from small code to large code 3 To get the proper signal from the throttle position sensor the sensor basic position...

Page 176: ...1 2 3 cylinders can run YES YES YES YES Yes means that the engine can start and can run even if the above signal is not received from each sensor But the engine running condition is not complete prov...

Page 177: ...al knocking Other Other Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened High Low r min Throttle valve is closed Unstable Load is app...

Page 178: ...arefully to have good understanding as to what func tions are available and how to use it Be sure to read PRECAUTIONS for Electrical Circuit Service 4 4 before inspection and observe what is written t...

Page 179: ...e sensor wiring coupler connection The sensor should produce following voltage 0 2 V sensor voltage 4 8 V Without the above range c14 is indicated Throttle position sensor wiring coupler connection Th...

Page 180: ...s indicated Gear position sensor wiring coupler connection Gearshift cam etc When fuel injection signal stops the c32 c33 c34 or c35 is indicated Injector wiring coupler connection power supply to the...

Page 181: ...ntinuity Infinity Terminal Ground 09900 25008 Multi circuit tester Tester knob indication Resistance No Replace the CMP sensor with a new one Yes Disconnect the CMP sensor coupler Crank the engine a f...

Page 182: ...ty Black Ground Green Ground 09900 25008 Multi circuit tester Tester knob indication Resistance No Replace the CKP sensor with a new one Yes Disconnect the CKP sensor coupler Crank the engine a few se...

Page 183: ...ure the IAP sensor output voltage at the wire side coupler between G B and B Br wires IAP sensor output voltage Approx 2 7 V at idle speed G B B Br 09900 25008 Multi circuit tester Tester knob indicat...

Page 184: ...uit tester Tester knob indication Voltage No If check result is not satisfactory replace IAP sensor with a new one Yes Red G B or B Br wire open or shorted to ground or poor h n or r connection 4 25 I...

Page 185: ...the Red wire and ground If OK then measure the voltage at the Red wire and B Br wire TPS sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tester Tester knob indication Volt...

Page 186: ...1 V Throttle valve is opened Approx 4 4 V 09900 25008 Multi circuit tester Tester knob indication Voltage No If check result is not satisfactory replace TP sensor with a new one Yes Red P B or B Br w...

Page 187: ...or poor contacts on the ECM coupler Open or short circuit in the B Bl wire or B Br wire Yes Turn the ignition switch OFF Measure the ECT sensor resistance ECT sensor resistance 2 3 2 6 k at 20 C 68 F...

Page 188: ...B Br 09900 25008 Multi circuit tester Tester knob indication Voltage No Loose or poor contacts on the ECM coupler Open or short circuit in the Dg wire or B Br wire Yes Turn the ignition switch OFF Mea...

Page 189: ...measure the AP sensor input voltage Turn the ignition switch ON Disconnect the AP sensor coupler Measure the voltage between Red wire and ground If OK then measure the voltage between Red wire and B B...

Page 190: ...ircuit tester Tester knob indication Voltage No If check result is not satisfactory replace AP sensor with a new one Yes Red G Y or B Br wire open or shorted to ground or poor h l or n connection 4 25...

Page 191: ...from its bracket and measure the voltage when it is leaned more than 43 left and right from the horizontal level TO sensor voltage 0 V Black B Br 09900 25008 Multi circuit tester Tester knob indicatio...

Page 192: ...h ON Measure the voltage between the Red wire terminal and B Br wire terminal Position sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tester Tester knob indication Voltag...

Page 193: ...ition Insert the copper wires into the back side of the position sensor lead wire coupler Disconnect the STVA motor lead wire coupler 2 To set the ST valve to fully close position apply 12 volts to A...

Page 194: ...above procedure until the output voltage be comes specified value Position sensor output voltage ST valve is fully close 0 2 Output Voltage 0 8 ST valve is fully open 4 2 Output Voltage 4 8 No Replac...

Page 195: ...otorcycle with a jack Turn the side stand to up right position Turn the engine stop switch ON Insert the copper wire to the lead wire coupler Turn the ignition switch ON Measure the voltage at the wir...

Page 196: ...ty Terminal Ground 09900 25008 Multi circuit tester Tester knob indication Resistance No Replace the injector with a new one 4 75 Yes Turn the ignition switch ON Measure the injector voltage between Y...

Page 197: ...e or poor contacts If OK then check the insulation and continuity Refer to page 4 55 for details No Replace the FP relay with a new one Yes Y B or O W wire open or shorted to ground or poor 9 or G con...

Page 198: ...p lead wire coupler 1 Place a rag under the fuel tank and disconnect the fuel feed hose 2 When removing the fuel tank do not remain the fuel feed hose 2 at the fuel tank side Gasoline is highly flamma...

Page 199: ...pressure Approx 300 kPa 3 0 kgf cm2 43 psi If the fuel pressure is lower than the specified inspect the follow ing items Fuel hose leakage Clogged fuel filter Pressure regulator Fuel pump If the fuel...

Page 200: ...fuel pump relay and tip over sensor FUEL DISCHARGE AMOUNT INSPECTION Gasoline is highly flammable and explosive Keep heat spark and flame away Lift and support the fuel tank with its prop stay 4 51 D...

Page 201: ...uel pump for 30 seconds and measure the amount of fuel discharged Battery terminal Power source lead wire 1 Yellow with red tracer Battery terminal Ground If the discharge amount is not specified it m...

Page 202: ...irst check the insulation between 1 and 2 terminals with pocket tester Then apply 12 volts to 3 and 4 terminals to 3 and to 4 and check the continuity between 1 and 2 If there is no continuity replace...

Page 203: ...4 51 Remove the fuel pump assembly by removing its mounting bolts diagonally Gasoline is highly flammable and explosive Keep heat spark and flame away Remove the nuts Remove the screws Remove the fuel...

Page 204: ...w smoothly and loss in engine power may result Blow the fuel filter with compressed air FUEL PUMP AND FUEL FILTER INSTALLATION Install the fuel pump and fuel filter in the reverse order of removal and...

Page 205: ...erminal for fuel pump B Thermistor for low level C Thermistor for high level Pass through the wires behind the thermistors Thermistor f mistor for high level Thermistor f mistor for low le w level The...

Page 206: ...ng the fuel pump assembly lightly tighten all the fuel pump assembly mounting bolts in the ascending order of numbers and then tighten them to the specified torque in the above manner Fuel pump mounti...

Page 207: ...1 TP sensor 2 Throttle stop screw 3 Fast idle adjusting screw 4 Fuel delivery pipe 5 O ring 6 Dust seal 7 Ignitor 8 Cusion seal 9 Vacuum hose 0 STV actuator bracket A STV actuator B STVA control cable...

Page 208: ...tool s switch ON turn the ignition switch ON 09930 82710 Mode select switch Check the slot A of the STV actuator facing downward as shown Before removing the throttle body be sure to set the STV actu...

Page 209: ...Disconnect the throttle cables from their drum Disconnect the fast idle cable from its cam After disconnecting the throttle cables do not snap the throttle valve from full open to full close It may ca...

Page 210: ...um hose 1 from the No 4 throttle body Disconnect the fuel injector lead wire coupler 2 Loosen the throttle body clamp screws at the intake pipe side Remove the throttle stop screw 3 from the cable gui...

Page 211: ...actuator pulley 3 with an adjustable wrench and loosen the pulley mounting bolt 4 When loosening or tightening the pulley bolt be sure to fix the pulley with an adjustable wrench or STV actuator may...

Page 212: ...4 65 Remove the STV actuator Remove the actuator bracket 1 A little portion of the ST valve is visible from the top of the throttle body Don t put the secondary valve s side of the throttle body down...

Page 213: ...ire coupler 1 Disconnect the fuel injector lead wire couplers 2 Remove the fuel delivery pipe assembly 3 by removing its mounting screws Remove the fuel injectors Disconnect the respective vaccum hose...

Page 214: ...an passageways Wire can damage passageways If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip type cleaning solution and allow them to soak Always follow the che...

Page 215: ...ints When installing the TP sensor align the groove 1 with the lib 2 TP sensor setting procedure 4 28 09930 11960 Torx wrench Apply thin coat of the engine oil to the new O rings 3 Replace the O ring...

Page 216: ...aight to each throttle body Replace the dust seal and O ring with the new ones Never turn the injector while pushing it Install the fuel delivery pipe assembly to the throttle body as sembly Never tur...

Page 217: ...he bolt A Install the STV actuator to the bracket STV actuator mounting bolt 5 N m 0 5 kgf m 3 5 lb ft Loosen the lock nuts 2 fully NOTE No 1 cable and No 2 cable can be distinguished by the letters 1...

Page 218: ...lley with an adjustable wrench and then tighten the pulley mounting bolt to the specified torque STV actuator pulley mounting bolt 5 N m 0 5 kgf m 3 5 lb ft When loosening or tightening the pulley bol...

Page 219: ...able adjuster 1 until the outer cable play A becomes zero NOTE Make sure that outer cable end is fixed into the rubber stopper B 3rd step Turn out the No 1 cable adjuster 2 to obtain a cable slack C o...

Page 220: ...f C28 is indicated repeat the adjustment procedure from 1st step to 4th step and also perform 5th step Don t pinch your fingers in the ST valve if the air cleaner is removed Slack 0 1 0 mm 0 0 04 in S...

Page 221: ...Voltage If the measured voltage is less than specification adjust the No 2 cable adjuster as follows Set the ST valve to adjustment position 4 61 Adjusting the No 2 cable with the ST valve fully clos...

Page 222: ...urn out the No 1 cable adjuster 1 until the output voltage be comes specified value Position sensor output voltage ST valve is fully open 4 2 output voltage 4 8 V Repeat the above procedure until the...

Page 223: ...d condition the engine speed rises to 3 500 rpm when warmed up Connect a tachometer Start up the engine and run it in idle condition for warming up Set the idle speed to 1 200 rpm Turn the fast idle l...

Page 224: ...t in idling condition for warming up Stop the warmed up engine Disconnect the IAT sensor coupler 1 and remove the IAT sen sor from the air cleaner box Connect the removed IAT sensor to its coupler and...

Page 225: ...amage the internal engine parts Turn the air screw 3 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 4 in the tube to the center line 5 NOTE The vacuum gauge...

Page 226: ...l level and in this position the four balls should be within one ball dia If the difference is larger than one ball turn the balance ad justing screw on the throttle body and bring the ball to the sam...

Page 227: ...uts 1 of the throttle returning cable 2 Turn the returning cable adjuster 3 to obtain proper cable play Loosen the lock nuts 4 of the throttle pulling cable 5 Turn the pulling cable adjuster 6 in or o...

Page 228: ...gnal rotor is mounted on the right end of the crankshaft and the crankshaft position sensor Pick up coil is installed on the right side of the middle crankcase 4 35 CKP SENSOR REMOVAL INSTALLATION 3 2...

Page 229: ...INSTALLATION Lift and support the fuel tank 4 51 Disconnect the coupler 1 and the AP sensor hose 2 Remove the AP sensor by removing the screws Installation is in the reverse order of removal TO SENSO...

Page 230: ...ATION 5 6 COOLING FANTHERMO SWITCH 5 6 REMOVAL 5 6 INSPECTION 5 7 INSTALLATION 5 7 ENGINE COOLANT TEMPERATURE SENSOR 5 8 REMOVAL 5 8 INSPECTION 5 8 INSTALLATION 5 9 THERMOSTAT 5 9 REMOVAL 5 9 INSPECTI...

Page 231: ...gine coolant including reserve tank capacity Anti freeze 1 200 ml 3 1 2 6 US lmp pt Water 1 200 ml 3 1 2 6 US lmp pt You can be injured by scalding fluid or steam if you open the radiator cap when the...

Page 232: ...he tester 2 to the filler Do not remove the radiator cap when the engine is hot Give a pressure of about 120 kPa 1 2 kgf cm2 17 psi and see if the system holds this pressure for 10 seconds If the pres...

Page 233: ...5 kgf cm2 13 5 17 8 psi and that with the tester held standstill the cap is capable of holding that pressure for at least 10 seconds Replace the cap if it is found not to satisfy either of these two...

Page 234: ...d in a cracked condition or flattened must be replaced Any leakage from the connecting section should be corrected by proper tightening RADIATOR REMOUNTING Install the radiator Route the radiator hose...

Page 235: ...does not turn replace the motor assembly with a new one NOTE When making above test it is not necessary to remove the cool ing fan INSTALLATION Install the radiator Route the radiator hoses 8 19 Pour...

Page 236: ...pens 09900 25008 Multi circuit tester set Tester knob indication Continuity test Cooling fan thermo switch operating temperature Standard OFF ON Approx 105 C 221 F ON OFF Approx 100 C 212 F Take speci...

Page 237: ...l contained in a pan which is placed on a stove Heat the oil to raise its temperature slowly and read the column thermometer 2 and the ohmmeter If the temperature sensor ohmic value does not change in...

Page 238: ...ts a sharp impact Install the throttle body Install the air cleaner box Install the fuel tank 4 51 Install the front and rear seats 6 8 Pour engine coolant 2 18 Install the under cowling 6 5 THERMOSTA...

Page 239: ...s temperature Just when the water temperature reaches specified value the thermostat valve should have lifted by at least 8 0 mm 0 31 in Thermostat valve lift Standard Over 8 0 mm at 95 C Over 0 31 in...

Page 240: ...ll the front and rear seats 6 8 Pour engine coolant 2 18 Install the under cowling 6 5 WATER PUMP REMOVAL AND DISASSEMBLY Remove the under cowling 6 5 Drain engine coolant 2 18 Drain engine oil 2 13 N...

Page 241: ...BRICATION SYSTEM Remove the engine sprocket cover 1 Disconnect the water hoses Remove the water pump Remove the water pump cover Remove the impeller securing bolt 2 by holding the impeller shaft with...

Page 242: ...ring removal is not necessary The removed bearing must be replaced with a new one Remove the mechanical seal using the special tool 09921 20220 Bearing remover set 12 NOTE If no abnormal the mechanica...

Page 243: ...ttention given to the sealing face Replace the mechanical seal that shows indications of leak age Also replace the seal ring if necessary OIL SEAL Visually inspect the oil seal for damage with particu...

Page 244: ...s outside Apply a small quantity of the SUZUKI SUPER GREASE A to the oil seal lip W 99000 25030 SUZUKI SUPER GREASE A Install the new mechanical seal using a suitable size socket wrench NOTE The new m...

Page 245: ...echanical seal ring faces the impel ler Install the seal washer and the washer onto the impeller secur ing bolt 2 NOTE The metal side B of the seal washer and the convex side C of the washer face the...

Page 246: ...he specified torque Water pump cover screw 6 N m 0 6 kgf m 4 5 lb ft Install the water pump and tighten its mounting bolt to the specified torque Water pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft NO...

Page 247: ...18 COOLINGANDLUBRICATIONSYSTEM LUBRICATION SYSTEM OIL PRESSURE 2 31 OIL FILTER 2 13 OIL PRESSURE REGULATOR 3 46 OIL STRAINER 3 46 OIL JET 3 58 OIL PUMP 3 44 OIL PRESSURE SWITCH 7 39 WATER PUMP OIL PUM...

Page 248: ...OIL FILTER OIL COOLER OIL PUMP OIL STRAINER OIL PRESSUER REGULATOR COUNTERSHAFT LEFT SIDE BEARING COUNTERSHAFT GEARS AND BUSHINGS DRIVESHAFT GEARS AND BUSHINGS CLUTCH PUSH PIECE CLUTCH PLATES PRIMARY...

Page 249: ...5 20 COOLINGANDLUBRICATIONSYSTEM ENGINE LUBRICATION SYSTEM MAIN GALLERY To sub gallery...

Page 250: ...COOLINGANDLUBRICATIONSYSTEM 5 21...

Page 251: ...NSPECTION 6 21 REASSEMBLY AND REMOUNTING 6 22 SUSPENSION SETTING 6 27 STEERING DAMPER 6 28 CONSTRUCTION 6 28 REMOVAL 6 28 INSPECTION 6 28 REMOUNTING 6 28 STEERING 6 29 CONSTRUCTION 6 29 REMOVAL AND DI...

Page 252: ...D DISASSEMBLY 6 65 MASTER CYLINDER INSPECTION 6 66 MASTER CYLINDER REASSEMBLY AND REMOUNTING 6 66 REAR BRAKE 6 68 CONSTRUCTION 6 68 BRAKE PAD REPLACEMENT 6 69 BRAKE FLUID REPLACEMENT 6 69 CALIPER REMO...

Page 253: ...Right air intake pipe Cowling brace 23 N m 2 3 kgf m 16 5 lb ft Wind screen Body cowling cover Right under inner cowling Right under cowling Center under cowling Body cowling Left air intake pipe Left...

Page 254: ...wling Left under cowling heat shield No 1 Left under cowling heat shield No 2 Center under cowling heat shield No 1 Center under cowling heat shield No 2 Left under cowling heat shield No 3 Center und...

Page 255: ...damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face FASTENER b REMOVAL Pull the head of fastener ce...

Page 256: ...tener With the bolts removed remove the right under cowling Disconnect the turn signal light coupler With the bolts removed remove the left under cowling Disconnect the turn signal light coupler BODY...

Page 257: ...the rear view mirrors right and left by removing the bolts Remove the fasteners Remove all the bolts Disconnect the headlight coupler REMOUNTING NOTE When remounting the body cowling install the hook...

Page 258: ...h the fastener removed remove the left air intake pipe 2 COWLING BRACE REMOVAL Remove the body cowling 6 6 Remove the cowling brace bolts and nut and remove the cowl ing brace REMOUNTING Tighten the c...

Page 259: ...remove the front seat REAR SEAT AND SEAT TAIL COVER Remove the rear seat seat tail cover with the ignition key FRAME COVER Remove the seats Remove the bolts Remove the fasteners Disconnect the rear co...

Page 260: ...CHASSIS 6 9 FRONT WHEEL CONSTRUCTION 1 Brake disc 2 Dust seal 3 Bearing 4 Spacer 5 Spacer nut 6 Front wheel A Front axle B Brake disc bolt Front ITEM N m kgf m lb ft A 100 10 0 72 5 B 23 2 3 16 5...

Page 261: ...10 CHASSIS Left Right 25 N m 2 5 kgf m 18 1 lb ft 25 N m 2 5 kgf m 18 1 lb ft 23 N m 2 3 kgf m 16 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft Left Right Left Right Clearance Spac...

Page 262: ...motor cycle with a jack or a wooden block NOTE Remove the left and right under cowlings if necessary 6 7 Do not work by using side stand Do not support the motorcycle with exhaust pipe Make sure that...

Page 263: ...100 mm Axle shaft runout Service Limit 0 25 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...

Page 264: ...CHASSIS 6 13 Remove the wheel bearings by using the special tool A or B 09921 20220 A Bearing remover set or 09944 60210 B Wheel bearing remover The removed bearings should be replaced with new ones...

Page 265: ...unt the front wheel in the reverse order of removal and disassembly Pay attention to the following points Left Right 25 N m 2 5 kgf m 18 1 lb ft 25 N m 2 5 kgf m 18 1 lb ft 23 N m 2 3 kgf m 16 5 lb ft...

Page 266: ...ing Steering race installer set First install the left wheel bearing then install the right wheel bearing The sealed cover of the bearing must face outside BRAKE DISC Make sure that the brake disc is...

Page 267: ...tion when remounting the wheel BRAKE CALIPER Tighten the brake caliper mounting bolts to the specified torque Front brake caliper mounting bolt 25 N m 2 5 kgf m 18 1 lb ft NOTE Push the pistons all th...

Page 268: ...t 2 O ring 3 Spring adjuster 4 Rebound damping force adjuster 5 Rubber seat 6 Spacer 7 Spring 8 Oil flow pipe 9 Inner rod damper rod cartridge 0 Outer tube A Anti friction metal B Oil seal C Oil seal...

Page 269: ...clamp bolts 2 left and right NOTE Slightly loosen the front fork cap bolts 3 before loosening the lower clamp bolts to facilitate later disassembly Loosen the front fork lower clamp bolts left and ri...

Page 270: ...move the front fork cap bolt from the inner rod by loosening the lock nut Compress the fork spring with the special tool A and remove the special tool B Remove the rubber seat 1 washer 2 spacer seat 3...

Page 271: ...E Be careful not to damage the inner tube The ANTI FRICTION metals oil seals and dust seals must be replaced with new ones when reassembling the front forks Remove the following parts 1 Dust seal 2 Oi...

Page 272: ...INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and outer tube inner sur face for scratches FORK SPRING Measure the fork spring free length If it is shorter than the service lim...

Page 273: ...30 SUZUKI SUPER GREASE A Install the dust seal oil seal stopper ring oil seal oil seal re tainer and anti friction metal onto the inner tube 1 Dust seal 2 Oil seal stopper ring 3 Oil seal 4 Oil seal r...

Page 274: ...ith a new one DAMPER ROD BOLT Insert the inner rod damper rod cartridge and the plate into the inner tube and tighten the damper rod bolt to the specified torque with a hexagon wrench Damper rod bolt...

Page 275: ...uring this procedure Take extream attention 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 remove the...

Page 276: ...ads before installing the cap bolt While holding the inner rod with the special tool C compress the spring with the special tool D and then insert the special tool E between the lock nut and washer 09...

Page 277: ...lb ft Tighten the front fork cap bolt to the specified torque and re check the front fork outer tube upper surface height A from the upper surface of the steering stem upper bracket Front fork cap bo...

Page 278: ...t Fine tune the adjuster by turn ing it slightly until two punch marks align Compression side Fully turn the damping force adjuster 2 clockwise It is at stiffest position and turn it out to standard s...

Page 279: ...ering damper INSPECTION Inspect the steering damper body bearing and oil seal for dam age and oil leaking Move the steering damper rod by hand to inspect for a smooth movement If any defects are found...

Page 280: ...ft A 90 9 0 65 0 B 80 8 0 58 0 C 23 2 3 16 5 D 23 2 3 16 5 E 10 1 0 7 0 F 23 2 3 16 5 1 Steering stem upper bracket 2 Handlebar 3 Handlebar balancer 4 Steering stem nut 5 Dust seal 6 Bearing 7 Steeri...

Page 281: ...not necessary to remove the ignition switch when only re placing the steering stem Ignition switch removal 7 38 Remove the brake hose clamp bolt Remove the steering stem lock nut the washer and the s...

Page 282: ...replaced with a new one Drive out the steering stem bearing outer races upper and lower using a suitable wedge bar The removed bearing outer race must be replaced with a new one REASSEMBLY AND REMOUN...

Page 283: ...nut wrench socket Steering stem nut 45 N m 4 5 kgf m 32 5 lb ft Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will be seated pro...

Page 284: ...ad state hitch the spring scale special tool on one handlebar grip end as shown in the figure and read the graduation when the handlebar starts mov ing Do the same on the other grip end Initial force...

Page 285: ...cer 3 Remove the right handle grip 4 LEFT HANDLEBAR Remove the clutch cable 1 Remove the left handle switch 2 With the screw removed remove the handle balancer 3 Remove the left handle grip 4 1 Left h...

Page 286: ...t the handlebar in the reverse order of removal and disassembly Pay attention to the following points Install the handlebars temporaly Install the steering stem upper bracket NOTE If it is difficult t...

Page 287: ...5 lb ft When remounting the clutch lever holder align the holder s mating surface with punch mark A on the handlebar When remounting the right and left handle switches engage the stopper with the han...

Page 288: ...ar 5 Bearing 6 Rear wheel 7 Spacer 8 Bearing 9 Cushion 0 Spacer A Sprocket drum B Sprocket C Bearing D Dust seal E Collar A Brake disc bolt B Rear sprocket nut C Rear axle nut ITEM N m kgf m lb ft A 3...

Page 289: ...f m 86 8 lb ft Left Right 110 N m 11 0 kgf m 79 6 lb ft 35 N m 3 5 kgf m 25 5 lb ft 26 N m 2 6 kgf m 19 0 lb ft 7 5 N m 0 75 kgf m 5 5 lb ft For E 03 28 33 For the others Left Right Left Right Spacer...

Page 290: ...e rear wheel by disengaging the drive chain Do not operate the brake pedal while removing the rear wheel Remove the collar 1 Draw out the rear sprocket mounting drum 2 from the wheel hub Remove the re...

Page 291: ...s the limit replace the rear axle Axle shaft runout Service Limit 0 25 mm 0 010 in 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm WHEEL DAMPER Inspect the da...

Page 292: ...wheel and drum Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Remove the sprocket mounting drum bearing and wheel bear...

Page 293: ...el in the reverse order of removal and disassembly Pay attention to the following points 120 N m 12 0 kgf m 86 8 lb ft Left Right 110 N m 11 0 kgf m 79 6 lb ft 35 N m 3 5 kgf m 25 5 lb ft 26 N m 2 6 k...

Page 294: ...000 25030 SUZUKI SUPER GREASE A Install the new bearing to the sprocket mounting drum using the special tool 09924 84510 Bearing installer set First install the right wheel bearing then install the le...

Page 295: ...torque NOTE Make sure that the brake disc is clean and free of any greasy matter J J J J J 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 35 N m 3 5 kgf m 25 5 lb ft REAR SPROCKET Tighten the spro...

Page 296: ...Adjust the chain slack after rear wheel installation 2 20 Tighten the rear axle nut 2 to the specified torque Rear axle nut 110 N m 11 0 kgf m 79 6 lb ft For E 03 28 33 120 N m 12 0 kgf m 86 8 lb ft...

Page 297: ...CHASSIS REAR SHOCK ABSORBER CONSTRUCTION 1 Rear shock absorber 2 Height adjuster A Rear shock absorber mounting bolt nut B Height adjuster nut ITEM N m kgf m lb ft A 50 5 0 36 0 B 115 11 5 83 2 Left R...

Page 298: ...orber lower mounting bolt and nut Take out the rear shock absorber to downward INSPECTION Inspect the shock absorber body and bushing for damage and oil leakage If any defects are found replace the sh...

Page 299: ...AS EVACUATION Remove the valve cap Evacuate gas through the valve hole Keep your face away from the valve hole REMOUNTING Remount the rear shock absorber in the reverse order of re moval Pay attention...

Page 300: ...in 1 and turns out 1 and turns out Stiffer 191 5 mm 7 54 in 1 turn out turn out Dual riding 191 5 mm 7 54 in 1 and turns out 1 and turns out Rebound side Compression side DAMPING FORCE ADJUSTMENT Reb...

Page 301: ...bsorber 2 Rear cushion rod 3 Rear cushion lever 4 Spacer 5 Bearing 6 Dust seal 7 Torque link 8 Chain cover 9 Chain buffer 0 Chain adjuster A Chain adjuster lock nut A Rear shock absorber mount ing bol...

Page 302: ...CHASSIS 6 51 Left Right 50 N m 5 0 kgf m 36 0 lb ft 78 N m 7 8 kgf m 56 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 90 N m 9 0 kgf m 65 0 lb ft 15 N m 1 5 kgf m 11 0 lb ft...

Page 303: ...t is necessary to cut the drive chain only when replacing drive chain or swingarm Remove the cushion lever mounting bolts nuts and rear shock absorber lower mounting bolt nut Remove the cushion lever...

Page 304: ...Hold the swingarm pivot shaft 1 with a 27 mm socket wrench and remove the swingarm pivot nut 2 with a 36 mm socket wrench Remove the swingarm pivot shaft Remove the rear suspension assembly Remove th...

Page 305: ...und replace the spacers with new ones SWINGARM BEARING Insert the spacer into bearing and check the play when moving the spacer up and down If excessive play is noted replace the bearing with a new on...

Page 306: ...ing remover set The removed bearings must be replaced with new ones SWINGARM PIVOT SHAFT Using a dial gauge check the pivot shaft runout and replace it if the runout exceeds the limit 09900 20606 Dial...

Page 307: ...0 lb ft 78 N m 7 8 kgf m 56 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 90 N m 9 0 kgf m 65 0 lb ft 15 N m 1 5 kgf m 11 0 lb ft REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and re...

Page 308: ...09941 34513 Steering race installer NOTE When reinstalling the bearing stamped mark on bearing must face outside CUSHION LEVER BEARING Press the bearings into the cushion lever with the special tool 0...

Page 309: ...DJUSTMENT Adjust swingarm pivot thrust clearance as following procedure Insert the swingarm pivot shaft and tighten it to the specified torque Swingarm pivot shaft 15 N m 1 5 kgf m 11 0 lb ft Hold the...

Page 310: ...hten the brake hose union bolt to the specified torque Brake hose routing 8 21 Brake fluid replacement 6 70 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft FINAL INSPECTION AND ADJUSTMENT After inst...

Page 311: ...different types of fluid such as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or st...

Page 312: ...uid level BRAKE FLUID REPLACEMENT 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 po...

Page 313: ...ing bolts to facilitate later disassembly Never reuse the brake fluid left over from previous ser vicing and stored for long periods of time Brake fluid if it leaks will interfere with safe running an...

Page 314: ...brake fluid Particularly wash the dust seal grooves and piston seal grooves N N N N N Specification and Classification DOT 4 Wash the caliper components with fresh brake fluid before reassembly Never...

Page 315: ...er 2 22 BRAKE DISC INSPECTION Visually check the brake disc for damage or cracks Measure the thickness with a micrometer Replace the disc if the thickness is less than the service limit or if damage i...

Page 316: ...the union bolt and dis connect the brake hose Immediately and completely wipe off any brake fluid contacting any part of the motorcycle The fluid reacts chemically with paint plastics and rubber mater...

Page 317: ...ce for any scratches or other damage Inspect the primary cup secondary cup and dust seal for wear or damage MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble the master cylinder in the reverse orde...

Page 318: ...cylinder holder s mating surface with punched mark A on the handlebar and tighten the upper clamp bolt first as shown Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Tighten the...

Page 319: ...When replenishing brake fluid take care not to get dust into fluid When washing brake components use fresh brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces brakin...

Page 320: ...be adversely affected Install the new brake pads and shims Be sure to install the shims properly as shown in the illustration NOTE After replacing the brake pads pump the brake pedal few times to ope...

Page 321: ...er mounting bolts 2 and torque link bolt 3 NOTE Slightly loosen the caliper housing bolts 4 to facilitate later dis assembly before removing the caliper mounting bolts Remove the brake pads 6 69 Remov...

Page 322: ...before reassembly Never use cleaning solvent or gaso line to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore N N N N N Specification and Classification DOT 4 PI...

Page 323: ...pliers Remove the push rod piston primary cup and spring Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Remove the union bolt 2 and disconnect the...

Page 324: ...inder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the com ponent to be inserted into the bore...

Page 325: ...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 repair ing puncture the tire may have to be balanced aga...

Page 326: ...mation replace the valve with a new one VALVE INSTALLATION Any dust or rust around the valve hole must be cleaned off Then install the valve in the rim NOTE To properly install the valve into the valv...

Page 327: ...nt In this condition check the rim line cast on the tire side walls The line must be equidistant from the wheel rim all around If the distance between the rim line and wheel rim varies this indicates...

Page 328: ...threaded parts of the special tool DRIVE CHAIN CUTTING Set up the special tool as shown in the illustration 1 Tool body 2 Grip handle 3 Pressure bolt A 4 Pressure bolt B 5 Bar 6 Adjuster bolt with th...

Page 329: ...plate Never reuse joint pins O rings and plates After joint pins O rings and plates have been removed from the drive chain the removed joint pins O rings and plates should be discarded and new joint...

Page 330: ...r using the bar 7 to press the joint plate over the joint pins Continue pressing the joint plate until the distance between the two joint plates come to the specification Joint plate distance specific...

Page 331: ...ecified dimension Pin end diameter specification D RK 5 45 5 85 mm 0 215 0 230 in After joining of the chain has been completed check to make sure that the link is smooth and no abnormal condition is...

Page 332: ...STARTER MOTOR REMOVAL AND DISASSEMBLY 7 14 STARTER MOTOR INSPECTION 7 14 STARTER MOTOR REASSEMBLY 7 15 STARTER RELAY INSPECTION 7 16 SIDE STAND IGNITION INTERLOCK SYSTEM PART INSPECTION 7 17 IGNITION...

Page 333: ...orrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRE HARNESS ROUTING 8 14 16 Bend the clamp properly so that the wire harness is clamped securely In clamping...

Page 334: ...cuit tester 09900 25008 Use well charged batteries in the tester Be sure to set the tester to the correct testing range Using the tester Incorrectly connecting the and _ probes may cause the inside of...

Page 335: ...sensor 4 44 4 Fuel pump relay 5 Secondary valve actuator 6 Throttle position sensor 7 Intake air temp sensor 8 Ignition switch 9 Front brake switch 0 Handlebar switch R A Rear brake switch B Starter m...

Page 336: ...on G Generator H Speedometer sensor I Gear position switch J Side stand switch 1 Clutch lever position switch 2 Handlebar switch L 3 Camshaft position sensor 4 34 4 Ignition coil No 1 2 3 4 5 Fuel pum...

Page 337: ...omposed of the generator regulator rectifier unit and battery The AC current generated from the generator is rectified by the rectifier and is turned into DC current then it charges the battery FUNCTI...

Page 338: ...te probe and the SCR will be turned ON Then the SCR becomes conductive in the direction from point A to point B At this time the current gener ated from the generator gets through the SCR without char...

Page 339: ...the battery terminals Correct Faulty battery 7 9 Abnormal driving condition Incorrect Measure the continuity of the generator coil No continuity Faulty generator coil or 7 10 disconnected lead wires C...

Page 340: ...on when measuring current CHARGING OUTPUT INSPECTION Remove the front seat 6 8 Start the engine and keep it running at 5 000 r min with lighting switch turned ON and dimmer switch turned HI position M...

Page 341: ...e 09900 25008 Multi circuit tester set Tester knob indication Voltage Generator no load performance More than 65 V at 5 000 r min When engine is cold REGULATOR RECTIFIER INSPECTION Remove the frame co...

Page 342: ...IPTION The starter system consists of the following components the starter motor starter relay clutch lever position switch turn signal side stand relay side stand switch gear position switch starter...

Page 343: ...down The gear position and side stand switches work to gether in this system The ignition coils work only in two situations as follows 1 Transmission Neutral ON Side stand Down OFF The current flow A...

Page 344: ...connectors between Y G No voltage Faulty ignition switch and B Y _ when the starter button is Faulty engine stop switch pushed Faulty clutch lever position switch Faulty gear position switch Faulty t...

Page 345: ...motor 3 16 Disassemble the starter motor as shown in the illustration STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear crack or smoothness in the brush holder If the brush...

Page 346: ...tween the segments or there is continu ity between the segments and shaft replace the starter motor with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test OIL SEAL...

Page 347: ...00 25008 Multi circuit tester set Tester knob indication Continuity test Do not apply a battery voltage more than 5 seconds to the starter relay as it may overheat and cause damage to the relay coil C...

Page 348: ...h a new one SIDE STAND SWITCH The side stand switch coupler is located behind the left upper fairing Lift the fuel tank 4 51 Disconnect the side stand switch coupler and measure the voltage between Gr...

Page 349: ...to the wir ing harness Turn the ignition switch to ON position and side stand to up right position Using a multi circuit tester measure the voltage between Pink and Black White lead wires with low to...

Page 350: ...D and C to D and to C and check the continuity between D and E If there is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indica...

Page 351: ...e ignition timing is also compensated according to the gear position and throttle position The following devices affects the ignition timing Crankshaft position sensor The pick up coil is provided at...

Page 352: ...uit is incorporated in this ECM to prevent over running of engine If engine rpm reaches 13 700 r min this circuit cuts off the ignition primary current for all spark plugs Under no load the engine can...

Page 353: ...witch Correct Broken wire harness or poor connection of related circuit couplers Measure the ignition coil primary peak voltage 7 23 24 Inspect the spark plugs NOTE This inspection method is Correct 2...

Page 354: ...avoid damage Be careful not to drop the ignition coil plug cap as it may open or short in a circuit Connect the new four spark plugs to each ignition coil plug cap Connect all the ignition coil plug...

Page 355: ...llow the instruction manual NOTE When connecting the multi circuit tester insert the stings O D is below 0 5 mm to the back side of the ignition coil lead wire coupler and connect the tester probes to...

Page 356: ...e in both primary and secondary windings If the resistance is not within the stan dard range replace the ignition coil plug cap with a new one 09900 25008 Multi circuit tester set Tester knob indicati...

Page 357: ...White Probe 09900 25008 Multi circuit tester set Tester knob indication Voltage When using the multi circuit tester and peak volt adap tor follow the instruction manual Shift the transmission into th...

Page 358: ...ire coupler Tester knob indication Voltage CKP sensor peak voltage More than 0 5 V Green Blue If the peak voltage is lower than the standard range check each coupler at both ends of the circuit or rep...

Page 359: ...his combination meter is light thin and high response on those currently in use because of this composition The rpm pointer is driven by the stepping motor The LCDs indicate speed Odo Trip1 Trip2 Cloc...

Page 360: ...tion switch is turned on to enable self calibration The stepping motor consists of the stator coils rotor angle position sensor exciter circuit and distribution circuit The stator has 6 poles and the...

Page 361: ...wise by the same amount of magnetic force both from a and b Step 3 When cut off the circuit B current and sending the current only through the circuit A the magnetic force is equilibrated and causes t...

Page 362: ...ion meter When disconnecting and connecting the combination meter coupler make sure to turn OFF the ignition switch or electronic parts may get damaged DISASSEMBLY Disassemble the combination meter as...

Page 363: ...sition even turning the ignition switch on under low temperature condition In that case you can reset the pointer to the proper position by following the instruction below 1 With the function switch A...

Page 364: ...itch ON Check the LCD and LED operations when the resistance is adjusted to the specified values Resistance A LED B LCD C LCD D Watertemperature Over 2 45 k OFF Under 19 C Approx 0 811 k OFF 50 Approx...

Page 365: ...lb should go out If the bulb remains lit replace the unit with a new one FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly check the fuel level indicat...

Page 366: ...Multi circuit tester set Tester knob indication Voltage Under above condition if a suitable screwdriver touching the pick up surface of the speed sensor is moved the tester read ing voltage changes 0...

Page 367: ...2 55W H7 Lo 1 Hi 1 2 Position light bulb 12V 5W Except for E 03 24 28 and 33 NOTE Adjust the headlight both vertical and horizontal after reassembling If you touch the bulb with your bare hands clean...

Page 368: ...in the reverse order of removal Remove the screw and take off the lens Remove the turn signal light bulb by turning it counterclock wise Reassemble the turn signal light bulb in the reverse order of r...

Page 369: ...the bulb turn signal switch and circuit connection are OK the turn signal relay may be faulty therefore replace the turn signal side stand relay with a new one NOTE Make sure that the battery is fully...

Page 370: ...W Y G PUSH Color Position HORN BUTTON B Bl B W PUSH Color Position FRONT BRAKE SWITCH B R B OFF ON Color Position REAR BRAKE SWITCH O G W B OFF ON Color Position CLUTCH LEVER POSITION SWITCH B Y B Y O...

Page 371: ...letely use the removed cap 2 as the sealed caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte container Insert the nozzles of the electrolyte container into the...

Page 372: ...remove the caps Using multi circuit tester measure the battery voltage The tester should indicate more than 12 5 12 6V DC as shown in the Fig If the battery voltage is lower than the specification ch...

Page 373: ...Recharging time 5A for one hour or 1 2A for 5 to 10 hours Be careful not to permit the charging current to exceed 5A at any time After recharging wait for more than 30 minutes and check the battery v...

Page 374: ...HARNESS ROUTING 8 14 CABLE ROUTING 8 17 FUEL TANK DRAIN HOSE ROUTING 8 18 COOLING SYSTEM HOSE ROUTING 8 19 FRONT BRAKE HOSE ROUTING 8 20 REAR BRAKE HOSE ROUTING 8 21 PAIR AIR SUPPLY SYSTEM HOSE ROUTI...

Page 375: ...r pressure sensor wiring coupler connection The sensor should produce following voltage 0 2 V sensor voltage 4 8 V Without the above range c14 is indicated Throttle position sensor wiring coupler conn...

Page 376: ...e c31 is indicated Gear position sensor wiring coupler connection Gearshift cam etc When fuel injection signal stops the c32 c33 c34 or c35 is indicated Injector wiring coupler connection power supply...

Page 377: ...ce 6 Open circuited wiring connections Repair or replace No fuel reaching intake manifold 1 Clogged fuel filter or fuel hose Clean or replace 2 Defective fuel pump Replace 3 Defective fuel pressure re...

Page 378: ...essure regulator Replace 5 Defective engine coolant temp sensor Replace 6 Defective thermostat Replace 7 Defective intake air temp sensor Replace Improperly working fuel injector 1 Defective fuel inje...

Page 379: ...ng bearings Replace 2 Worn and burnt big end bearings Replace 3 Worn and burnt journal bearings Replace 4 Too large thrust clearance Replace thrust bearing Noise seems to come from transmission 1 Worn...

Page 380: ...ernal electrical parts 1 Loss of valve clearance Adjust 2 Weakened valve springs Replace 3 Out of adjustment valve timing Adjust 4 Worn piston rings or cylinders Replace 5 Poor seating of valves Repai...

Page 381: ...Adjust Dirty or heavy 1 Too much engine oil in the engine Check with inspection exhaust smoke window drain out excess oil 2 Worn piston rings or cylinders Replace 3 Worn valve guides Replace 4 Scored...

Page 382: ...Faulty cooling fan Repair or replace 4 Defective cooling fan thermo switch Replace 5 Clogged water passage Clean 6 Air trapped in the cooling circuit Bleed out air 7 Defective water pump Replace 8 Us...

Page 383: ...force adjuster Adjust Front suspension 1 Too viscous fork oil Replace too stiff 2 Too much fork oil Drain excess oil 3 Improperly set front fork spring adjuster Adjust 4 Improperly set front fork damp...

Page 384: ...ace 4 Loosen front wheel axle or rear wheel axle Tighten to specified torque 5 Worn pads Replace 6 Foreign material in brake fluid Replace brake fluid 7 Clogged return port of master cylinder Disassem...

Page 385: ...oes not 1 Open or short lead wires or loose lead Repair or replace or charge connections retighten 2 Shorted grounded or open generator coils Replace 3 Shorted or punctured regulator rectifiers Replac...

Page 386: ...specified charging operation 2 Cell plates have lost much of their active Replace the battery material as a result of overcharging and correct the charg ing system 3 A short circuit condition exists w...

Page 387: ...de of headlight and not to be loosely Clamp Clamp Clamp to the frame INSIDE OF THE BODY COWLING INSIDE OF THE UNDER COWLING Wiring harness Wiring harness Handle switch L R Ignition switch Wiring harne...

Page 388: ...g harness Oil pressure switch Side stand switch Pass through the TO sensor lead wire inside the TO sensor Pass through the starter motor lead wire behind the box Wiring harness Regulator Rectifier Wir...

Page 389: ...r position sensor Starter motor Ground lead wire 90 45 5 N m 0 5 kgf m 3 6 lb ft 10 N m 1 0 kgf m 7 0 lb ft Generator Generator Clamp 45 Clamp CKP sensor CKP sensor Oil pressure switch Oil pressure sw...

Page 390: ...No 1 cable Throttle No 1 cable Fast idle cable Fast idle cable Fast idle cable Fast idle cable Boss Clamp Pass through the clutch cable outside of the frame and inside of the wire harness Pass throug...

Page 391: ...8 18 SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING Face the clamp to downside Fuel tank drain hose...

Page 392: ...face The clamp bolt head face Down side Marking Align the marking with the lib of pipe Left side Rear side Left side Right side Rear side Left side Rear side Left side Rear side Rear side Front side...

Page 393: ...e union bolts After touching the brake hose unions to the stopper tighten the union bolts Clamp the brake hose firmly After fixing the guide on outside tighten the clamp bolt Pass through the brake ho...

Page 394: ...touching the brake hose union to the stopper tighten the union bolt After touching the brake hose union to the stopper tighten the union bolt Face the clamp ends backward The white paint faces to out...

Page 395: ...PPLY SYSTEM HOSE ROUTING PAIR valve vacuum hose 530 mm PAIR valve 10 N m 1 0 kgf m 7 5 lb ft PAIR reed valve PAIR valve hose L 30 mm Matching mark PAIR cleaner hose PAIR valve hose R 50 mm To throttle...

Page 396: ...CING INFORMATION 8 23 FUEL TANK SET UP 23 N m 2 3 kgf m 16 5 lb ft Heat shield Align the front end of the heat shield with rear end of the bracket INNER SIDE 13 N m 1 3 kgf m 9 5 lb ft Adhere Adhere A...

Page 397: ...Right air intake pipe Cowling brace 23 N m 2 3 kgf m 16 5 lb ft Wind screen Body cowling cover Right under inner cowling Right under cowling Center under cowling Body cowling Left air intake pipe Lef...

Page 398: ...ing heat shield No 2 Center under cowling heat shield No 1 Center under cowling heat shield No 2 Left under cowling heat shield No 3 Center under cowling Right under cowling heat shield No 3 Right und...

Page 399: ...8 26 SERVICING INFORMATION 40 N m 4 0 kgf m 28 9 lb ft 50 N m 5 0 kgf m 36 2 lb ft SIDE STAND SET UP GEARSHIFT PEDAL SET UP Footrest 52 62 mm 2 05 2 44 in...

Page 400: ...Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 22401 10 18mm 09900 22403 18 35mm Small bore...

Page 401: ...9916 33310 Valve guide reamer 4 0 mm 09916 49030 Valve guide reamer 9 3 mm 09916 53310 Valve guide remover installer 09916 53321 Attachment 09916 84511 Tweezers 09917 47010 Vacuum pump gauge 09920 348...

Page 402: ...09940 14990 Engine mounting thrust adjuster socket wrench 09940 30221 Front fork assembling tool 09940 50120 Front fork inner rod holder 09940 92720 Spring scale 09940 94922 Front fork spring stop pe...

Page 403: ...Cylinder head side bolt 14 1 4 10 0 Cam chain tensioner bolt 10 1 0 7 0 Cylinder head bolt M 10 46 4 6 33 3 M 6 10 1 0 7 0 PAIR reed valve cover bolt 10 1 0 7 0 Water jacket plug 9 5 0 95 6 9 Water i...

Page 404: ...TEM N m kgf m lb ft Camshaft position sensor mounting bolt 8 0 8 6 0 Intake air temperature sensor 18 1 8 13 0 Fuel pressure check plug 5 0 5 3 5 Fuel delivery pipe mounting screw 5 0 5 3 5 Fuel pump...

Page 405: ...eeder valve 8 0 0 8 6 0 Brake disc bolt Front 23 2 3 16 5 Brake disc bolt Rear 35 3 5 25 5 Rear brake caliper mounting bolt 25 2 5 18 1 Rear brake caliper housing bolt 30 3 0 21 5 Rear brake master cy...

Page 406: ...bolt 7 marked bolt A mm N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32...

Page 407: ...2 IN EX IN EX 0 9 1 1 0 035 0 043 Valve seat width Valve head radial runout 37 8 1 49 IN EX 39 3 1 54 Valve spring free length IN EX 19 0 kgf 41 9 lbs at length 32 85 mm 1 29 in EX Valve spring tensio...

Page 408: ...ton diam 71 965 71 980 2 8332 2 8339 Measure at 15 mm 0 6 in from the skirt end 71 880 2 8230 Cylinder distortion 0 20 0 008 Approx 7 0 0 28 Piston ring free end gap 5 6 0 22 1st 6 2 0 24 2nd RN Unit...

Page 409: ...shaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing thickness 2 425 2 450 0 0955 0 0965 2 350 2 500 0 0925 0 0984 Crankshaft thrust clearance 0 055 0 110 0 0022 0 0043 Crankshaft r...

Page 410: ...d 20 30 0 79 1 18 Gearshift lever height 52 62 2 05 2 44 RK 525 ROZ4 Type 110 links Links 20 pitch length 319 4 12 57 5th 1 304 30 23 THERMOSTAT RADIATOR FAN COOLANT ITEM STD SPEC LIMIT Thermostat val...

Page 411: ...han 0 5 V IAP sensor input voltage IAP sensor output voltage 4 5 5 5 V Approx 2 7 V at idle speed TP sensor input voltage 4 5 5 5 V TP sensor resistance Approx 1 0 k Closed Opened Approx 4 3 k TP sens...

Page 412: ...tion coil resistance 70 220 G Bl Over 8 0 3 at 1 atm 0 8 1 2 Primary Terminal Terminal Secondary Plug cap Terminal 8 15 k Generator coil resistance 0 2 0 5 Generator Max output Approx 390 W at 5 000 r...

Page 413: ...ke disc thickness Brake disc runout Master cylinder piston diam Unit mm in 4 5 0 177 15 870 15 913 0 6248 0 6265 Front 15 827 15 854 0 6231 0 6242 Front Rear brake pedal height 50 60 1 97 2 36 Master...

Page 414: ...0 08 Tire type DUNLOP D207FU E 03 24 28 33 MICHELIN PILOT SPORT C The others Front DUNLOP D207U E 03 24 28 33 MICHELIN PILOT SPORT C The others Rear SUSPENSION ITEM STD SPEC Unit mm in LIMIT 125 4 92...

Page 415: ...vents and corrosion inhibitor is per missible Gasoline used should be graded 95 octane or higher An unleaded gasoline is recommended E 03 33 The others Fuel tank capacity 18 L 4 8 4 0 US Imp gal Engin...

Page 416: ...CONTENTS FUEL INJECTION SYSTEM 9 2 EVAPORATIVE EMISSION CONTROL SYSTEM 9 2 CANISTER HOSE ROUTING 9 3 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION 9 4 PAIR AIR SUPPLY SYSTEM DIAGRAM 9 5 PAIR AIR SUPP...

Page 417: ...r FUEL HC VAPOR FRESH AIR Breather pipe Fuel vapor separator FUEL INJECTION SYSTEM GSX R750 motorcycles are equipped with a fuel injection system for emission level control This fuel injection system...

Page 418: ...ISSION CONTROL INFORMATION 9 3 CANISTER HOSE ROUTING Only for E 33 Chacoal canister Surge hose Red tracer Surge hose Red tracer Purge hose Purge hose To carburetor TPC Valve Fuel shut off valve A VIEW...

Page 419: ...trol valve TANK PRESSURE CONTROL VALVE Inspect the tank pressure contorol valve body for damage Inspect the tank pressure control valve operation as following procedure Remove the tank pressure contro...

Page 420: ...EMISSION CONTROL INFORMATION 9 5 NEGATIVE PRESSURE Throttle body Air cleaner box FRESH AIR EXHAUST GAS PAIR control valve PAIR reed valve PAIR control valve OPEN CLOSE PAIR AIR SUPPLY SYSTEM DIAGRAM...

Page 421: ...R SUPPLY SYSTEM HOSE ROUTING PAIR valve vacuum hose 530 mm PAIR valve 10 N m 1 0 kgf m 7 5 lb ft PAIR reed valve PAIR valve hose L 30 mm Matching mark PAIR cleaner hose PAIR valve hose R 50 mm To thro...

Page 422: ...the photograph Apply negative pressure of the specification slowly to the con trol valve and inspect the air flow If air does not flow out the control valve is in normal condition If the control valv...

Page 423: ...P SCREW 10 15 AP SENSOR 10 15 GEAR POSITION SWITCH 10 15 ENGINE MOUNTING BOLT AND NUT 10 16 CANISTER HOSE ROUTING FOR E 33 10 17 This chapter describes service data service specifications and servicin...

Page 424: ...amped coil spring spring pre load fully adjustable rebound damping force and compression damping force fully adjustable Front fork stroke 125 mm 4 9 in Rear wheel travel 130 mm 5 1 in Steering angle 2...

Page 425: ...63 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Va...

Page 426: ...2 8346 2 8352 Scratches Piston diam 71 965 71 980 71 880 2 8332 2 8339 2 8230 Measure at 15 mm 0 6 in from the skirt end Cylinder distortion 0 20 0 008 Piston ring free end gap 1st R Approx 7 0 5 6 0...

Page 427: ...031 Crankshaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing Right side 2 425 2 450 thickness 0 0955 0 0965 Left side 2 350 2 500 0 0925 0 0984 Crankshaft thrust clearance 0 055 0...

Page 428: ...05 2 44 THERMOSTAT RADIATOR FAN COOLANT ITEM STD SPEC LIMIT Thermostat valve opening Approx 82 C 180 F temperature Thermostat valve lift Over 8 mm 0 31 in at 95 C 203 F Engine coolant temperature 20...

Page 429: ...sensor resistance Closed Approx 1 0 k Opened Approx 4 3 k TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 4 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance 2 3 2 6 k at 20 C 68...

Page 430: ...P sensor resistance 70 220 CKP sensor peak voltage More than 0 5 V G Bl Ignition coil resistance Primary 0 8 1 2 Terminal Terminal Secondary 8 15 k Plug cap Terminal Ignition coil primary peak voltage...

Page 431: ...C LIMIT Rear brake pedal height 50 60 1 97 2 36 Brake disc thickness Front 4 8 5 2 4 5 0 189 0 205 0 177 Rear 4 8 5 2 4 5 0 189 0 205 0 177 Brake disc runout 0 30 0 012 Master cylinder bore Front 15 8...

Page 432: ...The others Rear DUNLOP D207U E 03 24 28 33 MICHELIN PILOT SPORT C The others Tire tread depth Front 1 6 Recommended depth 0 06 Rear 2 0 0 08 SUSPENSION Unit mm in ITEM STD SPEC LIMIT Front fork strok...

Page 433: ...ecommended R M 2 ITEM STD SPEC LIMIT Rear wheel travel 130 5 1 Swingarm pivot shaft runout 0 3 0 01 FUEL OIL ITEM STD SPEC NOTE Fuel type E 03 28 33 The others Fuel tank capacity including 18 L reserv...

Page 434: ...pers 1 on claws DRIVEN PLATE Identify driven plates No 1 and No 2 according to the following table DRIVEN PLATE PART NO THICKNESS No 1 21451 31E00 1 6 mm 0 06 in No 2 21451 31E10 2 0 mm 0 08 in No 3 D...

Page 435: ...paint No 3 Dampers on claws Measure the drive plates with a vernier calipers If the thickness is not within the standard range or the claw width is less than the limit replace it with a new one Drive...

Page 436: ...rn on the ignition switch ON and check the fuel pressure Fuel pressure Approx 3 0 kgf cm2 300 kPa 43 psi If the fuel pressure is lower than the specified value inspect the following items Fuel hose le...

Page 437: ...and support the fuel tank Ajust the engine idle speed 2 15 AP SENSOR The AP sensor B Atmospheric pressure sensor is located over the ECM AP SENSOR WIRE COLOR 1 R Input 2 G Y or B Output 3 B Br or B W...

Page 438: ...DEL ITEM N m kgf m lb ft ABC 55 5 5 39 8 36 75 7 5 54 0 147 23 2 3 16 5 58 45 4 5 32 5 LENGTH ITEM mm in AC 45 1 77 Bolt B 55 2 17 DE 215 8 46 Spacer 2 30 5 1 20 Adjuster 47 40 1 57 Left Right ENGINE...

Page 439: ...X R750K1 01 MODEL 10 17 Chacoal canister Surge hose Red tracer Surge hose Red tracer Purge hose Purge hose To carburetor TPC Valve Fuel shut off valve A VIEW A Clamp Clamp CANISTER HOSE ROUTING FOR E...

Page 440: ...RQUE LINK 11 28 SERVICING INFORMATION 11 29 WIRE HARNESS ROUTING 11 29 COOLING SYSTEM HOSE ROUTING 11 32 FRONT BRAKE HOSE ROUTING 11 33 REAR BRAKE HOSE ROUTING 11 34 CANISTER HOSE ROUTING Only for E 3...

Page 441: ...umber of cylinders 4 Bore 72 0 mm 2 834 in Stroke 46 0 mm 1 811 in Piston displacement 749 cm3 45 7 cu in Compression ratio 12 0 1 Fuel system Fuel injection Air cleaner Paper element Starter system E...

Page 442: ...200 rpm Engine coolant temp 80 C Spark plug NGK CR9E DENSO U27ESR N Battery 12V 36 0 kC 10 Ah 10HR Generator Three phase A C Generator Main fuse 30A Fuse 15 15 15 15 10 10A Headlight 12V 55 55 55W H7...

Page 443: ...as follows TIGHTENING TORQUE FOR CAM CHAIN TENSION ADJUSTER CAP K2 MODEL Dry torque 35 N m 3 5 kgf m 25 5 lb ft Part No 09168 12019 NOTE When using LATE type gasket washer do not apply engine oil to t...

Page 444: ...ake air pressure sensor wiring coupler connection The sensor should produce following voltage 0 2 V sensor voltage 4 8 V Without the above range c14 is indicated Throttle position sensor wiring couple...

Page 445: ...econds Gear position sensor voltage 0 60 V Without the above value c31 is indicated Gear position sensor wiring coupler connection Gearshift cam etc When fuel injection signal stops the c32 c33 c34 or...

Page 446: ...tion ECM does not receive communication signal from STVA circuit open or short the STVA STVA motor malfunction Turn the ignition switch OFF Disconnect the STVA lead wire coupler Check the continuity b...

Page 447: ...re STP sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tester Tester knob indication Voltage No Loose or poor contacts on the ECM coupler Open or short circuit in the Red...

Page 448: ...r STP sensor output voltage Throttle valve is closed Approx 0 5 V Throttle valve is opened Approx 3 7 V 09900 25008 Multi circuit tester Tester knob indication Voltage No If check result is not satisf...

Page 449: ...LY Pass through the wires behind the thermistor 1 Fuel pressure regulator 2 O ring 3 Fuel pump case Fuel filter cartridge For high pressure 4 Thermistor 5 Fuel pump 6 Fuel mesh filter For low pressure...

Page 450: ...GSX R750K2 02 MODEL 11 11 Be sure to connecft the wires to the proper terminals A terminal for fuel pump B For thermistor C terminal for fuel pump Pass through the wires behind the thermistor...

Page 451: ...nsor 3 STP sensor 4 Throttle body Nos 3 4 5 Throttle body Nos 1 2 6 Synchronizing screw 7 Stay plate 8 Fast idle adjusting screw 9 Throttle stop screw 0 Fuel delivery pipe A O ring B Dust seal C Fuel...

Page 452: ...ank with its prop stay Disconnect the IAT sensor coupler 1 and PAIR hose 2 Disconnect the IAP sensor coupler 3 and vacuum hose 4 Disconnect the crankcase breather hose 5 Loosen the throttle body clamp...

Page 453: ...a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank Disconnect the vacuum hose 1 from the PAIR valve Disconnect the fuel injector lead wire coupler 2 Loosen the thrott...

Page 454: ...by removing its mounting screws Remove the fuel injectors Remove the TP sensor 6 with the special tool 09930 11950 Torx wrench NOTE Prior to disassembly mark the TP sensor s original position with a p...

Page 455: ...ove the nut 1 Separate the throttle body assembly to a pair of two bodies Nos 1 2 and Nos 3 4 by removing their connecting bolts NOTE Be careful not to lose the springs Never remove the secondary thro...

Page 456: ...l manufacturer s instructions for proper use and cleaning of the throttle body components Do not apply carburetor cleaning chemicals to the rubber and plastic materials THROTTLE BODY INSPECTION Check...

Page 457: ...m 2 5 lb ft 09930 11950 Torx wrench NOTE If the STP sensor adjustment is necessary refer to page 22 for STP sensor setting procedure NOTE Align the secondary throttle shaft end A with the groove B of...

Page 458: ...ling Apply thin coat of the engine oil to the new fuel injector cushion seals 1 and install them to each fuel injector Replace the cushion seal with a new one Install the seals 2 and O rings 3 to each...

Page 459: ...fuel feed hose Purge hose Only for E 33 Assemble the fuel delivery pipes Install the fuel delivery pipe assembly to the throttle body as sembly Never turn the fuel injectors while installing them Tigh...

Page 460: ...Set the ST valve to fully close position by finger and measure the resistance between yellow and black wires STP sensor setting resistance ST valve is fully closed Approx 0 5 k Yellow Black 09900 2500...

Page 461: ...the throttle valve to open and raise the engine speed When the engine has warmed up depending on the water temperature ambient temperature and lapsed time the fast idle is cancelled allowing the engin...

Page 462: ...n idling condition for warming up Stop the warmed up engine Disconnect the IAT sensor coupler 1 and remove the IAT sen sor from the air cleaner box Connect the removed IAT sensor to its coupler and pl...

Page 463: ...nto the engine will damage the internal engine parts Turn the air screw 4 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 5 in the tube to the center line 6 N...

Page 464: ...positioned approx 30 from the horizontal level and in this position the four balls should be within one ball dia If the difference is larger than one ball turn the balance ad justing screw on the thro...

Page 465: ...nch 24 mm Tighten the front axle to the specified torque Front axle 100 N m 10 0 kgf m 72 5 lb ft SWINGARM PIVOT BOSS REMOVAL Remove the swingarm 6 52 of the GSX R750 Service Manual Remove the swingar...

Page 466: ...by its set screws Tighten the swingarm boss nut to the specified torque Swingarm pivot boss nut 65 N m 6 5 kgf m 47 0 lb ft 100 N m 10 0 kgf m 72 5 lb ft 65 N m 6 5 kgf m 47 0 lb ft 15 N m 1 5 kgf m...

Page 467: ...R750K2 02 MODEL TORQUE LINK Front side of the torque link washer has been eliminated In accor dance with this elimination the torque link mounting bolt has been changed K2 model A 19 mm 0 7 in B 34 5...

Page 468: ...p Handlebar switch R Handlebar switch L Ignition switch Fix the wire harness clamp to the frame Fix the wire harness clamp to the frame Fix the wire harness clamp to the frame Pass the side stand swit...

Page 469: ...ter connecting the injector lead wire coupler Pass the speed sensor lead wire above the wire harness Guide Starter motor lead wire Side stand switch Pass the neutral switch lead wire behind the bypass...

Page 470: ...Gear position switch Starter motor Gear position switch 45 45 90 Water bypass hose Starter motor Ground lead wire 5 N m 0 5 kgf m 3 6 lb ft Clamp CKP sensor CKP sensor Oil pressure switch Oil pressure...

Page 471: ...ad of screw to the right E Face the head of screw to the back F Face the head of screw to the left G Face the head of screw to the front A Marking Align the marking with the lib of pipe B C B D E F G...

Page 472: ...rake hose unions to the stopper tighten the union bolts Insert the clamp to the hole of the front fender fully The green paint is right side and face upside Left Right 42 42 Clamp the brake hose firml...

Page 473: ...hing the brake hose union to the stopper tighten the union bolt Face the clamp ends backward Face the clamp ends forward Face the clamp ends forward The white paint faces to outside Stopper Pass throu...

Page 474: ...GSX R750K2 02 MODEL 11 35 CANISTER HOSE ROUTING Only for E 33 Chacoal canister Surge hose Red tracer Surge hose Red tracer Purge hose Purge hose To carburetor TPC Valve Fuel shut off valve A VIEW A...

Page 475: ...alve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve...

Page 476: ...2 8346 2 8352 Scratches Piston diam 71 965 71 980 71 880 2 8332 2 8339 2 8230 Measure at 15 mm 0 6 in from the skirt end Cylinder distortion 0 20 0 008 Piston ring free end gap 1st R Approx 7 0 5 6 0...

Page 477: ...0031 Crankshaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing Right side 2 425 2 450 thickness 0 0955 0 0965 Left side 2 350 2 500 0 0925 0 0984 Crankshaft thrust clearance 0 055 0...

Page 478: ...2 05 2 44 THERMOSTAT RADIATOR FAN COOLANT ITEM STD SPEC LIMIT Thermostat valve opening Approx 82 C 180 F temperature Thermostat valve lift Over 8 mm 0 31 in at 95 C 203 F Engine coolant temperature 20...

Page 479: ...sensor resistance Closed Approx 1 0 k Opened Approx 4 3 k TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 4 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance 2 3 2 6 k at 20 C 6...

Page 480: ...nsor resistance 70 220 CKP sensor peak voltage More than 0 5 V G Bl Ignition coil resistance Primary 0 8 2 5 Terminal Terminal Secondary 8 18 k Plug cap Terminal Ignition coil primary peak voltage Mor...

Page 481: ...STD SPEC LIMIT Rear brake pedal height 50 60 1 97 2 36 Brake disc thickness Front 4 8 5 2 4 5 0 189 0 205 0 177 Rear 4 8 5 2 4 5 0 189 0 205 0 177 Brake disc runout 0 30 0 012 Master cylinder bore Fr...

Page 482: ...03 24 28 33 MICHELIN PILOT SPORT C The others Rear DUNLOP D207U E 03 24 28 33 MICHELIN PILOT SPORT C The others Tire tread depth Front 1 6 Recommended depth 0 06 Rear 2 0 0 08 SUSPENSION Unit mm in IT...

Page 483: ...l lighting Engine oil type SAE 10W 40 API SF or SG Engine oil capacity Change 2 8 L 3 0 2 5 US lmp qt Filter change 3 1 L 3 3 2 7 US lmp qt Overhaul 3 4 L 3 6 3 0 US lmp qt Use only unleaded gasoline...

Page 484: ...Y Blue with Yellow tracer G B Green with Black tracer G Bl Green with Blue tracer G R Green with Red tracer G W Green with White tracer G Y Green with Yellow tracer O B Orange with Black tracer O Bl O...

Page 485: ...B Lg R B G B R B D R Y Dg V R R P B Gr Y Gr B Gr W Gr R B Br B Br G B R B R R B R Y B Br Gr P B Y W Br W Y R Or B Y R Gr V V R Gr R V R R P B B Br Dg B Br B Bl B Br B Br G Y B R B O D B Lg R B O D B...

Page 486: ...Br B Br B Br G B G B R B R R B R Y B Br Gr Gr P B Y W Br W Y R Or B Or B Y R Gr V Gr V V R Gr R Gr R V R R P B B Br Dg B Br B Bl B Br B Br G Y B R B O D O D B Lg R B O D O D B Lg B R B R O Bl O Bl B L...

Page 487: ...r R B Br B Br G B R B R R B R Y B Br Gr P B Y W Br W Y R Or B Y R Gr V V R Gr R V R R P B B Br Dg B Br B Bl B Br B Br G Y B R B O D B Lg R B O D B Lg B R O Bl B Lg B W G B Br O Y W O B O W O G W B Y B...

Page 488: ...B W G B W O G W B Gr W Bl Gr B Gr Y Gr G W Bl B Y Gr W Gr B Gr Y Gr R Y B G Bl R Bl Y O W B W B Y Bl B Br W R Bl W Bl B Bl G B W B W Y G B W W B Y Y O R R B Y R G W Br R P B Dg B Bl G Y B Br Y Bl B G...

Page 489: ...Or B Y R Gr V V R Gr R V R R P B B Br Dg B Br B Bl B Br B Br G Y B R B O D B Lg R B O D B Lg B R O Bl B Lg B W G B Br O Y W O B O W O G W B Y B O Bl O R O B O W B R B Y G B B W B B W B B W W B W Lg B...

Page 490: ...R B R R B R Y B Br Gr P B Y W Br W Y R Or B Y R Gr V V R Gr R V R R P B B Br Dg B Br B Bl B Br B Br G Y B R B O D B Lg R B O D B Lg B R O Bl B Lg B W G B Br O Y W O B O W O G W B Y B B B W B B W B B W...

Page 491: ...tracer White with Green tracer White with Red tracer Yellow with Black tracer Yellow with Blue tracer Yellow with Green tracer Yellow with Red tracer Yellow with White tracer WIRE COLORS IATS INTAKE A...

Page 492: ...l P B W B W B Y B Y Br Br Gr W Gr W Y R Y R Gr B Gr B Y R Y R Gr Y Gr Y Y R Y R Gr R Gr R Y R Y R R P B P B B Br B Br Dg Dg B Br B Br G W G W W Y Y Y Y Y Y R B W B W B B W B W Bl Bl P B W B W G B B B...

Page 493: ...B Br B Br Bl Bl P B W B W B Y B Y Br Br Gr W Gr W Y R Y R Gr B Gr B Y R Y R Gr Y Gr Y Y R Y R Gr R Gr R Y R Y R R P B P B B Br B Br Dg Dg B Br B Br G W G W W Y Y Y Y Y Y R B W B W B B W B W Bl Bl P B...

Page 494: ...Br Bl Bl P B W B W B Y B Y Br Br Gr W Gr W Y R Y R Gr B Gr B Y R Y R Gr Y Gr Y Y R Y R Gr R Gr R Y R Y R R P B P B B Br B Br Dg Dg B Br B Br G W G W W Y Y Y Y Y Y R B W B W B B W B W Bl Bl P B W B W...

Page 495: ...Prepared by 3rd Ed August 2002 1st Ed February 2000 Part No 99500 37112 03E Printed in Japan 488...

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