Page 1 GSX1300BK 9 9 5 0 0 - 3 9 3 2 0 - 0 1 E...
Page 2 FOREWORD This manual contains an introductory description on the SUZUKI GSX1300BK and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
Page 3 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
Page 4 GSX1300BK 9 9 5 0 0 - 3 9 3 2 0 - 0 1 E...
Page 5 FOREWORD This manual contains an introductory description on the SUZUKI GSX1300BK and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
Page 6 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
Page 8 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...
Page 9 CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner...
Page 10 Precautions: 00-2 • Never reuse a circlip. When installing a • Before refitting the sealed coupler, make sure its seal new circlip, take care not to expand the rubber is positioned properly. The seal rubber may end gap larger than required to slip the possibly come off the position during disconnecting circlip over the shaft.
Page 11: Section
00-3 Precautions: • Check the male connector for bend and female Switch connector for excessive opening. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc. prevent damage. ECM / Various sensors •...
Page 12 Precautions: 00-4 Battery • Never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its coupler is • Battery connection in reverse polarity is strictly disconnected. Otherwise, damage to electronic unit prohibited. Such a wrong connection will damage the may result.
Page 13 00-5 Precautions: 3) Using a test male terminal, check the female Continuity check terminals of the circuit being checked for contact 1) Measure resistance across coupler “B” (between “A” tension. and “C” in figure). Check each terminal visually for poor contact If no continuity is indicated (infinity or over limit), the (possibly caused by dirt, corrosion, rust, entry of circuit is open between terminals “A”...
Page 14 Precautions: 00-6 3) Also, if measured values are as listed following, a Short circuit check (Wire harness to ground) resistance (abnormality) exists which causes the 1) Disconnect the negative (–) cable from the battery. voltage drop in the circuit between terminals “A” and 2) Disconnect the connectors/couplers at both ends of “B”.
Page 15 : 09900–25008 (Multi-circuit tester set) I705H1000009-02 “D”: To other parts Using The Multi-Circuit Testers • Use the Suzuki multi-circuit tester set. • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi-circuit tester set)
Page 16: Table Of Contents
Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Spark Plug Replacement ........0B-9 Spark Plug Inspection and Cleaning ....0B-9 General Description ..........0A-1 Fuel Line Inspection ..........0B-10 Symbols .............. 0A-1 Engine Oil and Filter Replacement ....0B-10 Abbreviations ............
Page 17: General Description
Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.
Page 18: Vehicle Side View
Difference between illustrations and actual motorcycles may exist depending on the FI: Fuel Injection, Fuel Injector markets. FP: Fuel pump FPR: Fuel Pressure Regulator SUZUKI GSX1300BK (2008-model) FP Relay: Fuel Pump Relay GEN: Generator Right Side GND: Ground GP Switch: Gear Position Switch...
Page 19: Vehicle Identification Number
Use of SF/SG or SH/SJ in API with MA in JASO. head pipe. The engine serial number “B” is located on Suzuki recommends the use of SAE 10W-40 engine oil. the upper crankcase. These numbers are required If SAE 10W-40 engine oil is not available, select an especially for registering the machine and ordering alternative according to the chart.
Page 20: Engine Coolant Recommendation
2) Upon reaching an odometer reading of 1 600 km (1 Suzuki recommends the use of SUZUKI COOLANT anti- 000 miles) you can subject the motorcycle to full freeze/engine coolant. If this is not available, use an throttle operation.
Page 21: Country And Area Codes
0A-5 General Information: Country and Area Codes B823H10101010 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX1300BK K8 (E-02) U.K. JS1CR111100100001 – GSX1300BK K8 (E-19) E.U. JS1CR111100100001 – GSX1300BKUF K8 (E-19) E.U.
Page 22: Warning, Caution And Information Labels Location
General Information: 0A-6 Warning, Caution and Information Labels Location B823H10101012 16, 18 1, 15, 17 11, 12, 13, 14 9, 10 7, 8 I823H1010013-01 1. Noise label (For E-03, 24, 33) 12. General warning label (French) (For GSX1300BKUF, E-19) 2. Information label (For E-03, 28, 33) 13.
Page 23: Component Location
0A-7 General Information: Component Location Electrical Components Location B823H10103001 I823H1010010-06 1. Fuel pump 8. ECM 15. Regulator/Rectifier 2. Fuel level gauge 9. EXCV actuator 16. HO2 sensor 3. STV actuator 10. EVAP system purge control solenoid valve (E-33 only) 17. GP switch 4.
Page 24 General Information: 0A-8 I823H1010011-03 20. ISC valve 28. Primary fuel injector 36. Speed sensor 21. CMP sensor 29. ECT sensor 37. Side-stand switch 22. Ignition coil 30. IAP sensor 38. Turn signal/Side-stand relay 23. Information display switch 31. Fuse box 39.
Page 25: Specifications
0A-9 General Information: Specifications Specifications B823H10107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark 2 245 mm (88.4 in) E-03, 28, 33 Overall length 2 220 mm (87.4 in) Others Overall width 800 mm (31.5 in) Overall height 1 085 mm (42.7 in)
Page 26 General Information: 0A-10 Chassis Item Specification Remark Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 120 mm (4.7 in) Rear wheel travel 137 mm (5.4 in) Caster 25 30’ Tail 107 mm (4.21 in) Steering angle...
Page 27: Special Tools And Equipment
0A-11 General Information: Special Tools and Equipment Special Tool B823H10108002 09900–06104 09900–06107 09900–06108 09900–18740 09900–20102 Snap ring pliers Snap ring pliers Snap ring pliers Hexagon socket (24 Vernier calipers (1/20 mm, 200 mm) 09900–20202 09900–20204 09900–20205 09900–20530 09900–20602 Micrometer (1/100 Micrometer (75 –...
Page 28 General Information: 0A-12 09913–70210 09915–40610 09915–63311 09915–64512 09915–74521 Bearing installer set Oil filter wrench Compression gauge Compression gauge Oil pressure gauge attachment hose 09915–74540 09915–77331 09916–10911 09916–14510 09916–14522 Oil pressure gauge Meter (for high Valve lapper set Valve spring Valve spring attachment pressure) compressor...
Page 29 0A-13 General Information: 09924–84510 09924–84521 09925–18011 09930–10121 09930–11920 Bearing installer set Bearing installer set Steering bearing Spark plug wrench set Torx bit (JT40H) installer 09930–11940 09930–11950 09930–30104 09930–30450 09930–44530 Bit holder Torx wrench Rotor remover slide Rotor remover bolt Rotor holder shaft 09930–73130 09930–73140...
Page 30 General Information: 0A-14 09941–34513 09941–54911 09941–74911 09943–74111 09944–28320 Steering race installer Bearing outer race Steering bearing Fork oil level gauge Hexagon socket (19 remover installer 99565–01010–012 CD-ROM Ver.12...
Page 31: Maintenance And Lubrication
0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B823H10200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.
Page 32: Lubrication Points
Maintenance and Lubrication: 0B-2 Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months — Brake fluid Replace every 2 years. — Brake hoses Replace every 4 years. Tires —...
Page 33: Repair Instructions
0B-3 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Replacement B823H10206001 Replace air cleaner element Every 18 000 km (11 000 miles, 36 months) Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”. Air Cleaner Element Inspection B823H10206002 Inspect air cleaner element Every 6 000 km (4 000 miles, 12 months)
Page 34: Exhaust Control Valve Inspection
Maintenance and Lubrication: 0B-4 Exhaust Control Valve Inspection Valve Clearance Inspection and Adjustment B823H10206028 B823H10206006 Inspect exhaust control valve Inspect valve clearance Initially at 1 000 km (600 miles, 2 months) and every Initially every 24 000 km (14 500 miles, 48 months) 12 000 km (7 500 miles, 24 months) thereafter Inspection Inspect exhaust control valve as follows:...
Page 35 0B-5 Maintenance and Lubrication: 8) Remove the cylinder head cover. Refer to “Engine 10) Turn the crankshaft clockwise to bring the line “C” on Top Side Disassembly in Section 1D (Page 1D-28)”. the starter clutch to the slit “D” of valve timing inspection hole and also to bring the notches “E”...
Page 36 Maintenance and Lubrication: 0B-6 12) Turn the crankshaft clockwise 360 (one full rotation) Adjustment and position the notches “E” on the left end of both The clearance is adjusted by replacing the existing camshafts to the positions as shown in the figure. tappet shim with a thicker or thinner shim.
Page 37 0B-7 Maintenance and Lubrication: (INTAKE SIDE) I823H1020018-02...
Page 38 Maintenance and Lubrication: 0B-8 (EXHAUST SIDE) I823H1020019-01...
Page 39: Spark Plug Replacement
0B-9 Maintenance and Lubrication: 6) Install the camshafts and cam chain tension adjuster. Spark Plug Gap Refer to “Engine Top Side Assembly in Section 1D 1) Remove the spark plugs. Refer to “Ignition Coil / (Page 1D-32)”. Plug Cap and Spark Plug Removal and Installation in 7) Rotate the engine so that the tappet is depressed Section 1H (Page 1H-6)”.
Page 40: Fuel Line Inspection
Maintenance and Lubrication: 0B-10 Fuel Line Inspection Engine Oil and Filter Replacement B823H10206007 B823H10206009 Inspect fuel line Replace engine oil Every 6 000 km (4 000 miles, 12 months) Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect the fuel line in the following procedures: Replace oil filter...
Page 41 MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle.
Page 42: Throttle Cable Play Inspection And Adjustment
Maintenance and Lubrication: 0B-12 5) Install the new oil filter. Turn it by hand until you feel Throttle Cable Play Inspection and Adjustment B823H10206010 that the oil filter O-ring contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to Inspect throttle cable play specified torque) using the special tool.
Page 43: Evaporative Emission Control System Inspection (E-33 Only)
0B-13 Maintenance and Lubrication: Evaporative Emission Control System Engine Coolant Change Refer to “Engine Coolant Description in Section 1F Inspection (E-33 only) B823H10206008 (Page 1F-1)”. Inspect evaporative emission control system WARNING Every 12 000 km (7 500 miles, 24 months) Do not open the radiator cap when the engine Inspect the evaporative emission control system is hot, as you may be injured by escaping hot...
Page 44: Clutch System Inspection
Maintenance and Lubrication: 0B-14 9) After changing engine coolant, reinstall the removed Clutch System Inspection B823H10206014 parts. Inspect clutch hose and clutch fluid Air Bleeding From the Cooling Circuit Every 6 000 km (4 000 miles, 12 months) 1) Add engine coolant up to the radiator inlet. WARNING 2) Support the motorcycle upright.
Page 45: Clutch Hose Replacement
0B-15 Maintenance and Lubrication: 3) Inspect the clutch hose for crack, damage or clutch Drive Chain Inspection and Adjustment B823H10206017 fluid leakage. If it is damaged, replace the clutch hose with a new one. Inspect drive chain Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Drive Chain Visual Check 1) With the transmission in neutral, support the...
Page 46 Maintenance and Lubrication: 0B-16 Drive Chain Length Inspection 4) Loosen or tighten both chain adjuster bolts (3) until there is 20 – 30 mm (0.8 – 1.2 in) of slack “a” at the 1) Loosen the axle nut (1). middle of the chain between the engine and rear 2) Loosen the chain adjuster lock-nuts (2).
Page 47: Drive Chain Cleaning And Lubricating
Brake Fluid Level Check • The standard drive chain is a RK 1) Keep the motorcycle upright and place the GB50GSVZ4. SUZUKI recommends to use handlebars straight. this standard drive chain as a replacement. 2) Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs.
Page 48 Maintenance and Lubrication: 0B-18 Brake Pads Check Front and Rear Brake Hose Inspection The extent of brake pad wear can be checked by Inspect the brake hoses and hose joints for crack, observing the grooved limit line “A” on the pad. When the damage or brake oil leakage.
Page 49: Tire Inspection
0B-19 Maintenance and Lubrication: Brake Hose Replacement Tire Pressure If the tire pressure is too high or too low, steering will be Replace brake hose adversely affected and tire wear increased. Therefore, Every 4 years maintain the correct tire pressure for good roadability or Refer to “Front Brake Hose Removal and Installation in shorter tire life will result.
Page 50: Steering System Inspection
Maintenance and Lubrication: 0B-20 Steering System Inspection Rear Suspension Inspection B823H10206021 B823H10206023 Inspect steering system Inspect rear suspension Initially at 1 000 km (600 miles, 2 months) and every Every 12 000 km (7 500 miles, 24 months) 12 000 km (7 500 miles, 24 months) thereafter Inspect the rear shock absorber for oil leakage and Steering should be adjusted properly for smooth turning check that there is no play in the swingarm.
Page 51: Chassis Bolt And Nut Inspection
0B-21 Maintenance and Lubrication: Chassis Bolt and Nut Inspection B823H10206024 Tighten chassis bolt and nut Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Check that all chassis bolts and nuts are tightened to their specified torque.
Page 52: Compression Pressure Check
Maintenance and Lubrication: 0B-22 I823H1020056-01 I823H1020059-01 Union bolt (Front brake) 23 N m (2.3 kgf-m, 16.5 lb-ft) Union bolt (clutch) 23 N m (2.3 kgf-m, 16.5 lb-ft) Front axle bolt 100 N m (10.0 kgf-m, 72.5 lb-ft) Air bleeder valve (clutch) 6 N m (0.6 kgf-m, 4.5 lb-ft) Brake disc bolt (Front) 23 N m (2.3 kgf-m, 16.5 lb-ft) Front axle pinch bolt 23 N m (2.3 kgf-m, 16.5 lb-ft) Front brake caliper mounting bolt 39 N m (3.9 kgf-m, 28.0 lb-ft)
Page 53: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-14) /...
Page 54: Service Data
Service Data: 0C-1 Service Data General Information Specifications Service Data B823H10307001 Valve + Guide Unit: mm (in) Item Standard Limit 33 (1.30) — Valve diam. 27.5 (1.08) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...
Page 55 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 – 256 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —...
Page 56 Service Data: 0C-3 Oil Pump Item Standard Limit 200 – 500 kPa Oil pressure (at 60 C, 140 F) (2.0 – 5.0 kgf/cm , 28.4 – 71.1 psi) — at 3 000 r/min Clutch Unit: mm (in) Item Standard Limit No.
Page 57: 0C-4 Service Data
0C-4 Service Data: Thermostat + Radiator + Fan + Coolant Item Standard/Specification Note Thermostat valve opening Approx. 82 C (180 F) — temperature Thermostat valve lift Over 8 mm (0.31 in) and at 95 C (203 F) — 20 C Approx.
Page 58 Service Data: 0C-5 FI Sensors Item Standard/Specification Note CKP sensor resistance 180 – 280 CKP sensor peak voltage 3.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.7 V at idle speed TP sensor input voltage 4.5 –...
Page 59 0C-6 Service Data: Throttle Body Item Specification Bore size 44 mm (1.73 in) I.D. No. 23H1 (For E-33), 23H0 (For the others) Idle r/min 1 150 100 r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) Electrical Unit: mm Item Specification...
Page 60 Service Data: 0C-7 Wattage Unit: W Specification Item E-02, 19, 24 The other countries Headlight Parking or position light 5 x 2 Brake light/Taillight Turn signal light 21 x 4 License plate light Tachometer light Speedometer light Turn signal indicator light High beam indicator light Neutral position indicator light Oil pressure indicator light...
Page 61 Front fork oil level (Without spring, 100 (3.9) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (Each leg) 527 ml (17.8/18.6 US/lmp oz) — Front fork inner tube O.D.
Page 62: Tightening Torque List
Service Data: 0C-9 Tightening Torque List B823H10307002 Engine Item kgf-m lb-ft Exhaust pipe bolt 16.5 Exhaust pipe mounting bolt 16.5 Muffler mounting bolt (Front) 16.5 Muffler mounting bolt (Rear) 18.0 Muffler joint mounting bolt 16.5 Muffler connecting bolt 16.5 Speed sensor rotor bolt 20.0 Engine sprocket nut 14.5...
Page 63 0C-10 Service Data: Item kgf-m lb-ft Initial 15.0 Conrod bearing cap bolt Final Bearing retainer screw Cam chain guide retainer screw Balancer shaft arm bolt Balancer cover bolt Balancer pipe bolt Oil strainer bolt Oil pan bolt Oil pipe bolt (Camshaft housing) Oil pipe bolt [M6] Oil pipe union bolt...
Page 64 Service Data: 0C-11 Chassis Item kgf-m lb-ft Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt 16.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork inner rod lock-nut 11.0 Front fork damper rod bolt 16.5...
Page 65 0C-12 Service Data: Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) kgf-m lb-ft kgf-m lb-ft 0.15 0.23 0.45 0.55 16.5 21.0...
Page 66 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Precautions............. 1-1 Malfunction............1A-72 Precautions for Engine.......... 1-1 DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction....1A-72 Engine General Information and DTC “C29”...
Page 67 1-ii Table of Contents Crankcase Emission Control System AP Sensor Removal and Installation....1C-6 Description ............1B-2 TO Sensor Inspection .........1C-6 Exhaust Emission Control System TO Sensor Removal and Installation ....1C-6 Description ............1B-3 STP Sensor Inspection ........1C-7 Noise Emission Control System Description..1B-6 STP Sensor Adjustment........1C-7 Evaporative Emission Control System STP Sensor Removal and Installation ....1C-8...
Page 68 Table of Contents 1-iii Valve Guide Replacement ........1D-57 Engine Cooling System ......1F-1 Valve Seat Repair ..........1D-58 Precautions............1F-1 Cylinder Disassembly and Assembly ....1D-59 Precautions for Engine Cooling System....1F-1 Cylinder Inspection ...........1D-60 Precautions for Engine Coolant ......1F-1 Piston Ring Removal and Installation ....1D-61 General Description ..........
Page 69 1-iv Table of Contents Fuel Tank Construction ........1G-8 Starter Motor Inspection........1I-5 Fuel Tank Heat Shield Construction ....1G-9 Starter Relay Removal and Installation ....1I-6 Fuel Tank Removal and Installation....1G-10 Starter Relay Inspection........1I-7 Fuel Pump Components ........1G-12 Turn Signal / Side-stand Relay Removal and Fuel Pump Disassembly and Assembly...
Page 70 Table of Contents 1-v EXCVA Inspection ..........1K-9 Specifications .............1K-15 EXCVA Pulley Inspection........1K-9 Service Data............1K-15 EXCVA Adjustment ..........1K-9 Tightening Torque Specifications......1K-15 Muffler / Muffler Joint / Exhaust Pipe Removal Special Tools and Equipment ......1K-16 and Installation ..........1K-12 Recommended Service Material .......1K-16 Exhaust System Inspection.......
Page 71: 1-1 Precautions
1-1 Precautions: Precautions Engine Precautions Precautions for Engine B823H11000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.
Page 72: Engine General Information And Diagnosis
Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine General Description Injection Timing Description B823H11101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
Page 73: Self-Diagnosis Function
1A-2 Engine General Information and Diagnosis: Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions When atmospheric pressure is low, the sensor sends the signal to ATMOSPHERIC PRESSURE SENSOR SIGNAL the ECM and reduce the injection time (volume).
Page 74: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-3 For Example: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from the ECM, and the panel indicates “CHEC”. If CHEC is indicated, the LCD does not indicate the trouble code.
Page 75 1A-4 Engine General Information and Diagnosis: Combination meter Cooling Cooling fan relay Cooling IG switch/ Y/Bl Immobilizer 6 38 43 signal R/Bl O/Bl Speed sensor Br/Y (E-02, 19, 24) Lg/W (E-03, 28, 33) Lg/G Lg/Bl CMPS Gr/W Gr/B Gr/Y Gr/R Secondary fuel injector...
Page 76: Terminal Alignment Of Ecm Coupler
Engine General Information and Diagnosis: 1A-5 Terminal Alignment of ECM Coupler B823H11102002 I823H1110002-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT STVA signal (STVA, 2A) ISC valve signal (ISC, 2A) STVA signal (STVA, 1A) ISC valve signal (ISC, 1A) EXCVA power (EXCVA–) Drive mode selector (DMS 1) EXCVA power (EXCVA+) Tachometer...
Page 77: Component Location
1A-6 Engine General Information and Diagnosis: Component Location FI System Parts Location B823H11103001 I823H1110182-01 “A”: ECM “F”: PAIR control solenoid valve (PAIR valve) “K”: Engine coolant temperature sensor (ECTS) “B”: Secondary fuel injector “G”: Ignition coil (IG coil) “L”: Fuel pump relay (FP relay) “C”: Primary fuel injector “H”: Speedometer “M”: Fuel pump...
Page 78 Engine General Information and Diagnosis: 1A-7 I823H1110183-01 “A”: ECM “U”: Secondary throttle position sensor (STPS) “O”: Atmospheric pressure sensor (APS) “V”: Throttle position sensor (TPS) “P”: Tip-over sensor (TOS) “W”: Intake air pressure sensor (IAPS) “Q”: Exhaust control valve actuator (EXCVA) “X”: Idle speed control valve (ISC valve) “R”: Cooling fan relay “Y”: Driving mode selection switch (DMSS)
Page 79: Diagnostic Information And Procedures
1A-8 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis B823H11104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guide or poor seating of Repair or replace.
Page 80 Engine General Information and Diagnosis: 1A-9 Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensor or circuit. Repair or replace. (Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace.
Page 81 1A-10 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Noisy engine (Noise Too much play on pump shaft bearing. Replace. seems to come from Worn or damaged impeller shaft. Replace. water pump) Worn or damaged mechanical seal. Replace.
Page 82 Engine General Information and Diagnosis: 1A-11 Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP switch. Replace.
Page 83: Self-Diagnostic Procedures
1A-12 Engine General Information and Diagnosis: Self-Diagnostic Procedures 5) Check the DTC to determine the malfunction part. B823H11104002 Refer to “DTC Table (Page 1A-20)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select switch) • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming DTC (Diagnostic Trouble Code)
Page 84: Precautions For Electrical Circuit Service
Engine General Information and Diagnosis: 1A-13 Use of SDS 2) Set up the SDS tools. (Refer to the SDS operation manual for further details.) NOTE Special tool • Do not disconnect the coupler from ECM, (A): 09904–41010 (SDS Set) battery cable from battery, ECM ground (B): 99565–01010–012 (CD-ROM Ver.12) wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code)
Page 85: Use Of Sds Diagnosis Reset Procedures
1A-14 Engine General Information and Diagnosis: 3) Click the DTC inspection button (1). Use of SDS Diagnosis Reset Procedures B823H11104003 NOTE The malfunction code is memorized in the ECM also when the lead wire coupler of any sensor is disconnected. Therefore, when a lead wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.
Page 86: Show Data When Trouble (Displaying Data At The Time Of Dtc)
Engine General Information and Diagnosis: 1A-15 6) Follow the displayed instructions. 7) Check that both “Current DTC” (3) and “Past DTC” (4) are deleted (NIL). I705H1110006-01 I705H1110008-01 8) Close the SDS tool and turn the ignition switch OFF. 9) Disconnect the SDS tool and install the right frame cover.
Page 87 1A-16 Engine General Information and Diagnosis: 1) Click “Show data when trouble” (1) to display the data. I718H1110269-02 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110270-01...
Page 88: Sds Check
Engine General Information and Diagnosis: 1A-17 SDS Check B823H11104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
Page 89 1A-18 Engine General Information and Diagnosis: Data at 3 000 r/min under no load Approx. 3 000 r/min Check the water temperature. XX ˚C Check the manifold absolute pressure. XXX kPa I823H1110209-02 Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens...
Page 90 Engine General Information and Diagnosis: 1A-19 Data of intake negative pressure during idling (100 C) Check the manifold absolute pressure. XXX kPa Check the engine coolant temperature. XX ˚C I823H1110211-01 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure.
Page 91: Dtc Table
1A-20 Engine General Information and Diagnosis: Example of Trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.
Page 92 Engine General Information and Diagnosis: 1A-21 Code Malfunction Part Remarks C23 (P1651-H/L) Tip-over sensor (TOS) (Page 1A-65) C24 (P0351) Ignition signal #1 (IG coil #1) For #1 cylinder (Page 1A-72) C25 (P0352) Ignition signal #2 (IG coil #2) For #2 cylinder (Page 1A-72) C26 (P0353) Ignition signal #3 (IG coil #3)
Page 93: Fail-Safe Function Table
1A-22 Engine General Information and Diagnosis: Fail-Safe Function Table B823H11104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item Fail-Safe Mode Starting Ability Running Ability When camshaft position signal has failed...
Page 94 Engine General Information and Diagnosis: 1A-23 Item Fail-Safe Mode Starting Ability Running Ability EVAP system purge control ECM stops controlling EVAP system purge “YES” “YES” solenoid valve (E-33 only) control solenoid valve. The engine can start and can run even if the signal in the table is not received from each sensor. But, the engine running condition is not complete, providing only emergency help (by fail-safe circuit).
Page 95: Fi System Troubleshooting
1A-24 Engine General Information and Diagnosis: FI System Troubleshooting B823H11104008 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as following will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 96: Malfunction Code And Defective Condition Table
Engine General Information and Diagnosis: 1A-25 Visual Inspection Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.
Page 97 1A-26 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following. 0.15 V Sensor voltage < 4.85 V ECT sensor, lead wire/coupler In other than the above range, C15 (P0115) is connection indicated.
Page 98 Engine General Information and Diagnosis: 1A-27 Malfunction Detected Item Detected Failure Condition Check For Code Gear position signal voltage should be higher than the following for 3 seconds and more. GP switch, wiring/coupler Gear position signal Gear position sensor voltage 0.6 V P0705 connection, gearshift cam, etc.
Page 99 1A-28 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code EXCVA position sensor produces following voltage. 0.1 V sensor voltage < 4.9 V in other than the above range, C46 (P1675) is indicated. EXCVA, EXCVA lead wire/ When no actuator control signal is supplied coupler from the ECM, communication signal does not...
Page 100: Dtc "C11" (P0340) Cmp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-29 DTC “C11” (P0340) CMP Sensor Circuit Malfunction B823H11104029 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 4 sec. or more, after • CMP sensor circuit open or short. receiving the starter signal.
Page 101 1A-30 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Y, R or B/Br wire • Inspect that metal open or shorted to particles or foreign 2) Lift and support the fuel tank. Refer to “Fuel Tank the ground.
Page 102: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-31 DTC “C12” (P0335): CKP Sensor Circuit Malfunction B823H11104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 4 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.
Page 103 1A-32 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Remove the engine sprocket outer cover. Refer to “Engine Sprocket Removal and Installation in Section 3A (Page 3A-2)”.
Page 104 Engine General Information and Diagnosis: 1A-33 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi-circuit tester set) CKP sensor continuity (Infinity) (Bl –...
Page 105: Dtc "C13" (P0105-H/L): Iap Sensor Circuit Malfunction
1A-34 Engine General Information and Diagnosis: DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B823H11104011 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.
Page 106 Engine General Information and Diagnosis: 1A-35 C13 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
Page 107 1A-36 Engine General Information and Diagnosis: P0105-H for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 108 Engine General Information and Diagnosis: 1A-37 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. G/B wire shorted to and Installation in Section 1C (Page 1C-2)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the G/B wire and terminal “9”.
Page 109 1A-38 Engine General Information and Diagnosis: P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/B wire open, G/ B wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 110 Engine General Information and Diagnosis: 1A-39 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/B wire open, G/ and Installation in Section 1C (Page 1C-2)”. B wire shorted to the ground. 7) Insert the needle pointed probes to the lead wire coupler.
Page 111 1A-40 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor. Refer to “IAP Sensor Removal the ground, or poor IAP sensor with a new and Installation in Section 1C (Page 1C-3)”.
Page 112: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-41 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B823H11104012 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...
Page 113 1A-42 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
Page 114 Engine General Information and Diagnosis: 1A-43 P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. P/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 115 1A-44 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 3. P/B wire shorted to “8”. Also, check the continuity between the B/Br wire and VCC, or B/Br wire open. terminal “29”.
Page 116 Engine General Information and Diagnosis: 1A-45 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and P/B wire open, or P/B wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 117 1A-46 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and P/B wire open, or and Installation in Section 1C (Page 1C-2)”. P/B wire shorted to the ground. 7) Check the continuity between the P/B wire and terminal “8”.
Page 118 Engine General Information and Diagnosis: 1A-47 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the special tool between the TP sensor and its the ground, or poor sensor with a new one.
Page 119: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction
1A-48 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B823H11104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V Sensor voltage <...
Page 120 Engine General Information and Diagnosis: 1A-49 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
Page 121 1A-50 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”. 3) Check the ECT sensor coupler (1) for loose or poor contacts.
Page 122 Engine General Information and Diagnosis: 1A-51 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to the ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 123 1A-52 Engine General Information and Diagnosis: Step Action 9) Measure the output voltage between the B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. the ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...
Page 124: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-53 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B823H11104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V Sensor voltage <...
Page 125 1A-54 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
Page 126 Engine General Information and Diagnosis: 1A-55 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 127 1A-56 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to the ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 128 Engine General Information and Diagnosis: 1A-57 Step Action 9) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. the ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...
Page 129: Dtc "C22" (P01450-H/L): Ap Sensor Circuit Malfunction
1A-58 Engine General Information and Diagnosis: DTC “C22” (P01450-H/L): AP Sensor Circuit Malfunction B823H11104031 Detected Condition and Possible Cause Detected Condition Possible Cause AP sensor voltage is not within the • Clogged vacuum passage with dust. following range. • AP sensor circuit open or shorted to the ground. 0.5 V Sensor voltage <...
Page 130 Engine General Information and Diagnosis: 1A-59 C22 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the front seat. Refer to “Exterior Parts Removal coupler.
Page 131 1A-60 Engine General Information and Diagnosis: P1450-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. G/Y wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.
Page 132 Engine General Information and Diagnosis: 1A-61 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. G/Y wire shorted to and Installation in Section 1C (Page 1C-2)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the G/Y wire and terminal “26”.
Page 133 1A-62 Engine General Information and Diagnosis: P01450-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/Y wire open, G/ Y wire shorted to the 2) Remove the front seat. Refer to “Exterior Parts Removal ground.
Page 134 Engine General Information and Diagnosis: 1A-63 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/Y wire open, G/ and Installation in Section 1C (Page 1C-2)”. Y wire shorted to the ground. 7) Insert the needle pointed probes to the lead wire coupler.
Page 135 1A-64 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/Y, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the AP sensor. Refer to “IAP Sensor Removal the ground, or poor AP sensor with a new and Installation in Section 1C (Page 1C-3)”.
Page 136: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-65 DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B823H11104016 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...
Page 137 1A-66 Engine General Information and Diagnosis: C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the right frame cover. Refer to “Exterior Parts “TO Sensor Removal Removal and Installation in Section 9D (Page 9D-14)”.
Page 138 Engine General Information and Diagnosis: 1A-67 P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 139 1A-68 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. B wire shorted to VCC, and Installation in Section 1C (Page 1C-2)”. or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the B wire and terminal “22”.
Page 140 Engine General Information and Diagnosis: 1A-69 P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or B wire open, or B wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 141 1A-70 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or B wire open, or B and Installation in Section 1C (Page 1C-2)”. wire shorted to the ground. 7) Insert the needle pointed probes to the lead wire coupler.
Page 142 Engine General Information and Diagnosis: 1A-71 Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Remove the TO sensor. Refer to “TO Sensor Removal the ground, or poor coupler.
Page 143: Dtc "C24" (P0351), "C25" (P0352), "C26" (P0353) Or "C27" (P0354): Ignition System Malfunction
1A-72 Engine General Information and Diagnosis: DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B823H11104017 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-5)” for details. DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction B823H11104018 Detected Condition and Possible Cause Detected Condition...
Page 144 Engine General Information and Diagnosis: 1A-73 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 145 1A-74 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Lg, P/W, W/B and • Loose or poor Y/W wire open or contacts on the ECM 2) Disconnect the STVA lead wire coupler. shorted to the coupler.
Page 146 Engine General Information and Diagnosis: 1A-75 Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” (1). I823H1110200-02 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.
Page 147: Dtc "C29" (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction
1A-76 Engine General Information and Diagnosis: DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B823H11104019 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •...
Page 148 Engine General Information and Diagnosis: 1A-77 C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
Page 149 1A-78 Engine General Information and Diagnosis: P1654-H (Use of SDS) Step Action 7) Check the continuity between the Y/W wire and R wire. Go to Step 3. Y/W wire shorted to If the sound is not heard from the tester, the circuit VCC, or B/Br wire open.
Page 150 Engine General Information and Diagnosis: 1A-79 Step Action 1) Turn the ignition switch OFF. Go to Step 3. Y/W wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”. 3) Check the STP sensor coupler (1) for loose or poor contacts.
Page 151 1A-80 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Y/W wire shorted to and Installation in Section 1C (Page 1C-2)”. VCC, or B/Br wire open. 7) Check the continuity between the Y/W wire and terminal “20”.
Page 152 Engine General Information and Diagnosis: 1A-81 P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Y/W wire open, or Y/W wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 153 1A-82 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 2. R or Y/W wire open, or “20”. Also, check the continuity between the R wire and Y/W wire shorted to the terminal “11”.
Page 154 Engine General Information and Diagnosis: 1A-83 Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM coupler and STP sensor coupler. the ground, or poor STP sensor with a new 3) Disconnect the STVA lead wire coupler.
Page 155: Dtc "C31" (P0705): Gp Switch Circuit Malfunction
1A-84 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B823H11104020 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range. •...
Page 156 Engine General Information and Diagnosis: 1A-85 Step Action 1) Turn the ignition switch OFF. • P wire open or • R or B wire open, or shorted to the R wire shorted to the 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 157: Dtc "C32" (P0201), "C33" (P0202), "C34" (P0203) Or "C35" (P0204): Primary Fuel Injector Circuit Malfunction
1A-86 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction B823H11104021 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is •...
Page 158 Engine General Information and Diagnosis: 1A-87 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-10)”.
Page 159 1A-88 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-12)”.
Page 160 Engine General Information and Diagnosis: 1A-89 Step Action 1) Turn the ignition switch ON. • Gr/W wire open or Open circuit in the Y/R shorted to the wire. 2) Measure the injector voltage between the Y/R wire and ground, or poor “48” ground.
Page 161: Dtc "C36" (P1764), "C37" (P1765), "C38" (P1766) Or "C39" (P1767): Secondary Fuel Injector Circuit Malfunction
1A-90 Engine General Information and Diagnosis: DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction B823H11104032 Detected Condition and Possible Cause Detected Condition Possible Cause Some failure exists in the fuel injector signal in a high •...
Page 162 Engine General Information and Diagnosis: 1A-91 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-10)”.
Page 163 1A-92 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-12)”.
Page 164 Engine General Information and Diagnosis: 1A-93 Step Action 1) Turn the ignition switch ON. • Lg wire open or Open circuit in the Y/R shorted to the wire. 2) Measure the injector voltage between the Y/R wire and ground, or poor “64” ground.
Page 165: Dtc "C40" (P0505 / P0506 / P0507): Isc Valve Circuit Malfunction
1A-94 Engine General Information and Diagnosis: DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B823H11104022 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is • ISC valve circuit open or shorted to the ground. C40/P0505 unusual.
Page 166 Engine General Information and Diagnosis: 1A-95 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Bl/R, Y, W/Bl or Br wire open. 2) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-6)”. 3) Check the ISC valve coupler (1) for loose or poor contacts.
Page 167 1A-96 Engine General Information and Diagnosis: Step Action 1) Check the continuity between each ISC valve terminal If wire is OK, Replace the ISC valve and ground. intermittent trouble or with a new one. Refer to faulty ECM. “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set)
Page 168 Engine General Information and Diagnosis: 1A-97 ACTIVE CONTROL INSPECTION (ISC RPM Check 2 CONTROL) 1) Click the button (4) and decrease the “Spec” (2) to 1 Check 1 050 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation 2) Check that the “Desired idle speed”...
Page 169 1A-98 Engine General Information and Diagnosis: Check 3 Check 4 1) Click the button (6) and increase the “Spec” (2) to 1 1) Click the button (6) and increase the “Spec” (2) to 1 500 rpm slowly. 900 rpm. 2) Check that the “Desired idle speed” (3) is nearly 2) Check that the “Desired idle speed”...
Page 170: Dtc "C41" (P0230-H/L): Fp Relay Circuit Malfunction
Engine General Information and Diagnosis: 1A-99 DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction B823H11104023 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to fuel pump. • Fuel pump relay circuit open or short. • Fuel pump relay malfunction. Voltage is applied to fuel pump although •...
Page 171 1A-100 Engine General Information and Diagnosis: C41 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. • ECM power input Replace the FP relay signal malfunction. with a new one. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 172 Engine General Information and Diagnosis: 1A-101 P0230-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. • Y/B wire open or poor Replace the FP relay “39” connection. with a new one. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 173: Dtc "C41" (P2505): Ecm Power Input Signal Malfunction
1A-102 Engine General Information and Diagnosis: DTC “C41” (P2505): ECM Power Input Signal Malfunction B823H11104024 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the ECM. • Lead wire/coupler connection of ECM terminal to fuel fuse.
Page 174 Engine General Information and Diagnosis: 1A-103 Step Action 1) Turn the ignition switch OFF. • Fuel pump relay Open or short circuit in circuit malfunction. the R/Bl wire. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. Refer to “DTC “C41”...
Page 175: Dtc "C42" (P1650): Ig Switch Circuit Malfunction
1A-104 Engine General Information and Diagnosis: DTC “C42” (P1650): IG Switch Circuit Malfunction B823H11104025 Detected Condition and Possible Cause Detected Condition Possible Cause Ignition switch signal is not input to the ECM. • Ignition system circuit open or short. • ECM malfunction. When the ID agreement is not verified.
Page 176 Engine General Information and Diagnosis: 1A-105 Troubleshooting (When Indicating C44/P0130:) CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. NOTE After repairing the trouble, clear the DTC using SDS tool.
Page 177 1A-106 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the W/G wire terminal “A” Go to Step 2. W/G wire shorted to the and terminal “12”. Also, check the continuity between the power source, or W/G B/Br wire terminal “B”...
Page 178 Engine General Information and Diagnosis: 1A-107 Step Action 1) Connect the ECM coupler and HO2 sensor coupler. • W/G or B/Br wire Replace the HO2 open or shorted to sensor with a new one. 2) Warm up the engine enough. the power source, or Refer to “Heated 3) Insert the needle pointed probes to the lead wire coupler.
Page 179 1A-108 Engine General Information and Diagnosis: Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.
Page 180 Engine General Information and Diagnosis: 1A-109 Step Action 1) Connect the HO2 sensor coupler. • O/W or W wire open • Open or short circuit or shorted to the in the W wire or O/W 2) Insert the needle pointed probes to the lead wire coupler. ground, or poor “41”...
Page 181: Dtc "C46" (P1657-H/L Or P1658): Excv Actuator Circuit Malfunction
1A-110 Engine General Information and Diagnosis: DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction B823H11104033 Detected Condition Possible Cause The operation signal does not reach the • EXCVA maladjusted. EXCV actuator. • EXCVA circuit open or short. EXCVA position sensor voltage low or •...
Page 182 Engine General Information and Diagnosis: 1A-111 C46 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Go to Step 6. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”. 3) Check the EXCVA position sensor coupler (1) and EXCVA motor coupler (2) for loose or poor contacts.
Page 183 1A-112 Engine General Information and Diagnosis: P1657-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 4. Y wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-10)”.
Page 184 Engine General Information and Diagnosis: 1A-113 Step Action 8) Check the continuity between Lbl wire and terminal “5”. Go to Step 4. Lbl wire shorted to VCC, or B/Br wire open. 9) Also, check the continuity between B/Br wire and terminal “29”.
Page 185 1A-114 Engine General Information and Diagnosis: P1657-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2 and go to R or Lbl wire open, or Step 4. Lbl wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.
Page 186 Engine General Information and Diagnosis: 1A-115 Step Action 9) Also, check the continuity between R wire and terminal Go to Step 2 and go to R or Y wire open, or Y “11”. Step 4. wire shorted to ground. Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...
Page 187 1A-116 Engine General Information and Diagnosis: Step Action 1) Disconnect the EXCVA position sensor coupler (1). Go to Step 3. • Loose or poor contacts on the ECM coupler (terminal “11” or “29”). • Open or short circuit in the R or B/Br wire. I823H1110160-01 2) Turn the ignition switch ON.
Page 188 Engine General Information and Diagnosis: 1A-117 Step Action 1) Turn the ignition switch OFF. Go to Step 4. Replace the EXCVA with a new one. 2) Check the continuity between Y wire and ground. EXCVA position sensor continuity (Infinity) I823H1110162-01 3) If OK, then measure the EXCVA position sensor resistance.
Page 189 1A-118 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Go to Step 5. known good one, and 2) Connect the EXCVA position sensor coupler (1). inspect it again. 3) Disconnect the EXCVA motor coupler (2). 4) Measure the EXCVA position sensor output voltage at EXCV fully closed position and fully opened position.
Page 190 Engine General Information and Diagnosis: 1A-119 Step Action 8) Then, to set the EXCV to fully opened position, apply 12 Replace the ECM with a Go to Step 5. V to the terminals oppositely. known good one, and Positive wire – Gr wire terminal inspect it again.
Page 191 1A-120 Engine General Information and Diagnosis: Step Action 1) If the EXCVA position sensor output voltage is 0.45 V Replace the ECM with a Replace the EXCVA and less at EXCV fully closed position, adjust the output known good one, and with a new one.
Page 192 Engine General Information and Diagnosis: 1A-121 Step Action 1) Turn the ignition switch OFF. • Loose or poor • Replace the EXCVA contacts on the with a new one. 2) Disconnect the EXCVA motor coupler (1). EXCVA or ECM • Inspect that the coupler (terminal “4”...
Page 193 1A-122 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click ”EXhaust valve operating control” (1). I823H1110202-02 4) Click each button (2). At this time, if an operation sound is heard from the EXCVA, the function is normal.
Page 194: Dtc "C49" (P1656): Pair Control Solenoid Valve Circuit Malfunction
Engine General Information and Diagnosis: 1A-123 DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B823H11104027 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve voltage is not input to ECM. • PAIR control solenoid valve circuit open or short. •...
Page 195 1A-124 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the PAIR control solenoid with a 2) Remove the air cleaner box. Refer to “Air Cleaner Box new one. Refer to “PAIR Removal and Installation in Section 1D (Page 1D-6)”.
Page 196 Engine General Information and Diagnosis: 1A-125 Step Action 1) Turn the ignition switch ON. • W/G wire open or Open or short circuit in shorted to the the O/W wire. 2) Measure the voltage between the O/W wire and ground. ground, or poor “44”...
Page 197 1A-126 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “PAIR Sol operating control” (1). I823H1110215-01 4) Click each button (2). At this time, if an operating sound is heard from the PAIR control solenoid valve, the function is normal.
Page 198: Dtc "C60" (P0480): Cooling Fan Relay Circuit Malfunction
Engine General Information and Diagnosis: 1A-127 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B823H11104028 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •...
Page 199 1A-128 Engine General Information and Diagnosis: Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-14)”.
Page 200 Engine General Information and Diagnosis: 1A-129 Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Start the engine and run it in idling condition. 3) Click “Cooling fan relay control” (1). I823H1110217-01 4) Click the “Operate”...
Page 201: Dtc "C62" (P0443): Evap System Purge Control Solenoid Valve Circuit Malfunction (E-33 Only)
1A-130 Engine General Information and Diagnosis: DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) B823H11104030 Detected Condition and Possible Cause Detected Condition Possible Cause EVAP system purge control valve voltage is not input to • EVAP system purge control valve circuit open or short. ECM.
Page 202 Engine General Information and Diagnosis: 1A-131 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the EVAP system purge control 2) Lift and support the fuel tank. Refer to “Fuel Tank with a new one. Refer to Removal and Installation in Section 1G (Page 1G-10)”.
Page 203 1A-132 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • W/Y wire open or Open or short circuit in shorted to the the O/W wire. 2) Measure the voltage between the O/W wire and ground. ground, or poor “15”...
Page 204 Engine General Information and Diagnosis: 1A-133 Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “EVAP purge operating control” (1). I823H1110218-01 4) Click each button (2). At this time, if an operating sound is heard from the EVAP system purge control valve, the function is normal.
Page 205: Specifications
1A-134 Engine General Information and Diagnosis: Specifications Service Data B823H11107001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note Injector resistance 11 – 13 at 20 C (68 F) FI Sensors Item Standard/Specification Note CKP sensor resistance 180 – 280 CKP sensor peak voltage 3.0 V and more When cranking...
Page 206: Special Tools And Equipment
Engine General Information and Diagnosis: 1A-135 Special Tools and Equipment Special Tool B823H11108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-30) / (Page 1A-113) / (Page 1A-32) / (Page 1A-115) / (Page 1A-33) / (Page 1A-118) / (Page 1A-112) / (Page 1A-119) / (Page 1A-113) /...
Page 207 1A-136 Engine General Information and Diagnosis: 09900–28630 09904–41010 TPS test wire harness SDS set (Page 1A-47) (Page 1A-13) / (Page 1A-17) 09917–47011 09930–82720 Vacuum pump gauge Mode select switch (Page 1A-40) / (Page 1A-3) / (Page 1A- (Page 1A-64) 12) / (Page 1A-12) 99565–01010–012 CD-ROM Ver.12...
Page 208: Emission Control Devices
Fuel Injection System Description B823H11201001 GSX1300BK motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.
Page 209: Crankcase Emission Control System Description
1B-2 Emission Control Devices: Crankcase Emission Control System Description B823H11201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.
Page 210: Exhaust Emission Control System Description
Emission Control Devices: 1B-3 Exhaust Emission Control System Description B823H11201003 The exhaust emission control system is composed of the PAIR system, exhaust control system, HO2 sensor, three- way catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve.
Page 211 1B-4 Emission Control Devices: PAIR System Diagram “A” “B” I823H1120004-01 1. PAIR control solenoid valve 2. PAIR reed valve “A”: Fresh air “B”: Exhaust gas...
Page 212 Emission Control Devices: 1B-5 Pair System Hose Routing Diagram “A” “C” “D” “B” “A” “A” “D” “D” “D” “B” “B” I823H1120039-01 1. PAIR control solenoid valve 2. PAIR reed valve 3. PAIR hose (Air inlet) : Pass the PAIR hose through under the wire harness and front of the PCV hose. 4.
Page 213: Noise Emission Control System Description
1B-6 Emission Control Devices: Noise Emission Control System Description B823H11201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: • The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or •...
Page 214: Evaporative Emission Control System Diagram (Only For
Emission Control Devices: 1B-7 Evaporative Emission Control System Diagram (Only for E-33) B823H11201005 “A” “B” “C” “D” I823H1120033-04 1. Fuel tank 6. Fuel tank pressure control valve 11. IAP sensor 2. Fuel pump 7. EVAP canister “A”: Fuel 3. Fuel feed hose 8.
Page 215: Schematic And Routing Diagram
1B-8 Emission Control Devices: Schematic and Routing Diagram EVAP Canister Hose Routing Diagram (Only for E-33) B823H11202001 “B” “D” “B” “B” “C” “C” “A” “E” “F” I823H1120005-03 1. EVAP canister “A”: The ends of the clamp should face outside. 2. Fuel shut-off valve “B”: The ends of the clamp should face backward.
Page 216: Repair Instructions
Emission Control Devices: 1B-9 Repair Instructions Heated Oxygen Sensor (HO2S) Construction B823H11206011 I823H1120040-04 1. HO2 sensor : 25 N m (2.5 kgf-m, 18.0 lb-ft) Heated Oxygen Sensor (HO2S) Removal and 3) Disconnect the HO2 sensor coupler (1). Installation B823H11206001 Removal WARNING Do not remove the HO2 sensor while it is hot.
Page 217: Heated Oxygen Sensor (Ho2S) Inspection
1B-10 Emission Control Devices: Installation 4) Remove the PAIR reed valves (3). Install the HO2 sensor in the reverse order of removal. Pay attention to the following points: CAUTION Do not apply oil or other materials to the sensor air hole. •...
Page 218: Pair Control Solenoid Valve Removal And Installation
Emission Control Devices: 1B-11 PAIR Control Solenoid Valve Removal and PAIR System Inspection B823H11206005 Installation PAIR Hose B823H11206004 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal Removal and Installation in Section 1G (Page 1G- 10)”. 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 2) Remove the air cleaner box.
Page 219: Crankcase Breather (Pcv) Hose Inspection
1B-12 Emission Control Devices: 3) Reinstall the PAIR reed valves. Refer to “PAIR Reed 4) Check the resistance between the terminals of the Valve Removal and Installation (Page 1B-10)”. PAIR control solenoid valve. Special tool PAIR Control Solenoid Valve : 09900–25008 (Multi-circuit tester set) 1) Remove the PAIR control solenoid valve.
Page 220: Crankcase Breather (Pcv) Hose / Reed Valve / Cover Removal And Installation
Installation is in the reverse order of removal. Pay attention to the following points: • Apply bond to the mating surface of the PCV cover. : Sealant 99000–31140 (SUZUKI BOND I823H1120017-02 No.1207B or equivalent) 3) Remove the PCV reed valve cover (2).
Page 221: Crankcase Breather (Pcv) Cover Inspection
1B-14 Emission Control Devices: Crankcase Breather (PCV) Cover Inspection Evaporative Emission Control System Removal B823H11206008 and Installation (Only for E-33) Inspect the crankcase breather (PCV) cover in the B823H11206009 following procedures: Hose Removal 1) Remove the PCV cover. Refer to “Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal 1) Lift and support the fuel tank.
Page 222 Emission Control Devices: 1B-15 EVAP System Purge Control Solenoid Valve Fuel Shut-off Valve Removal Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- Removal and Installation in Section 1G (Page 1G- 10)”.
Page 223: Evaporative Emission Control System Inspection (For E-33 Only)
1B-16 Emission Control Devices: Evaporative Emission Control System 2) Connect the 12 V battery to the terminals of the EVAP system purge control solenoid valve and Inspection (For E-33 only) B823H11206010 check the air flow. If air flows out, the solenoid valve Refer to “Evaporative Emission Control System is in normal condition.
Page 224 Emission Control Devices: 1B-17 Tank Pressure Control Valve Fuel Shut-Off Valve Inspect the tank pressure control valve body for damage. Inspect the fuel shut-off valve body for damage.Inspect Inspect the tank pressure control valve operation in the the fuel shut-off valve operation in the following following procedures: procedures: 1) When air pressure is applied lightly to the tank...
Page 225: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H11208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1B-13)
Page 226 Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B823H11300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B823H11303001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 227 1C-2 Engine Electrical Devices: ECM Removal and Installation CMP Sensor Inspection B823H11306001 B823H11306002 Removal Refer to “DTC “C11” (P0340) CMP Sensor Circuit Malfunction in Section 1A (Page 1A-29)”. 1) Remove the front seat and frame side covers. Refer to “Exterior Parts Removal and Installation in Section CMP Sensor Removal and Installation 9D (Page 9D-14)”.
Page 228 Engine Electrical Devices: 1C-3 CKP Sensor Inspection TP Sensor Inspection B823H11306024 B823H11306006 Refer to “CKP Sensor Inspection in Section 1H Refer to “DTC “C14” (P0120-H/L): TP Sensor Circuit (Page 1H-10)”. Malfunction in Section 1A (Page 1A-41)”. CKP Sensor Removal and Installation TP Sensor Removal and Installation B823H11306025 B823H11306007...
Page 229 3) Turn the mode select switch ON. necessary. 4) Check the position of the bar in the left of C code displayed on the LCD panel. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool : 09930–11950 (Torx wrench) “A”...
Page 230 Engine Electrical Devices: 1C-5 ECT Sensor Removal and Installation ECT Sensor Inspection B823H11306008 B823H11306009 Removal Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction in Section 1A (Page 1A-48)”. 1) Lift and support the fuel tank. Refer to “Fuel Tank Inspect the ECT sensor in the following procedures: Removal and Installation in Section 1G (Page 1G- 10)”.
Page 231 1C-6 Engine Electrical Devices: IAT Sensor Removal and Installation AP Sensor Removal and Installation B823H11306029 B823H11306031 Removal Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank 1) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 1G (Page 1G- Removal and Installation in Section 9D (Page 9D- 10)”.
Page 232 Engine Electrical Devices: 1C-7 Installation 5) Close the secondary throttle valve by finger and Install the TO sensor in the reverse order of removal. measure the STP sensor output voltage. Pay attention to the following point: Special tool • When installing the TO sensor, bring the “UP” letters (A): 09900–25008 (Multi-circuit tester set) upward.
Page 233 1C-8 Engine Electrical Devices: STP Sensor Removal and Installation : Grease 99000–25010 (SUZUKI SUPER B823H11306014 GREASE A or equivalent) Removal Special tool 1) Remove the throttle body. Refer to “Throttle Body : 09930–11950 (Torx wrench) Removal and Installation in Section 1D (Page 1D- 10)”.
Page 234 Engine Electrical Devices: 1C-9 STV Actuator Removal and Installation 4) Click the “ISC learned value reset” (1). B823H11306016 Refer to “Throttle Body Disassembly and Assembly in Section 1D (Page 1D-12)”. CAUTION Never remove the STVA from the throttle body. ISC Valve Inspection B823H11306017 Refer to “DTC “C40”...
Page 235 1C-10 Engine Electrical Devices: 6) Close the SDS tool and turn the ignition switch OFF. HO2 Sensor Removal and Installation B823H11306021 Refer to “Heated Oxygen Sensor (HO2S) Removal and NOTE Installation in Section 1B (Page 1B-9)”. The ISC valve opening initialization is automatically started after the ignition switch GP Switch Inspection is turned OFF position.
Page 236: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H11308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-4) /...
Page 237: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B823H11402001 I823H1140001-01...
Page 238: Throttle Cable Routing Diagram
Engine Mechanical: 1D-2 Throttle Cable Routing Diagram B823H11402002 “A” “B” I823H1140572-02 1. Throttle cable No. 1 5. Right handlebar switch harness 2. Throttle cable No. 2 6. Front brake hose 3. Clutch hose “A”: Pass the throttle cables to inside of the headlight brace. 4.
Page 239: Diagnostic Information And Procedures
1D-3 Engine Mechanical: Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B823H11404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-8)”. Compression Pressure Check B823H11404002 The compression pressure reading of a cylinder is a good indicator of its internal condition.
Page 240: Repair Instructions
Engine Mechanical: 1D-4 Repair Instructions Engine Components Removable with the Engine in Place B823H11406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal...
Page 241 1D-5 Engine Mechanical: Engine Right Side Item Removal Inspection Installation Refer to “Clutch Removal in Refer to “Clutch Installation Clutch cover — Section 5C (Page 5C-15)”. in Section 5C (Page 5C-17)”. Refer to “Clutch Parts Refer to “Clutch Removal in Refer to “Clutch Installation Clutch plates Inspection in Section 5C...
Page 242: Air Cleaner Element Removal And Installation
Engine Mechanical: 1D-6 Air Cleaner Element Removal and Installation Air Cleaner Box Removal and Installation B823H11406002 B823H11406004 Removal Removal 1) Remove the air cleaner box. Refer to “Air Cleaner 1) Lift and support the fuel tank. Refer to “Fuel Tank Box Removal and Installation (Page 1D-6)”.
Page 243: Air Cleaner Element Inspection And Cleaning
1D-7 Engine Mechanical: 6) Loosen the clamp screws (LH & RH) and remove the Throttle Cable Removal and Installation B823H11406005 air cleaner box. Removal 1) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation (Page 1D-6)”. 2) Remove the right handlebar switch box.
Page 244: Throttle Body Components
Engine Mechanical: 1D-8 Throttle Body Components B823H11406008 I823H1140584-03 1. TP sensor 8. Secondary fuel injector 15. Fuel delivery pipe 2. STP sensor 9. Primary fuel injector 16. Fuel delivery pipe T-joint 3. O-ring 10. Cushion seal 17. EVAP system purge control solenoid valve 4.
Page 245: Throttle Body Construction
1D-9 Engine Mechanical: Throttle Body Construction B823H11406009 “A” Air cleaner side “ a ” “ a ” “ a ” “ a ” Engine side Throttle body side I823H1140579-06 1. Fuel feed hose “a”: 45 2. ISC valve hose “A”: First, tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending order of numbers.
Page 246: Throttle Body Removal And Installation
Engine Mechanical: 1D-10 Throttle Body Removal and Installation 4) Disconnect the TP sensor lead wire coupler (2), STP B823H11406010 sensor lead wire coupler (3) and STVA lead wire Removal coupler (4). 1) Remove the air cleaner box. Refer to “Air Cleaner 5) Remove the clamp (5).
Page 247 1D-11 Engine Mechanical: 9) Disconnect the vacuum hose (10) from the IAP Installation sensor. Installs in the reverse order of removal. Pay attention to the following points: 10) Disconnect the purge hose (11). (E-33 only) • Connect the primary injector couplers (1) and secondary infector couplers (2) to the respective fuel injectors.
Page 248: Throttle Body Disassembly And Assembly
Engine Mechanical: 1D-12 Throttle Body Disassembly and Assembly 3) Remove the primary fuel injectors (5) and secondary B823H11406011 fuel injectors (6) from the fuel delivery pipe. Refer to “Throttle Body Removal and Installation (Page 1D-10)”. Disassembly CAUTION Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions.
Page 249 1D-13 Engine Mechanical: 7) Remove the TP sensor (11) and STP sensor (12) CAUTION with the special tool. These adjusting screws (16), (17) and (18) are Special tool factory-adjusted at the time of delivery and : 09930–11950 (Torx wrench) do not turn or remove them. NOTE Prior to disassembly, mark the each sensor’s original position with a paint or scribe for...
Page 250 • Align the secondary throttle shaft end “A” with the groove “B” of the STP sensor. • Apply grease to the secondary throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1140593-01 Special tool •...
Page 251 1D-15 Engine Mechanical: NOTE • Assemble the fuel delivery pipes as shown in the figure. • Make sure the throttle valves smoothly open and close. CAUTION • For TP sensor setting procedure, refer to Be careful not to twist the fuel delivery pipe “TP Sensor Adjustment in Section 1C T-joint when installing the fuel delivery pipes, (Page 1C-4)”.
Page 252: Throttle Body Inspection And Cleaning
Engine Mechanical: 1D-16 Throttle Body Inspection and Cleaning ISC Valve Visual Inspection B823H11406012 B823H11406045 Refer to “Throttle Body Disassembly and Assembly Visually inspect the ISC valve if necessary. (Page 1D-12)”. • Inspect the ISC valve for any carbon deposition defects. Clean or replace the ISC valve if necessary. Cleaning WARNING Some carburetor cleaning chemicals,...
Page 253 1D-17 Engine Mechanical: 4) Connect the respective vacuum tester hoses to each 9) Click “Active control”. vacuum nipple. 10) Click “ISC air volume control” (3). I823H1140526-02 5) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 6) Start the engine.
Page 254: Isc Valve Reset
Engine Mechanical: 1D-18 12) Check for the synchronization of vacuum from #1 to ISC Valve Reset B823H11406044 #4 cylinders. When removing or replacing the throttle body assembly, reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tools.
Page 255: Engine Assembly Removal
1D-19 Engine Mechanical: NOTE Engine Assembly Removal B823H11406014 The learned value of the ISC valve is set at Before taking the engine out of the frame, wash the RESET position. engine using a steam cleaner. Engine removal is sequentially explained in the following steps: 1) Drain engine oil.
Page 256 Engine Mechanical: 1D-20 9) Remove the oil hoses (2) and (3). 13) Remove the radiator outlet pipe bolts. 14) Disconnect the left cooling fan lead wire coupler (8). I823H1140533-02 I823H1140537-02 15) Remove the radiator with oil cooler by removing their mounting bolts.
Page 257 1D-21 Engine Mechanical: 16) Remove the radiator heat shield (9). 21) Remove the exhaust pipe gaskets (13). I823H1140540-01 I823H1140544-01 17) Disconnect the HO2 sensor lead wire coupler (10). 22) Remove the radiator bracket (14) and oil cooler bracket (15). I823H1140541-01 18) Loosen the muffler joint connecting bolt (11).
Page 258 Engine Mechanical: 1D-22 24) Disconnect the starter motor lead wire (17). 28) Disconnect the CKP sensor lead wire coupler (21), generator lead wire coupler (22) and side-stand lead wire coupler (23). I823H1140547-01 25) Disconnect the engine ground lead wire (18). I823H1140550-01 29) Disconnect the CMP sensor lead wire coupler (24), ignition coil/plug cap lead wire couplers (25) and...
Page 259 1D-23 Engine Mechanical: 31) Remove the engine sprocket inner cover. Refer to 37) Remove the engine mounting bolts (32) and (33). “Engine Sprocket Removal and Installation in Section 3A (Page 3A-2)”. 32) Remove the clutch push rod (28), sprocket cover protector (29) and dowel pins.
Page 260 Engine Mechanical: 1D-24 40) Loosen the engine mounting thrust adjuster lock-nut 42) Remove the engine mounting nuts (39) and (40). (37) with the special tool. 41) Loosen the engine mounting thrust adjuster (38) fully. Special tool (A): 09940–14990 (Engine mounting thrust adjuster socket wrench) I823H1140561-01 43) Loosen the engine mounting thrust adjuster lock-...
Page 261: Engine Assembly Installation
1D-25 Engine Mechanical: Engine Assembly Installation • Tighten the engine mounting thrust adjusters (1) to the B823H11406015 specified torque with the special tool. Install the engine in the reverse order of engine removal. Tightening torque Pay attention to the following points: Engine mounting thrust adjuster (a): 10 N·m (1.0 •...
Page 262 Engine Mechanical: 1D-26 • Tighten the engine mounting thrust adjuster lock-nuts • Tighten all engine mounting bolts and nuts to the (2) to the specified torque withe the special tool. specified torque. Tightening torque NOTE Engine mounting thrust adjuster lock-nut (b): 45 The engine mounting nuts are self-locking.
Page 263 1D-27 Engine Mechanical: 1 “b” “a” “e” “b” “h” “a” 2 “ d ” 2 “ d ” “ g ” “c” “ g ” 1 “f” 3 “h” “ g ” “ g ” I823H1140301-03 1. Bolt : 75 N m (7.5 kgf-m, 54.0 lb-ft) “b”: 60 mm (2.36 in) “g”: 43 mm (1.69 in) 2.
Page 264: Engine Top Side Disassembly
Engine Mechanical: 1D-28 4. Nut : 45 N m (4.5 kgf-m, 32.5 lb-ft) “e”: 37.5 mm (1.48 in) : 55 N m (5.5 kgf-m, 40.0 lb-ft) “a”: 45 mm (1.77 in) “f”: 243 mm (9.56 in) • Install the engine sprocket. Refer to “Engine Sprocket NOTE Removal and Installation in Section 3A (Page 3A-2)”.
Page 265 1D-29 Engine Mechanical: 3) Turn the crankshaft to bring the line “A” on the starter 5) Remove the gasket (4). clutch to the slit “B” of the valve timing inspection hole and also to bring the cams to the position as shown in the figure.
Page 266 Engine Mechanical: 1D-30 8) Remove the dowel pins. 2) Remove the oil hoses (2) and (3). 9) Remove the intake camshaft (9) and exhaust camshaft (10). I823H1140322-01 I823H1140320-01 Cylinder Head NOTE The cylinder head can not be serviced with the engine installed in the frame. 1) Remove the water hose (1).
Page 267 1D-31 Engine Mechanical: 4) Remove the cylinder head bolts (M6) (6). Cam Chain Guide No. 1 5) Remove the cylinder head bolt (M6) (7). NOTE 6) Loosen the cylinder nuts (8). The cam chain guide can not be serviced with the engine installed in the frame. Remove the cam chain guide No.
Page 268: Engine Top Side Assembly
Engine Mechanical: 1D-32 4) Remove the dowel pins and cylinder base gasket Engine Top Side Assembly B823H11406017 (3). Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: Piston • When installing the pistons, apply molybdenum oil solution onto each piston pin.
Page 269 1D-33 Engine Mechanical: NOTE Cylinder • Fit the dowel pins and a new gasket (1) to the End gap of the circlip “B” should not be crankcase. aligned with the cutaway in the piston pin bore. CAUTION Use a new gasket to prevent oil leakage. •...
Page 270 Engine Mechanical: 1D-34 • Insert the No. 2 and No. 3 pistons into the cylinder. Cylinder Head • Pull the cam chain out of the cylinder and install the NOTE cam chain guide No. 1 (1). Some light resistance must be overcome to CAUTION lower the cylinder.
Page 271 1D-35 Engine Mechanical: • Place the cylinder head on the cylinder. • After firmly tightening the cylinder head bolts (M10), install the cylinder head bolts (M6) (3). NOTE • Tighten the cylinder head bolts (3) and the cylinder • When installing the cylinder head, keep the nuts (4) to the specified torque.
Page 272 Engine Mechanical: 1D-36 • With the oil hose union contacted to the stopper “C”, • Turn the crankshaft clockwise and align the line “A” on tighten the bolts to the specified torque. the starter clutch with the index mark “B” of the valve timing inspection hole while keeping the cam chain Tightening torque pulled upward.
Page 273 1D-37 Engine Mechanical: • Pull the cam chain lightly. • Bind the cam chain and the sprocket with a proper clamp (4) to prevent the cam chain disengagement • Turn the exhaust camshaft so that the arrow is aligned while installing the camshaft journal holders. with the gasket surface of the cylinder head.
Page 274 Engine Mechanical: 1D-38 I823H1140077-02 • Install the dowel pins. • Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque. • Install the camshaft journal holders. Tightening torque Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) CAUTION The camshaft journal holder bolts are made...
Page 275 1D-39 Engine Mechanical: 5 (1) 6 (2) 6 (2) 5 (1) I823H1140079-03 • Install the oil pipe (4) and tighten oil pipe bolts to the • Install the cam chain guide No. 2 (8). specified torque. Tightening torque Cam chain guide No. 2 bolt: 10 N·m (1.0 kgf-m, NOTE 7.0 lb-ft) •...
Page 276 Engine Mechanical: 1D-40 • Fit a new gasket (1). • Unhook the outer circlip “A” from its groove by pushing in the stepped part (4) of the plunger head CAUTION with a (–) screwdriver. Use a new gasket to prevent oil leakage. •...
Page 277 1D-41 Engine Mechanical: “B” I823H1140577-02 NOTE The cam chain tension adjuster can be serviced with the engine installed in the frame. • After installing the cam chain tension adjuster, turn the crankshaft approx. 180 counterclockwise to make the plunger come out from the adjuster against the cam chain, via chain tensioner.
Page 278 Make sure that the adjuster works properly • Apply bond to the cam end caps of the gasket as by checking no slack at point “B”. shown in the figure. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) CAUTION “B”...
Page 279: Camshaft Inspection
1D-43 Engine Mechanical: • Tighten the head cover bolts (1) to the specified Cam Wear torque. Check the camshaft for wear or damage. Measure the cam height “a” with a micrometer. Tightening torque Replace a camshaft if the cams are worn to the service Head cover bolt (a): 14 N·m (1.4 kgf-m, 10.0 lb-ft) limit.
Page 280 Engine Mechanical: 1D-44 Camshaft Journal Wear 5) Tighten the camshaft journal holder bolts in Inspect the camshaft journal wear in the following ascending order of numbers to the specified torque. procedures: Refer to “Engine Top Side Assembly (Page 1D-32)”. 1) Remove the water bypass union. Refer to “Cylinder NOTE Head Disassembly and Assembly (Page 1D-48)”.
Page 281: Camshaft Sprocket / Bearing Inspection
1D-45 Engine Mechanical: 8) If the camshaft journal oil clearance exceeds the Camshaft Sprocket / Bearing Inspection B823H11406020 limit, measure the inside diameter of the camshaft Inspect the camshaft sprockets/bearings in the following journal holder and the outside diameter of the procedures: camshaft journal.
Page 282: Cam Chain Tension Adjuster Inspection
Engine Mechanical: 1D-46 Cam Chain Tension Adjuster Inspection B823H11406043 The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted. “C” 1) Remove the cam chain tension adjuster. Refer to “Engine Top Side Disassembly (Page 1D-28)”. 2) Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body until the outer circlip “A”...
Page 283: Cam Chain Guide Removal And Installation
1D-47 Engine Mechanical: Cam Chain Guide Removal and Installation Cam Chain Guide Inspection B823H11406023 B823H11406024 Removal Inspect the cam chain guide in the following procedures: 1) Remove the cylinder head cover. Refer to “Engine 1) Remove the cam chain guides. Refer to “Cam Chain Top Side Disassembly (Page 1D-28)”.
Page 284: Cylinder Head Disassembly And Assembly
Engine Mechanical: 1D-48 4) Check the contacting surface of the cam chain 2) Insert the special tool (A) between the valve spring tensioner. If it is worn or damaged, replace it with a and cylinder head. new one. 3) Using the special tools, compress the valve spring and remove the two cotter halves (3) from the valve stem.
Page 285 1D-49 Engine Mechanical: 4) Remove the valve spring retainer (4) and valve 9) Remove the thermostat cover (10). spring (5). 10) Remove the thermostat (11). 5) Pull out the valve (6) from the combustion chamber side. I823H1140377-01 11) Remove the intake pipes (12). I823H1140374-01 6) Remove the oil seal (7) and spring seat (8).
Page 286 Assembly is in the reverse order of disassembly. Pay union (3) and tighten it to the specified torque. attention to the following points: : Sealant 99000–31140 (SUZUKI BOND • Tighten the cam chain tension adjuster service cap (1) No.1207B or equivalent) and oil gallery plug (2) to the specified torque.
Page 287 1D-51 Engine Mechanical: • Set the clamp screws as shown in the figure. “B” “D” “E” “ a ” “a ” “ a” “ a” “C” I823H1140121-03 “B”: Upper “C”: Lower “D”: Left “E”: Right “a”: 45 • Install the thermostat. •...
Page 288 Engine Mechanical: 1D-52 • Install the valve spring seat. • Put on the valve spring retainer (7), and using the special tools, press down the spring, fit the cotter • Apply engine oil to the oil seal (6), and press-fit it into halves to the stem end, and release the lifter to allow the position.
Page 289: Cylinder Head Related Parts Inspection
1D-53 Engine Mechanical: • Be sure that the rounded lip “K” of the cotter fits Cylinder Head Related Parts Inspection B823H11406027 snugly into the groove “L” in the stem end. Refer to “Cylinder Head Disassembly and Assembly (Page 1D-48)”. “K” “L”...
Page 290 Engine Mechanical: 1D-54 Valve Head Radial Runout Valve Stem Deflection Place the dial gauge at a right angle to the valve head Lift the valve about 10 mm (0.39 in) from the valve seat. face and measure the valve head radial runout. If it Measure the valve stem deflection in two directions, “X”...
Page 291 1D-55 Engine Mechanical: Valve Stem Wear Valve Spring Measure the valve stem O.D. using the micrometer. If it The force of the coil spring keeps the valve seat tight. A is out of specification, replace the valve with a new one. weakened spring results in reduced engine power output If the valve stem O.D.
Page 292 Engine Mechanical: 1D-56 Valve Seat Width Valve Seat Sealing Condition 1) Visually check for valve seat width on each valve 1) Clean and assemble the cylinder head and valve face. If the valve face has worn abnormally, replace components. the valve. 2) Fill the intake and exhaust ports with gasoline to 2) Coat the valve seat with a red lead (Prussian Blue) check for leaks.
Page 293: Valve Guide Replacement
1D-57 Engine Mechanical: Valve Guide Replacement 5) Cool down the new valve guides in a freezer for B823H11406028 about one hour and heat the cylinder head to 100 – 1) Remove the cylinder head. Refer to “Engine Top 150 C (212 – 302 F) with a hot plate. Side Disassembly (Page 1D-28)”.
Page 294: Valve Seat Repair
Engine Mechanical: 1D-58 8) After installing the valve guides, refinish their guiding Valve Seat Repair B823H11406029 bores using the reamer. Be sure to clean and oil the The valve seats (1) for both the intake and exhaust guides after reaming. valves are machined to three different angles.
Page 295: Cylinder Disassembly And Assembly
1D-59 Engine Mechanical: Cylinder Disassembly and Assembly • Apply engine coolant to O-ring of water inlet B823H11406030 connector. Refer to “Engine Top Side Disassembly (Page 1D-28)”. Refer to “Engine Top Side Assembly (Page 1D-32)”. CAUTION Replace the O-ring with a new one. Disassembly 1) Remove the water inlet connector (1).
Page 296: Cylinder Inspection
Engine Mechanical: 1D-60 Cylinder Inspection Cylinder Bore B823H11406031 Measure the cylinder bore diameter at six places. If any Refer to “Engine Top Side Disassembly (Page 1D-28)”. one of the measurements exceed the limit, overhaul the Refer to “Engine Top Side Assembly (Page 1D-32)”. cylinder and replace the piston with an oversize piston.
Page 297: Piston Ring Removal And Installation
1D-61 Engine Mechanical: Piston Ring Removal and Installation CAUTION B823H11406032 Removal When installing the spacer, be careful not to allow its two ends to overlap in the groove. 1) Draw out the piston pin and remove the piston. Refer to “Engine Top Side Disassembly (Page 1D-28)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to “A”...
Page 298: Piston And Piston Ring Inspection
Engine Mechanical: 1D-62 2) Position the gaps of the three rings and side rails as Piston-to-cylinder Clearance shown. Before inserting piston into the cylinder, Subtract the piston diameter from the cylinder bore check that the gaps are so located. diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.
Page 299 1D-63 Engine Mechanical: Piston ring thickness Piston Pin and Pin Bore Standard (1st): 0.76 – 0.81 mm (0.0299 – 0.0319 in) Measure the piston pin bore inside diameter using the Standard (1st): 1.08 – 1.10 mm (0.0425 – 0.0433 in) small bore gauge.
Page 300: Engine Bottom Side Disassembly
Engine Mechanical: 1D-64 Engine Bottom Side Disassembly 2) Remove the reed valve (2). B823H11406034 NOTE The crankcase must be separated to service the crankshaft and conrod. 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal (Page 1D-19)”. 2) Remove the engine top side.
Page 301 1D-65 Engine Mechanical: Starter Torque Limiter Oil Pump Remove the starter torque limiter (1) and starter idle gear 1) Remove the snap ring (1). (2). Refer to “Starter Torque Limiter / Starter Clutch 2) Remove the oil pump driven gear (2). Removal and Installation in Section 1I (Page 1I-10)”.
Page 302 Engine Mechanical: 1D-66 Gear Position Switch Cam Chain Tensioner Remove the cam chain tensioner (1). 1) Remove the gear position switch lead wire clamps. 2) Remove the gear position switch (1). I823H1140418-01 I823H1140415-02 Generator Remove the generator component parts (1). Refer to Starter Clutch “Generator Removal and Installation in Section 1J Remove the starter clutch (1).
Page 303 1D-67 Engine Mechanical: Gearshift System 4) Remove the gearshift cam plate bolt (5). 1) Remove the gearshift cover (1). 5) Remove the gearshift cam plate (6). I823H1140421-01 I823H1140424-01 2) Remove the gasket (2) and dowel pins. 6) Remove the gearshift cam stopper (7) and gearshift arm stopper (8).
Page 304 Engine Mechanical: 1D-68 Oil Pipe Oil Pressure Regulator Remove the oil pressure regulator (1). 1) Remove the oil pipe (1). 2) Remove the cushion (2). I823H1140431-01 I823H1140427-01 Oil Strainer 1) Remove the oil strainer (1). Oil Pressure Switch Remove the oil pressure switch (1). I823H1140432-01 2) Remove the O-ring (2).
Page 305 1D-69 Engine Mechanical: Crank Balancer Crankcase 1) Remove the oil separator (1). 1) Remove the crankcase bolts. NOTE Loosen the crankcase bolts diagonally and the smaller sizes first. I823H1140435-01 2) Remove the balancer shaft arm (2). I823H1140439-01 I823H1140436-01 3) Remove the balancer shaft (3). I823H1140440-02 2) Remove the crankshaft journal bolts.
Page 306 Engine Mechanical: 1D-70 3) Make sure that all of the bolts are removed. Then, Transmission tap the sides of the lower crankcase using a plastic Remove the transmission component. Refer to hammer to separate the upper and lower crankcase “Transmission Removal in Section 5B (Page 5B-3)”. halves and then lift the lower crankcase off of the upper crankcase.
Page 307 1D-71 Engine Mechanical: 3) Remove the oil jet (3) (for generator) from the upper Crankshaft Journal Bearing crankcase. Remove the crankshaft journal bearings, upper and lower. CAUTION • When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.
Page 308: Engine Bottom Side Assembly
Engine Mechanical: 1D-72 Oil Gallery Plug 2) Remove the oil gallery plugs (M6) (5), (M8) (6), (M10) (7), (M6) (8) and (M16) (9) from the lower 1) Remove the oil gallery plug (M6) (1), (M14) (2), crankcase. (M14) (3) and (M6) (4) from the upper crankcase. I823H1140454-01 I823H1140451-01 I823H1140455-01...
Page 309 1D-73 Engine Mechanical: Tightening torque Oil gallery plug (M6) and (M8) (a): 10 N·m (1.0 kgf- m, 7.0 lb-ft) Oil gallery plug (M10) (b): 18 N·m (1.8 kgf-m, 13.0 lb-ft) Oil gallery plug (M14) (c): 23 N·m (2.3 kgf-m, 16.5 lb-ft) Oil gallery plug (M16) (d): 35 N·m (3.5 kgf-m, 25.5 lb-ft)
Page 310 Engine Mechanical: 1D-74 Oil Jet • Install the oil jets (for transmission (2) and oil spray (3)). • Fit the new O-rings (1) to each piston cooling oil jet and apply engine oil to them. CAUTION Use the new O-rings to prevent oil pressure leakage.
Page 311 Selection (Page 1D-97)”. • Apply sealant to distorted surfaces as it forms a comparatively thick film. • Apply sealant to both mating surface of crankcases at hatched parts. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) “A” “A” I823H1140214-02...
Page 312 Engine Mechanical: 1D-76 “A” I823H1140306-01 “A”: Apply bond to both surfaces of the upper and lower cases. : Apply bond.
Page 313 1D-77 Engine Mechanical: • Match the upper and lower crankcases. • Tighten the other crankcase bolts a little at a time to equalize the pressure. NOTE CAUTION Align the gearshift forks with each gearshift groove. Fit the new copper washers to the bolts “B”. Tightening torque Crankcase bolt (M6): 11 N·m (1.1 kgf-m, 8.0 lb-ft) Crankcase bolt (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
Page 314 Engine Mechanical: 1D-78 • After the crankshaft journal bolts and crankcase bolts • Hold the crankshaft and install the crank balancer have been tightened, check that the crankshaft assembly. rotates smoothly. • Also check that the driveshaft and countershaft rotate smoothly.
Page 315 1D-79 Engine Mechanical: • Install the balancer shaft arm. • Slowly turn the balancer shaft (2) clockwise until it stops (position “F”) with a (–) screwdriver. NOTE • From this position, turn the balancer shaft (2) Apply a small quantity of thread lock to the counterclockwise by 1.5 –...
Page 316 Apply a small quantity of thread lock to the balancer cover bolt and tighten it to the Apply grease to the O-ring. specified torque. : Grease 99000–25010 (SUZUKI SUPER : Thread lock cement 99000–32110 GREASE A or equivalent) (THREAD LOCK CEMENT SUPER 1322 or...
Page 317 • Apply grease to the new O-ring and press in the oil NOTE pressure regulator to the crankcase. Fit the new gasket washer to the oil pan bolt : Grease 99000–25010 (SUZUKI SUPER (2). GREASE A or equivalent) Tightening torque CAUTION Oil pan bolt (a): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Page 318 Apply a small quantity of thread lock to the oil pipe bolts (3). Use a new O-ring to prevent oil leakage. : Thread lock cement 99000–32110 : Grease 99000–25010 (SUZUKI SUPER (THREAD LOCK CEMENT SUPER 1322 or GREASE A or equivalent) equivalent) Tightening torque Oil pipe bolt (M6) (a): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Page 319 1D-83 Engine Mechanical: Gearshift System • Install the gearshift cam stopper plate (5). • Install the gearshift cam stopper (1), bolt (2), washer NOTE (3) and return spring (4). Align the gearshift cam pin “B” with the • Apply a small quantity of thread lock to the gearshift gearshift cam stopper plate hole “C”.
Page 320 Use a new gasket to prevent oil leakage. Use the new O-ring to prevent oil leakage. • Apply grease to the lip of the gearshift cover oil seal. : Grease 99000–25010 (SUZUKI SUPER : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)
Page 321 1D-85 Engine Mechanical: Cam Chain Tensioner • Install the cam chain (2) onto the cam chain drive sprocket. • Install the cam chain tensioner (1). • Apply thread lock to the cam chain tensioner bolt (2). Tightening torque Cam chain tensioner bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) I823H1140498-01 Starter Clutch...
Page 322 • Apply a bond lightly to the groove of signal generator lead wire grommet. CAUTION : Sealant 99000–31140 (SUZUKI BOND Use the new O-ring to prevent oil leakage. No.1207B or equivalent) : Grease 99000–25010 (SUZUKI SUPER NOTE GREASE A or equivalent) •...
Page 323 1D-87 Engine Mechanical: • Install the washer (1) and pin (2). Starter Torque Limiter • Install the starter idle gear and starter torque limiter. NOTE Refer to “Starter Torque Limiter / Starter Clutch Be careful not to drop the washer or pin into Removal and Installation in Section 1I (Page 1I-10)”.
Page 324 • Apply to distorted surfaces as it forms a comparatively thick film. I823H1140506-01 • Install the reed valve cover (4). : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque PCV reed valve cover bolt (b): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Page 325: Crank Balancer Disassembly And Assembly
1D-89 Engine Mechanical: Crank Balancer Disassembly and Assembly Assembly B823H11406036 Assemble the crank balancer in the reverse order of Refer to“Engine Bottom Side Disassembly (Page 1D- disassembly. Pay attention to the following points: 64)”. • Apply molybdenum oil solution to the dampers. Refer to “Engine Bottom Side Assembly (Page 1D-72)”.
Page 326: Crank Balancer Inspection
Engine Mechanical: 1D-90 • Apply molybdenum oil solution to the bearings, Balancer Shaft spacers and washers. Inspect the balancer shaft for wear or damage. Replace the balancer shaft if there is anything unusual. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) I823H1140275-01 I823H1140272-04 Conrod Removal and Installation B823H11406038...
Page 327 1D-91 Engine Mechanical: 4) Remove the bearings (1). 3) When fitting the conrod cap, make sure that I.D. code “B” on each conrod faces intake side. NOTE • Do not remove the bearings (1) unless absolutely necessary. “B” • Make a note of where the bearings are removed from so that they can be reinstalled in their original positions.
Page 328: Conrod And Crankshaft Inspection
Engine Mechanical: 1D-92 Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B823H11406039 and measure the conrod big end width and crank pin Refer to “Conrod Removal and Installation (Page 1D- width. Refer to “Conrod Removal and Installation 90)”.
Page 329: Conrod Crank Pin Bearing Inspection And Selection
1D-93 Engine Mechanical: Conrod Crank Pin Bearing Inspection and 4) Remove the conrod caps and measure the width of the compressed plastigauge using the envelope Selection B823H11406040 scale. This measurement should be taken at the Refer to “Conrod Removal and Installation (Page 1D- widest part of the compressed plastigauge.
Page 330 Engine Mechanical: 1D-94 2) Check the corresponding crank pin O.D. code 4) Select the specified bearings from the bearing numbers ([1], [2] or [3]) “B”. selection table. CAUTION The bearings should be replaced as a set. Bearing selection table Crank pin O.D. “B ”...
Page 331: Crankshaft Journal Bearing Inspection And Selection
1D-95 Engine Mechanical: Crankshaft Journal Bearing Inspection and 2) Set the crankshaft onto the upper crank case. Selection 3) Install the plastigauge onto each crankshaft journal B823H11406041 as shown in the figure. Refer to “Engine Bottom Side Disassembly (Page 1D- 64)”.
Page 332 Engine Mechanical: 1D-96 6) Remove the lower crankcase and measure the width 2) Check the corresponding crankshaft journal O.D. of compressed plastigauge using the envelope codes “B” ([A], [B] or [C]), which are stamped on the scale. This measurement should be taken at the crankshaft.
Page 333: Crankshaft Thrust Clearance Inspection And Selection
1D-97 Engine Mechanical: 4) Select the specified bearings from the bearing Crankshaft Thrust Clearance Inspection and selection table. Selection Bearing selection table B823H11406042 Refer to “Engine Bottom Side Disassembly (Page 1D- 64)”. Crankshaft O.D. “B” Refer to “Engine Bottom Side Assembly (Page 1D-72)”. Code Green Black...
Page 334 Engine Mechanical: 1D-98 Selection 2) If the right-side thrust bearing is within the standard range, reinsert the right-side thrust bearing and 1) Remove the right-side thrust bearing and measure remove the left-side thrust bearing. its thickness using the micrometer. If the thickness of the right-side thrust bearing is below standard, 3) With the left-side thrust bearing removed, measure replace it with a new bearing and measure the thrust...
Page 335: Specifications
1D-99 Engine Mechanical: Specifications Service Data B823H11407001 Valve + Guide Unit: mm (in) Item Standard Limit 33 (1.30) — Valve diam. 27.5 (1.08) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...
Page 336 Engine Mechanical: 1D-100 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 – 256 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —...
Page 337: Tightening Torque Specifications
1D-101 Engine Mechanical: Tightening Torque Specifications B823H11407002 Tightening torque Fastening part Note kgf-m lb-ft STP sensor mounting screw 0.35 (Page 1D-14) ISC valve mounting screw (Page 1D-14) TP sensor mounting screw 0.35 (Page 1D-14) Fuel delivery pipe mounting screw 0.35 (Page 1D-15) Engine mounting thrust adjuster (Page 1D-25)
Page 338: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H11408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-14) /...
Page 339: Special Tool
1D-103 Engine Mechanical: NOTE Required service material is also described in the following. “Throttle Body Components (Page 1D-8)” “Engine Bottom Side Assembly (Page 1D-72)” Special Tool B823H11408002 09900–06107 09900–20102 Snap ring pliers Vernier calipers (1/20 mm, 200 mm) (Page 1D-87) (Page 1D-55) / (Page 1D-63) 09900–20202...
Page 340 Engine Mechanical: 1D-104 09900–22301 09900–22302 Plastigauge (0.025 – 0.076 Plastigauge (0.051 – 0.152 (Page 1D-44) / (Page 1D-44) (Page 1D-93) / (Page 1D-95) 09900–22403 09915–40610 Small bore gauge (18 – 35 Oil filter wrench (Page 1D-45) / (Page 1D-67) / (Page 1D-63) / (Page 1D-82) (Page 1D-92)
Page 341 1D-105 Engine Mechanical: 09916–84511 09919–28620 Valve adjuster driver Sleeve protector (Page 1D-48) / (Page 1D-48) / (Page 1D-52) (Page 1D-52) 09930–11950 09940–14990 Torx wrench Engine mounting thrust adjuster socket wrench (Page 1D-13) / (Page 1D-24) / (Page 1D-14) / (Page 1D-24) / (Page 1D-14) (Page 1D-26)
Page 342: Engine Lubrication System
Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B823H11500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”. Schematic and Routing Diagram Engine Lubrication System Chart Diagram B823H11502001...
Page 343: Oil Pan
1E-2 Engine Lubrication System: CAMSHAFT JOURNALS, CAMFACES AND TAPPETS RH-BEARING AND INTAKE CAMSHAFT INTAKE CAMSHAFT CAM CHAIN CAM SPROCKET HOUSING TENSION OIL PIPE ADJUSTER EXHAUST CAMSHAFT RH-BEARING AND EXHAUST CAMSHAFT HOUSING CAM SPROCKET CYLINDER HEAD CAMSHAFT JOURNALS, CAMFACES AND TAPPETS CAM DRIVE CHAIN OIL HOSE SUB GALLERY...
Page 344: Engine Lubrication Circuit Diagram
Engine Lubrication System: 1E-3 Engine Lubrication Circuit Diagram B823H11502002 I823H1150042-01 1: Main gallery...
Page 345 1E-4 Engine Lubrication System: I823H1150043-02 1: Main gallery...
Page 346: Diagnostic Information And Procedures
Engine Lubrication System: 1E-5 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B823H11504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler. Clean or replace.
Page 347: Repair Instructions
1E-6 Engine Lubrication System: 4) Warm up the engine as follows: 6) Stop the engine and remove the oil pressure gauge Summer: 10 min. at 2 000 r/min and attachment. Winter: 20 min. at 2 000 r/min 7) Reinstall the main oil gallery plug and tighten it to the 5) After warming up, increase the engine speed to 3 specified torque.
Page 348 • Apply grease to the O-rings. CAUTION Use the new O-rings to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1150006-01 7) Remove the oil pressure regulator (6), breather pipe (7) and oil strainer (8).
Page 349: Oil Pressure Regulator / Oil Strainer Inspection
1E-8 Engine Lubrication System: • Tighten the oil pan bolts diagonally. Oil Strainer Clean the oil strainer if necessary. CAUTION Inspect the oil strainer body for damage. If necessary, replace it with a new one. • Use the new oil pan gasket to prevent oil leakage.
Page 350: Oil Cooler / Oil Cooler Hose Removal And Installation
Engine Lubrication System: 1E-9 Oil Cooler Cleaning 3) Remove the oil hoses (1) and (2). Blow out any foreign matter that is stuck in the oil cooler fins using compressed air. CAUTION • Make sure not to bend the fins when using compressed air.
Page 351: Oil Pressure Switch Removal And Installation
1E-10 Engine Lubrication System: Installation Oil Pressure Switch Removal and Installation B823H11506006 Install the oil cooler and oil cooler hoses in the reverse Refer to “Electrical Components Location in Section 0A order of removal. Pay attention to the following points: (Page 0A-7)”.
Page 352: Oil Pressure Switch Inspection
1) Install the oil pressure switch (1), apply a bond lightly Refer to “Oil Pressure Indicator Inspection in Section 9C to its thread and tighten it to the specified torque. (Page 9C-8)”. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) Oil Jet / Oil Gallery Jet Removal and Installation B823H11506008...
Page 353 1E-12 Engine Lubrication System: • Apply a small quantity of thread lock to the bolts and Installation tighten them to the specified torque. Installation is in the reverse order of removal. : Thread lock cement 99000–32110 Oil Jet (For Generator) (THREAD LOCK CEMENT SUPER 1322 or Removal equivalent)
Page 354: Oil Jet / Oil Gallery Jet Inspection
Engine Lubrication System: 1E-13 Oil Gallery Jet Oil Gallery Jet Inspect the oil gallery jet for clogging. Clean the oil Removal gallery if necessary. 1) Remove the oil filter. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”. 2) Remove the oil gallery jet (1) from the lower crankcase.
Page 355: Oil Pump Inspection
: 09900–06107 (Snap ring pliers) to the following points: • Apply grease to the O-ring. CAUTION Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Install the oil pump. NOTE I823H1150021-02 Set the oil pump shaft end “A”...
Page 356: Specifications
Engine Lubrication System: 1E-15 Specifications Service Data B823H11507001 Oil Pump Item Standard Limit 200 – 500 kPa Oil pressure (at 60 C, 140 F) (2.0 – 5.0 kgf/cm , 28.4 – 71.1 psi) — at 3 000 r/min Item Specification Note Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA...
Page 357: Special Tools And Equipment
1E-16 Engine Lubrication System: Special Tools and Equipment Recommended Service Material B823H11508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-7) / (Page 1E- equivalent Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140...
Page 358: Engine Cooling System
Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B823H11600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
Page 359: Schematic And Routing Diagram
1F-2 Engine Cooling System: Schematic and Routing Diagram Cooling Circuit Diagram B823H11602001 ENGINE COOLANT RESERVOIR THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER RADIATOR WATER PUMP I823H1160001-01...
Page 360: Water Hose Routing Diagram
Engine Cooling System: 1F-3 Water Hose Routing Diagram B823H11602002 “E” “I” “A” “H” “A” “I” “J” “B” “F” “C” “G” “C” “ b ” “ a ” “ a” “ a ” “K” “K” “L” “E” “D” “I” “J” “C” “H”...
Page 361: Diagnostic Information And Procedures
1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B823H11604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.
Page 362: Radiator Cap Inspection
Engine Cooling System: 1F-5 3) Pressurize the cooling system with 110 kPa (1.1 kgf/ Radiator Cap Inspection B823H11606002 cm, 15.6 psi) of pressure, and then check if it holds Inspect the radiator cap in the following procedures: the pressure for 10 seconds. 1) Remove the radiator cap.
Page 363: Radiator / Cooling Fan Motor Removal And Installation
1F-6 Engine Cooling System: Radiator Cleaning Radiator / Cooling Fan Motor Removal and Blow out any foreign matter that is stuck in the radiator Installation fins using compressed air. B823H11606004 Removal CAUTION 1) Remove the frame body covers (1) and under cowling (2).
Page 364: Water Hose Inspection
Engine Cooling System: 1F-7 5) Remove the radiator assembly (9) by removing the 3) Check the water hoses for crack, damage or engine bolts. coolant leakage. If any defect is found, replace the radiator hose with a new one. 4) Any leakage from the connecting section should be corrected by proper tightening.
Page 365: Water Hose Removal And Installation
1F-8 Engine Cooling System: Water Hose Removal and Installation 5) After moving the reservoir tank (7) up, disconnect B823H11606006 the reservoir hose (8). Removal 1) Remove the frame body cover and under cowl. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.
Page 366: Radiator Reservoir Tank Inspection
Engine Cooling System: 1F-9 Radiator Reservoir Tank Inspection 2) Test the cooling fan motor for load current with an B823H11606020 ammeter connected as shown in the figure. Inspect the radiator reservoir tank cooling leaks. If any If the fan motor does not turn, replace the cooling fan defects are found, replace the radiator reservoir tank assembly with a new one.
Page 367: Cooling Fan Relay Inspection
1F-10 Engine Cooling System: Cooling Fan Relay Inspection Thermostat Cover / Thermostat Removal and B823H11606010 Installation Inspect the fan relay in the following procedures: B823H11606013 Removal 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. 1) Drain a small amount of engine coolant.
Page 368: Thermostat Inspection
Engine Cooling System: 1F-11 Installation Thermostat Inspection B823H11606014 Install the thermostat in the reverse order of removal. Inspect the thermostat in the following procedures: Pay attention to the following points: 1) Remove the thermostat. Refer to “Thermostat Cover • Install the thermostat. / Thermostat Removal and Installation (Page 1F- 10)”.
Page 369: Water Pump Components
1F-12 Engine Cooling System: 6) Read the thermometer just when opening the 8) Just when the water temperature reaches specified thermostat. If this reading, which is the temperature value, the thermostat valve should have been lifted level at which the thermostat valve begins to open, is by at least 8 mm (0.31 in).
Page 370: Water Pump Construction
Engine Cooling System: 1F-13 Water Pump Construction B823H11606016 I823H1160028-03 1. Impeller 5. O-ring : Apply thread lock. 2. Mechanical seal : 8 N m (0.8 kgf-m, 6.0 lb-ft) : Apply molybudenum oil solution. 3. Oil seal : Apply grease. : Do not reuse. 4.
Page 371: Water Pump Disassembly And Assembly
CAUTION 1) Remove the water pump case (1). Replace the O-ring with the a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Install the water pump assembly with the slot on the pump shaft end “A” securely engaged with the flat “B”...
Page 372 Special tool (A): 09921–20240 (Bearing remover set) I823H1160039-01 2) Apply a small quantity of the grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1160037-02 6) Remove the oil seal. NOTE If there is no abnormal condition, the oil seal removal is not necessary.
Page 373 “D” I823H1160042-01 4) Apply molybudenum solution to the impeller shaft (1) and washer (2). M/O: Moly paste 99000–25140 (SUZUKI MOLY PASTE or equivalent) I823H1160045-03 9) Install the impeller and tighten the impeller securing 5) Install the impeller shaft (1) and washer (2) to the bolt (8) to the specified torque.
Page 374: Water Pump Related Parts Inspection
Replace the mechanical seal that shows indications of • Apply engine coolant to the O-ring (9). leakage. • Apply grease to the O-ring (10). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1160049-01 Oil Seal Visually inspect the oil seal for damage, with particular I823H1160047-03 attention given to the lip.
Page 375: Specifications
1F-18 Engine Cooling System: Impeller / Shaft Impeller Shaft Journal Visually inspect the impeller and its shaft for damage. Visually inspect the journal for damage or scratch. Replace the impeller or shaft if necessary. Replace the water pump body if necessary. I823H1160052-01 I823H1160053-01 Specifications...
Page 376: Tightening Torque Specifications
(Page 1F-14) / equivalent (Page 1F-15) / (Page 1F-17) Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1F-16) NOTE Required service material is also described in the following. “Water pump Components (Page 1F-12)” “Water Pump Construction (Page 1F-13)”...
Page 377: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions for Fuel System B823H11700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. •...
Page 378: General Description
Fuel System: 1G-2 General Description Fuel Injection System Description B823H11701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filters (3) and (4), fuel feed hose (5), fuel delivery pipes (6) including fuel injectors (7) and (8), fuel pressure regulator (9). There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injectors installed in the fuel delivery pipe.
Page 379: Schematic And Routing Diagram
1G-3 Fuel System: Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B823H11702001 “E” “ a ” “A” “B” “C” “D” I823H1170038-02 1. Fuel tank drain hose 2. Fuel tank breather hose 3. Hose clamp : Clamp the hoses at white marking point. “A”: Pass the fuel tank drain hose and fuel tank breather hose behind of the engine sprocket cover bracket.
Page 380: Diagnostic Information And Procedures
Fuel System: 1G-4 Diagnostic Information and Procedures Fuel System Diagnosis B823H11704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.
Page 381: Repair Instructions
1G-5 Fuel System: Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B823H11706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...
Page 382: Fuel Pump Inspection
Fuel System: 1G-6 Fuel Pump Inspection 3) Connect a proper fuel hose (2) to the fuel pump. B823H11706002 4) Place the measuring cylinder and insert the fuel Turn the ignition switch ON and check that the fuel pump hose end into the measuring cylinder. operates for a few seconds.
Page 383: Fuel Pump Relay Inspection
1G-7 Fuel System: Fuel Pump Relay Inspection Fuel Hose Inspection B823H11706004 B823H11706005 Refer to “Electrical Components Location in Section 0A Refer to “Fuel Line Inspection in Section 0B (Page 0B- (Page 0A-7)”. 10)”. Inspect the fuel pump relay in the following procedures: Fuel Level Gauge Inspection 1) Lift and support the fuel tank.
Page 384: Fuel Tank Construction
Fuel System: 1G-8 Fuel Tank Construction B823H11706009 “ a ” I823H1170030-03...
Page 385: Fuel Tank Heat Shield Construction
1G-9 Fuel System: 1. Fuel tank cushion 6. Fuel tank cover guide : Clean the adhesive surface and then apply an adhesive agent. 2. Dent mark 7. Fuel tank cover cushion : Align the fuel tank cushion with the dent mark (2). 3.
Page 386: Fuel Tank Removal And Installation
Fuel System: 1G-10 Fuel Tank Removal and Installation 4) Remove the front frame side covers (3). Refer to B823H11706010 “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. Removal WARNING • Keep away from fire or spark. • Spilled gasoline should be wiped off immediately.
Page 387 1G-11 Fuel System: 7) Remove the fasteners and bolts. 10) Disconnect the fuel tank drain hose (7) and fuel tank breather hose (8). 11) Place a rag under the fuel feed hose (9) and disconnect the fuel feed hose from the fuel tank. CAUTION When removing the fuel tank, do not leave the fuel feed hose on the fuel pump side.
Page 388: Fuel Pump Components
Fuel System: 1G-12 Fuel Pump Components B823H11706011 I823H1170037-02 1. Fuel level gauge 6. Fuel pump holder : 10 N m (1.0 kgf-m, 7.0 lb-ft) 2. Fuel filter cartridge 7. Fuel mesh filter : Apply grease. 3. Bushing 8. O-ring : Apply engine oil. 4.
Page 389: Fuel Pump Disassembly And Assembly
1G-13 Fuel System: Fuel Pump Disassembly and Assembly 5) Disconnect the ground read wire (4). B823H11706012 6) Remove the fuel pump plate (5). Disassembly 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation (Page 1G-10)”. 2) Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.
Page 390 3. Fuel pump (–) lead wire (B) 4. Fuel level gauge (–) lead wire (B) 5. Ground lead wire • Install a new O-ring and apply grease to it. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) WARNING I823H1170019-01 The O-ring must be replaced with a new one to prevent fuel leakage.
Page 391: Fuel Mesh Filter Inspection And Cleaning
1G-15 Fuel System: • When installing the fuel pump assembly, first tighten Fuel Injector / Fuel Delivery Pipe / T-joint all the fuel pump mounting bolts lightly and then to the Removal and Installation specified torque, in the ascending of numbers. B823H11706015 Refer to “Throttle Body Disassembly and Assembly in Tightening torque...
Page 392: Specifications
Fuel System: 1G-16 Specifications Service Data B823H11707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note Injector resistance 11 – 13 at 20 C (68 F) Fuel pump discharge amount 220 ml (7.4/7.7 US/lmp oz) and more/10 sec. Fuel pressure regulator operating Approx.
Page 393: Special Tools And Equipment
1G-17 Fuel System: Special Tools and Equipment Recommended Service Material B823H11708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-14) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-12)”...
Page 394: Ignition System
Ignition System: 1H-1 Ignition System Engine General Description Immobilizer Description (For E-02, 19, 24) Operation B823H11801001 When the ignition switch is turned ON with the engine The immobilizer, an anti-theft system, is installed as a stop switch in ON, the immobi-antenna and ECM are standard equipment.
Page 395: Drive Mode Selector Description
1H-2 Ignition System: Also, when the ignition switch is turned ON, the indicator Drive Mode Selector Description B823H11801002 light flashes as many as the number of IDs registered in Engine power characteristics can be changed in 2 ECM. Thereafter, if the IDs are in agreement, the modes by operating the drive mode selector to meet indicator light turns on for two seconds to notify of various riding conditions and rider’s preference.
Page 396: Schematic And Routing Diagram
Ignition System: 1H-3 Schematic and Routing Diagram Ignition System Diagram B823H11802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery sensor sensor switch I823H1180025-01 Ignition System Components Location B823H11802002 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 397: Diagnostic Information And Procedures
1H-4 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis B823H11804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defective ignition coil/plug caps.
Page 398: No Spark Or Poor Spark
Ignition System: 1H-5 No Spark or Poor Spark B823H11804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.
Page 399: Repair Instructions
1H-6 Ignition System: Repair Instructions Ignition Coil / Plug Cap and Spark Plug Removal 5) Remove the spark plugs with a spark plug wrench. and Installation Special tool B823H11806001 (A): 09930–10121 (Spark plug wrench set) Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch.
Page 400: Spark Plug Inspection And Cleaning
Ignition System: 1H-7 • Install the ignition coil/plug caps and connect their Spark Plug Inspection and Cleaning B823H11806002 lead wire couplers. Refer to “Spark Plug Inspection and Cleaning in Section 0B (Page 0B-9)”. CAUTION Do not hit the ignition coil/plug cap with a Ignition Coil / Plug Cap Inspection plastic hammer when installing it.
Page 401 1H-8 Ignition System: 4) Connect all the ignition coil/plug cap lead wire 5) Insert the needle pointed probe to the lead wire couplers to the ignition coil/plug caps respectively, coupler. and ground them on the cylinder head (each spark CAUTION plug hole).
Page 402 Ignition System: 1H-9 7) Measure the ignition coil primary peak voltage in the Ignition Coil / Plug Cap Resistance following procedures: 1) Remove the ignition coil/plug caps. Refer to “Ignition Coil / Plug Cap and Spark Plug Removal and WARNING Installation (Page 1H-6)”.
Page 403: Ckp Sensor Inspection
1H-10 Ignition System: CKP Sensor Inspection 3) Measure the CKP sensor peak voltage in the B823H11806004 following procedures: Refer to “Electrical Components Location in Section 0A a) Shift the transmission into neutral, turn the (Page 0A-7)”. ignition switch ON and grasp the clutch lever. b) Press the starter button and allow the engine to CKP Sensor Peak Voltage crank for a few seconds, and then measure the...
Page 404: Ckp Sensor Removal And Installation
Ignition System: 1H-11 CKP Sensor Resistance 3) Disconnect the right handlebar switch coupler (1). 1) Disconnect the CKP sensor coupler (1). I823H1180014-01 4) Inspect the engine stop switch for continuity with a I823H1180012-01 tester. 2) Measure the resistance between the lead wires and If any abnormality is found, replace the right ground.
Page 405: Ignition Switch Inspection
1H-12 Ignition System: Ignition Switch Inspection 6) Remove the throttle cable guide (4). B823H11806007 Refer to “Ignition Switch Inspection in Section 9C (Page 9C-9)”. Ignition Switch Removal and Installation B823H11806008 Removal 1) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-6)”.
Page 406 Ignition System: 1H-13 9) Remove the ignition switch (7). • Route the throttle cable. I823H1180021-01 I823H1180023-01 • Tighten the steering damper mounting bolts (2) to the Installation specified torque. Refer to “Steering Damper Install the ignition switch in the reverse order of removal. Construction in Section 6B (Page 6B-6)”.
Page 407: Drive Mode Selector Inspection
1H-14 Ignition System: Drive Mode Selector Inspection B823H11806010 Inspect the drive mode selector in the following procedures: 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Date monitor”. 4) Make sure each of “Driving mode selection”...
Page 408: Immobilizer Antenna Removal And Installation (For
Ignition System: 1H-15 Immobilizer Antenna Removal and Installation (For E-02, 19, 24) B823H11806009 Removal 1) Turn the ignition switch OFF. 2) Remove the fuel tank upper cover (center). Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. 3) Remove the immobilizer antenna (1).
Page 409: Special Tools And Equipment
1H-16 Ignition System: Special Tools and Equipment Special Tool B823H11808001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1H-8) / (Page 1H- (Page 1H-8) 9) / (Page 1H-10) / (Page 1H-11) 09930–10121 09930–11920 Spark plug wrench set Torx bit (JT40H) (Page 1H-6) / (Page 1H- (Page 1H-12) /...
Page 410: Starting System
Starting System: 1I-1 Starting System Engine Schematic and Routing Diagram Starting System Diagram B823H11902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Ignition Engine stop switch switch Fuse (30 A) ignition coil Gear Fuse position Starter Starter (15 A) switch button motor...
Page 411: Starter Motor Will Not Run
1I-2 Starting System: Starter Motor Will Not Run B823H11904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to Step 2. Go to Step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”...
Page 412: Repair Instructions
Starting System: 1I-3 Repair Instructions Starter Motor Components B823H11906001 I823H1190037-06 1. O-ring 5. O-ring : 5 N m (0.5 kgf-m, 3.5 lb-ft) 2. Housing end (Inside) 6. Starter motor case : 6 N m (0.6 kgf-m, 4.5 lb-ft) 3. O-ring 7: Housing end assembly (Outside) : Apply grease to sliding surface.
Page 413: Starter Motor Removal And Installation
CAUTION Replace the O-rings with new ones to prevent oil leakage and moisture. • Apply grease to the lip of the oil seal. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1190038-01 Installation Install the starter motor in the reverse order of removal.
Page 414: Starter Motor Inspection
Starting System: 1I-5 • Tighten the starter motor housing bolts to the Starter Motor Inspection B823H11906004 specified torque. Refer to “Starter Motor Disassembly and Assembly Tightening torque (Page 1I-4)”. Starter motor housing bolt (a): 5 N·m (0.5 kgf-m, 3.5 lb-ft) Carbon Brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.
Page 415: Starter Relay Removal And Installation
1I-6 Starting System: Armature Coil Starter Relay Removal and Installation B823H11906005 Inspect for continuity between each segment. Removal Inspect for continuity between each segment and the 1) Turn the ignition switch OFF. armature shaft. If there is no continuity between the segments or there is 2) Disconnect the battery (–) lead wire from the battery.
Page 416: Starter Relay Inspection
Starting System: 1I-7 Starter Relay Inspection 3) Measure the relay coil resistance between the B823H11906006 terminals using the multi-circuit tester. If the Inspect the starter relay in the following procedures: resistance is not within the specified value, replace 1) Remove the starter relay. Refer to “Starter Relay the starter relay with a new one.
Page 417: Side-Stand / Ignition Interlock System Parts Inspection
1I-8 Starting System: Side-stand / Ignition Interlock System Parts 5) Connect the side-stand switch coupler. Inspection 6) Install the engine sprocket outer cover. Refer to B823H11906008 “Exterior Parts Removal and Installation in Section Check the interlock system for proper operation. If the 9D (Page 9D-14)”.
Page 418 Starting System: 1I-9 4) Install the turn signal/side-stand relay. Refer to “Turn Gear Position Switch Signal / Side-stand Relay Removal and Installation 1) Lift and support the fuel tank. Refer to “Fuel Tank (Page 1I-7)”. Removal and Installation in Section 1G (Page 1G- 10)”.
Page 419: Starter Torque Limiter / Starter Clutch Removal And Installation
1I-10 Starting System: 7) Measure the voltage between R and B lead wires 3) Remove the gasket (2) and dowel pins. using the multi-circuit tester when shifting the 4) Remove the starter torque limiter (3) and shaft (4). gearshift lever from low to top. Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe...
Page 420 • Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases. CAUTION : Sealant 99000–31140 (SUZUKI BOND Replace the gaskets with new ones to No.1207B or equivalent) prevent oil leakage.
Page 421: Starter Torque Limiter Inspection
1I-12 Starting System: Starter Torque Limiter Inspection Starter Clutch Inspection B823H11906012 B823H11906010 Refer to “Starter Torque Limiter / Starter Clutch Removal CAUTION and Installation (Page 1I-10)”. • Do not attempt to disassemble the starter Starter Clutch torque limiter. 1) Install the starter driven gear onto the starter clutch. •...
Page 422: Starter Button Inspection
Starting System: 1I-13 Starter Button Inspection 3) Inspect the starter button for continuity with the B823H11906011 tester. Inspect the starter button in the following procedures: If any abnormality is found, replace the right handle 1) Remove the left fuel tank cover. Refer to “Exterior switch assembly with a new one.
Page 423: Special Tools And Equipment
1I-14 Starting System: Special Tools and Equipment Recommended Service Material B823H11908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-4) equivalent (Page 1I-4) / (Page 1I- Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140...
Page 424: Charging System
Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B823H11A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B823H11A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B823H11A04001 Condition...
Page 425: Battery Runs Down Quickly
1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.
Page 426: Repair Instructions
Charging System: 1J-3 Repair Instructions Battery Cushion Rubber Attachment Construction B823H11A06012 VIEW OF TOP “ a ” “ b ” “ c ” VIEW OF SIDE I823H11A0022-02 “a”: 140 mm (5.5 in) “b”: 10 mm (0.4 in) “c”: 40 mm (1.6 in)
Page 427: Battery Current Leakage Inspection
1J-4 Charging System: Battery Current Leakage Inspection Regulated Voltage Inspection B823H11A06001 B823H11A06002 Inspect the battery current leakage in the following Inspect the regulated voltage in the following procedures: procedures: 1) Turn the ignition switch OFF. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”.
Page 428: Generator Inspection
Charging System: 1J-5 Generator Inspection No-load Performance B823H11A06003 1) Disconnect the generator coupler (1). Generator Coil Resistance 1) Disconnect the generator coupler (1). I823H11A0002-01 2) Start the engine and keep it running at 5 000 r/min. I823H11A0001-01 3) Using the multi-circuit tester, measure the voltage 2) Measure the resistance between the three lead between three lead wires.
Page 429: Generator Removal And Installation
1J-6 Charging System: Generator Removal and Installation 6) Remove the gasket (5) and dowel pins (6). B823H11A06004 Removal 1) Disconnect the battery (–) lead wire. Refer to “Battery Removal and Installation (Page 1J-14)”. 2) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”.
Page 430 Charging System: 1J-7 10) Remove the key (8). Installation Install the generator in the reverse order of removal. Pay attention to the following points: • Tighten the generator starter set bolts and CKP sensor mounting bolts to the specified torque. NOTE Be sure the grommet (1) is set to the generator cover.
Page 431 • Apply a bond lightly to the mating surfaces at the Be careful not to pinch the finger between the parting line between the upper and lower crankcases generator cover and crankcase. as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I823H11A0017-01 I823H11A0015-01...
Page 432: Regulator / Rectifier Construction
Charging System: 1J-9 Regulator / Rectifier Construction B823H11A06005 I823H11A0018-01 1. Regulator/rectifier 2. Clamp 3. Under cowling : 10 N m (1.0 kgf-m, 7.0 lb-ft) Regulator / Rectifier Removal and Installation 3) Remove the under cowling. Refer to “Exterior Parts B823H11A06011 Removal and Installation in Section 9D (Page 9D- Removal 14)”.
Page 433: Regulator / Rectifier Inspection
1J-10 Charging System: Regulator / Rectifier Inspection B823H11A06006 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch OFF. 2) Disconnect the regulator/rectifier couplers (1). I823H11A0019-01 3) Measure the voltage between the terminals using the multi-circuit testers as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
Page 434: Battery Components
Charging System: 1J-11 Battery Components 2) Remove the caps (2) from the electrolyte container. B823H11A06007 NOTE • Do not remove or pierce the sealed areas “B” of the electrolyte container. • After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes.
Page 435 1J-12 Charging System: 5) Make sure that air bubbles (4) rise to the top of each 6) After confirming that the electrolyte has entered the electrolyte container, and leave in this position for battery completely, remove the electrolyte containers about more than 20 minutes. from the battery.
Page 436 Charging System: 1J-13 Charging 3) After recharging, wait at least 30 minutes and then For initial charging, use the charger specially designed measure the battery voltage using the multi-circuit for MF battery. tester. If the battery voltage is less than 12.5 V, recharge CAUTION the battery again.
Page 437: Battery Removal And Installation
1J-14 Charging System: Battery Removal and Installation Installation B823H11A06009 Install the battery in the reverse order of removal. Removal Pay attention to following points: 1) Remove the seat. Refer to “Exterior Parts Removal CAUTION and Installation in Section 9D (Page 9D-14)”. 2) Disconnect the battery (–) lead wire (1).
Page 438: Specifications
Charging System: 1J-15 Specifications Service Data B823H11A07001 Electrical Unit: mm Item Specification Note Generator coil resistance 0.2 – 0.7 Generator maximum output Approx. 400 W at 5 000 r/min Generator no-load voltage (When 70 V (AC) and more at 5 000 r/min engine is cold) Regulated voltage 13.5 –...
Page 439: Special Tools And Equipment
1J-16 Charging System: Special Tools and Equipment Recommended Service Material B823H11A08001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1J-8) equivalent Special Tool B823H11A08002 09900–25008 09930–30450 Multi-circuit tester set Rotor remover bolt (Page 1J-4) /...
Page 440: Exhaust System
Exhaust System: 1K-1 Exhaust System Engine Precautions Precautions for Exhaust System B823H11B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipes, muffler joint and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 441: Exhaust Control System Operation
1K-2 Exhaust System: Exhaust Control System Operation B823H11B01002 The EXCS is operated by the signal supplied from the ECM.The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then the ECM determines the EXCV opening angle based on the engine rpm and gear positions.
Page 442: Repair Instructions
Exhaust System: 1K-3 Repair Instructions Exhaust Control System Construction B823H11B06005 “ a ” “ b ” “A” I823H11B0024-05 1. No. 1 EXCV cable “a”: 43 – 44 mm (1.69 – 1.73 in) “A”: Adjustment position 2. No. 2 EXCV cable “b”: 47 –...
Page 443: Exhaust System Components
1K-4 Exhaust System: Exhaust System Components B823H11B06001 I823H11B0045-07 1. Gasket 5. Heat shield plate : 11 N m (1.1 kgf-m, 8.0 lb-ft) 2. Connector : 23 N m (2.3 kgf-m, 16.5 lb-ft) : 5 N m (0.5 kgf-m, 3.5 lb-ft) 3.
Page 444: Excv Cable Removal And Installation
Exhaust System: 1K-5 CAUTION Replace the gaskets, connectors and O-rings with new ones when reassembling. EXCV Cable Removal and Installation 7) Remove the EXCV cover. B823H11B06008 Removal 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 10)”.
Page 445 1K-6 Exhaust System: 11) Remove the EXCV cables from its bracket (1). 4) Remove the EXCV cable bracket along with cables by removing the nut (7). “ a ” “ b ” I823H11B0046-03 I823H11B0047-02 Installation CAUTION The cable slots of EXCVA pulley must be located adjustment position.
Page 446: Excva Removal And Installation
Exhaust System: 1K-7 6) Reinstall the bracket and cables and tighten the nut EXCVA Removal and Installation B823H11B06009 (7) to the specified torque. Removal Tightening torque 1) Turn the ignition switch OFF. EXCV cable bracket nut (a): 10 N·m (1.0 kgf-m, 2) Lift and support the fuel tank.
Page 447 1K-8 Exhaust System: 9) Remove the EXCV cover. Installation Install the EXCVA in the reverse order of removal. Pay attention to the following points: • Install the EXCVA pulley to the shaft. NOTE Align the shaft’s line “A” and cable slots “B”. “B”...
Page 448: Excva Inspection
Exhaust System: 1K-9 • Install the EXCVA. EXCVA Pulley Inspection B823H11B06011 Tightening torque Inspect the EXCVA pulley in the following procedures: EXCVA mounting bolt (b): 10 N·m (1.0 kgf-m, 7.0 1) Remove the EXCVA pulley. Refer to “EXCV Cable lb-ft) Removal and Installation (Page 1K-5)”.
Page 449 1K-10 Exhaust System: 4) Turn the mode select switch ON. If DTC “C46” is not 5) Turn the ignition switch ON. indicated on the LCD display, the adjustment is 6) Measure the EXCVA position sensor output voltage correctly completed. If “C46” is indicated, repeat the at fully closed position.
Page 450 Exhaust System: 1K-11 Step 4 3) If the measured voltage is more than specification, adjust the No. 2 cable adjuster as follows: 1) To set the EXCV to fully opened position, apply 12 V to the terminal oppositely. a) Set the EXCVA to the adjustment position. Refer Positive wire —...
Page 451: Muffler / Muffler Joint / Exhaust Pipe Removal And Installation
1K-12 Exhaust System: Muffler / Muffler Joint / Exhaust Pipe Removal 5) Remove the muffler assembly (5). and Installation B823H11B06002 Removal 1) Remove the frame cover and muffler covers. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-14)”. 2) Disconnect the taillight/rear turn signal light lead wire coupler (1).
Page 452 Exhaust System: 1K-13 9) Loosen the muffler joint connecting bolt (10). 14) Remove the regulator/rectifier bracket. Refer to “Regulator / Rectifier Removal and Installation in Section 1J (Page 1J-9)”. 15) Move the radiator and oil cooler forward. Refer to “Radiator Inspection and Cleaning in Section 1F (Page 1F-5)”.
Page 453 1K-14 Exhaust System: 18) Remove the HO2 sensor (15). • Install the exhaust pipe gaskets (2) and connectors (3). CAUTION CAUTION • Take care not to expose the HO2 sensor to an excessive shock. Replace the gaskets and connectors with new ones.
Page 454: Exhaust System Inspection
Exhaust System: 1K-15 • Route the HO2 sensor lead wire properly. Refer to EXCV Inspection B823H11B06004 “Wiring Harness Routing Diagram in Section 9A Inspect the EXCV in the following procedures: (Page 9A-5)”. 1) Remove the exhaust pipe assembly. Refer to •...
Page 455: Special Tools And Equipment
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H11B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-14)
Page 456 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Swingarm Bearing Removal and Installation ..2C-12 Specifications .............2C-13 Precautions............. 2-1 Service Data............2C-13 Precautions for Suspension ........2-1 Tightening Torque Specifications......2C-13 Suspension General Diagnosis....2A-1 Special Tools and Equipment ......2C-14 Recommended Service Material .......2C-14 Diagnostic Information and Procedures....2A-1 Special Tool ............2C-14...
Page 457: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B823H12000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.
Page 458: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B823H12104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.
Page 459: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B823H12206001 I823H1220081-03 1. Front fork cap bolt 9. Inner rod/Damper rod (cartridge) 17. Damper rod bolt 2. O-ring 10. Outer tube 18. Front axle pinch bolt 3. Adjuster rod 11.
Page 460: Front Fork Removal And Installation
Front Suspension: 2B-2 Front Fork Removal and Installation 6) After removing of the headlight cover upper screws B823H12206002 (4), move the headlight assembly forward. NOTE The right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.
Page 461 2B-3 Front Suspension: 8) Loosen the front fork lower clamp bolts (8) and 4) Set the front fork with the upper surface “T” of the remove the front fork. outer tube positioned 3.0 mm (0.12 in) “a” from the upper surface of the steering stem upper bracket. NOTE Hold the front fork by the hand to prevent sliding out of the steering stem.
Page 462 Front Suspension: 2B-4 7) Install the headlight assembly. Spring pre-load adjustment 8) Install the front fender. • There are five grooved lines on the side of the spring adjuster. 9) Install the front wheel assembly. Refer to “Front Position 0 provides the maximum spring pre-load and Wheel Assembly Removal and Installation in Section position 5 provides the minimum spring pre-load.
Page 463: Front Fork Disassembly And Assembly
2B-5 Front Suspension: Damping force adjustment Front Fork Disassembly and Assembly B823H12206005 Refer to “Front Fork Removal and Installation (Page 2B- NOTE 2)”. Make sure to check the 1st click position by the last click sound when turning in the NOTE adjuster.
Page 464 Front Suspension: 2B-6 4) Remove the front fork cap bolt (1) from the inner rod 9) Remove the outer tube from the inner tube. by loosening the lock-nut (2). 5) Compress the fork spring with the special tool (A) and remove the special tool (B). Special tool (A): 09940–94930 (Front fork spacer holder) (B): 09940–94922 (Front fork spring stopper...
Page 465 2B-7 Front Suspension: 12) Remove the inner rod/damper rod (cartridge) (9). 15) Remove the oil seal retainer (13). Special tool CAUTION (D): 09913–50121 (Oil seal remover) Do not disassemble the inner rod/damper rod (cartridge). CAUTION The removed oil seal must be replaced with a new one.
Page 466 Tightening torque • Apply fork oil to the oil seal lip. Front fork damper rod bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) : Fork Oil 99000–99044–L01 (SUZUKI FORK OIL L01 or equivalent) I823H1220068-01 I823H1220080-02 • Apply fork oil to the anti-friction metals “A” and “B”.
Page 467 • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube. : Fork Oil 99000–99044–L01 (SUZUKI FORK OIL L01 or equivalent) Front fork oil capacity (each leg) 527 ml (17.8/18.6 US/lmp oz)
Page 468 Front Suspension: 2B-10 • Hold the front fork vertically and adjust fork oil level Front fork cap bolt with the special tool. • Adjust the height “a” of the inner rod threads by turning the lock-nut (1) as shown in the figure. NOTE When adjusting the fork oil level, remove the fork spring and compress the outer tube...
Page 469: Front Fork Parts Inspection
• Make sure that the rebound damping force “A” and “B”. adjuster (1) to the softest position before installing the cap bolt. • Use a new O-ring to prevent oil leakage. : Fork Oil 99000–99044–L01 (SUZUKI FORK OIL L01 or equivalent) “B” “A” I823H1220064-02 Fork Spring Measure the fork spring free length.
Page 470: Specifications
Front fork oil level (Without spring, 100 (3.9) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (Each leg) 527 ml (17.8/18.6 US/lmp oz) — Front fork inner tube O.D.
Page 471: Special Tools And Equipment
Special Tools and Equipment Recommended Service Material B823H12208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL L01 or equivalent P/No.: 99000–99044– (Page 2B-8) / (Page 2B- 8) / (Page 2B-9) / (Page 2B-11) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110...
Page 472: Rear Suspension
Rear Suspension: 2C-1 Rear Suspension Suspension Repair Instructions Rear Suspension Components B823H12306001 I823H1230049-03 1. Rear shock absorber 8. Swingarm pivot shaft : 50 N m (5.0 kgf-m, 36.0 lb-ft) 2. Rear shock absorber mounting nut 9. Swingarm pivot nut : 78 N m (7.8 kgf-m, 56.5 lb-ft) 3.
Page 473: Rear Suspension Assembly Construction
2C-2 Rear Suspension: Rear Suspension Assembly Construction B823H12306002 I823H1230050-01 1. Rear shock absorber mounting nut (Upper) 6. Swingarm pivot shaft : 15 N m (1.5 kgf-m, 11.0 lb-ft) 2. Rear shock absorber mounting nut (Lower) 7. Swingarm pivot nut : 100 N m (10.0 kgf-m, 72.5 lb-ft) 3.
Page 474: Rear Shock Absorber Removal And Installation
Rear Suspension: 2C-3 Rear Shock Absorber Removal and Installation Installation B823H12306003 Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: Removal • Temporarily install the rear shock absorber and 1) Support the motorcycle with a jack to relieve load on cushion lever mounting bolt.
Page 475: Rear Shock Absorber Inspection
2C-4 Rear Suspension: Rear Shock Absorber Inspection Rear Suspension Adjustment B823H12306005 B823H12306006 Inspect the rear shock absorber in the following After installing the rear suspension, adjust the spring procedures: pre-load and damping force as follows: 1) Remove the rear shock absorber. Refer to “Rear Spring Pre-load Adjustment Shock Absorber Removal and Installation (Page 2C- 3)”.
Page 476: Rear Shock Absorber Disposal
Rear Suspension: 2C-5 Compression side 1) Mark the drill center at the location “A” using a center Turn the damping force adjuster (2) to the desired punch. position. STD position 2 turns out of from stiffest position “ a ” “A”...
Page 477: Cushion Lever Removal And Installation
2C-6 Rear Suspension: Cushion Lever Removal and Installation Cushion Lever Inspection B823H12306008 B823H12306009 Refer to “Cushion Lever Removal and Installation Removal (Page 2C-6)”. 1) Support the motorcycle with a jack to relieve load on Spacer the cushion lever. 1) Remove the spacers from the cushion lever. 2) Remove the cushion lever by removing its related bolts, nuts and washers.
Page 478: Cushion Lever Bearing Removal And Installation
(A): 09924–84521 (Bearing installer set) “A” I823H1230016-01 I823H1230043-01 “B” “B” I823H1230017-02 I823H1230044-01 2) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1230018-01 I823H1230019-01 3) Install the cushion lever. Refer to “Cushion Lever Removal and Installation (Page 2C-6)”.
Page 479: Swingarm / Cushion Rod Removal And Installation
2C-8 Rear Suspension: Swingarm / Cushion Rod Removal and 6) Remove the front and rear seats as an assembly. Refer to “Exterior Parts Removal and Installation in Installation B823H12306011 Section 9D (Page 9D-14)”. 7) Remove the frame covers. Refer to “Exterior Parts Removal Removal and Installation in Section 9D (Page 9D- 1) Cut the drive chain.
Page 480 Rear Suspension: 2C-9 14) Remove the swingarm pivot shaft. Installation Install the swingarm in the reverse order of removal. Pay 15) Remove the swingarm. attention to the following points: 16) Remove the cushion rods (7). • Temporarily install the cushion rod mounting nut. NOTE The stamped marks “A”...
Page 481 2C-10 Rear Suspension: – Hold the swingarm pivot shaft and tighten the – Tighten the cushion lever, cushion rod and rear swingarm pivot nut to the specified torque. shock absorber mounting nut to the specified torque. Tightening torque Swingarm pivot nut: 100 N·m (10.0 kgf-m, 72.5 Tightening torque lb-ft) Cushion rod mounting nut (a): 78 N·m (7.8 kgf-...
Page 482: Swingarm Related Parts Inspection
Rear Suspension: 2C-11 Swingarm Related Parts Inspection Swingarm B823H12306012 Inspect the swingarm for damage. If any defect is found, Refer to “Swingarm / Cushion Rod Removal and replace the swingarm with a new one. Installation (Page 2C-8)”. Spacers 1) Remove the spacers from the swingarm. 2) Inspect the spacers for wear and damage.
Page 483: Swingarm Bearing Removal And Installation
2C-12 Rear Suspension: Swingarm Bearing Removal and Installation Installation B823H12306013 CAUTION Removal The removed bearings must be replaced with 1) Remove the rear wheel assembly. Refer to “Rear new ones. Wheel Assembly Removal and Installation in Section 2D (Page 2D-11)”. 1) Press the bearings into the swingarm cushion rod at 2) Remove the swingarm.
Page 484: Specifications
4) Apply grease to the bearings. 5) Install the swingarm. Refer to “Swingarm / Cushion Rod Removal and Installation (Page 2C-8)”. : Grease 99000–25010 (SUZUKI SUPER 6) Install the rear wheel assembly. Refer to “Rear GREASE A or equivalent) Wheel Assembly Removal and Installation in Section 2D (Page 2D-11)”.
Page 485: Special Tools And Equipment
2C-14 Rear Suspension: Special Tools and Equipment Recommended Service Material B823H12308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-7) / (Page 2C- equivalent NOTE Required service material is also described in the following.
Page 486: Wheels And Tires
Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B823H12400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •...
Page 487: Repair Instructions
2D-2 Wheels and Tires: Repair Instructions Front Wheel Components B823H12406001 I823H1240060-02 1. Front axle 7. Front wheel : 23 N m (2.3 kgf-m, 16.5 lb-ft) 2. Brake disc bolt 8. Collar : 100 N m (10.0 kgf-m, 72.5 lb-ft) 3. Brake disc 9.
Page 488: Front Wheel Assembly Construction
Wheels and Tires: 2D-3 Front Wheel Assembly Construction B823H12406002 “ a ” I823H1240061-01 1. Brake disc bolt “a”: Clearance : 100 N m (10.0 kgf-m, 72.5 lb-ft) 2. Brake caliper mounting bolt : 23 N m (2.3 kgf-m, 16.5 lb-ft) : Apply grease.
Page 489: Front Wheel Assembly Removal And Installation
2D-4 Wheels and Tires: Front Wheel Assembly Removal and Installation 5) Loosen two axle pinch bolts (3) on the left front fork B823H12406003 leg. 6) Draw out the front axle and remove the front wheel. Removal 1) Raise the front wheel off the ground and support the NOTE motorcycle with a jack or a wooden block.
Page 490 Wheels and Tires: 2D-5 2) Install the front wheel with the front axle and tighten 5) Tighten two axle pinch bolts (4) on the right fork leg the front axle bolt temporarily. to the specified torque. Tightening torque WARNING Front axle pinch bolt (c): 23 N·m (2.3 kgf-m, 16.5 The directional arrow on the tire should point lb-ft) to the wheel rotation, when remounting the...
Page 491: Front Wheel Related Parts Inspection
2D-6 Wheels and Tires: Front Wheel Related Parts Inspection Wheel B823H12406004 1) Remove the brake pads. Refer to “Front Brake Pad Refer to “Front Wheel Assembly Removal and Replacement in Section 4B (Page 4B-2)”. Installation (Page 2D-4)”. 2) Make sure that the wheel runout checked as shown does not exceed the service limit.
Page 492: Front Wheel Dust Seal / Bearing Removal And Installation
1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation 1) Apply grease to the wheel bearings. (Page 2D-4)”. : Grease 99000–25010 (SUZUKI SUPER 2) Remove the dust seals (1) using the special tool. GREASE A or equivalent) Special tool (A): 09913–50121 (Oil seal remover)
Page 493 (A): 09924–84510 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I823H1240043-01 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240020-03 Left Right I823H1240044-01 5) Install the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (Page 2D-4)”.
Page 494: Rear Wheel Components
Wheels and Tires: 2D-9 Rear Wheel Components B823H12406006 I823H1240062-01 1. Spacer 8. Spacer : 100 N m (10.0 kgf-m, 72.5 lb-ft) 2. Rear sprocket 9. Rear wheel : 60 N m (6.0 kgf-m, 43.5 lb-ft) 3. Dust seal 10. Tire : 35 N m (3.5 kgf-m, 25.5 lb-ft) 4.
Page 495: Rear Wheel Assembly Construction
2D-10 Wheels and Tires: Rear Wheel Assembly Construction B823H12406007 “ a ” “A” I823H1240063-01 1. Rear sprocket nut : 100 N m (10.0 kgf-m, 72.5 lb-ft) 2. Rear axle nut : 35 N m (3.5 kgf-m, 25.5 lb-ft) 3. Brake disc bolt : 33 N m (3.3 kgf-m, 24.0 lb-ft) 4.
Page 496: Rear Wheel Assembly Removal And Installation
Wheels and Tires: 2D-11 Rear Wheel Assembly Removal and Installation 5) Remove the spacer (2) and collar (3). B823H12406008 Removal 1) Support the motorcycle with a jack or wooden block. CAUTION Make sure that the motorcycle is supported securely. 2) Remove the rear axle nut (1). I823H1240047-01 Installation 1) Install the spacer (1) and collar (2).
Page 497: Rear Wheel Related Parts Inspection
2D-12 Wheels and Tires: Rear Wheel Related Parts Inspection Wheel Axle B823H12406009 Using a dial gauge, check the wheel axle for runout, If Refer to “Rear Wheel Assembly Removal and the runout exceeds the limit, replace the axle shaft. Installation (Page 2D-11)”. Wheel axle runout Service limit: 0.25 mm (0.010 in) Tire...
Page 498: Rear Wheel Dust Seal / Bearing Removal And Installation
2) Remove the rear sprocket mounting drum assembly (1) from the rear wheel. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1240051-01 3) Remove the dust seal (2).
Page 499 (B): 09924–84510 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I823H1240054-01 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240030-02 Left Right I823H1240055-01 5) Install the rear sprocket mounting drum assembly.
Page 500: Tire Removal And Installation
Wheels and Tires: 2D-15 Tire Removal and Installation Installation B823H12406011 Removal CAUTION The most critical factor of a tubeless tire is the seal Do not reuse the valve which has been once between the wheel rim and the tire bead. For this removed.
Page 501: Wheel / Tire / Air Valve Inspection And Cleaning
2D-16 Wheels and Tires: 3) Bounce the tire several times while rotating. This Wheel / Tire / Air Valve Inspection and Cleaning B823H12406012 makes the tire bead expand outward to contact the Refer to “Tire Removal and Installation (Page 2D-15)”. wheel, thereby facilitating air inflation.
Page 502: Air Valve Removal And Installation
Wheels and Tires: 2D-17 Air Valve Installation Inspect the air valve for peeling and damage. If any Install the air valve in the reverse order of removal. Pay defect is found, replace the air valve with a new one. attention to the following points: Refer to “Air Valve Removal and Installation (Page 2D- •...
Page 503: Wheel Balance Check And Adjustment
2D-18 Wheels and Tires: Wheel Balance Check and Adjustment 4) When installing the balancer weight to the wheel, set B823H12406014 the balancer weight on center rib of the wheel. Check and adjust the wheel balance in the following procedures: 1) Removal the wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (Page 2D-4)”...
Page 504: Specifications
Wheels and Tires: 2D-19 Specifications Service Data B823H12407001 Wheel Unit: mm (in) Item Standard Limit Axial Wheel rim runout — 2.0 (0.08) Radial Front 17 M/C x MT 3.50 — Wheel rim size Rear 17 M/C x MT 6.00 — Front Wheel axle runout —...
Page 505: Special Tools And Equipment
2D-20 Wheels and Tires: Special Tools and Equipment Recommended Service Material B823H12408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-7) / (Page 2D- equivalent 8) / (Page 2D-13) / (Page 2D-14) NOTE Required service material is also described in the following.
Page 506 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation ......3A-4 Precautions............. 3-1 Drive Chain Related Parts Inspection ....3A-5 Precautions for Driveline / Axle ......3-1 Sprocket Mounting Drum Dust Seal / Bearing Drive Chain / Drive Train / Drive Shaft...
Page 507: Precautions
• Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is RK GB50GSVZ4. Suzuki recommends to use this standard drive chain as a replacement.
Page 508: Drive Chain / Drive Train / Drive Shaft
Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B823H13104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.
Page 509: Engine Sprocket Removal And Installation
3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 6) Remove the speed sensor rotor (5) by removing its B823H13106002 bolt while depressing the rear brake pedal. Removal 1) Support the motorcycle with a jack or wooden block. 2) Remove the engine sprocket outer cover (1).
Page 510 20.0 lb-ft) • Before installing the engine sprocket inner cover, apply a small quantity of grease to the clutch push rod. : Grease 99000–25010 (SUZUKI SUPER I823H1310011-01 GREASE A or equivalent) • Adjust the drive chain slack. Refer to “Drive Chain Inspection and Adjustment in Section 0B (Page 0B- 15)”.
Page 511: Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation
1) Remove the rear wheel assembly by disengaging rear wheel hub and rear sprocket mounting drum. the drive chain. Refer to “Rear Wheel Assembly : Grease 99000–25010 (SUZUKI SUPER Removal and Installation in Section 2D (Page 2D- GREASE A or equivalent) 11)”.
Page 512: Drive Chain Related Parts Inspection
Drive Chain / Drive Train / Drive Shaft: 3A-5 Drive Chain Related Parts Inspection Wheel Damper B823H13106004 Inspect the dampers for wear and damage. Replace the Refer to “Rear Sprocket / Rear Sprocket Mounting Drum damper if there is anything unusual. Removal and Installation (Page 3A-4)”.
Page 513 3) Apply grease to the dust seal lip. 1) Apply grease to the bearing before installing. 4) Apply grease to the retainer before installing the rear sprocket mounting drum. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)
Page 514: Drive Chain Replacement
Drive Chain / Drive Train / Drive Shaft: 3A-7 5) Install the rear sprocket mounting drum assembly to Drive Chain Cutting rear wheel hub. Refer to “Rear Sprocket / Rear 1) Set up the special tool as shown in the figure. Sprocket Mounting Drum Removal and Installation (Page 3A-4)”.
Page 515 3A-8 Drive Chain / Drive Train / Drive Shaft: 2) Place the drive chain link being disjointed on the 6) Remove the joint pin (9) of the other side of joint holder part (8) of the tool. plate. 3) Turn in both the adjuster bolt (6) and pressure bolt CAUTION [A] (3) so that each of their end hole fits over the Never reuse joint pins, O-rings and plates.
Page 516 Drive Chain / Drive Train / Drive Shaft: 3A-9 2) Apply grease to the joint pins (8), O-rings (9) and 6) Turn in the pressure bolt [A] (6) and align two joint plates (10). pins (11) properly with the respective holes of the joint plate (10).
Page 517 3A-10 Drive Chain / Drive Train / Drive Shaft: Joint pin staking 2) Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [A] (3) with the bar until the pin end 1) Set up the special tool as shown in the figure. diameter becomes the specified dimension.
Page 518: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H13108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-3) /...
Page 519: Special Tool
3A-12 Drive Chain / Drive Train / Drive Shaft: Special Tool B823H13108002 09913–50121 09913–70210 Oil seal remover Bearing installer set (Page 3A-5) (Page 3A-6) 09921–20240 09922–22711 Bearing remover set Drive chain cutting and joining tool (Page 3A-6) (Page 3A-7) 09924–84510 Bearing installer set (Page 3A-6)
Page 520 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Tightening Torque Specifications......4A-18 Special Tools and Equipment ......4A-19 Precautions............. 4-1 Recommended Service Material .......4A-19 Precautions for Brake System ......4-1 Special Tool ............4A-19 Brake Fluid Information ......... 4-1 Front Brakes ..........4B-1 Brake Control System and Diagnosis ...
Page 521: Precautions
4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B823H14000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B823H14000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.
Page 522: Brake Control System And Diagnosis
Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B823H14102001 “ a ” “ b ” “ a ” “ c” “ b ” “ b ” “ a ” I823H1410047-02 1.
Page 523: Rear Brake Hose Routing Diagram
4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B823H14102002 “A” “ b ” “ a ” “ a ” “A” “B” “ c” I823H1410049-03 1. Stopper “b”: 21 : After the brake hose union has contacted the stopper, tighten the union bolt. 2.
Page 524: Diagnostic Information And Procedures
Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B823H14104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.
Page 525: Rear Brake Light Switch Inspection
4A-4 Brake Control System and Diagnosis: Rear Brake Light Switch Inspection Rear Brake Light Switch Inspection and B823H14106003 Adjustment Inspect the rear brake light switch in the following B823H14106004 procedures: Check the rear brake light switch so that the brake light will come on just before pressure is felt when the brake 1) Disconnect the rear brake light switch lead coupler pedal is depressed.
Page 526 Brake Control System and Diagnosis: 4A-5 Front Brake 5) Close the air bleeder valve, pump and squeeze the lever, and open the valve. 1) Fill the master cylinder reservoir to the top of the inspection window. Place the reservoir cap to 6) Repeat this process until the fluid flowing into the prevent dirt from entering.
Page 527: Brake Fluid Replacement
4A-6 Brake Control System and Diagnosis: Rear Brake Brake Fluid Replacement B823H14106008 Bleed air from the rear brake system as the same CAUTION manner of front brake. • Remove the right frame cover. Refer to “Exterior Parts Handle brake fluid with care: the fluid reacts Removal and Installation in Section 9D (Page 9D- chemically with paint, plastic, rubber 14)”.
Page 528 Brake Control System and Diagnosis: 4A-7 7) Close the air bleeder valve (1) and disconnect the Rear Brake clear hose. 1) Place the motorcycle on a level surface. 2) Remove the right frame cover. Refer to “Exterior Tightening torque Air bleeder valve (Front) (a): 6 N·m (0.6 kgf-m, Parts Removal and Installation in Section 9D (Page 9D-14)”.
Page 529: Front Brake Hose Removal And Installation
4A-8 Brake Control System and Diagnosis: 8) Close the air bleeder valve (1) and disconnect the Front Brake Hose Removal and Installation B823H14106009 clear hose. Removal Tightening torque 1) Remove the headlight. Refer to “Headlight Removal Air bleeder valve (Rear) (a): 7.5 N·m (0.75 kgf-m, and Installation in Section 9B (Page 9B-4)”.
Page 530: Front Brake Master Cylinder Components
Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Components B823H14106011 I823H1410045-02 1. Reservoir cap 7. Brake hose union bolt : 6.0 N m (0.6 kgf-m, 4.5 lb-ft) 2. Plate 8. Brake lever : 1.0 N m (0.1 kgf-m, 0.7 lb-ft) 3.
Page 531: Front Brake Master Cylinder Assembly Removal And Installation
4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal • After setting the brake hose union to the stopper, tighten the union bolt (3) to the specified torque. and Installation B823H14106012 CAUTION Removal The seal washers should be replaced with the 1) Drain brake fluid.
Page 532 Brake Control System and Diagnosis: 4A-11 2) Remove the brake lever (4) and brake light switch Assembly (5). Assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: CAUTION • Wash the master cylinder components with new brake fluid before reassembly.
Page 533: Front Brake Master Cylinder Parts Inspection
Brake lever pivot bolt lock-nut (b): 6 N·m (0.6 kgf-m, 4.5 lb-ft) I823H1410029-01 • Apply grease to the push rod. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) I823H1410032-02 Front Brake Master Cylinder Parts Inspection B823H14106014 Refer to “Front Brake Master Cylinder / Brake Lever Disassembly and Assembly (Page 4A-10)”.
Page 534: Rear Brake Master Cylinder Components
Brake Control System and Diagnosis: 4A-13 Rear Brake Master Cylinder Components B823H14106015 I823H1410046-05 1. Reservoir tank 6. Piston/Cup set : Apply silicone grease. 2. Reservoir hose 7. Push rod : Apply brake fluid. 3. Brake hose union bolt : 10 N m (1.0 kgf-m, 0.7 lb-ft) : Do not reuse.
Page 535: Rear Brake Master Cylinder Assembly Removal And Installation
4A-14 Brake Control System and Diagnosis: Rear Brake Master Cylinder Assembly Removal Installation Install the rear brake master cylinder in the reverse order and Installation B823H14106016 of removal. Pay attention to the following points: Removal CAUTION 1) Remove the right frame cover. Refer to “Exterior The seal washers should be replaced with the Parts Removal and Installation in Section 9D new ones to prevent fluid leakage.
Page 536: Rear Brake Master Cylinder Disassembly And Assembly
Brake Control System and Diagnosis: 4A-15 Rear Brake Master Cylinder Disassembly and 5) Remove the push rod (8), piston/cup set (9) and spring (10). Assembly B823H14106017 Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-10)”. Disassembly 1) Disconnect the reservoir hose (1). I823H1410041-02 2) Remove the lock-nut (2).
Page 537: Rear Brake Master Cylinder Parts Inspection
Rear Brake Master Cylinder Parts Inspection • Apply grease to the push rod end. B823H14106018 Refer to “Rear Brake Master Cylinder Disassembly and : Grease 99000–25100 (SUZUKI Silicone Assembly (Page 4A-15)”. Grease or equivalent) Master Cylinder Inspect the master cylinder bore for any scratches or other damage.
Page 538: Rear Brake Pedal Construction
Brake Control System and Diagnosis: 4A-17 Rear Brake Pedal Construction B823H14106019 I823H1410050-01 1. Washer 2. Snap ring : Apply grease. : Do not reuse. Rear Brake Pedal Removal and Installation Installation B823H14106020 Removal CAUTION 1) Remove the master cylinder assembly. Refer to Replace the snap ring with a new one.
Page 539: Service Data
4A-18 Brake Control System and Diagnosis: Specifications Service Data B823H14107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 55 – 65 (2.2 – 2.6) — Front 19.050 – 19.093 (0.7500 – 0.7517) — Master cylinder bore Rear 12.700 –...
Page 540: Special Tools And Equipment
Brake Control System and Diagnosis: 4A-19 Special Tools and Equipment Recommended Service Material B823H14108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) / (Page 4A- 7) / (Page 4A-11) / (Page 4A-15) Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100...
Page 541: Front Brakes
4B-1 Front Brakes: Front Brakes Brake Repair Instructions Front Brake Components B823H14206001 I823H1420023-07 1. O-ring 7. Brake pad spring : 23 N m (2.3 kgf-m, 16.5 lb-ft) 2. Piston seal : 27 N m (2.7 kgf-m, 19.5 lb-ft) : Apply thread lock to the thread part. 3.
Page 542: Front Brake Pad Inspection
Front Brakes: 4B-2 Front Brake Pad Inspection Front Brake Pad Replacement B823H14206002 B823H14206003 The extent of brake pads wear can be checked by 1) Remove the plug (1). observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones.
Page 543: Front Brake Caliper Removal And Installation
4B-3 Front Brakes: 3) Clean up the caliper especially around the caliper Front Brake Caliper Removal and Installation B823H14206004 piston. 4) Install the new brake pads. NOTE The right and left calipers are installed CAUTION symmetrically and therefore the removal Replace the brake pads as a set, otherwise procedure for one side is the same as that for braking performance will be adversely...
Page 544: Front Brake Caliper Disassembly And Assembly
Front Brakes: 4B-4 Installation • Bleed air from the brake system after installing the Install the brake caliper in the reverse order of removal. caliper. Refer to “Air Bleeding from Brake Fluid Circuit Pay attention to the following points: in Section 4A (Page 4A-4)”. •...
Page 545 4B-5 Front Brakes: 3) Remove the O-ring. 5) Remove the dust seals (1) and piston seals (2). I823H1420011-01 I823H1420014-04 4) Place a rag over the pistons to prevent it from Assembly popping out and then force out the pistons using Assemble the caliper in the reverse order of compressed air.
Page 546: Front Brake Caliper Parts Inspection
Front Brakes: 4B-6 • Apply the brake fluid to piston seals (1) and dust seals • Temporarily tighten the brake caliper housing bolts. (2). CAUTION CAUTION After installing the brake caliper to the front Replace the piston seals (1) and dust seals fork, tighten the brake caliper housing bolts (2) with new ones.
Page 547: Front Brake Disc Removal And Installation
4B-7 Front Brakes: Brake Caliper Piston Front Brake Disc Removal and Installation B823H14206007 Inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, Removal replace the piston with a new one. 1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation in Section 2D (Page 2D-4)”.
Page 548: Front Brake Disc Inspection
Front Brakes: 4B-8 Front Brake Disc Inspection Brake Disc Runout B823H14206008 1) Dismount the front brake caliper. Refer to “Front Brake Disc Thickness Brake Caliper Removal and Installation (Page 4B- Check the brake disc for damage or cracks and measure 3)”.
Page 549: Service Data
4B-9 Front Brakes: Specifications Service Data B823H14207001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Front 5.3 – 5.7 (0.21 – 0.22) 5.0 (0.20) Brake disc runout — 0.30 (0.012) Leading 30.230 – 30.280 (1.1902 – 1.1921) — Brake caliper cylinder bore Front Trailing...
Page 550: Special Tools And Equipment
Front Brakes: 4B-10 Special Tools and Equipment Recommended Service Material B823H14208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) / (Page 4B- Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130 (Page 4B-7)
Page 551: Rear Brakes
4C-1 Rear Brakes: Rear Brakes Brake Repair Instructions Rear Brake Components B823H14306001 I823H1430025-04 1. Rear caliper 7. Rear brake disc : 35 N m (3.5 kgf-m, 2.5 lb-ft) 2. Piston seal 8. Brake pad spring : Apply silicone grease to sliding surface. 3.
Page 552: Rear Brake Pad Inspection
Rear Brakes: 4C-2 Rear Brake Pad Inspection 3) Remove the brake pads (3) with the rear caliper B823H14306002 pivoted up. The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When NOTE the wear exceeds the grooved limit line, replace the When removing the pads, push the piston all...
Page 553: Rear Brake Caliper Removal And Installation
4C-3 Rear Brakes: 6) Tighten the caliper mounting bolt (4) and pad 3) Remove the brake pads. Refer to “Rear Brake Pad mounting pin (5) to the specified torque. Replacement (Page 4C-2)”. 4) Pivot the caliper up and remove the caliper from the Tightening torque caliper bracket.
Page 554: Rear Brake Caliper Disassembly And Assembly
Rear Brakes: 4C-4 Rear Brake Caliper Disassembly and Assembly 5) Remove the dust seal (7) and piston seal (8). B823H14306005 Refer to “Rear Brake Caliper Removal and Installation (Page 4C-3)”. Disassembly 1) Remove the pad spring (1), rubber boot (2) and sliding pin (3).
Page 555 • Apply the brake fluid to piston seal (1) and dust seal • Tighten the sliding pin (3) and apply grease to the (2). sliding pin. : Grease 99000–25100 (SUZUKI Silicone CAUTION Grease or equivalent) Replace the piston seal (1) and dust seal (2) Tightening torque with new ones.
Page 556: Rear Brake Caliper Parts Inspection
Rear Brakes: 4C-6 Rear Brake Caliper Parts Inspection Boot and Spacer B823H14306006 Inspect the boots and spacer for damage and wear. If Refer to “Rear Brake Caliper Disassembly and any defects are found, replace them with new ones. Assembly (Page 4C-4)”. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage.
Page 557: Rear Brake Disc Inspection
4C-7 Rear Brakes: Installation Brake Disc Runout Install the rear brake disc in the reverse order of 1) Dismount the rear brake caliper. Refer to “Rear removal. Pay attention to the following points: Brake Caliper Removal and Installation (Page 4C- •...
Page 558: Specifications
Rear Brakes: 4C-8 Specifications Service Data B823H14307001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Rear 5.3 – 5.7 (0.21 – 0.22) 5.0 (0.20) Brake disc runout — 0.30 (0.012) Brake caliper cylinder bore Rear 38.180 – 38.256 (1.5031 – 1.5061) —...
Page 559: Special Tools And Equipment
4C-9 Rear Brakes: Special Tools and Equipment Recommended Service Material B823H14308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-4) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-5) / (Page 4C-...
Page 560 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Clutch ............5C-1 Precautions............. 5-1 Precautions............5C-1 Precautions for Transmission / Transaxle..... 5-1 Precautions for Clutch System......5C-1 Clutch Fluid (Brake Fluid) Information....5C-1 Manual Transmission......5B-1 Schematic and Routing Diagram ......5C-2 Diagnostic Information and Procedures....5B-1 Clutch Hose Routing Diagram (Except for E- Manual Transmission Symptom Diagnosis ..
Page 561: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B823H15000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 562: Manual Transmission
Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B823H15204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.
Page 563: Repair Instructions
5B-2 Manual Transmission: Repair Instructions Transmission Components B823H15206001 I823H1520090-04 1. 2nd drive gear 12. 1st driven gear : 10 N m (1.0 kgf-m, 7.0 lb-ft) 2. 6th drive gear 13. Gearshift cam stopper : 13 N m (1.3 kgf-m, 9.5 lb-ft) 3.
Page 564: Transmission Removal
Manual Transmission: 5B-3 Transmission Removal Gearshift Fork and Gearshift Cam B823H15206002 1) Remove the gearshift cam bearing retainer (1) from 1) Remove the engine assembly from the frame. Refer the lower crankcase. to “Engine Assembly Removal in Section 1D (Page 1D-19)”. 2) Remove the engine top side.
Page 565: Transmission Installation
5B-4 Manual Transmission: Bearing Transmission Installation B823H15206017 1) Remove the gearshift shaft bearing using the special Install the transmission in the reverse order of removal. tool. Pay attention to the following points: Special tool Bearing (A): 09921–20240 (Bearing remover set) CAUTION Replace the removed bearings with new ones.
Page 566 Manual Transmission: 5B-5 • Install the gearshift cam along with the bearing. • Install the bearing retainer (4). NOTE NOTE The stamped mark side of the gearshift cam Apply a small quantity of thread lock to the bearing faces outside. bearing retainer screws and tighten them to the specified torque.
Page 567 5B-6 Manual Transmission: • Install the driveshaft assembly on the upper • Install the oil seal (5). crankcase. • Turn each bearing to set the bearing dowel pin “F” and “G” in position. NOTE Align the bearing ring “A” with the groove “B”...
Page 568: Transmission Construction
Manual Transmission: 5B-7 Transmission Construction B823H15206004 I823H1520086-02 1. Countershaft 2. Driveshaft Countershaft Gear / Driveshaft Gear Countershaft Disassembly and Assembly • Remove the 6th drive gear snap ring (1) from its B823H15206005 groove and slide it towards the 3rd/4th drive gears (2). Refer to “Transmission Removal (Page 5B-3)”...
Page 569 5B-8 Manual Transmission: • Slide the 6th (3) and 2nd (4) drive gears toward the • Remove the driveshaft bearing (2) along with the 3rd/4th drive gears (2), then remove the 2nd drive spacer (3) using a hydraulic press. gear circlip (5). •...
Page 570 • Before installing the oil seal, apply grease to the oil seal lip. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I823H1520023-02 • When installing a new snap ring (1), pay attention to •...
Page 571: Transmission Related Parts Inspection
5B-10 Manual Transmission: • When installing the gear bushings onto the driveshaft, • When installing the gear bushing onto the align the shaft oil holes “A” with the bushing oil hole countershaft, align the shaft oil hole “A” with the “B”.
Page 572: Gear Position (Gp) Switch Inspection
Manual Transmission: 5B-11 Gearshift Fork Groove Width Gear Position (GP) Switch Inspection B823H15206007 Measure the gearshift fork groove width using the Refer to “Side-stand / Ignition Interlock System Parts vernier calipers. Inspection in Section 1I (Page 1I-8)”. Special tool (A): 09900–20102 (Vernier calipers (1/20 mm, Gear Position (GP) Switch Removal and 200 mm)) Installation...
Page 573 • Apply a bond lightly to the gear position switch bolt Install the gear position switch in the reverse order of lead wire grommet (1). removal. Pay attention to the following points: : Sealant 99000–31140 (SUZUKI BOND NOTE No.1207B or equivalent) Align the gear position switch pin “A” with NOTE the gearshift cam hole “B”.
Page 574: Gearshift Lever Construction
Manual Transmission: 5B-13 Gearshift Lever Construction B823H15206009 “ a ” Footrest top position “ b” I823H1520048-03 : 10 N m (1.0 kgf-m, 7.0 lb-ft) “a”: Approx. 14 : Apply grease. : 40 N m (4.0 kgf-m, 29.0 lb-ft) “b”: 55 – 65 mm (2.2 – 2.6 in)
Page 575: Gearshift Lever Removal And Installation
5B-14 Manual Transmission: Gearshift Lever Removal and Installation 2) Loosen the lock-nuts (1). B823H15206010 3) Turn the gearshift link rod (2) until the gearshift lever Removal is 55 – 65 mm (2.2 – 2.6 in) below the top of the Remove the gearshift lever as shown in the gearshift footrest.
Page 576: Gearshift Shaft Construction
Manual Transmission: 5B-15 Gearshift Shaft Construction B823H15206013 I823H1520049-04 1. Gearshift shaft 6. Gearshift cam drive plate : Apply thread lock to the thread part. 2. Washer : 10 N m (1.0 kgf-m, 7.0 lb-ft) : Apply thread lock to the thread part. 3.
Page 577: Gearshift Shaft / Gearshift Cam Plate Removal And Installation
5B-16 Manual Transmission: Gearshift Shaft / Gearshift Cam Plate Removal Installation Refer to “Engine Bottom Side Assembly in Section 1D and Installation B823H15206014 (Page 1D-72)”. Refer to “Engine Assembly Removal in Section 1D Install the gearshift shaft and gearshift cam plate in the (Page 1D-19)”.
Page 578: Gearshift Linkage Inspection
Manual Transmission: 5B-17 Gearshift Linkage Inspection Gearshift Shaft Oil Seal / Bearing Removal and B823H15206015 Installation Refer to “Gearshift Shaft / Gearshift Cam Plate Removal B823H15206016 and Installation (Page 5B-16)”. Removal 1) Remove the gearshift shaft. Refer to “Gearshift Shaft Gearshift Shaft / Gearshift Cam Plate Removal and Installation Check the gearshift shaft for bend or wear.
Page 579 (A): 09913–70210 (Bearing installer set) CAUTION • Apply grease to the oil seal lip. The removed oil seal and bearings must be : Grease 99000–25010 (SUZUKI SUPER replaced with new ones. GREASE A or equivalent) • Install the bearings with the special tool.
Page 580: Specifications
Manual Transmission: 5B-19 Specifications Service Data B823H15207001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.596 (83/52) — Final reduction ratio 2.388 (43/18) — 2.615 (34/13) — 1.937 (31/16) — 1.526 (29/19) — Gear ratios 1.285 (27/21) —...
Page 581: Special Tools And Equipment
5B-20 Manual Transmission: Special Tools and Equipment Recommended Service Material B823H15208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-9) / (Page 5B- equivalent Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 5B-9) Sealant SUZUKI BOND No.1207B or...
Page 582: Clutch
Clutch: 5C-1 Clutch Transmission / Transaxle Precautions Precautions for Clutch System B823H15300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Clutch Fluid (Brake Fluid) Information B823H15300002 WARNING • This clutch system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based.
Page 583: Schematic And Routing Diagram
5C-2 Clutch: Schematic and Routing Diagram Clutch Hose Routing Diagram (Except for E-33) B823H15302001 “ b ” “ a ” “ c ” “ a ” I823H1530001-04 1. Stopper : 6 N m (0.6 kgf-m, 4.5 lb-ft) : After the clutch hose union has contacted the stopper, tighten the union bolt. 2.
Page 584 Clutch: 5C-3 Clutch Hose Routing Diagram (For E-33) B823H15302002 “ b ” “ a ” “ c ” “ a ” I823H1530060-01 1. Stopper : 6 N m (0.6 kgf-m, 4.5 lb-ft) : After the clutch hose union has contacted the stopper, tighten the union bolt. 2.
Page 585: Diagnostic Information And Procedures
5C-4 Clutch: Diagnostic Information and Procedures Clutch System Symptom Diagnosis B823H15304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn countershaft spline. Replace countershaft. seems to come from the Worn clutch hub spline. Replace clutch hub. clutch) Worn clutch plate teeth.
Page 586: Air Bleeding From Clutch Fluid Circuit
Clutch: 5C-5 Air Bleeding from Clutch Fluid Circuit 6) Loosen the air bleeder valve by turning it a quarter of B823H15306004 a turn so that the fluid runs into the receptacle; this CAUTION will remove the tension of the clutch lever causing it to touch the handlebar grip.
Page 587: Clutch Hose Removal And Installation
5C-6 Clutch: 6) Connect a clear hose to the air bleeder valve and Clutch Hose Removal and Installation B823H15306006 insert the other end of hose into a receptacle. Removal 1) Drain clutch fluid. Refer to “Clutch Fluid Replacement (Page 5C-5)”. 2) Remove the air cleaner box.
Page 588: Clutch Control System Components
Clutch: 5C-7 Clutch Control System Components B823H15306007 I823H1530058-04 1. Push rod 7. Push rod : Apply brake fluid. 2. Piston/Cup set 8. Clutch release cylinder set : Apply grease. 3. Clutch hose 9. Air bleeder valve : Apply silicone grease. 4.
Page 589: Clutch Master Cylinder Assembly Removal And Installation
5C-8 Clutch: Clutch Master Cylinder Assembly Removal and Installation Install the clutch master cylinder in the reverse order of Installation B823H15306008 removal. Pay attention to the following points: • When installing the clutch master cylinder (1) onto the Removal handlebars (2), align the master cylinder holder’s 1) Drain clutch fluid.
Page 590: Clutch Master Cylinder / Clutch Lever Disassembly And Assembly
Clutch: 5C-9 • After setting the clutch hose union to the stopper, 2) Remove the clutch lever (4). tighten the union bolt (3) to the specified torque. CAUTION The seal washers should be replaced with new ones to prevent fluid leakage. Tightening torque Clutch hose union bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Page 591 5C-10 Clutch: 6) Remove the following parts from the master cylinder. • Apply silicone grease to the push rod ends. • Washer (9) : Grease 99000–25100 (SUZUKI Silicone • Secondary cup (10) Grease or equivalent) • Piston (11) • Primary cup (12) •...
Page 592: Clutch Master Cylinder Components Inspection
Clutch: 5C-11 Clutch Master Cylinder Components Inspection Clutch Release Cylinder / Push Rod Removal B823H15306010 and Installation Refer to “Clutch Master Cylinder / Clutch Lever B823H15306011 Disassembly and Assembly (Page 5C-9)”. Removal 1) Drain clutch fluid. Refer to “Clutch Fluid Master Cylinder Replacement (Page 5C-5)”.
Page 593: Clutch Push Rod Inspection
1) Remove the clutch push rod. Refer to “Clutch • Apply a small quantity of grease to the push rod. Release Cylinder / Push Rod Removal and : Grease 99000–25010 (SUZUKI SUPER Installation (Page 5C-11)”. GREASE A or equivalent) 2) Inspect the push rod for wear or bend. If any defects are found, replace it with a new one.
Page 594: Clutch Release Cylinder Inspection
Clutch: 5C-13 Assembly Clutch Release Cylinder Inspection B823H15306014 Assemble the clutch release cylinder in the reverse order Refer to “Clutch Release Cylinder Disassembly and of disassembly. Pay attention to the following points: Assembly (Page 5C-12)”. • Wash the cylinder bore and piston with specified Inspect the clutch cylinder bore wall for nicks, scratches brake fluid.
Page 595: Clutch Components
5C-14 Clutch: Clutch Components B823H15306015 “A” I823H1530059-06 1. Clutch pressure plate 7. No. 1 driven plate (8 – 5 pcs.) 13. Push rod 2. Clutch push piece 8. No. 2 driven plate (1 – 4 pcs.) “A”: The No. 1 and No. 2 driven plates are 9 in total. 3.
Page 596: Clutch Removal
Clutch: 5C-15 Clutch Removal 5) Remove the clutch drive plates (4) and driven plates B823H15306016 (5). 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”. 2) Remove the clutch cover (1). I823H1530025-01 6) Remove the spring washer (6) and its seat (7). I823H1530022-01 3) Remove the gasket (2) and dowel pins.
Page 597 5C-16 Clutch: 8) Remove the clutch push rod (11). 12) Remove the conical spring washer (12). NOTE If it is difficult to pull out the push rod (11), use a magnetic hand or wire. I823H1530031-01 13) Remove the clutch sleeve hub (13), clutch lifter drive cam (14) and its driven cam (15).
Page 598: Clutch Installation
Clutch: 5C-17 16) Remove the oil pump drive gear (20) from the • Install the oil pump drive gear to the primary driven primary driven gear assembly. gear assembly. NOTE The off-set side “B” of the oil pump drive gear faces the primary driven gear side. I823H1530034-01 “B”...
Page 599 5C-18 Clutch: • Install the clutch lifter drive cam (4), driven cam (5) to • Install the clutch sleeve hub along with the clutch lifter the clutch sleeve hub (6). drive and driven cams onto the countershaft. • Install the conical spring washer (8). NOTE NOTE •...
Page 600 Clutch: 5C-19 • Tighten the clutch sleeve hub nut to the specified torque. Tightening torque Clutch sleeve hub nut: 150 N·m (15.0 kgf-m, 108.5 lb-ft) “G” • Lock the clutch sleeve hub nut with a center punch. 14/15 I823H1530049-03 11. No. 3 drive plate 12.
Page 601 • Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcase as shown in the figure. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I823H1530054-01 • Tighten the clutch outer cover bolts (20) with the washers (21) securely.
Page 602: Clutch Parts Inspection
Clutch: 5C-21 • Install the clutch cover and tighten its bolts (22) to the Measure the claw width of drive plates with a vernier specified torque. calipers. Replace the drive plates found to have worn down to the limit. Tightening torque Clutch cover bolt (c): 10 N·m (1.0 kgf-m, 7.0 lb-ft) Special tool (A): 09900–20102 (Vernier calipers (1/20 mm,...
Page 603 5C-22 Clutch: Clutch Spring Push Rod Measure the free length of each coil spring with a vernier Inspect the push rod for wear and damage. calipers, and compare the length with the specified limit. If any defects are found, replace the push rod with a new Replace all the springs if any spring is not within the one.
Page 604: Specifications
Clutch: 5C-23 Specifications Service Data B823H15307001 Clutch Unit: mm (in) Item Standard Limit No. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) Clutch drive plate thickness No. 2 & 3 3.72 – 3.88 (0.146 – 0.153) 3.42 (0.135) No. 1 13.85 –...
Page 605: Special Tools And Equipment
5C-24 Clutch: Special Tools and Equipment Recommended Service Material B823H15308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 5C-5) / (Page 5C- 10) / (Page 5C-13) Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5C-12)
Page 606 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Steering Components .........6B-5 Steering Damper Construction......6B-6 Precautions............. 6-1 Steering Removal and Installation ......6B-7 Precautions for Steering ........6-1 Steering Related Parts Inspection.....6B-10 Steering General Diagnosis....6A-1 Steering System Inspection ......6B-10 Steering Stem Bearing Removal and Diagnostic Information and Procedures....6A-1 Installation ............6B-10...
Page 607: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions for Steering B823H16000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 608: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B823H16104001 Condition Possible cause Correction / Reference Item Heavy steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.
Page 609: Steering / Handlebar
6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Components B823H16206001 “A” I823H1620029-07 I823H1620030-04 1. Throttle grip 6. Handle balancer expander : 23 N m (2.3 kgf-m, 16.5 lb-ft) 2. Handlebars 7. Handlebar balancer : 10 N m (1.0 kgf-m, 7.0 lb-ft) 3.
Page 610: Handlebar Construction
Steering / Handlebar: 6B-2 Handlebar Construction B823H16206002 “A” “A” “ a ” “ a ” “B” “B” “A” “ a ” I823H1620031-04 1. Front brake master cylinder “A”: Punch mark : 10 N m (1.0 kgf-m, 7.0 lb-ft) 2. Clutch master cylinder “B”: UP mark : 23 N m (2.3 kgf-m, 16.5 lb-ft) 3.
Page 611 6B-3 Steering / Handlebar: Handlebar Removal and Installation 3) Remove the caps and handlebar holder bolts. B823H16206003 Removal 1) Remove the following parts from the left handlebar. a) Rear view mirror (1) b) Clutch master cylinder/clutch lever (2) CAUTION Do not turn the clutch master cylinder upside down.
Page 612: Handlebars Inspection
• Insert the projection “D” of the left handlebar switch cable pulley. box into the hole of the handlebars. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Insert the projection “B” of the right handlebar switch box into the hole of the handlebars.
Page 613: Steering Components
6B-5 Steering / Handlebar: Steering Components B823H16206005 I823H1620033-05 1. Handlebar holder bolt 9. Handlebar holder mounting bolt 17. Steering stem lower bracket 2. Handlebar holder (Upper) 10. Steering stem lock-nut : 23 N m (2.3 kgf-m, 16.5 lb-ft) 3. Handlebar holder (Lower) 11.
Page 614: Steering Damper Construction
Steering / Handlebar: 6B-6 Steering Damper Construction B823H16206011 I823H1620034-02 1. Steering damper 2. Dust seal : 23 N m (2.3 kgf-m, 16.5 lb-ft) : Apply grease.
Page 615: Steering Removal And Installation
6B-7 Steering / Handlebar: Steering Removal and Installation 8) Remove the steering stem upper bracket (4) by B823H16206006 removing the steering stem head nut (5) and washer (6). Removal 1) Support the motorcycle with a jack or a wooden block. 2) Remove the front wheel assembly.
Page 616 NOTE • Apply grease to the bearings, bearing races and dust seals before remounting the steering stem. This adjustment will vary from motorcycle to motorcycle. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “ a” I649G1620026-02 I823H1620013-03 • When installing the washer (2), align the lug of the washer to the groove of the steering stem.
Page 617 Install the front forks and steering stem upper bracket in • Apply grease to the bearings and dust seals. the following steps: : Grease 99000–25010 (SUZUKI SUPER 1) Temporarily install the upper bracket, washer (1) and GREASE A or equivalent) steering stem head nut (2).
Page 618: Steering Related Parts Inspection
Steering / Handlebar: 6B-10 Steering Related Parts Inspection Steering System Inspection B823H16206007 B823H16206008 Refer to “Steering Removal and Installation (Page 6B- Refer to “Steering System Inspection in Section 0B 7)”. (Page 0B-20)”. Inspect the removed parts for the following abnormalities: Steering Stem Bearing Removal and Installation B823H16206009 •...
Page 619: Steering Tension Adjustment
6B-11 Steering / Handlebar: Installation 4) With the front wheel in the straight ahead state, hitch Install the steering stem bearings in the reverse order of the spring scale (special tool) on one handlebar grip removal. Pay attention to the following points: end as shown in the figure and read the graduation when the handlebar starts moving.
Page 620: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-4) /...
Page 621: Special Tool
6B-13 Steering / Handlebar: Special Tool B823H16208002 09910–60611 09925–18011 Universal clamp wrench Steering bearing installer (Page 6B-11) (Page 6B-11) 09940–14911 09940–14960 Steering stem nut wrench Steering nut wrench socket (Page 6B-7) / (Page 6B- (Page 6B-7) / (Page 6B- 8) / (Page 6B-8) 8) / (Page 6B-8)
Page 622 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Turn Signal Switch Inspection......9B-15 Passing Light Switch Inspection......9B-16 Precautions............. 9-1 Dimmer Switch Inspection.........9B-16 Precautions for Electrical System ......9-1 Specifications .............9B-17 Component Location ..........9-1 Service Data............9B-17 Electrical Components Location ......
Page 623 9-ii Table of Contents Frame Cover Construction ........9D-2 Wiring Harness Protector Attachment ....9D-13 Frame Side Cover Cushion Attachment....9D-3 Fastener Removal and Installation....9D-13 Exterior Parts Removal and Installation ....9D-14 Front Frame Cover Cushion Attachment ....9D-3 Frame Body Cover Construction......9D-4 Specifications .............9D-18 Under Cowling Construction .......9D-5 Tightening Torque Specifications......9D-18 Under Cowling Heat Shield Attachment....9D-6...
Page 624: Precautions
Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B823H19000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B823H19003001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.
Page 625: Wiring Systems
9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B823H19102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”.
Page 626 Wiring Systems: 9A-2 For E-02, 19, 24 I823H1910901-09...
Page 627 9A-3 Wiring Systems: For E-03, 28 I823H1910902-08...
Page 628 Wiring Systems: 9A-4 For E-33 I823H1910903-09...
Page 629: Wiring Harness Routing Diagram
9A-5 Wiring Systems: Wiring Harness Routing Diagram B823H19102005 “A” “B” “C” I823H1910904-04 1. Wiring harness protector 7. Starter motor lead wire : Stick the wiring harness protector onto the seat rail bolt. 2. Clamp 8. Battery (–) lead wire : Bind the wiring harness, oil pressure switch lead wire and HO2 sensor lead wire with the clamp.
Page 630 Wiring Systems: 9A-6 “A” “C” “A” “B” “D” I823H1910905-05...
Page 631 9A-7 Wiring Systems: 1. Clamp 14. Ignition switch : Pass the radiator breather hose above the horn bracket. Be careful not to contact the lead wires with the horn bracket. 2. Clamp 15. Spacer : Bind the handlebar switch wiring harnesses. Cut off the excess end of the clamp.
Page 632 Wiring Systems: 9A-8 “ a ” “C” “D” “A” “B” I823H1910906-07 1. Clutch hose 9. Clamp : Bind the clutch hose and left handlebar switch lead wires. Cut off the excess end of the clamp. 2. Left handlebar switch lead wire 10.
Page 633 9A-9 Wiring Systems: “ c ” “ a ” “ b ” “A” I823H1910907-04...
Page 634: Specifications
Wiring Systems: 9A-10 1. CMP sensor : 14 N m (1.4 kgf-m, 10.0 lb-ft) “a”: Approx. 45 2. Oil pressure switch : 5 N m (0.5 kgf-m, 3.5 lb-ft) “b”: Within 20 3. Engine ground lead wire : 6 N m (0.6 kgf-m, 4.3 lb-ft) “c”: Within 10 4.
Page 635: Lighting Systems
9B-1 Lighting Systems: Lighting Systems Body and Accessories Repair Instructions Headlight Housing Cover Construction B823H19206028 To headlight “ a ” I823H1920048-01 “a”: Approx. 1 mm (0.04 in)
Page 636: Headlight Housing Cover Cushion Construction
Lighting Systems: 9B-2 Headlight Housing Cover Cushion Construction B823H19206027 “ a ” “b ” “ b ” I823H1920047-02 1. Headlight upper housing 5. Headlight lower cover 2. Cushion rubber 6. Protective tape : Clean an adhesive surface before adhering the cushion. 3.
Page 637: Headlight Components
9B-3 Lighting Systems: Headlight Components B823H19206001 I823H1920046-02 1. Headlight bulb (12 V 60/55 W, H4) 2. Position light bulb (12 V 5 W) Headlight Construction B823H19206029 I823H1920049-02 1. Headlight 2. Headlight cover 3. Cushion...
Page 638: Headlight Removal And Installation
Lighting Systems: 9B-4 Headlight Removal and Installation 4) Disconnect the position light coupler (3). B823H19206002 Removal 1) Remove the combination meter. Refer to “Combination Meter Removal and Installation in Section 9C (Page 9C-2)”. 2) Remove the headlight cover screws (1). I823H1920003-01 5) Disconnect the headlight coupler (4).
Page 639: Headlight Bulb And Position Light Bulb Replacement
9B-5 Lighting Systems: Headlight Bulb and Position Light Bulb 4) Replace the headlight bulb with a new one. Replacement 5) Remove the headlight housing cover (6). B823H19206023 CAUTION When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.
Page 640 Lighting Systems: 9B-6 8) Remove the position light socket (9). Headlight Beam Adjustment B823H19206004 Insert a (+) screwdriver as shown in the figure and adjust the headlight beam horizontally and vertically. “A” I823H1920010-03 9) Replace the position light bulb (10) with a new one. I823H1920013-01 “A”: Vertical adjuster I823H1920012-03...
Page 641: Front Turn Signal Light Components
9B-7 Lighting Systems: Front Turn Signal Light Components B823H19206012 I823H1920050-01 I823H1920015-01 1. Turn signal light bulb (12 V 21 W x 2) 2. Front turn signal light...
Page 642: Front Turn Signal Light Bulb Replacement
Lighting Systems: 9B-8 Removal Front Turn Signal Light Bulb Replacement B823H19206015 1) Remove the fuel tank cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- CAUTION 14)”. When you touch the bulb with your bare 2) Remove the front turn signal light (1). hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.
Page 643: Rear Lighting System Construction
9B-9 Lighting Systems: Rear Lighting System Construction B823H19206006 I823H1920019-05 : 7 N m (0.7 kgf-m, 5.0 lb-ft) : 5 N m (0.5 kgf-m, 3.5 lb-ft) [A]: For E-03, 28, 33 [B]: For E-02, 19, 24...
Page 644: Rear Combination Light Removal And Installation
Lighting Systems: 9B-10 Rear Combination Light Removal and 4) Remove the turn signal mounting nuts (5) and remove the rear fender bracket (6) by removing the Installation B823H19206007 screw (7). Removal 1) Remove the rear fender cover (1). I823H1920023-03 5) Remove the rear combination light (7). I823H1920020-01 2) Disconnect the combination light coupler (2), license plate light coupler (3) and turn signal light couplers...
Page 645: Rear Combination Light Replacement
9B-11 Lighting Systems: Installation : Thread lock cement 99000–32110 Install the rear combination light in the reverse order of (THREAD LOCK CEMENT SUPER 1322 or removal. Pay attention to the following point: equivalent) • Tighten the turn signal light mounting nuts (1) and rear fender mounting bolts (2) to the specified torque.
Page 646: License Plate Light Removal And Installation
Lighting Systems: 9B-12 License Plate Light Removal and Installation Installation B823H19206010 Install the rear license plate light in the reverse order of Removal removal. Pay attention to the following point: 1) Remove the rear fender cover (1). • Tighten the rear license plate light mounting nuts (1) to the specified torque.
Page 647: Rear Turn Signal Light Components
9B-13 Lighting Systems: Rear Turn Signal Light Components B823H19206025 I823H1920033-01 1. Rear turn signal light bulb (12 V 21 W x 2) 2. Lens : 7.0 N m (0.7 kgf-m, 5.0 lb-ft) Rear Turn Signal Light Removal and Installation Installation B823H19206014 Install the rear turn signal light in the reverse order of Removal...
Page 648: Rear Turn Signal Light Bulb Replacement
Lighting Systems: 9B-14 Rear Turn Signal Light Bulb Replacement 2) Remove the lens by removing the screw. B823H19206026 CAUTION When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.
Page 649: Turn Signal / Side-Stand Relay Inspection
9B-15 Lighting Systems: Turn Signal / Side-Stand Relay Inspection 2) Disconnect the left handlebar switch coupler (1). B823H19206017 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. NOTE Make sure that the battery is fully charged. Before removing the turn signal/side-stand relay, check the operation of the turn signal light.
Page 650: Passing Light Switch Inspection
Lighting Systems: 9B-16 3) Inspect the turn signal switch for continuity with a 4) After finishing the passing light switch inspection, tester. If any abnormality is found, replace the left reinstall the removed parts. handlebar switch assembly with a new one. Refer to “Handlebar Removal and Installation in Dimmer Switch Inspection Section 6B (Page 6B-3)”.
Page 651: Service Data
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B823H19208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9B-11)
Page 652: Combination Meter / Fuel Meter / Horn
Combination Meter / Fuel Meter / Horn: 9C-1 Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B823H19301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
Page 653: Repair Instructions
9C-2 Combination Meter / Fuel Meter / Horn: Repair Instructions Combination Meter Components B823H19306001 I823H1930002-03 Combination Meter Removal and Installation 2) Remove the headlight housing cover (2) by B823H19306002 removing the screws. Removal 1) Remove the headlight cover screws (1). I823H1930028-01 I823H1930026-01...
Page 654: Combination Meter Disassembly And Assembly
Combination Meter / Fuel Meter / Horn: 9C-3 3) Remove the bolt (3) and pull out the combination Combination Meter Inspection B823H19306004 meter from the headlight cover (4). LED Inspection Check that the LEDs (FI indicator light, Oil pressure, Engine coolant temperature indicator light, Immobilizer indicator light (For E-02, 19, 24), and Meter panel illumination) immediately light up when the ignition switch is turned to ON.
Page 655: Engine Coolant Temperature Indicator And Indicator Light Inspection
9C-4 Combination Meter / Fuel Meter / Horn: 2) With the adjuster button (1) pressed, turn the ignition Engine Coolant Temperature Indicator and switch ON. Indicator Light Inspection B823H19306005 3) Keep pushing the ADJ button for more than 3 sec. Inspect the engine coolant temperature indicator light in the following procedures: 1) Lift and support the fuel tank.
Page 656: Ect Sensor Removal And Installation
Combination Meter / Fuel Meter / Horn: 9C-5 4) Turn the ignition switch ON. ECT Sensor Removal and Installation B823H19306006 5) Check the engine coolant temperature indicator LCD Refer to “ECT Sensor Removal and Installation in (3) and LED (4) operations when the resistance is Section 1C (Page 1C-5)”.
Page 657: Fuel Level Gauge Inspection
9C-6 Combination Meter / Fuel Meter / Horn: NOTE Fuel Level Gauge Inspection B823H19306009 It takes approx. 30 seconds that the fuel level Inspect the fuel level gauge in the following procedures: indicator indicates the detected fuel level. 1) Remove the fuel level gauge. Refer to “Fuel Pump Disassembly and Assembly in Section 1G (Page 1G- 13)”.
Page 658: Speedometer Inspection
Combination Meter / Fuel Meter / Horn: 9C-7 Speedometer Inspection Installation B823H19306010 Install the speed sensor in the reverse order of removal. If the speedometer, odometer or tripmeter does not Pay attention to the following points: function properly, inspect the speed sensor and the •...
Page 659: Oil Pressure Indicator Inspection
9C-8 Combination Meter / Fuel Meter / Horn: 3) Move a screwdriver back and forth across the pick- 3) Turn the ignition switch ON. up surface of the speed sensor. The voltage 4) Check if the oil pressure indicator (LED) will light up readings should cycle as follows (0 V 12 V or 12 V when grounding the lead wire (1).
Page 660: Ignition Switch Inspection
Combination Meter / Fuel Meter / Horn: 9C-9 Ignition Switch Inspection Ignition Switch Removal and Installation B823H19306015 B823H19306016 Inspect the ignition switch in the following procedures: Refer to “Ignition Switch Removal and Installation in Section 1H (Page 1H-12)”. 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- Horn Inspection 10)”.
Page 661: Horn Removal And Installation
9C-10 Combination Meter / Fuel Meter / Horn: Horn Inspection Horn Removal and Installation B823H19306018 1) Remove the right frame body cover. Refer to Removal “Exterior Parts Removal and Installation in Section 1) Remove the right frame body cover. Refer to 9D (Page 9D-14)”.
Page 662: Specifications
Combination Meter / Fuel Meter / Horn: 9C-11 Specifications Service Data B823H19307001 Wattage Unit: W Specification Item E-02, 19, 24 The other countries Headlight Parking or position light 5 x 2 Brake light/Taillight Turn signal light 21 x 4 License plate light Tachometer light Speedometer light Turn signal indicator light...
Page 663: Exterior Parts
9D-1 Exterior Parts: Exterior Parts Body and Accessories Schematic and Routing Diagram Seat Lock Cable Routing Diagram B823H19402001 I823H1940078-01 1. Frame cover 4. Seat lock cable guide 2. Front seat lock cable 5. Plate : Set the plate in the reverse side of the guide. 3.
Page 664: Repair Instructions
Exterior Parts: 9D-2 Repair Instructions Frame Cover Construction B823H19406013 “A” I823H1940079-01 1. Cushion rubber 2. Velcro fastening “A” To seat rail...
Page 665: Frame Side Cover Cushion Attachment
9D-3 Exterior Parts: Frame Side Cover Cushion Attachment B823H19406014 “A” “ a ” “ b ” “c ” View of backside I823H1940080-01 “A”: Clean the adhesive surface before adhering the cushion rubber. “a”: 20 mm (0.8 in) “b”: 2 mm (0.08 in) “c”: 15 mm (0.6 in) Front Frame Cover Cushion Attachment B823H19406015...
Page 666: Frame Body Cover Construction
Exterior Parts: 9D-4 Frame Body Cover Construction B823H19406027 “A” I823H1940093-01 1. Frame body cover 2. Cushion 3. Screw “A” To the frame : 4.5 N m (0.45 kgf-m, 3.3 lb-ft)
Page 667: Under Cowling Construction
9D-5 Exterior Parts: Under Cowling Construction B823H19406016 I823H1940082-01...
Page 668: Under Cowling Heat Shield Attachment
Exterior Parts: 9D-6 Under Cowling Heat Shield Attachment B823H19406017 “A” I823H1940083-01 1. Heat shield “A”: Align the tips of the heat shield to the alignment points on the under cowling. : Clean the adhesive surface before adhering the heat shield. Frame Cover Cushion Attachment B823H19406018 “...
Page 669: Muffler Cover Construction
9D-7 Exterior Parts: Muffler Cover Construction B823H19406019 VIEW OF BOTTOM VIEW OF TOP I823H1940085-01...
Page 670: Muffler Cover Heat Shield Attachment
Exterior Parts: 9D-8 Muffler Cover Heat Shield Attachment B823H19406020 “F” “G” “E” “D” “C” “ a ” “B” “A” I823H1940086-01 1. Heat shield No. 1 “C”: Align “C” point to “C1” point. 2. Heat shield No. 2 “D”: Align “D” point to “D1” point. 3.
Page 671: Tool Box Heat Shield Attachment
9D-9 Exterior Parts: Tool Box Heat Shield Attachment B823H19406021 “ a ” “ b ” I823H1940087-01 “a”: 25 mm (1.0 in) “b”: 10 mm (0.4 in)
Page 672: Engine Sprocket Outer Cover Cushion
Exterior Parts: 9D-10 Engine Sprocket Outer Cover Cushion Attachment (Except for E-33) B823H19406022 I823H1940088-01 1. Engine sprocket cover bracket 2. Protective tape No. 1 3. Protective tape No. 2 4. Cushion rubber Engine Sprocket Outer Cover Cushion Attachment (For E-33) B823H19406023 “...
Page 673: Rear Fender Construction
9D-11 Exterior Parts: Rear Fender Construction B823H19406024 “ a ” “ b ” I823H1940090-03 1. Heat shield cushion 2. Heat shield cushion “a”: 1 mm (0.04 in) “b”: 0.5 – 3 mm (0.02 – 0.12 in)
Page 674: Rear Fender Heat Shield / Cushion Attachment
Exterior Parts: 9D-12 Rear Fender Heat Shield / Cushion Attachment B823H19406025 “ c” “ b ” “ a ” “ a ” “ a ” “B” “A” I823H1940091-03 1. Heat shield No. 1 “B”: Align the heat shield No. 2 to the heat shield No. 1. : Clean the adhesive surface before adhering the heat shield.
Page 675: Wiring Harness Protector Attachment
9D-13 Exterior Parts: Wiring Harness Protector Attachment B823H19406026 I823H1940092-01 1. Wiring harness protector : Stick the wiring harness protector onto the harness guide as shown in the figure. Fastener Removal and Installation 2) Insert the fastener into the installation hole. B823H19406005 Type A NOTE...
Page 676: Exterior Parts Removal And Installation
Exterior Parts: 9D-14 Type B Exterior Parts Removal and Installation B823H19406006 Removal Front Seat 1) Pry up the head of fastener center piece (1) with a Removal screwdriver. Remove the front seat with the ignition key. 2) Pull out the fastener “A”. “A”...
Page 677 9D-15 Exterior Parts: Installation Fuel Tank Cover Slide the hook into the hook retainer and push down Removal firmly until the seat (seat tail cover) snaps into the locked 1) Remove the fasteners and bolts. position. 2) Remove the fuel tank cover(-s) (1) from the guides by sliding it forward.
Page 678 Exterior Parts: 9D-16 3) Remove the bolts. Installation Install the fuel tank upper cover(-s) in the reverse order of removal. Under Cowling Removal 1) Remove the bolts. 2) Open the clamps (1) and remove the under cowling (2). I823H1940066-01 4) Disconnect the information display switch coupler (3) and driving mode selector coupler (4).
Page 679 9D-17 Exterior Parts: Frame Cover 4) Remove the front seat lock cable (2) from the frame cover by removing the plate (5). Removal 1) Remove the frame cover center lid (1). 2) Disconnect the front seat lock cable (2) and rear seat lock cable (3).
Page 680: Specifications
Exterior Parts: 9D-18 Frame Body Cover Installation Install the frame body cover(-s) in the reverse order of Removal removal. Remove the frame body cover(-s) (1) (LH & RH). Front Fender Removal Refer to “Front Fork Removal and Installation in Section 2B (Page 2B-2)”.
Page 681: Body Structure
9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction B823H19506001 I823H1950001-03 1. Frame 5. Adjuster : 10 N m (1.0 kgf-m, 7.0 lb-ft) 2. Seat rail 6. Adjuster lock-nut : 45 N m (4.5 kgf-m, 32.5 lb-ft) 3.
Page 682: Front Footrest Bracket Construction
Body Structure: 9E-2 Front Footrest Bracket Construction B823H19506004 I823H1950002-01 1. Bolt 2. Washer 3. Washer 4. Bushing : 23 N m (2.3 kgf-m, 16.5 lb-ft)
Page 683: Side-Stand Construction
9E-3 Body Structure: Side-stand Construction B823H19506005 I823H1950003-01 : 50 N m (5.0 kgf-m, 36.0 lb-ft) : 95 N m (9.5 kgf-m, 68.5 lb-ft) : 60 N m (6.0 kgf-m, 43.5 lb-ft) : Apply grease to sliding surface.
Page 684: Side-Stand Removal And Installation
Body Structure: 9E-4 Side-stand Removal and Installation B823H19506006 Removal 1) Support the motorcycle with a jack or wooden block. CAUTION • Do not support the motorcycle with the exhaust pipes. • Make sure that the motorcycle is supported securely. 2) Remove the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction (Page 9E-3)”. Installation Install the side-stand as shown in the side-stand construction.
Page 685 Prepared by July, 2007 Part No. 99500-39320-01E Printed in Japan...
Page 686 Printed in Japan...

Suzuki GSX1300BK B-King Service Manual

Section 0 General Information

General Information

Maintenance and Lubrication

Service Data

Section 1 Engine

1-1 Precautions

Engine General Information and Diagnosis

Emission Control Devices

Engine Electrical Devices

Engine Mechanical

Engine Lubrication System

Engine Cooling System

Fuel System

Ignition System

Starting System

Charging System

Exhaust System

Quick Links

Chapters

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Summary of Contents for Suzuki GSX1300BK B-King