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ENGINE 3-1

ENGINE COMPONENTS REMOVABLE WITH

THE ENGINE IN PLACE ................................................................... 3- 2

ENGINE REMOVAL AND INSTALLATION ....................................... 3- 3

ENGINE REMOVAL ....................................................................... 3- 3

ENGINE INSTALLATION .............................................................. 3-11

ENGINE DISASSEMBLY.................................................................. 3-15

ENGINE COMPONENTS INSPECTION AND SERVICE ................. 3-29

PAIR VALVE .................................................................................. 3-29

CYLINDER HEAD COVER ........................................................... 3-30

CAMSHAFT .................................................................................. 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

GEARSHIFT SYSTEM .................................................................. 3-45

OIL PRESSURE REGULATOR .................................................... 3-46

OIL STRAINER ............................................................................. 3-46

TRANSMISSION ........................................................................... 3-47

CYLINDER .................................................................................... 3-50

PISTON AND PISTON RING ......................................................... 3-51

CRANKCASE ............................................................................... 3-54

CRANKSHAFT AND CONROD ................................................... 3-60

CRANKSHAFT JOURNAL BEARING ......................................... 3-63

CRANKSHAFT THRUST BEARING ............................................ 3-65

ENGINE REASSEMBLY .................................................................. 3-67

ENGINE

CONTENTS

Содержание GSX-R750

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 46: ...PERIODIC MAINTENANCE 2 29...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 250: ...COOLINGANDLUBRICATIONSYSTEM 5 21...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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