Page 1 GSX-R750 99500-37112-03E SUZUKI MOTOR CORPORATION PRINTED IN JAPAN FEBRUARY, 2000...
Page 2: Table Of Contents
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX-R750 and procedures for its inspection/service and overhaul of its main com- ponents. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa- miliarize yourself with the motorcycle and its mainte- nance.
Page 3: How To Use This Manual
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 4 99000-99001-SS8 (99000-99044-10G) Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25030 (For USA) 99000-25010 (For the other countries) Apply SUZUKI MOLY PASTE.
Page 5 ABBREVIATIONS MAY BE USED IN THIS MANUAL ABDC : After Bottom Dead Center : Hydrocarbons : Alternating Current : Air Cleaner, Air Cleaner Box : American Petroleum Institute IAP Sensor : Intake Air Pressure ATDC : After Top Dead Center Sensor (IAPS) ATM Pressure : Atmospheric Pressure IAT Sensor...
Page 6 SAE-TO-FORMER SUZUKI TERM (ONLY FOR U.S.A.) This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM...
Page 7 SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION Idle Speed Control ––– Ignition Control Electronic Spark Advance(ESA) Ignition Control Module ––– Intake Air Temperature Intake Air Temperature(IAT), Air Temperature Malfunction Indicator Lamp LED Lamp Malfunction Indicator Lamp(MIL) Manifold Absolute Pressure...
Page 8: General Information
GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ............. 1- 2 GENERAL PRECAUTIONS .............. 1- 2 SUZUKI GSX-R750Y (2000-MODEL) ..........1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ... 1- 5 FUEL....................1- 5 ENGINE OIL .................. 1- 5 BRAKE FLUID ................
Page 9: Warning/Caution/Note
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 10 GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
Page 11: Suzuki Gsx-R750Y (2000-Model)
1-4 GENERAL INFORMATION SUZUKI GSX-R750Y (2000-MODEL) RIGHT SIDE LEFT SIDE * Difference between photograph and actual motorcycle depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) A is stamped on the right side of the steering head pipe. The engine serial number B is located on the rear side of the crank- case.
Page 12: Fuel, Oil And Engine Coolant Recommendation
Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom- mended. ENGINE OIL (For U.S.A. model) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recom- MULTIGRADE mended viscosity is SAE 10W/40.
Page 13: Engine Coolant
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
Page 14: Information Labels
GENERAL INFORMATION 1-7 INFORMATION LABELS GSX-R750 GSX-R750UD GSX-R750UF 1 Noise label For E-03, 24, 33 2 Information label For E-03, 24, 33 3 Vacuum hose routing label For E-33 4 Fuel caution label For E-02, 24 5 Manual notice label...
Page 15: Specifications
1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 040 mm (80.3 in) Overall width ..............715 mm (28.1 in) Overall height ..............1 135 mm (44.7 in) Wheelbase ..............1 410 mm (55.5 in) Ground clearnce ............130 mm (5.1 in) Seat height ..............
Page 16 GENERAL INFORMATION 1-9 CHASSIS Front suspension ............Inverted telescopic, coil spring, spring pre-load fully adjustable, rebound and compression damping force fully adjustable. Rear suspension ............Link type system, gas/oil damped, coil spring, spring pre-road fully adjustable, rebound and com- pression damping force fully adjustable. Caster ................
Page 17: Country And Area Codes
1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). MODEL CODE COUNTRY or AREA E-02 U.K. E-03 USA (Except for california) E-19 GSX-R750 E-24 Australia E-28 Canada E-33 California (USA) GSX-R750UD E-19 GSX-R750UF E-19...
Page 18: Periodic Maintenance
PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ......... 2- 2 PERIODIC MAINTENANCE CHART ..........2- 2 LUBRICATION POINTS ..............2- 3 MAINTENANCE AND TUNE-UP PROCEDURES......2- 4 AIR CLEANER ................2- 4 SPARK PLUG ................2- 5 VALVE CLEARANCE ..............2- 8 ENGINE OIL AND OIL FILTER .............
Page 19: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below 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 kilometer, miles and months, and are dependant on whichever comes first. IMPORTANT (USA only): The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.
Page 20: Lubrication Points
PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Brake pedal pivot and footrest pivot Clutch lever holder Footrest pivot Side-stand pivot and gearshift and spring hook...
Page 21: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months). •...
Page 22: Spark Plug
PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front and rear seat. ( 6-8) •...
Page 23 PERIODIC MAINTENANCE HEAT RANGE • Check to see the heat range of the plug. If the electrode of the plug is wet appearing or dark color, re- place the plug with hotter type one. If it is white or glazed ap- pearing, replace the plug with colder type one.
Page 24 PERIODIC MAINTENANCE SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION • Install the spark plugs to the cylinder head by finger tight, and then tighten them to the specified torque. ! Spark plug: 11 N . m (1.1 kgf . m, 8.0 Ib-ft) To avoid damaging the cylinder head threads, first finger tighten the spark plug and then tighten it to the proper torque using the spark plug wrench.
Page 25: Valve Clearance
PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (15 000 miles, 24 months). • Remove the right under cowling. ( 6-5) • Remove the front and rear seats. ( 6-8) • Lift and support the fuel tank. ( 4-51) •...
Page 26 PERIODIC MAINTENANCE • Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches A on the left ends of both camshafts (Ex and In) to the positions as shown. Front •...
Page 27 2-10 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. ( 3-17) • Remove the tappet and shim by fingers or magnetic hand. •...
Page 28 PERIODIC MAINTENANCE 2-11 (INTAKE SIDE)
Page 29 2-12 PERIODIC MAINTENANCE (EXHAUST SIDE)
Page 30: Engine Oil And Oil Filter
PERIODIC MAINTENANCE 2-13 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 1 month) and ev- ery 18 000 km (11 000 miles, 18 months) thereafter.
Page 31 Other manufacturer’s oil filters may differ in thread speci- fications (thread diameter and pitch), filtering perfor- mance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automo- bile oil filter on this motorcycle.
Page 32: Fuel Hose
PERIODIC MAINTENANCE 2-15 FUEL HOSE Inspect every 6 000 km (4 000 miles,6 months). Replace every 4 years. Inspect the fuel hose 1 for damage and fuel leakage. If any de- fects are found, the hoses must be replaced. ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter.
Page 33: Throttle Cable Play
2-16 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. Adjust the throttle cable play A as follows. MINOR ADJUSTMENT 1st step: •...
Page 34: Clutch
PERIODIC MAINTENANCE 2-17 MAJOR ADJUSTMENT • Lift and support the fuel tank with its prop stay. ( 4-51) • Loosen the lock nuts 1 of the throttle returning cable 2. • Turn the returning cable adjuster 3 to obtain proper cable play.
Page 35: Cooling System
2-18 PERIODIC MAINTENANCE COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 6 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank.
Page 36 PERIODIC MAINTENANCE 2-19 AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •...
Page 37: Drive Chain
2-20 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed be- low.
Page 38 * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is a RK 525R0Z4 Suzuki rec- ommends to use this standard drive chain as a re- placement.
Page 39: Brake
2-22 PERIODIC MAINTENANCE BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years.
Page 40 PERIODIC MAINTENANCE 2-23 REAR BRAKE • The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ( 6-69) Replace the brake pads as a set, otherwise braking per- formance will be adversely affected.
Page 41 2-24 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
Page 42: Tire
PERIODIC MAINTENANCE 2-25 REAR BRAKE • Bleed air from the rear brake system as the same manner of front brake. NOTE: The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal. TIRES Inspect every 6 000 km (4 000 miles, 6 months).
Page 43: Steering
2-26 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Cold inflation tire pressure , 36 psi) Solo riding: Front: 250 kPa (2.50 kgf/cm...
Page 44: Front Fork
PERIODIC MAINTENANCE 2-27 FRONT FORK Inspect every 12 000 km (7 500 miles, 12 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( 6-17) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 12 months).
Page 45 2-28 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle.:2-29 N .
Page 46 PERIODIC MAINTENANCE 2-29...
Page 47: Compression Pressure Check
2-30 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
Page 48: Oil Pressure Check
PERIODIC MAINTENANCE 2-31 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 200 – 500 kPa (2.0 – 5.0 kgf/cm , 28 – 71 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) If the oil pressure is lower or higher than the specification, the following causes may be considered.
Page 49 ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ..............3- 2 ENGINE REMOVAL AND INSTALLATION ........3- 3 ENGINE REMOVAL ............... 3- 3 ENGINE INSTALLATION .............. 3-11 ENGINE DISASSEMBLY..............3-15 ENGINE COMPONENTS INSPECTION AND SERVICE ....3-29 PAIR VALVE ..................
Page 50 3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION REINST ALLA TION 1 PAIR valve...
Page 51: Engine Removal And Installation
ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure.
Page 52 3-4 ENGINE • Remove the air cleaner box. ( 4-61) • Remove the throttle body and STV actuator. ( 4-61) RADIATOR • Disconnect the reserve tank hose. • Disconnect the radiator inlet hoses.
Page 53 ENGINE 3-5 • Disconnect the cooling fan thermo-switch coupler 1 and cool- ing fan coupler 2. • Remove the radiator mounting bolt. • Remove the radiator. Be careful not to bent the radiator fin. • Remove the front engine cover 1. EXHAUST PIPE AND MUFFLER •...
Page 54 3-6 ENGINE • Remove the radiator mounting bracket 1. ELECTRIC PARTS • Disconnect the oil pressure switch lead wire 1 and remove it from the clamps. • Disconnect the starter motor lead wire 2. • Disconnect the ground lead wire 3. •...
Page 55 ENGINE 3-7 • Disconnect the lead wire couplers from each ignition coil/plug cap and camshaft position sensor. Do not remove the ignition coil/plug cap before discon- necting its lead wire coupler. • Remove the ignition coils/plug caps. * Do not pry up the ignition coil/plug cap with a driver or a bar to avoid its damage.
Page 56 3-8 ENGINE • Remove the speed sensor rotor 1. • Remove the engine sprocket nut 2 and the washer. • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut 3 and the rear torque link nut 4. •...
Page 57 ENGINE 3-9 ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolts 1, 2. • Loosen the engine mounting pinch bolts 3. • Remove the engine mounting bolts 4. • Remove the engine mounting nut 5. •...
Page 58 3-10 ENGINE • Remove the engine mounting nut 1. • Loosen the engine mounting thrust adjuster locknut 2. • Loosen the engine mounting thrust adjuster 3. NOTE: Do not remove the engine mounting bolts at this stage. • Remove the engine mounting bolts and gradually lower the front side of the engine.
Page 59: Engine Installation
ENGINE 3-11 ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: Be careful not to damage the frame and engine when installing the engine. • Before installing the engine, install the spacer 1. •...
Page 60 3-12 ENGINE Left Right LENGTH N . m kgf . m ITEM lb-ft ITEM 39.8 1.77 54.0 Bolt 2.17 16.5 8.46 Spacer 30.5 1.20 32.5 Adjuster 1.57...
Page 61 ! Speed sensor rotor bolt: 20 N . m (2.0 kgf . m, 14.4 lb-ft) • Apply grease to the clutch push rod and install it. W 99000-25030: SUZUKI SUPER GREASE “A” • Align the hole of the clutch release cylinder with the end of the clutch push rod when installing the engine sprocket cover.
Page 62 3-14 ENGINE • Install the radiator mounting bracket 1. • Install the exhaust pipe/muffler. Replace the gaskets with new ones. 23 N . m (2.3 kgf . m, 16.5 lb-ft) 23 N . m (2.3 kgf . m, 16.5 lb-ft) 23 N .
Page 63: Engine Disassembly
ENGINE 3-15 ENGINE DISASSEMBLY ENGINE DISASSEMBLY PROCEDURE FLOW CHART Cylinder head cover Cam chain tensioner adjuster Generator cover Cam shaft (IN. & EX) Starter Idle gear Cylinder head Starter clutch Generator rotor Cam chain guide No.1 and Piston, conrod and Cam chain tensioner upper crankcase (Cylinder) Cam chain and sprocket...
Page 64 3-16 ENGINE ENGINE DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original posi- tions. • Remove the spark plugs. ( 2-5) STARTER MOTOR •...
Page 65 ENGINE 3-17 CAMSHAFTS • Remove the valve timing inspection cap 1. • Turn the crankshaft to bring the line A on the starter clutch to the index mark B of the valve timing inspection hole and also to bring the cams to the position as shown. •...
Page 66 3-18 ENGINE • Remove the intake camshaft 1. • Remove the exhaust camshaft 2. CYLINDER HEAD • Remove the water hose 1. • Remove the thermostat cover 2 and thermostat. THERMOSTAT INSPECTION: 5-9 • Remove the engine coolant temp. gauge 3. ENGINE COOLANT TEMP.
Page 67 ENGINE 3-19 CLUTCH • Remove the clutch cover. • Hold the clutch housing with the special tool. Do not damage the clutch plates by the special tool. [ 09920-53740: Clutch sleeve hub holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. •...
Page 68 3-20 ENGINE • Unlock the clutch sleeve hub nut. • Hold the clutch sleeve hub with the special tool. [ 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the wave washer 1 washer 2, clutch sleeve hub 3 and washer 4.
Page 69 ENGINE 3-21 OIL PUMP • Remove the circlip 1. • Remove the oil pump driven gear 2. NOTE: Do not drop the circlip 1 , the pin 3 and the washer 4 into the crankcase. • Remove the pin 3 and the washer 4. •...
Page 70 3-22 ENGINE STARTER IDLE GEAR • Remove the starter idle gear cover. • Remove the shaft 1, wave washer 2 washer 3 starter idle gear No.1 4, bearing 5 and washer 6. • Remove the starter clutch cover. • Remove the wave washer 1, the starter idle gear No.2 2 and its shaft 3.
Page 71 ENGINE 3-23 STARTER CLUTCH • Hold the starter clutch with the special tool. [ 09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. • Remove the starter clutch assembly. CAM CHAIN, CAM CHAIN TENSIONER, CAM CHAIN GUIDE •...
Page 72 3-24 ENGINE GENERATOR COVER • Remove the generator cover. GENERATOR ROTOR • Hold the generator rotor with the special tool. [ 09930-44530: Rotor holder • Loosen the generator rotor bolt. NOTE: Install the bolt (M 12, length: 28 – 38 mm) to the left end of crankshaft as shown in illustration.
Page 73 ENGINE 3-25 GEAR POSITION SWITCH • Remove the gear position switch. • Remove the switch contacts and springs. BREATHER COVER • Remove the breather cover. OIL FILTER • Remove the oil filter with the special tool. ( 2-14) [ 09915-40610: Oil filter wrench OIL COOLER •...
Page 74 3-26 ENGINE OIL PAN • Remove the cowling brackets 1. • Remove the oil pan. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL PRESSURE SWITCH • Remove the oil pressure switch 2. OIL STRAINER • Remove the oil strainer 3 and O-ring. LOWER CRANK CASE •...
Page 75 ENGINE 3-27 MIDDLE CRANKCASE • Remove the crankcase bolts (6 mm). NOTE: Loosen the crankcase bolts diagonally and the smaller sizes first. • Remove the crankcase bolts (8 mm). CRANKSHAFT • Remove the O-ring 1. • Loosen the bearing cap bolts by using 10 mm, 12 point socket wrench, and tap the bearing cap bolt lightly with plastic ham- mer to remove the bearing cap.
Page 76 3-28 ENGINE PISTON AND CONROD • Push the conrod to upward and remove the piston and conrod from the upper crankcase. Be careful not to damage the cylinder wall by the conrod. • Remove the piston pin circlip. • Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the head of the piston.
Page 77: Engine Components Inspection And Service
ENGINE 3-29 ENGINE COMPONENTS INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. PAIR VALVE PAIR REED VALVE •...
Page 78: Cylinder Head Cover
3-30 ENGINE CYLINDER HEAD COVER CAM POSITION SENSOR • Install the oil seal 1 and cam position sensor 2. NOTE: When installing, clean the cam position sensor’s face. ! Cam position sensor bolt: 8 N . m (0.8 kgf . m, 5.8 lb-ft) CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the...
Page 79 ENGINE 3-31 CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge to read the clearance at the widest por- tion, which is specified as follows: Camshaft journal oil clearance: Service Limit: (IN &...
Page 80: Camshaft Runout
3-32 ENGINE CAMSHAFT RUNOUT • Measure the runout using the dial gauge. • Replace the camshaft if the runout exceeds the limit. [ 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) Camshaft runout: Service Limit (IN & EX): 0.10 mm (0.004 in) CAM SPROCKET •...
Page 81: Cylinder Head And Valve
ENGINE 3-33 CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY • Remove the tappets 1 and shims 2 by fingers or magnetic hand. Identify the position of each removed part. • Using special tools, compress the valve springs and remove the two cotter halves 3 from valve stem.
Page 82 3-34 ENGINE • Remove the oil seal 1 and the spring seat 2. Do not reuse the removed oil seal. • Remove the other valves in the same manner as described previously. CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. •...
Page 83 ENGINE 3-35 VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.
Page 84 3-36 ENGINE VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out to- ward the intake or exhaust camshaft side. [ 09916-53310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No.
Page 85 ENGINE 3-37 VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with Prussian Blue and set the valve in place.
Page 86 3-38 ENGINE INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. • If the valve seat is pitted or burned, use the 45° cutter to condi- tion the seat some more.
Page 87 ENGINE 3-39 FINAL SEAT CUT Contact area too low and too • If the contact area W is too low or too narrow, use the 45° cutter narrow on face of valve to raise and widen the contact area. NOTE: After cutting the 15°, 30°...
Page 88 3-40 ENGINE VALVE STEM END CONDITION • Check the valve stem end face for pitting and wear. VALVE SPRING The force of the coil springs keeps the valve seat tight. Weak- ened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism.
Page 89 ENGINE 3-41 VALVE AND VALVE SPRING REASSEMBLY • Install the valve spring seats. • Apply molybdenum oil solution to each oil seal, and press-fit them into position with the valve guide installer. [ 09916-44310: Valve guide remover/installer O MOLYBDENUM OIL SOLUTION Do not reuse the removed oil seals.
Page 90 I 99000-32050: THREAD LOCK “1342” WATER BYPASS UNION • Apply SUZUKI BOND “1207B” to the thread part of the water bypass union and tighten it to the specified torque. C 99104-31140: SUZUKI BOND “1207B” ! Water bypass union: 14 N . m (1.4 kgf . m, 10.0 lb-ft)
Page 91: Clutch
ENGINE 3-43 CLUTCH CLUTCH DRIVE PLATES INSPECTION NOTE: * Wipe off engine oil from the clutch drive plates with a clean rag. * Clutch drive plate No.1: Purple paint * Clutch drive plate No.2: Green paint • Measure the thickness of drive plates with a vernier calipers. •...
Page 92: Oil Pump
3-44 ENGINE OIL PUMP INSPECTION • Rotate the oil pump by hand and check that it moves smoothly. • If it does not move smoothly, replace the oil pump assembly. * Do not attempt to disassemble the oil pump assembly. * The oil pump is available only as an assembly.
Page 93: Gearshift System
ENGINE 3-45 GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. 1 Washer 5 Plate return spring 2 Circlip 6 Washer 3 Gearshift shaft return spring 7 Circlip 4 Gearshift cam drive plate [ 09900-06107: Snap ring pliers GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION •...
Page 94: Oil Pressure Regulator
3-46 ENGINE OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regula- tor with a new one. OIL STRAINER •...
Page 95: Transmission
ENGINE 3-47 TRANSMISSION • Disassemble the countershaft and drive shaft. Pay attention to the following point. [ 09900-06104: Snap ring pliers • Remove the 6th drive gear circlip from its groove and slide it towards the 3rd/4th drive gear. • Slide the 6th 1 and 2nd 2 drive gears toward the 3rd/4th drive gears, then remove the 2nd drive gear circlip 3.
Page 96 * Before installing the oil seal, apply grease to oil seal. W 99000-25030: SUZUKI SUPER GREASE “A” * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
Page 97 ENGINE 3-49 TRANSMISSION PARTS LOCATION...
Page 98: Cylinder
3-50 ENGINE CYLINDER CRANKCASE SERVICING: 3-54 CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. • If the largest reading at any position of the straightedge ex- ceeds the limit, replace the cylinder.
Page 99: Piston And Piston Ring
ENGINE 3-51 PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) from the piston skirt end. • If the measurement is less than the limit, replace the piston. Piston diameter: Service Limit: 71.880 mm (2.8230 in) at 15 mm (0.6 in) from the skirt end [ 09900-20204: Micrometer (75 –...
Page 100: Piston Ring Groove Width
3-52 ENGINE PISTON RING TO GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston rings. [ 09900-20803: Thickness gauge 09900-20205: Micrometer (0 –...
Page 101 ENGINE 3-53 PISTON RING REASSEMBLY • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. NOTE: Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way.
Page 102: Crankcase
3-54 ENGINE CRANKCASE LOWER CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer 1 and gearshift fork retainer 2 from the lower crankcase. • Remove the gearshift fork shafts and gearshift forks from the lower crankcase. •...
Page 103 ENGINE 3-55 • Inspect the gearshift cam bearing for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Inspect the gearshift cam bearing 1, gearshift fork bearing 2 and gearshift shaft bearing 3 for abnormal noise and smooth rotation while they are in the crankcase.
Page 104 3-56 ENGINE Installation • Install the bearings using the special tool. [ 09913-70210: Bearing installer set NOTE: The stamped mark side of the gearshift shaft bearing faces outside. • Install the oil seal. • Install the gearshift cam with the bearing. NOTE: The stamped mark side of the gearshift cam bearing faces out- side.
Page 105 ENGINE 3-57 • Install the gearshift forks and their shafts as shown. 1 For 3rd/4th drive gears 2 For 6th driven gear 3 For 5th driven gear • Apply a small quantity of THREAD LOCK “1342” to the bearing retainer screws and the shift fork shaft retainer bolt. •...
Page 106 3-58 ENGINE OIL JET Removal • Remove the piston cooling oil jets 1 from the upper crank- case. • Remove the oil jet (for transmission) from the lower crankcase. Inspection and cleaning • Check the oil jets for clogging. • If they are clogged, clean their oil passage with a proper wire and compressed air.
Page 107 ENGINE 3-59 Installation • Fit the new O-rings 1 to each piston cooling oil jet as shown and apply engine oil to them. Use the new O-rings to prevent oil pressure down. NOTE: Be sure to face the oil holes A on each piston cooling oil jet to the top when installing them.
Page 108: Crankshaft And Conrod
3-60 ENGINE CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with “V” blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. •...
Page 109 ENGINE 3-61 CONROD-CRANK PIN BEARING INSPECTION • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. CONROD-CRANK PIN BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown.
Page 110 3-62 ENGINE • Check the corresponding conrod I.D. code number (“1” or “2”) • Check the corresponding crank pin O.D. code number (“1” , “2” or “3”) B. Bearing selection table Conrod I.D. Code I.D. specification 36.000 – 36.008 mm (1.4173 –...
Page 111: Crankshaft Journal Bearing
ENGINE 3-63 CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and lower crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoid- ing the oil hole, as shown. [ 09900-22301: Plastigauge Never rotate the crankshaft when a piece of plastigauge is installed.
Page 112 3-64 ENGINE • Check the corresponding crankcase journal I.D. code number A, “A” or “B” which are stamped on the rear of upper crank- case. • Check the corresponding crankshaft journal O.D. code number B, “A”, “B” or “C” which are stamped on the crankshaft. Bearing selection table Crankcase I.D.
Page 113: Crankshaft Thrust Bearing
ENGINE 3-65 CRANKSHAFT THRUST BEARING • With the crankshaft right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. R: Right-side thrust bearing L: Left-side thrust bearing NOTE: Pull the crankshaft to the left-side, so that there is no clearance on the right-side thrust bearing.
Page 114 3-66 ENGINE Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.560 – 2.585 mm White 2.475 – 2.500 mm 0.060 – 0.110 mm (0.1008 – 0.1018 in) (12228-17E00-0F0) (0.0974 – 0.0984 in) (0.0024 –...
Page 115: Engine Reassembly
ENGINE 3-67 ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reassem- bling. •...
Page 116 3-68 ENGINE der walls. • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent A of the piston head must be faced to each exhaust side. Be carefull not to damage the cylinder wall by the conrod. •...
Page 117 ENGINE 3-69 CRANKSHAFT • Position the No.2 and No.3 conrod big ends toward same side, and position the No.1 and No.4 conrod big ends toward oppo- site side of No.2 and No.3. • Set the crankshaft to the conrods and upper crankcase. •...
Page 118 NOTE: Right-thrust bearing has green painting. CRANKCASE • Clean the mating surfaces of the crankcases. • Install the dowel pins 1 and O-ring 2 to the upper crankcase. • Apply SUZUKI BOND to the mating surface of the middle crank-...
Page 119 ENGINE 3-71 case. C 99104-31140: SUZUKI BOND “1207B” (For USA) D 99000-31110: SUZUKI BOND “1215” (For the others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes.
Page 120 3-72 ENGINE • Tighten the other crankcase bolts a little at a time to equalize the pressure. ! Crankcase bolt: 6 N . m (0.6 kgf . m, 4.5 lb-ft) (M6) initial: Final: 11 N . m (1.1 kgf . m, 8.0 lb-ft) NOTE: Fit the clamp to the crankcase bolt A .
Page 121 ENGINE 3-73 TRANSMISSION • Install the bearing pins 1 and the C-ring 2 on the upper crank- case. • Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove on the bearing and the bearing pin with the indent on the bearing.
Page 122 3-74 ENGINE • Apply SUZUKI BOND to the mating surface of the lower crank- case. C 99104-31140: SUZUKI BOND “1207B” (For USA) D 99000-31110: SUZUKI BOND “1215” (For the others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
Page 123 ENGINE 3-75 • Tighten the crankcase bolts a little at a time to equalize the pres- sure. ! Crankcase bolt: (M6) initial: 6 N . m (0.6 kgf . m, 4.5 lb-ft) Final : 11 N . m (1.1 kgf . m, 8.0 lb-ft) (M8) initial: 15 N .
Page 124 • Install the O-ring. NOTE: Apply grease to the O-ring. W 99000-25030: SUZUKI SUPER GREASE “A” Use the new O-ring to prevent oil leakage. • Install the oil strainer as shown. ! Oil strainer bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) OIL PRESSURE REGULATOR •...
Page 125 ENGINE 3-77 OIL PRESSURE SWITCH • Apply SUZUKI BOND “1207B” to the thread part of the oil pres- sure switch 1 and tighten it to the specified torque. C 99104-31140: SUZUKI BOND “1207B” ! Oil pressure switch: 14 N . m (1.4 kgf . m, 10.0 lb-ft) NOTE: Be careful not to apply SUZUKI BOND “1207B”...
Page 126 • Install the gear position switch contacts 1 and the springs 2. • Apply the grease to the O-ring. W 99000-25030: SUZUKI SUPER GREASE “A” • Apply the THREAD LOCK to the gear position switch bolt, in- stall the gear position switch as shown.
Page 127 • Apply grease to the O-ring. Use the new O-ring to prevent oil leakage. W 99000-25030: SUZUKI SUPER GREASE “A” • Tighten the water pump mounting bolts to the specified torque. ! Water pump mounting bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft)
Page 128 [ 09930-44530: Rotor holder ! Generator rotor bolt: 100 N . m (10.0 kgf . m, 72.3 lb-ft) GENERATOR COVER • Apply SUZUKI BOND “1207B” lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.
Page 129 ENGINE 3-81 • Install the CKP sensor. • Apply SUZUKI BOND “1207B” light to the groove of the signal generator lead wire gromet. C 99104-31140: SUZUKI BOND “1207B” CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft.
Page 130 • Install the starter idle gear No.2 1, its shaft 2 and the wave washer 3. • Apply SUZUKI BOND “1207B” lightly to the mating surfaces A at the parting line between the upper and lower crankcases and surface B as shown.
Page 131 ENGINE 3-83 • Install the new gasket 1 and the dowel pins. Use a new gasket to prevent oil leakage. • Install the starter clutch cover and tighten its bolt as shown. NOTE: * Fit the wire clamp to the starter clutch cover bolt A as shown. * Fit the new gasket washer to the starter clutch cover bolt B as shown.
Page 132 3-84 ENGINE GEARSHIFT SYSTEM • Install the gearshift cam stopper 1, its bolt 2, the washer 3 and the return spring 4. NOTE: Apply a small quantity of THREAD LOCK “1342” to the gearshift cam stopper bolt 2 and tighten it to the specified torque. I 99000-32050: THREAD LOCK “1342”...
Page 133 OIL PUMP • Install the O-ring to the oil pump and apply grease to it. Use the new O-ring to prevent oil leakage. W 99000-25030: SUZUKI SUPER GREASE “A” NOTE: Set the oil pump shaft end to the water pump shaft.
Page 134 3-86 ENGINE CLUTCH • Install the thrust washer onto the countershaft. NOTE: The chamfer side A of the thrust washer faces crankcase side. • Install the oil pump drive gear 1 to the primary driven gear assembly. NOTE: Rotate the crankshaft so as not to contact the primary driven gear and crankshaft balance weight.
Page 135 ENGINE 3-87 • Install the clutch sleeve hub 2 onto the countershaft. • Install the washer 3 and spring washer 4. NOTE: The convex side of the washer 4 faces outside. • Install the clutch sleeve hub nut. • Hold the clutch sleeve hub using the special tool. [ 09920-53740: Clutch sleeve hub holder •...
Page 136 3-88 ENGINE the clutch sleeve hub in the prescribed order. NOTE: Insert the outermost No.1 drive plate claws A to the other slits B of clutch housing as shown. DRIVE PLATE: Direction of outside A No.1 Drive Plate (Thickness): 3.0 mm (0.12 in) ... 8 pcs [Purple paint] B No.2 Drive Plate (Thickness): 3.0 mm (0.12 in) ...
Page 137 ! Clutch spring set bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) NOTE: Tighten the clutch spring set bolts diagonally. CLUTCH COVER • Apply SUZUKI BOND “1207B” lightly to the mating surfaces at the parting line between the upper, middle and lower crankcases as shown. C 99104-31140: SUZUKI BOND “1207B”...
Page 138 3-90 ENGINE cylinder. Use the new gasket to prevent gas leakage. • Place the cylinder head on the cylinder. • Install the cylinder head side bolt 2 and gasket 3 and tighten it to the specified torque. ! Cylinder head side bolt: 14 N . m (1.4 kgf . m, 10.0 lb-ft) NOTE: * The metal side of the gasket A faces out.
Page 139 ENGINE 3-91 • Fit the gasket 1 and tighten the water temp. gauge. ! Water temp. gauge: 18 N . m (1.8 kgf . m, 13.0 lb-ft) • Install the thermostat. (5-10) • Install the thermostat cover. ! Thermostat cover bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) NOTE: Fit the clamp to the bolt A .
Page 140 3-92 ENGINE CAMSHAFT • Turn the crankshaft clockwise with the box wrench and align the line A on the starter clutch with the index mark B of the valve timing inspection hole while keeping the cam chain pulled up- ward. Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.
Page 141 ENGINE 3-93 • Engage the 14 roller pin C on the cam chain with the arrow marked “3” on the intake sprocket. • Bind the cam chain and the sprocket with a proper wire clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders.
Page 142 3-94 ENGINE • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust and cam chain guide. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. NOTE: * Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.
Page 143 ENGINE 3-95 Cam chain tension adjuster • Retract the push rod by pushing the stopper. • Install the ball 1 to the cam chain tension adjuster. • Install the new gasket 2. Use the new gasket to prevent oil leakage. •...
Page 144 3-96 ENGINE...
Page 145 • Install the dowel pins. • Install the O-rings. • Install the new gaskets to the cylinder head cover. • Apply SUZUKI BOND “1207B” to the cam end caps of the gas- kets as shown. C 99104-31140: SUZUKI BOND “1207B”...
Page 146 ! PAIR reed valve cover bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) STARTER MOTOR • Apply the grease to the O-ring. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the starter motor. ! Starter motor mounting bolt: 10 N . m (1.0 kgf . m, 7 lb-ft)
Page 147: Fi System And Intake Air
FI SYSTEM AND INTAKE AIR SYSTEM CONTENTS PRECAUTIONS IN SERVICING ............4- 2 FI SYSTEM TECHNICAL FEATURES ..........4- 8 INJECTION TIME ................4- 8 COMPENSATION OF INJECTION TIME ........4- 9 INJECTION STOP CONTROL ............4- 9 FUEL DELIVERY SYSTEM ............4-10 FUEL PUMP ..................
Page 148 FI SYSTEM AND INTAKE AIR SYSTEM 4-1 FUEL SYSTEM ................. 4-51 FUEL TANK LIFT-UP ..............4-51 FUEL TANK REMOVAL ..............4-51 FUEL TANK INSTALLATION ............4-51 FUEL PRESSURE INSPECTION ..........4-52 FUEL PUMP INSPECTION ............4-53 FUEL PUMP RELAY INSPECTION ..........4-55 FUEL PUMP AND FUEL FILTER REMOVAL ......
Page 149: Precautions In Servicing
4-2 FI SYSTEM AND INTAKE AIR SYSTEM PRECAUTIONS IN SERVICING When handling the FI component parts or servicing the FI sys- tem, observe the following points for the safety of the system. Click CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.
Page 150 FI SYSTEM AND INTAKE AIR SYSTEM 4-3 FUSE • When a fuse blows, always investigate the cause, correct it and then replace the fuse. • Do not use a fuse of a different capacity. • Do not use wire or any other substitute for the fuse. ECM/VARIOUS SENSORS •...
Page 151: Electrical Circuit Inspection Procedure
4-4 FI SYSTEM AND INTAKE AIR SYSTEM • Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electro- motive force will be applied to the ECM which may result in serious damage.
Page 152 FI SYSTEM AND INTAKE AIR SYSTEM 4-5 • Disconnect the negative cable from the battery. • Check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock if equipped. Sensor Check for loose connection •...
Page 153 4-6 FI SYSTEM AND INTAKE AIR SYSTEM VOLTAGE CHECK If voltage is supplied to the circuit being checked, voltage check can be used as circuit check. • With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each ter- minal and body ground.
Page 154: Using Testers
If continuity is indicated, the circuit is shorted to the ground between terminals A and B. USING TESTERS • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range.
Page 155: Fi System Technical Features
4-8 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM TECHNICAL FEATURES 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 which are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 156: Compensation Of Injection Time
FI SYSTEM AND INTAKE AIR SYSTEM 4-9 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR SIG- When atmospheric pressure is low, the sensor sends the signal to the ECM and reduce the injection time (volume).
Page 157: Fuel Delivery System
4-10 FI SYSTEM AND INTAKE AIR SYSTEM FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel to flow into the injector installed in the fuel delivery pipe.
Page 158: Fuel Pump
FI SYSTEM AND INTAKE AIR SYSTEM 4-11 FUEL PUMP The electric fuel pump is located under the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM.
Page 159: Fuel Pressure Regulator
4-12 FI SYSTEM AND INTAKE AIR SYSTEM FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm , 43 psi) applied to the injector at all times. When the fuel pressure rises more than 300 kPa (3.0 kgf/cm , 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank.
Page 160: Fuel Pump Control System
FI SYSTEM AND INTAKE AIR SYSTEM 4-13 FUEL PUMP CONTROL SYSTEM When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the side-stand relay and the fuel pump relay causing the motor to turn. Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has been turned on.
Page 161: Ecm (Fi Control Unit)
4-14 FI SYSTEM AND INTAKE AIR SYSTEM ECM (FI CONTROL UNIT) The ECM is located under the seat. The ECM consists of CPU (Central Processing Unit), memory (ROM) and I/O (Input/Output) sections. The signal from each sensor is sent to the input section and then sent to CPU. On the basis of signal information received, CPU calculates the volume of fuel necessary for injection using maps programmed for varying engine conditions.
Page 162: Injection Timing
FI SYSTEM AND INTAKE AIR SYSTEM 4-15 INJECTION TIMING The system employs a sequential, four-cylinder independent injection type, using the crankshaft position sensor (signal generator) to determine the piston position (injection timing and ignition timing) and the cam- shaft position sensor to identify the cylinder during operation, and these information are sent to the ECM. This makes it possible to inject the optimum volume of fuel in the best timing for the engine operating conditions.
Page 163: Sensors
4-16 FI SYSTEM AND INTAKE AIR SYSTEM SENSORS INTAKE AIR PRESSURE SENSOR (IAP SENSOR) The intake air pressure sensor is located at the rear side of the air cleaner box and its vacuum hose is connected to the throttle body. The sensor detects the intake air pressure, which is then con- verted into voltage signal and sent to the ECM.
Page 164 FI SYSTEM AND INTAKE AIR SYSTEM 4-17 CRANKSHAFT POSITION SENSOR (CKP SENSOR) The signal rotor is mounted on the right end of the crankshaft, and the crankshaft position sensor (Pick-up coil) is installed on the right side of the middle crankcase. The sensor generates the pick-up signal to be supplied to the ECM.
Page 165 4-18 FI SYSTEM AND INTAKE AIR SYSTEM ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) The engine coolant temperature sensor is installed at the rear side of the cylinder head. The sensor detects the engine coolant temperature in thermistor resistance value, which is then converted to voltage signal and sent to the ECM.
Page 166 FI SYSTEM AND INTAKE AIR SYSTEM 4-19 TIP OVER SENSOR (TO SENSOR) The tip over sensor is located in ahead of the rear fender. The sensor detects the leaning of the motorcycle. When it leans more than 43°, the mechanical switch turns ON and a signal is sent to the ECM.
Page 167: Intake Air System
4-20 FI SYSTEM AND INTAKE AIR SYSTEM INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM The secondary throttle control system (STC system) consists of the secondary throttle valve (ST valve), secondary throttle valve actuator (STV actuator) and ST valve control cables. ST valve is installed in each throttle body.
Page 168: Operation
FI SYSTEM AND INTAKE AIR SYSTEM 4-21 OPERATION The secondary throttle control system (STC system) operates on the signal supplied from the ECM. The open/close operation of the secondary throttle valve (ST valve) is performed by the secondary throttle valve actuator (STV actuator) which is controlled by the ECM to change the current direction into the motor of the STV actuator.
Page 169: Fi System Parts Location
4-22 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM PARTS LOCATION...
Page 170 FI SYSTEM AND INTAKE AIR SYSTEM 4-23...
Page 171: Fi System Diagram
4-24 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM DIAGRAM BATTERY RELAY SWITCH FI #1 FI #2 FI #3 FI #4 IATS STVA CMPS ECTS STARTER MOTOR IAPS SPEED SENSOR CKPS...
Page 172: Fi System Wiring Diagram
FI SYSTEM AND INTAKE AIR SYSTEM 4-25 FI SYSTEM WIRING DIAGRAM...
Page 173: Self-Diagnosis Function
4-26 FI SYSTEM AND INTAKE AIR SYSTEM SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.
Page 174: Dealer Mode
FI SYSTEM AND INTAKE AIR SYSTEM 4-27 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices.
Page 175 4-28 FI SYSTEM AND INTAKE AIR SYSTEM CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMP sensor) Crankshaft position sensor (CKP sensor) Pick-up coil signal, signal generator Intake air pressure sensor (IAP sensor) Throttle position sensor (TP sensor) Engine coolant temp.
Page 176: Fail-Safe Function
FI SYSTEM AND INTAKE AIR SYSTEM 4-29 FAIL-SAFE FUNCTION 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 Camshaft position When camshaft position...
Page 177: Fi System Troubleshooting
4-30 FI SYSTEM AND INTAKE AIR SYSTEM FI SYSTEM TROUBLESHOOTING 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 will facilitate collecting information to the point required for proper analysis and diagnosis.
Page 178: Self-Diagnostic Procedures
FI SYSTEM AND INTAKE AIR SYSTEM 4-31 SELF-DIAGNOSTIC PROCEDURES • Don’t disconnect couplers from ECM, battery cable from bat- tery, ECM ground wire harness from engine or main fuse be- fore confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized information in ECM memory.
Page 179: Malfunction Code And Defective Condition
4-32 FI SYSTEM AND INTAKE AIR SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 4 sec. after re- sensor ceiving the starter signal.
Page 180 FI SYSTEM AND INTAKE AIR SYSTEM 4-33 Secondary throttle STVA position sensor produces following voltage. valve actuator (0.1 sensor voltage < 4.9) Without the above value, c28 is indicated. STVA motor can not move. STV actuator, STV actuator adjustment, lead wire/coupler. Gear position signal voltage should be higher than the follow- Gear position signal ing for more than 3 seconds.
Page 181: C11" Cmp Sensor Circuit Malfunction
4-34 FI SYSTEM AND INTAKE AIR SYSTEM “C11” CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CMP sensor signal for 4 seconds at engine • Metal particles or foreign material being cranking. attached on the CMP sensor and rotor tip. •...
Page 182: C12" Ckp Sensor Circuit Malfunction
FI SYSTEM AND INTAKE AIR SYSTEM 4-35 “C12” CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for 4 seconds at engine • Metal particles or foreign material being cranking. attached on the CKP sensor and rotor tips. •...
Page 183: C13" Iap Sensor Circuit Malfunction
4-36 FI SYSTEM AND INTAKE AIR SYSTEM “C13” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. • Clogged vacuum passage between throttle High pressure and high voltage. body and IAP sensor. 0.5 V Sensor voltage < 4.85 V •...
Page 184 FI SYSTEM AND INTAKE AIR SYSTEM 4-37 Remove the IAP sensor. Ground Connect the vacuum pump gauge to the vacuum port of Vout the IAP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect - terminal to the ground terminal and + terminal to the Vcc terminal.
Page 185: C14" Tp Sensor Circuit Malfunction
4-38 FI SYSTEM AND INTAKE AIR SYSTEM “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. • TP sensor maladjusted. Difference between actual throttle opening and • TP sensor circuit open or short. opening calculated by ECM in larger than specified • TP sensor malfunction. value.
Page 186 FI SYSTEM AND INTAKE AIR SYSTEM 4-39 Connect the TP sensor coupler. Insert the copper wires to the lead wire coupler. Turn the ignition switch ON. Measure the TP sensor output voltage at the coupler (be- tween Yellow and Black wires) by turning the throttle grip. Yellow Yellow TP sensor output voltage...
Page 187: C15" Ect Sensor Circuit Malfunction
4-40 FI SYSTEM AND INTAKE AIR SYSTEM “C15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High engine coolant temp. (Low voltage – Low • B/Bl circuit shorted to ground. resistance) • B/Br circuit open. Low engine coolant temp. (High voltage – High •...
Page 188: C21" Iat Sensor Circuit Malfunction
FI SYSTEM AND INTAKE AIR SYSTEM 4-41 “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High intake air temp. (Low voltage – Low • Dg circuit shorted to ground. resistance) • B/Br circuit open. Low intake air temp. (High voltage – High •...
Page 189: C22" Ap Sensor Circuit Malfunction
4-42 FI SYSTEM AND INTAKE AIR SYSTEM “C22” AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Low pressure and low voltage. • Clogged air passage with dust. High pressure and high voltage. • Red wire circuit open or shorted to ground. 0.5 V Sensor Voltage <...
Page 190 FI SYSTEM AND INTAKE AIR SYSTEM 4-43 Remove the AP sensor. Connect the vacuum pump gauge to the air passage port Vout Ground of the AP sensor. Arrange 3 new 1.5 V batteries in series (check that total voltage is 4.5 – 5.0 V) and connect - terminal to the ground terminal and + terminal to the Vcc terminal.
Page 191: C23" To Sensor Circuit Malfunction
4-44 FI SYSTEM AND INTAKE AIR SYSTEM “C23” TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No TO sensor signal for more than 2 seconds, • TO sensor circuit open or short. after ignition switch turns ON. • TO sensor malfunction. Sensor voltage high.
Page 192: C24", "C25", "C26" Or "C27" Ignition System Malfunction
FI SYSTEM AND INTAKE AIR SYSTEM 4-45 “C24”, “C25”, “C26” or “C27” IGNITION SYSTEM MALFUNCTION *Refer to the IGNITION SYSTEM for details. (7-20) “C28” STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the STV •...
Page 193 4-46 FI SYSTEM AND INTAKE AIR SYSTEM Turn the ignition switch OFF. Check the continuity between Yellow wire and ground. Position sensor continuity: ∞Ω ∞Ω ∞Ω ∞Ω ∞Ω (Infinity) If OK, then measure the position sensor resistance. Yellow Yellow Connect the position sensor coupler 1.
Page 194 FI SYSTEM AND INTAKE AIR SYSTEM 4-47 If the position sensor output voltage is less than 0.2 V at fully close position, adjust the output voltage to specified by turning out the No.2 cable adjuster 1. Adjusting the cable with the ST valve fully opened or fully closed can damage the STV actuator.
Page 195: C31" Gear Position Switch Circuit Malfunction
4-48 FI SYSTEM AND INTAKE AIR SYSTEM “C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short. Switch voltage low. • Gear Position switch malfunction. Sensor Voltage > 0.6 V •...
Page 196: C32", "C33", "C34" Or "C35" Fuel Injection Malfunction
FI SYSTEM AND INTAKE AIR SYSTEM 4-49 “C32”, “C33”, “C34” or “C35” FUEL INJECTION MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No injector current. • Injector circuit open or short. • Injector malfunction. • ECM malfunction. INSPECTION • Lift and support the fuel tank with its prop stay. ( 4-51) Turn the ignition switch OFF.
Page 197: C41" Fp Relay Circuit Malfunction
4-50 FI SYSTEM AND INTAKE AIR SYSTEM “C41” FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No signal from fuel pump relay. • Fuel pump relay circuit open or short. • Fuel pump relay malfunction. • ECM malfunction. INSPECTION • Remove the front and rear seats. •...
Page 198: Fuel System
FI SYSTEM AND INTAKE AIR SYSTEM 4-51 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the front and rear seats. • Remove the fuel tank mounting bolts. • Lift and support the fuel tank with the fuel tank prop stay 1. FUEL TANK REMOVAL •...
Page 199: Fuel Pressure Inspection
4-52 FI SYSTEM AND INTAKE AIR SYSTEM FUEL PRESSURE INSPECTION • Lift and support the fuel tank with its prop stay. (4-51) • Place a rag under the fuel pressure check bolt 1 and slowly loosen it and catch the remaining fuel using a suitable con- tainer.
Page 200: Fuel Pump Inspection
FI SYSTEM AND INTAKE AIR SYSTEM 4-53 FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor.
Page 201 4-54 FI SYSTEM AND INTAKE AIR SYSTEM • Pull out the power source lead wire 1 (Yellow with red tracer). ECM couplers • Place the measuring cylinder and insert the fuel hose end into the measuring cylinder. • Apply 12 volts to the fuel pump for 30 seconds and measure the amount of fuel discharged.
Page 202: Fuel Pump Relay Inspection
FI SYSTEM AND INTAKE AIR SYSTEM 4-55 FUEL PUMP RELAY INSPECTION Fuel pump relay is located in ahead of the rear fender. • Remove the front and rear seats. • Lift and support the fuel tank with its prop stay. (4-51) •...
Page 203 4-56 FI SYSTEM AND INTAKE AIR SYSTEM REMOVAL • Remove the fuel tank. (4-51) • Remove the fuel pump assembly by removing its mounting bolts diagonally. " Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the nuts. •...
Page 204: Fuel Filter Inspection And Cleaning
FI SYSTEM AND INTAKE AIR SYSTEM 4-57 • Remove the fuel filter. • Remove the fuel pressure regulator holder 1 and the fuel pres- sure regulator 2. FUEL FILTER INSPECTION AND CLEANING If the fuel filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.
Page 205 4-58 FI SYSTEM AND INTAKE AIR SYSTEM • Pass through the wires behind the thermistors. Thermistor f Thermistor for mistor for high level high level Thermistor f Thermistor for mistor for low le low level w level • Be sure to connect the wires to the proper terminals. A ..
Page 206 FI SYSTEM AND INTAKE AIR SYSTEM 4-59 • Install the O-ring and apply grease to it. W 99000-25030: SUZUKI SUPER GREASE “A” " The O-ring must be replaced with a new one to prevent fuel leakage. • When installing the fuel pump assembly, lightly tighten all the...
Page 207: Throttle Body And Stv Actuator
4-60 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY AND STV ACTUATOR CONSTRUCTION 1 TP sensor 2 Throttle stop screw 3 Fast idle adjusting screw 4 Fuel delivery pipe 5 O-ring 6 Dust seal 7 Ignitor 8 Cusion seal 9 Vacuum hose 0 STV actuator bracket A STV actuator N .
Page 208: Throttle Body And Stv Actuator Removal
FI SYSTEM AND INTAKE AIR SYSTEM 4-61 THROTTLE BODY AND STV ACTUATOR REMOVAL ADJUSTMENT POSITION SETTING PROCEDURE • Turn the ignition switch OFF. • Remove the rear seat. • Connect the special tool to the dealer mode coupler. • After turning the special tool’s switch ON, turn the ignition switch [ 09930-82710: Mode select switch •...
Page 209 4-62 FI SYSTEM AND INTAKE AIR SYSTEM • Loosen the throttle body clamp screws. • Remove the air cleaner box mounting bolt. • Remove the air cleaner box. THROTTLE BODY • Disconnect the throttle cables from their drum. • Disconnect the fast idle cable from its cam. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close.
Page 210 FI SYSTEM AND INTAKE AIR SYSTEM 4-63 • Disconnect the vacuum hose 1 from the No.4 throttle body. • Disconnect the fuel injector lead wire coupler 2. • Remove the throttle stop screw 3 from the cable guide. • Loosen the throttle body clamp screws at the intake pipe side. •...
Page 211 4-64 FI SYSTEM AND INTAKE AIR SYSTEM SECONDARY THROTTLE VALVE ACTUATOR • Disconnect the STV actuator lead wire couplers 1. • Loosen the lock nuts 2. • Hold the actuator pulley 3 with an adjustable wrench, and loosen the pulley mounting bolt 4. When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or STV actuator may get damaged.
Page 212 FI SYSTEM AND INTAKE AIR SYSTEM 4-65 • Remove the STV actuator. • Remove the actuator bracket 1. A little portion of the ST valve is visible from the top of the throttle body. Don’t put the secondary valve’s side of the throttle body down, for it may damage the ST valve.
Page 213: Throttle Body Disassembly
4-66 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY DISASSEMBLY • Disconnect the TP sensor lead wire coupler 1. • Disconnect the fuel injector lead wire couplers 2. • Remove the fuel delivery pipe assembly 3 by removing its mounting screws. •...
Page 214: Throttle Body Cleaning
FI SYSTEM AND INTAKE AIR SYSTEM 4-67 THROTTLE BODY CLEANING " Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
Page 215: Throttle Body Reassembly
4-68 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- bly. Pay attension to the following points: • When installing the TP sensor, align the groove 1 with the lib TP sensor setting procedure 4-28 [ 09930-11960: Torx wrench...
Page 216 FI SYSTEM AND INTAKE AIR SYSTEM 4-69 • Apply thin coat of the engine oil to the new fuel injector cushion seals 1, and install them to each fuel injector. Replace the cushion seal with a new one. • Install the seals 2 and O-rings 3 to each fuel injector. •...
Page 217: Throttle Body And Stv Actuator Installation
4-70 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE BODY AND STV ACTUATOR INSTALLATION STV ACTUATOR INSTALLATION • Install the STV actuator bracket 1 to the throttle body. • Fit the clamp to the bolt A. • Install the STV actuator to the bracket. ! STV actuator mounting bolt: 5 N .
Page 218 FI SYSTEM AND INTAKE AIR SYSTEM 4-71 • Connect the two cables temporarily to the throttle body. No.1 Cable No.1 Cable No.2 Cable No.2 Cable • Connect the cables to the inside slots 1 of the STV actuator pulley. • Install the pulley to the shaft by aligning the groove 2 with the line 3.
Page 219: Stv Actuator Adjustment
4-72 FI SYSTEM AND INTAKE AIR SYSTEM STV ACTUATOR ADJUSTMENT 1st step: • Set the STV actuator to adjustment position. (4-61) 2nd step: • Turn out the No.2 cable adjuster 1 until the outer cable play A becomes zero. NOTE: Make sure that outer cable end is fixed into the rubber stopper B .
Page 220 FI SYSTEM AND INTAKE AIR SYSTEM 4-73 No.2 cable (2-35 F) 5 N . m (0.5 kgf . m, 3.5 lb-ft) Slack Slack 0 – 1,0 mm 0 – 1.0 mm (0 – 0.04 in) (0 – 0.04 in) Play Play 0 mm 0 mm...
Page 221 4-74 FI SYSTEM AND INTAKE AIR SYSTEM 5th step: This procedure is only required when C28 is indicated. • Turn the ignition switch OFF. • Insert the two copper wires into the back side of the position sensor lead wire coupler 1. B/Br B/Br •...
Page 222: Fuel Injector Inspection
FI SYSTEM AND INTAKE AIR SYSTEM 4-75 To set the ST valve to fully open position, apply 12 volts to A and B terminals. Positive wire ––– B (Gray wire) terminal Negative wire ––– A (Pink wire) terminal Pink Pink Gray Gray To prevent the motor damage, stop to apply 12V as soon...
Page 223: Fuel Injector Installation
4-76 FI SYSTEM AND INTAKE AIR SYSTEM FUEL INJECTOR INSTALLATION • Apply thin coat of the engine oil to new injector cushion seals and O-rings. • Install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. ( 4-68) FAST IDLE ADJUSTMENT The fast idle system is a kind of starter system, which opens throttle valve by the fast idle cam mechanically.
Page 224: Throttle Valve Synchronization
FI SYSTEM AND INTAKE AIR SYSTEM 4-77 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH GAUGE • Lift and support the fuel tank. ( 4-51) • Start up the engine and run it in idling condition for warming •...
Page 225 4-78 FI SYSTEM AND INTAKE AIR SYSTEM • Connect one of the four rubber hoses of the vacuum balancer gauge to the nipple 1 on the No.1 throttle body. [ 09913-13121: Vacuum balancer gauge • Connect a tachometer. • Start up the engine and keep it running at 1 200 rpm by turning throttle stop screw 2.
Page 226 FI SYSTEM AND INTAKE AIR SYSTEM 4-79 THROTTLE VALVE SYNCHRONIZATION • To synchronize throttle valves, remove the rubber caps 1 from each vacuum nipple and connect the vacuum balancer gauge hoses to the vacuum nipples respectively. [ 09913-13121: Vacuum balancer gauge •...
Page 227: Throttle Position Sensor (Tps) Setting
4-80 FI SYSTEM AND INTAKE AIR SYSTEM THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS set- ting condition. (Refer to page 4-28 for TPS setting procedure.) THROTTLE CABLE ADJUSTMENT NOTE: Minor adjustment can be made by the throttle grip side adjuster. ( 2-16) MAJOR ADJUSTMENT •...
Page 228: Sensors
FI SYSTEM AND INTAKE AIR SYSTEM 4-81 SENSORS IAP SENSOR INSPECTION The intake air pressure sensor is located at the rear side of the air cleaner box. ( 4-36) IAP SENSOR REMOVAL/INSTALLATION • Lift and support the fuel tank. ( 4-51) •...
Page 229: Ect Sensor Inspection
4-82 FI SYSTEM AND INTAKE AIR SYSTEM ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the rear side of the cylinder head. ( 4-40 and 5-8) ECT SENSOR REMOVAL/INSTALLATION ( 5-8 and -9) AP SENSOR INSPECTION The atmospheric pressure sensor is located beneath the left side of the seat rail.
Page 230: Cooling And Lubrication
COOLING AND LUBRICATION SYSTEM 5-1 COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ................5- 2 COOLING CIRCUIT ................5- 3 COOLING CIRCUIT INSPECTION ..........5- 3 RADIATOR AND WATER HOSES ............ 5- 4 RADIATOR REMOVAL ..............5- 4 RADIATOR CAP INSPECTION ............. 5- 4 RADIATOR INSPECTION AND CLEANING .........
Page 231: Engine Coolant
5-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a Anti-freeze Freezing point 50:50 mixture of distilled water and ethylene glycol anti-freeze. density This 50:50 mixture will provide the optimum corrosion protection –30°C (–24°F) and excellent heat protection, and will protect the cooling system –40°C (–44°F)
Page 232: Cooling Circuit
COOLING AND LUBRICATION SYSTEM 5-3 COOLING CIRCUIT RESERVE ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER COOLING FAN THERMO RADIATOR SWITCH WATER PUMP OIL COOLER COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. •...
Page 233: Radiator And Water Hoses
5-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowling. (6-5) • Drain engine coolant. (2-18) • Remove the radiator. (3-4 and -5) RADIATOR CAP INSPECTION • Fit the cap 1 to the radiator cap tester 2. •...
Page 234: Radiator Remounting
COOLING AND LUBRICATION SYSTEM 5-5 RADIATOR REMOUNTING • Install the radiator. • Route the radiator hoses. (8-24) • Pour engine coolant. (2-18) • Bleed the air from the cooling circuit. (2-19) • Install the under cowling. (6-5) WATER HOSE INSPECTION •...
Page 235: Cooling Fan
5-6 COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the under cowling. (6-5) • Drain engine coolant. (2-18) • Remove the radiator. (3-4 and -5) • Remove the cooling fan. INSPECTION • Remove the under cowling. (6-5) • Disconnect the cooling fan lead wire coupler 1. •...
Page 236: Inspection
COOLING AND LUBRICATION SYSTEM 5-7 INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure. Connect the thermo-switch to a circuit tester and place it in the oil contained in a pan, which is placed on a stove. •...
Page 237: Engine Coolant Temperature Sensor
5-8 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SENSOR REMOVAL • Remove the under cowling. (6-5) • Drain engine coolant. (2-18) • Remove the front and rear seats. (6-8) • Lift and support the fuel tank. (4-51) • Remove the air cleaner box. (4-60 and -61) •...
Page 238: Installation
COOLING AND LUBRICATION SYSTEM 5-9 INSTALLATION • Tighten the engine coolant temperature sensor to the specified torque. ! Engine coolant temperature sensor: 18 N . m (1.8 kgf . m, 13.0 lb-ft) Take special care when handling the temperature sen- sor.
Page 239: Inspection
5-10 COOLING AND LUBRICATION SYSTEM INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner. • Pass a string between flange, as shown in the illustration. • Immerse the thermostat in the water contained in a beaker, as shown in the illustration.
Page 240: Water Pump
COOLING AND LUBRICATION SYSTEM 5-11 • Install the thermostat case. NOTE: Fit the clamp to the thermostat case bolt A . • Tighten the thermostat case bolt to the specified torque. ! Thermostat case bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) •...
Page 241 5-12 COOLING AND LUBRICATION SYSTEM • Remove the engine sprocket cover 1. • Disconnect the water hoses. • Remove the water pump. • Remove the water pump cover. • Remove the impeller securing bolt 2 by holding the impeller shaft with a water pump pliers.
Page 242 COOLING AND LUBRICATION SYSTEM 5-13 • Remove the mechanical seal ring 1 and the rubber seal 2 from the impeller. • Remove the impeller shaft 3. • Remove the bearing using the special tool. [ 09921-20220: Bearing remover set ( φ 10) NOTE: If no abnormal noise, bearing removal is not necessary.
Page 243: Inspection
5-14 COOLING AND LUBRICATION SYSTEM INSPECTION BEARING • Inspect the play of the bearing by hand while it is in the water pump case. • Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • Replace the bearing if there is anything unusual. MECHANICAL SEAL •...
Page 244: Reassembly And Installation
[ 09913-70210: Bearing installer set ( φ 20) NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. W 99000-25030: SUZUKI SUPER GREASE “A”...
Page 245 5-16 COOLING AND LUBRICATION SYSTEM • Apply grease to the impeller shaft. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the impeller shaft to the water pump body. • Install the rubber seal 1 into the impeller. • After wiping off the oily or greasy matter from the mechanical seal ring, install it into the impeller.
Page 246 * Apply engine coolant to the O-ring 1 . * Apply grease to the O-ring 2 . W 99000-25030: SUZUKI SUPER GREASE “A” • Tighten the water pump cover screws to the specified torque. ! Water pump cover screw: 6 N . m (0.6 kgf . m, 4.5 lb-ft) •...
Page 247: Lubrication System
5-18 COOLING AND LUBRICATION SYSTEM WATER PUMP OIL PUMP LUBRICATION SYSTEM OIL PRESSURE 2-31 OIL FILTER 2-13 OIL PRESSURE REGULATOR 3-46 OIL STRAINER 3-46 OIL JET 3-58 OIL PUMP 3-44 OIL PRESSURE SWITCH 7-39...
Page 248: Engine Lubrication System Chart
COOLING AND LUBRICATION SYSTEM 5-19 ENGINE LUBRICATION SYSTEM CHART INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER CAMSHAFT JOURNALS, CAMFACES AND TAPPETS EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER CAMSHAFT JOURNALS, CAM DRIVE CHAIN CAMFACES AND TAPPETS STARTER CLUTCH SUB-GALLERY OIL HOSE #1 PISTON COOLING #2 PISTON COOLING #3 PISTON COOLING #4 PISTON COOLING...
Page 249: Engine Lubrication System
5-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM To sub-gallery MAIN GALLERY...
Page 250: System
COOLING AND LUBRICATION SYSTEM 5-21...
Page 251 CHASSIS CONTENTS EXTERIOR PARTS ................6- 2 CONSTRUCTION................6- 2 FASTENER REMOVAL AND REINSTALLATION ....... 6- 4 SCREEN ..................6- 4 BODY COWLING COVER ............. 6- 5 RIGHT AND LEFT UNDER COWLINGS ........6- 5 BODY COWLING ................6- 6 RIGHT AND LEFT AIR INTAKE PIPES........
Page 252 CHASSIS 6-1 REAR SUSPENSION ............... 6-50 CONSTRUCTION................6-50 REMOVAL ..................6-52 INSPECTION AND DISASSEMBLY ..........6-54 REASSEMBLY ................6-56 REMOUNTING ................6-58 FINAL INSPECTION AND ADJUSTMENT ........6-59 FRONT BRAKE ................6-60 CONSTRUCTION................6-60 BRAKE PAD REPLACEMENT ............. 6-61 BRAKE FLUID REPLACEMENT ..........6-61 CALIPER REMOVAL AND DISASSEMBLY ........
Page 253: Exterior Parts
6-2 CHASSIS EXTERIOR PARTS CONSTRUCTION...
Page 254: Heat Shield
CHASSIS 6-3 Front seat 23 N . m (2.3 kgf . m, 16.5 lb-ft) Frame cover HEAT SHIELD Left under cowling Left under cowling heat shield No.1 Right under cowling Left under cowling Left under cowling heat shield No.3 heat shield No.2 Right under cowling heat shield No.1 Center under cowling...
Page 255: Fastener Removal And Reinstallation
6-4 CHASSIS FASTENER REMOVAL AND REINSTALLATION FASTENER a REMOVAL • Depress the head of fasteners center piece 1. • Pull out the fastener. INSTALLATION • Let the center piece stick out toward the head so that the pawls 2 close. •...
Page 256: Body Cowling Cover
CHASSIS 6-5 BODY COWLING COVER • With all the fasteners removed, remove the body cowling cover RIGHT AND LEFT UNDER COWLINGS • Remove the fastener. • Remove the fastener. • With the bolts removed, remove the right under cowling. • Disconnect the turn signal light coupler. •...
Page 257: Body Cowling
6-6 CHASSIS BODY COWLING • Remove the rear view mirrors, right and left, by removing the bolts. • Remove the fasteners. • Remove all the bolts. • Disconnect the headlight coupler. REMOUNTING NOTE: When remounting the body cowling, install the hooks A to the cowling brace holes.
Page 258: Right And Left Air Intake Pipes
CHASSIS 6-7 RIGHT AND LEFT AIR INTAKE PIPES • Remove the body cowling. • With the fastener removed, remove the right air intake pipe • With the fastener removed, remove the left air intake pipe 2. COWLING BRACE REMOVAL • Remove the body cowling. ( 6-6) •...
Page 259: Front Seat
6-8 CHASSIS FRONT SEAT • With the bolts removed, remove the front seat. REAR SEAT AND SEAT TAIL COVER • Remove the rear seat (seat tail cover) with the ignition key. FRAME COVER • Remove the seats. • Remove the bolts. •...
Page 260: Front Wheel
CHASSIS 6-9 FRONT WHEEL CONSTRUCTION 1 Brake disc 2 Dust seal 3 Bearing 4 Spacer 5 Spacer nut 6 Front wheel A Front axle B Brake disc bolt (Front) N . m kgf . m ITEM lb-ft 10.0 72.5 16.5...
Page 261 6-10 CHASSIS Left Right 25 N . m (2.5 kgf . m, 18.1 lb-ft) 25 N . m (2.5 kgf . m, 18.1 lb-ft) 23 N . m (2.3 kgf . m, 16.5 lb-ft) 23 N . m (2.3 kgf . m, 16.5 lb-ft) 100 N .
Page 262: Removal
CHASSIS 6-11 REMOVAL • Remove the brake calipers, left and right. Do not operate the brake lever while removing the cali- pers. • Loosen two axle pinch bolts 1 on the right front fork leg. • Loosen the front axle 2. •...
Page 263: Inspection And Disassembly
6-12 CHASSIS INSPECTION AND DISASSEMBLY TIRE INSPECTION: 6-71 • Remove the brake disc. BRAKE DISC INSPECTION: 6-62 • Remove both side dust seals by using the oil seal remover. [ 09913-50121: Oil seal remover The removed dust seals must be replaced with new ones.
Page 264 CHASSIS 6-13 • Remove the wheel bearings by using the special tool A or B. [ 09921-20220: A Bearing remover set or 09944-60210: B Wheel bearing remover The removed bearings should be replaced with new ones.
Page 265: Reassembly And Remounting
6-14 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 25 N . m (2.5 kgf . m, 18.1 lb-ft) 25 N . m (2.5 kgf .
Page 266 CHASSIS 6-15 WHEEL BEARING • Apply grease to the wheel bearings. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the wheel bearings as follows by using the special tools. [ 09941-34513: Bearing/Steering race installer set First install the left wheel bearing, then install the right wheel bearing.
Page 267 6-16 CHASSIS SPACER NUT After touching the flange of spacer nut being contact with the left front fork leg, tighten the two axle pinch bolts on the left front fork leg to the specified torque. ! Front axle pinch bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) WHEEL Install the front wheel with the front axle and hand-tighten the front axle temporarily.
Page 268: Front Fork
CHASSIS 6-17 FRONT FORK CONSTRUCTION 1 Spring adjuster bolt 2 O-ring 3 Spring adjuster 4 Rebound damping force adjuster 5 Rubber seat 6 Spacer 7 Spring 8 Oil flow pipe 9 Inner rod/damper rod (cartridge) 0 Outer tube A Anti-friction metal B Oil seal N .
Page 269: Removal And Disassembly
6-18 CHASSIS REMOVAL AND DISASSEMBLY • Remove the body cowling. ( 6-6) • Remove the front wheel. ( 6-11) • Disconnect the brake hose from the brake hose guides on the front fender. • Remove the front fender. • Loosen the front fork upper clamp bolts 1, left and right. •...
Page 270 CHASSIS 6-19 • Remove the front fork cap bolt from the inner rod by loosening the lock nut. • Compress the fork spring with the special tool A and remove the special tool B. • Remove the rubber seat 1, washer 2, spacer seat 3, spacer 4, oil flow pipe 5 and spring 6.
Page 271 6-20 CHASSIS • Remove the inner rod/damper rod (cartridge) 1 and plate 2. Do not disassemble the inner rod/damper rod (cartridge). • Remove the dust seal 3 and the oil seal stopper ring 4. • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the inner tube.
Page 272: Inspection
CHASSIS 6-21 FRONT FORK CAP BOLT DISASSEMBLY • Remove the spring adjuster stopper ring. • Remove the spring adjuster bolt 1 and adjuster 2. • Remove the rebound damping force adjuster 3. INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and outer tube inner sur- face for scratches.
Page 273: Reassembly And Remounting
• Apply grease to the oil seal lip lightly before installing it. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the dust seal, oil seal stopper ring, oil seal, oil seal re- tainer and anti-friction metal onto the inner tube.
Page 274 CHASSIS 6-23 COMPRESSION DAMPING FORCE ADJUSTER • Tighten the compression damping force adjuster to the speci- fied torque. ! Compression damping force adjuster: 18 N . m (1.8 kgf . m, 13.0 lb-ft) The removed O-ring must be replaced with a new one. DAMPER ROD BOLT Insert the inner rod/damper rod (cartridge) and the plate into the inner tube and tighten the damper rod bolt to the specified...
Page 275 [ 09943-74111: Front fork oil level gauge Fork oil level: 103 mm (4.06 in) 99000-99001-SS8: SUZUKI FORK OIL SS-08 (#10) or an equivalent fork oil Capacity (each leg): 473 ml (16.0/16.7 US/lmp oz)
Page 276 CHASSIS 6-25 FORK SPRING Upper side • Install the fork spring as shown in the illustration. Lower side FRONT FORK CAP BOLT • Adjust the height A of the rebound damping force adjuster at 1.5 mm (0.06 in). • Install the rebound damping force adjuster housing to the cap bolt.
Page 277 6-26 CHASSIS • Install the front fork cap bolt to the outer tube temporarily. • Set the upper surface of the outer tube at 4.0 mm (0.16 in) height A from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts to the speci- fied torque.
Page 278: Suspension Setting
CHASSIS 6-27 SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damp- ing force as follows. SPRING PRE-LOAD ADJUSTMENT There are seven grooved lines on the side of the spring ad- juster. Position 0 provides the maximum spring pre-load and position 7 provides the minimum spring pre-load.
Page 279: Steering Damper
• Install the steering damper and tighten the bolt and nut. ! Steering damper bolt and nut: 23 N . m (2.3 kgf . m, 16.5 lb-ft) • Apply grease to the bearings and dust seals. W 99000-25030: SUZUKI SUPER GREASE “A”...
Page 280: Steering
CHASSIS 6-29 STEERING CONSTRUCTION 1 Steering stem upper bracket 2 Handlebar 3 Handlebar balancer 4 Steering stem nut 5 Dust seal 6 Bearing 7 Steering stem lower bracket A Steering stem head nut B Steering stem lock nut C Front fork upper clamp bolt D Handlebar clamp bolt E Handlebar set bolt F Front fork lower clamp bolt...
Page 281 6-30 CHASSIS • Remove the left and right handlebars by removing its set bolts. • Remove the left and right handlebar switch lead wires from the guide. NOTE: Place the rags under each handlebar to prevent scratching the upper fairing and the air intake pipes. •...
Page 282: Inspection And Disassembly
CHASSIS 6-31 INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal noise of bearing If any abnormal points are found, replace defective parts with the new ones.
Page 283 6-32 CHASSIS BEARING • Apply grease to the bearings and bearing races. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race. STEM NUT •...
Page 284: Steering Tension Adjustment
CHASSIS 6-33 FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem upper bracket following steps: 1) Install the upper bracket, washer 1 and steering stem head nut 2 temporarily. 2) Set the front forks and tighten the steering stem head nut 2. ! Steering stem head nut: 90 N .
Page 285: Handlebar
6-34 CHASSIS HANDLEBAR CONSTRUCTION 1 Left handle grip 2 Right handle grip 3 Right handle switch 4 Left handle switch N . m kgf . m 5 handlebar ITEM lb-ft 6 Handle balancer 16.5 A Handlebar clamp bolt B Handlebar set bolt REMOVAL AND DISASSEMBLY RIGHT HANDLEBAR •...
Page 286: Reassembly And Remounting
CHASSIS 6-35 • Remove the handlebar set bolts. • With the handlebar clamp bolts and steering stem head nut loosened, remove the steering stem upper bracket. • With the handlebar clamp bolts loosened, draw out the handle- bars to upward. REASSEMBLY AND REMOUNTING Reassemble and remount the handlebar in the reverse order of removal and disassembly.
Page 287 • When remounting the right and left handle switches, engage the stopper with the handlebar hole. • Apply the grease to the throttle cables and their holder. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the front brake master cylinder. ( 6-64)
Page 288: Rear Wheel
CHASSIS 6-37 REAR WHEEL CONSTRUCTION 1 Rear axle 2 Caliper bracket 3 Brake disc 4 Collar 5 Bearing 6 Rear wheel 7 Spacer 8 Bearing 9 Cushion 0 Spacer A Sprocket drum B Sprocket C Bearing D Dust seal E Collar A Brake disc bolt B Rear sprocket nut C Rear axle nut...
Page 289 6-38 CHASSIS Left Right 35 N . m (3.5 kgf . m, 25.5 lb-ft) 120 N . m (12.0 kgf . m, 86.8 lb-ft) 26 N . m (2.6 kgf . m, 19.0 lb-ft) For the others 110 N . m 7.5 N .
Page 290: Removal
CHASSIS 6-39 REMOVAL • Remove the cotter pin. (For Canada and USA) • Loosen the axle nut. • Raise the rear wheel off the ground and support the motor- cycle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. •...
Page 291: Inspection And Disassembly
6-40 CHASSIS • Remove the collar 1. • Remove the brake disc. INSPECTION AND DISASSEMBLY TIRE INSPECTION: 2-25 and 6-71 WHEEL INSPECTION: 6-11 and 71 REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. Axle shaft runout: Service Limit: 0.25 mm (0.010 in) [ 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand...
Page 292 CHASSIS 6-41 BEARINGS Inspect the play of the wheel and sprocket mounting drum bear- ings by hand while they are in the wheel and drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. •...
Page 293: Reassembly And Remounting
6-42 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 35 N . m (3.5 kgf . m, 25.5 lb-ft) 120 N . m (12.0 kgf .
Page 294 CHASSIS 6-43 BEARINGS • Apply grease to the bearings before installing. W 99000-25030: SUZUKI SUPER GREASE “A” • Install the new bearing to the sprocket mounting drum using the special tool. [ 09924-84510: Bearing installer set • First install the right wheel bearing, then install the left wheel bearing using the special tool.
Page 295 • Install the new dust seal using proper drift. • Apply grease to the dust seal lip before assembling rear wheel. W 99000-25030: SUZUKI SUPER GREASE “A” BRAKE DISC • Apply THREAD LOCK SUPER “1360” to the disc bolts and tighten them to the specified torque.
Page 296 CHASSIS 6-45 REAR AXLE • Remount the rear wheel and rear axle shaft, install the washer 1 and rear axle nut 2. • Adjust the chain slack after rear wheel installation. ( 2-20) • Tighten the rear axle nut 2 to the specified torque. ! Rear axle nut: 110 N .
Page 297: Rear Shock Absorber
6-46 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION 1 Rear shock absorber 2 Height adjuster A Rear shock absorber mounting bolt/nut B Height adjuster nut N . m kgf . m ITEM lb-ft 36.0 11.5 83.2 Left Right...
Page 298: Removal
CHASSIS 6-47 REMOVAL • Support the motorcycle with a jack to be no load for the rear shock absorber. • Remove the rear shock absorber upper mounting bolt and nut. • Remove the rear cushion lever bolt and nut. • Remove the rear shock absorber lower mounting bolt and nut. •...
Page 299: Rear Shock Absorber Scrapping Procedure
6-48 CHASSIS REAR SHOCK ABSORBER SCRAPPING PROCEDURE " * Handle the rear shock absorber with caution since a high pressure nitrogen gas is contained. * Avoid incineration, exposure to high pressure or over- hauling. * In the case of scrapping the rear shock absorber, evacuate gas in the following procedures.
Page 300: Suspension Setting
CHASSIS 6-49 SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The set length 186.5 mm provides the maximum spring pre- load. The set length 196.5 mm provides the minimum spring pre-load. (STD length: 191.5 mm) DAMPING FORCE ADJUSTMENT (Rebound side)
Page 301 6-50 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Rear cushion rod 3 Rear cushion lever 4 Spacer 5 Bearing 6 Dust seal 7 Torque link 8 Chain cover 9 Chain buffer 0 Chain adjuster A Chain adjuster lock nut A Rear shock absorber mount- ing bolt/nut B Rear cushion lever bolt/nut...
Page 302 CHASSIS 6-51 Left Right 50 N . m (5.0 kgf . m, 36.0 lb-ft) 78 N . m (7.8 kgf . m, 56.5 lb-ft) 15 N . m 1.5 kgf . m 11.0 lb-ft 90 N . m 100 N . m 9.0 kgf .
Page 303 6-52 CHASSIS REMOVAL • Raise the rear wheel off the ground and support the motor- cycle with a jack or a wooden block. • Remove the rear wheel. ( 6-39) • Remove the side-stand. ( 8-26) • Remove the rear brake hose union bolt. •...
Page 304 CHASSIS 6-53 • Remove the swingarm pivot shaft lock nut by using the special tool. [ 09940-14970: Swingarm pivot thrust adjuster socket wrench • Hold the swingarm pivot shaft 1 with a 27 mm socket wrench and remove the swingarm pivot nut 2 with a 36 mm socket wrench.
Page 305 6-54 CHASSIS INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm. • Remove the spacers from the cushion lever. • Inspect the spacers for any flaws or other damage. If any de- fects are found, replace the spacers with new ones. SWINGARM BEARING Insert the spacer into bearing and check the play when moving the spacer up and down.
Page 306 CHASSIS 6-55 CUSHION LEVER BEARING Insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Draw out the cushion lever bearings with the special tool. [ 09921-20220: Bearing remover set The removed bearings must be replaced with new ones.
Page 307: Reassembly
6-56 CHASSIS REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: Left Right 50 N . m (5.0 kgf . m, 36.0 lb-ft) 78 N . m (7.8 kgf . m, 56.5 lb-ft) 15 N .
Page 308 • Press the bearings into the cushion lever with the special tool. [ 09941-34513: Steering race installer NOTE: When installing the bearing, stamped mark on bearing must face outside. • Apply grease to the bearings, spacers, washers and dust seals. W 99000-25030: SUZUKI SUPER GREASE “A”...
Page 309: Remounting
6-58 CHASSIS • Assemble the cushion rod onto the swingarm. ( 6-58) ! Cushion rod mounting nut: 78 N . m (7.8 kgf . m, 56.5 lb-ft) • Install the torque link and tighten the rear torque link nut. ! Torque link nut (Front): 28 N . m (2.8 kgf . m, 20.0 lb-ft) REMOUNTING Remount the swingarm in the reverse order of disassembly and removal, and pay attention to the following points.
Page 310: Final Inspection And Adjustment
CHASSIS 6-59 SHOCK ABSORBER AND CUSHION LEVER MOUNTING • Install the washers A and cushion lever. ! Cushion lever mounting nut: 78 N . m (7.8 kgf . m, 56.5 lb-ft) • Assemble the cushion lever, cushion rod and rear shock ab- sorber.
Page 311: Front Brake
6-60 CHASSIS FRONT BRAKE CONSTRUCTION 1 Front brake lever 2 Dust boot 3 Piston set 4 Piston set (Trailing) 5 Piston set (Leading) 6 Brake pad 7 Brake pad spring 8 Pad mounting pin 9 Brake hose 0 Brake hose A Front master cylinder mounting bolt B Brake hose union bolt C Caliper mounting bolt...
Page 312: Brake Pad Replacement
CHASSIS 6-61 BRAKE PAD REPLACEMENT • Remove the spring 1. • Remove the brake pads by removing the clip 2 and pad mount- ing pin 3. * Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected.
Page 313: Caliper Removal And Disassembly
6-62 CHASSIS CALIPER REMOVAL AND DISASSEMBLY • Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.
Page 314: Caliper Inspection
CHASSIS 6-63 • Remove the dust seals and piston seals. Do not reuse the dust seals and piston seals to pre- vent fluid leakage. CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches or other damage.
Page 315: Brake Disc Inspection
6-64 CHASSIS • Tighten each bolt to the specified torque. ! Front brake caliper housing bolt 1: 21 N . m (2.1 kgf . m, 15.1 lb-ft) Front brake caliper mounting bolt 2: 25 N . m (2.5 kgf . m, 18.1 lb-ft) Front brake hose union bolt 3: 23 N .
Page 316: Master Cylinder Removal And Disassembly
CHASSIS 6-65 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Disconnect the front brake light switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid. Remove the union bolt and dis- connect the brake hose.
Page 317: Master Cylinder Inspection
6-66 CHASSIS • Pull out the dust boot 1 and remove the circlip 2. [ 09900-06108: Snap ring pliers. • Remove the piston/secondary cup, primary cup and return spring. 3 Secondary cup 4 Piston 5 Primary cup 6 Return spring •...
Page 318 CHASSIS 6-67 • When remounting the brake master cylinder onto the handle- bar, align the master cylinder holder’s mating surface with punched mark A on the handlebar and tighten the upper clamp bolt first as shown. ! Front brake master cylinder mounting bolt: 10 N . m (1.0 kgf .
Page 319: Rear Brake
6-68 CHASSIS REAR BRAKE CONSTRUCTION N . m kgf . m ITEM lb-ft 1 Brake pedal 2 Piston/cup set 16.5 3 Reservoir tank hose 4 Brake hose A Caliper air bleeder valve 18.1 5 Pad B Brake hose union bolt 6 Inner shim C Rear brake caliper mounting bolt 7 Outer shim...
Page 320: Brake Pad Replacement
CHASSIS 6-69 BRAKE PAD REPLACEMENT • Remove the brake pad cover. • Remove the clip 1. • Remove the brake pads along with the shims by removing the brake pad mounting pins 2 and springs 3. * Do not operate the brake pedal while dismounting the pads.
Page 321: Caliper Removal And Disassembly
6-70 CHASSIS CALIPER REMOVAL AND DISASSEMBLY • Remove the union bolt 1 and catch the brake fluid in a suitable receptacle. Never reuse the brake fluid left over from previous ser- vicing and stored for long periods. " Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.
Page 322: Caliper Inspection
CHASSIS 6-71 CALIPER INSPECTION CALIPER INSPECTION: 6-63 6-63 PISTON: DISC: 6-64 Service Limit: Rear disc thickness: 4.5 mm (0.18 in) Rear disc runout: 0.30 mm (0.012 in) CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of re- moval and disassembly.
Page 323: Master Cylinder Removal And Disassembly
6-72 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY • Remove the frame cover. ( 6-8) • Remove the brake fluid reservoir tank mounting bolt 1. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 2 and disconnect the brake hose.
Page 324: Master Cylinder Inspection
CHASSIS 6-73 MASTER CYLINDER INSPECTION CYLINDER, PISTON AND CUP SET Inspect the cylinder bore wall for any scratches or other damage. Inspect the cup set and each rubber part for damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse or- der of removal and disassembly.
Page 325: Tire And Wheel
6-74 CHASSIS TIRE AND WHEEL TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
Page 326: Valve Inspection
CHASSIS 6-75 VALVE INSPECTION Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal rubber is peeling or has dam- age. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.
Page 327 6-76 CHASSIS • When installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation. • Align the chalk mark put on the tire at the time of removal with the valve position. •...
Page 328: Drive Chain
CHASSIS 6-77 DRIVE CHAIN Use the special tool in the following procedures, to cut and re- join the drive chain. [ 09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.
Page 329: Drive Chain Connecting
6-78 CHASSIS • Place the drive chain link being disjointed on the holder part 8 of the tool. • Turn in both the adjuster bolt 6 and pressure bolt “A” 3 so that each of their end hole fits over the chain joint pin properly. •...
Page 330 CHASSIS 6-79 • Apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0. NOTE: When positioning the joint plate 0 on the tool, face its stamp mark on the joint plate holder 3 side. •...
Page 331 6-80 CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pres- sure bolt “A” 3 with the bar until the pin end diameter becomes the specified dimension. Pin end diameter specification D 5.45 – 5.85 mm (0.215–0.230 in) * After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.
Page 332: Electrical System
ELECTRICAL SYSTEM 7-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ............... 7- 2 LOCATION OF ELECTRICAL COMPONENTS ........ 7- 4 CHARGING SYSTEM ............... 7- 6 DESCRIPTION ................7- 6 TROUBLESHOOTING ..............7- 8 INSPECTION ................. 7- 9 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM ..............
Page 333: Cautions In Servicing
7-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it.
Page 334 • Route the wire harness properly according to “WIRE HARNESS ROUTING”. ( 8-14 – 16) USING MULTI CIRCUIT TESTER • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range.
Page 335: Location Of Electrical Components
7-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Battery 0 Handlebar switch (R) 2 ECM (Engine Control Module) A Rear brake switch 3 Tip over sensor ( 4-44) B Starter motor 4 Fuel pump relay C Crankshaft position sensor 5 Secondary valve actuator D Oil pressure switch 6 Throttle position sensor E Horn...
Page 336 ELECTRICAL SYSTEM 7-5 1 Clutch lever position switch B Cooling fan thermo-switch ( 5-6) 2 Handlebar switch (L) C Cooling fan ( 5-5) 3 Camshaft position sensor ( 4-34) D Intake air pressure sensor ( 4-36) 4 Ignition coil (No. 1, 2, 3, 4) E Engine coolant temp.
Page 337: Charging System
7-6 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in the figure, which is composed of the generator, regulator/ rectifier unit and battery. The AC current generated from the generator is rectified by the rectifier and is turned into DC current, then it charges the battery.
Page 338 ELECTRICAL SYSTEM 7-7 When the engine r/min becomes higher, the generated voltage of the generator also becomes higher and the voltage between the battery terminals becomes high accordingly. When it reaches the adjusted voltage of the I.C., (Integrated Circuit) and it is turned “ON”, a signal will be sent to the SCR (Thyristor) gate probe and the SCR will be turned “ON”.
Page 339: Troubleshooting
7-8 ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories. are installed amounts of electricity. No accessories Check the battery for current Current leaks • Short circuit of wire harness leaks. ( 7-9) •...
Page 340: Inspection
ELECTRICAL SYSTEM 7-9 INSPECTION BATTERY CURRENT LEAK INSPECTION • Remove the front seat. ( 6-8) • Turn the ignition switch to the OFF position. • Disconnect the battery lead wire. • Connect the multi circuit tester between the terminal and lead wire of the battery.
Page 341 7-10 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE INSPECTION • Remove the frame cover. ( 6-8) • Disconnect the generator coupler. Measure the resistance between the three lead wires. Also check that the stator core is insulated. If the resistance is not specified value, replace the stator with a new one.
Page 342: Starter System And Side-Stand/Ignition Interlock System
ELECTRICAL SYSTEM 7-11 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, turn signal/side-stand relay, side-stand switch, gear position switch, starter button, engine stop switch, ignition switch and battery.
Page 343 7-12 ELECTRICAL SYSTEM The circuit consists of the turn signal/side-stand relay, neutral indicator light, gear position switch and side- stand switch. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side-stand is either up or down. The gear position and side-stand switches work to- gether in this system.
Page 344: Troubleshooting
ELECTRICAL SYSTEM 7-13 TROUBLE SHOOTING Starter motor will not run. The transmission is in neutral. Grasp the Check if the starter motor runs clutch lever, turn on the ignition switch when its terminal is connected with the engine stop switch in the “RUN” Clicks to the battery terminal (Do...
Page 345: Starter Motor Removal And Disassembly
7-14 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND DISASSEMBLY • Disconnect the starter motor lead wire. ( 3-6) • Remove the starter motor. ( 3-16) • Disassemble the starter motor as shown in the illustration. 10 N . m (1.0 kgf . m, 7.0 lb-ft) 1 O-ring 2 Housing end (inside) 3 Starter motor case...
Page 346: Starter Motor Reassembly
Replace the O-ring with a new one to prevent oil leak- age and moisture. • Apply grease to the lip of the oil seal. W 99000-25030: SUZUKI SUPER GREASE “A” • Apply grease to the O-ring, and remount the starter motor. (3-98)
Page 347: Starter Relay Inspection
7-16 ELECTRICAL SYSTEM STARTER RELAY INSPECTION • Remove the front seat and frame cover. ( 6-8) • Disconnect the battery lead wire, and starter relay cover • Disconnect the starter motor lead wire 2, and battery lead wire 3 and starter relay coupler 4 from the starter relay. •...
Page 348: Side-Stand/Ignition Interlock System Part Inspection
ELECTRICAL SYSTEM 7-17 SIDE-STAND/IGNITION INTERLOCK SYSTEM PART INSPECTION If the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH The side-stand switch coupler is located behind the left upper fairing.
Page 349 7-18 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Lift the fuel tank. ( 4-51) • Disconnect the gear position switch lead wire and check the continuity between Blue and Black/White with the transmission in “NEUTRAL”. [ 09900-25008: Multi circuit tester set <...
Page 350 ELECTRICAL SYSTEM 7-19 TURN SIGNAL/SIDE-STAND RELAY REMOVAL The turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode. • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.
Page 351: Ignition System
7-20 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION The ignition system is controlled by the ECM. The system is called fully transistorized ignition system which decides accurate ignition timing according to the engine rpm, gear position and throttle position. The ignition system has four ignition coils called DIRECT IGNITION. In this system, the plug cap and ignition coil for each cylinder are unified.
Page 352 ELECTRICAL SYSTEM 7-21 Engine stop switch Side- stand Power source relay circuit Fuse sensor Wave form arrangement Ignition circuit switch Battery Wave form arrangement circuit Cam position sensor Throttle Engine Gear position coolant position sensor temp. switch sensor NOTE: The ignition cut-off circuit is incorporated in this ECM to prevent over-running of engine. If engine rpm reaches 13 700 r/min., this circuit cuts off the ignition primary current for all spark plugs.
Page 353: Troubleshooting
7-22 ELECTRICAL SYSTEM TROUBLESHOOTING * Check that the transmission is in neutral and the No spark or poor spark 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. Check the ignition system couplers for Looseness •...
Page 354: Inspection
ELECTRICAL SYSTEM 7-23 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. ( 4-61) • Disconnect all the ignition coil/plug cap lead wire couplers be- fore removing the ignition coil/plug caps. • Remove all of the ignition coil/plug caps. * Do not remove the ignition coil/plug cap before dis- connecting the lead wire coupler, or the lead wire will be damaged.
Page 355 7-24 ELECTRICAL SYSTEM Inspect each ignition coil primary peak voltage at the ignition coil/plug cap coupler. • Connect the multi circuit tester with peak voltage adaptor as follows. No.1 ignition coil/plug cap: W/Bl terminal (+ Probe) – Ground (- Probe) terminal No.2 ignition coil/plug cap: B terminal (+ Probe) –...
Page 356 ELECTRICAL SYSTEM 7-25 IGNITION COIL/PLUG CAP RESISTANCE • Check the ignition coil/plug cap for resistance in both primary and secondary windings. If the resistance is not within the stan- dard range, replace the ignition coil/plug cap with a new one. [ 09900-25008: Multi circuit tester set U Tester knob indication: Resistance (Ω...
Page 357 7-26 ELECTRICAL SYSTEM CKP SENSOR PEAK VOLTAGE • Remove the front seat. ( 6-8) NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Connect the multi circuit tester with peak volt adaptor as fol- lows.
Page 358 ELECTRICAL SYSTEM 7-27 • Lift up the fuel tank. ( 4-51) • Disconnect the CKP sensor lead wire coupler and connect the multi circuit tester with the peak volt adaptor. Green (+ Probe) – Blue (- Probe) • Measure the CKP sensor peak voltage at the CKP sensor lead wire coupler.
Page 359: Combination Meter
7-28 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and high response on those currently in use because of this composition.
Page 360 ELECTRICAL SYSTEM 7-29 STEPPING MOTOR The following contents and illustration shows the explanation of stepping motor’s basic principle by using a simple structure. Tachometer is driven by stepping motor. Its pointer moves to the full-scale immediately after the ignition switch is turned on to enable self-calibration. The stepping motor consists of the stator, coils, rotor, angle position sensor, exciter circuit and distribution circuit.
Page 361 7-30 ELECTRICAL SYSTEM STEPPING MOTOR OPERATION Step.1) When current is sent only through circuit B, the magnetic force is equilibrated and causes the rotor to stay at position b. Step.2) When the same amount of current as circuit B is sent also through circuit A, the rotor turns 15° counterclockwise by the same amount of magnetic force both from a and b.
Page 362: Removal
ELECTRICAL SYSTEM 7-31 REMOVAL • Remove the screw 1. • Draw out the hook 2 from the body cowling. • Disconnect the lead wire coupler. • Remove the combination meter. When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
Page 363: Inspection
7-32 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights immediately after turning the ignition switch on. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire harness/coupler. STEPPING MOTOR Check that the pointer calibrates itself immediately after turning the ignition switch on and stops at starting point.
Page 364 ELECTRICAL SYSTEM 7-33 ENGINE COOLANT TEMPERATURE METER AND INDICATOR Engine coolant temp. sensor inspection: 5-8 • Lift up the fuel tank. ( 4-51) • Disconnect the engine coolant temp. sensor coupler 1. When connecting and disconnecting the engine cool- ant temp.
Page 365 7-34 ELECTRICAL SYSTEM FUEL LEVEL INDICATOR SWITCH INSPECTION • Remove and disassemble the fuel pump assembly. (4- • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel level indicator switch as shown in the right illustlations. The Battery Test Battery...
Page 366 ELECTRICAL SYSTEM 7-35 SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of cou- plers. If the speedometer sensor and connection are all right, replace the meter with a new one. SPEEDOMETER SENSOR •...
Page 367: Lamps
7-36 ELECTRICAL SYSTEM LAMPS HEADLIGHT BULB REPLACEMENT • Disconnect the socket 1 and the rubber cap 2. • Remove the bulb by removing the bulb holder spring. • Reassemble the headlight bulb in the reverse order of removal. Headlight bulb 1: 55W (H7) 2: 55W (H7) Lo: 1 Hi: 1 + 2...
Page 368 ELECTRICAL SYSTEM 7-37 BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT BULB REPLACEMENT • Remove the lens. • Remove the brake light/taillight bulb by turning it counterclock- wise. • Reassemble the brake light/taillight bulb in the reverse order of removal. • Remove the screw and take off the lens. •...
Page 369: Switches
7-38 ELECTRICAL SYSTEM TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the op- eration of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
Page 370 ELECTRICAL SYSTEM 7-39 Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. IGNITION SWITCH PUSH (For E-24) HORN BUTTON Color Color Position B/Bl Position PUSH LOCK FRONT BRAKE SWITCH...
Page 371: Battery
7-40 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YT12A-BS Capacity 12V, 36 kC (10 Ah)/10HR INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes. • Remove the caps 2. NOTE: * After filling the electrolyte completely, use the removed cap 2 as the sealed caps of battery-filler holes.
Page 372: Servicing
ELECTRICAL SYSTEM 7-41 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.
Page 373: Recharging Operation
7-42 ELECTRICAL SYSTEM RECHARGING OPERATION • Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0V (DC), recharge the bat- tery with a battery charger. * When recharging the battery, remove the battery from the motorcycle.
Page 374 SERVICING INFORMATION 8-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ..............8- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION .............. 8- 2 ENGINE ..................8- 4 RADIATOR (COOLING SYSTEM) ..........8- 9 CHASSIS ..................8-10 BRAKES ..................8-11 ELECTRICAL ................8-12 BATTERY ..................8-13 WIRE HARNESS, CABLE AND HOSE ROUTING ......
Page 375: Troubleshooting
8-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 4 sec. after re- sensor ceiving the starter signal. The camshaft position sensor wiring and mechanical parts.
Page 376 SERVICING INFORMATION 8-3 Secondary throttle The position sensor of the STV actuator produces following valve actuator voltage. (0.1 sensor voltage 4.9) Without the above value, c28 is indicated. STVA motor can not move. STV actuator, STV actuator adjustment, lead wire/coupler. Gear position signal voltage should be higher than the follow- Gear position signal ing for more than 3 seconds.
Page 377: Engine
8-4 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start, Compression too low or is hard to start. 1. Out of adjustment valve clearance. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
Page 378 SERVICING INFORMATION 8-5 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Out of adjustment valve clearance. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn down camshaft. Replace. 5. Too wide spark plug gaps. Adjust or replace.
Page 379 8-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter 1. Too large valve clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace.
Page 380 SERVICING INFORMATION 8-7 Complaint Symptom and possible causes Remedy Engine runs poorly Defective air flow system in high speed range. 1. Clogged air cleaner element. Clean or replace. 2. Defective throttle valve. Adjust or replace. 3. Defective secondary throttle valve. Adjust or replace.
Page 381 8-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. Defective engine internal parts 1. Heavy carbon deposit on piston crowns. Clean. 2. Not enough oil in the engine. Add oil. 3. Defective oil pump or clogged oil circuit. Replace or clean.
Page 382: Radiator (Cooling System)
SERVICING INFORMATION 8-9 RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats. 1. Not enough engine coolant. Add coolant. 2. Clogged with dirt or trashes radiator core. Clean. 3. Faulty cooling fan. Repair or replace. 4. Defective cooling fan thermo-switch. Replace.
Page 383: Chassis
8-10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. Adjust.
Page 384: Brakes
SERVICING INFORMATION 8-11 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace. power. 2. Worn pads. Replace. 3. Oil adhesion of engaging surface of pads/shoe. Clean disc and pads. 4.
Page 385: Electrical
8-12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil/plug cap or camshaft Replace. sparking. position sensor. 2. Defective spark plugs. Replace. 3. Defective crankshaft position sensor. Replace. 4. Defective ECM. Replace. 5.
Page 386: Battery
SERVICING INFORMATION 8-13 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case. Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates.
Page 387: Wiring Harness Routing
8-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Install the wiring harness to left side of headlight, and not to be loosely. Wiring harness Clamp INSIDE OF THE BODY COWLING Clamp Wiring harness Handle switch (L, R) Ignition switch Clamp to the frame.
Page 388 SERVICING INFORMATION 8-15 Pass through the side-stand switch Clamp lead wire over the starter motor lead wire and engine ground lead wire. Handle switch (L, R) Clamp Clamp Clamp Clamp Handle switch Ignition switch Wiring harness Do not put the tip (L, R) Starter motor Battery...
Page 389 8-16 SERVICING INFORMATION...
Page 390: Cable Routing
SERVICING INFORMATION 8-17 CABLE ROUTING...
Page 391: Fuel Tank Drain Hose Routing
8-18 SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING...
Page 392: Cooling System Hose Routing
SERVICING INFORMATION 8-19 COOLING SYSTEM HOSE ROUTING...
Page 393: Front Brake Hose Routing
8-20 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING...
Page 394: Rear Brake Hose Routing
SERVICING INFORMATION 8-21 REAR BRAKE HOSE ROUTING...
Page 395: Pair (Air Supply) System Hose Routing
8-22 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR valve vacuum hose (530 mm) To throttle body (No.4 cylinder) PAIR valve hose R (50 mm) PAIR cleaner hose PAIR valve 10 N . m (1.0 kgf . m, 7.5 lb-ft) Matching mark PAIR valve hose L (30 mm) PAIR reed valve...
Page 396: Fuel Tank Set-Up
SERVICING INFORMATION 8-23 FUEL TANK SET-UP...
Page 397: Cowling Set-Up
8-24 SERVICING INFORMATION COWLING SET-UP...
Page 398: Frame Cover Set-Up
SERVICING INFORMATION 8-25 FRAME COVER SET-UP Front seat 23 N . m (2.3 kgf . m, 16.5 lb-ft) Frame cover HEAT SHIELD SET-UP Left under cowling Left under cowling heat shield No.1 Right under cowling Left under cowling Left under cowling heat shield No.3 heat shield No.2 Right under cowling...
Page 399: Side-Stand Set-Up
8-26 SERVICING INFORMATION SIDE-STAND SET-UP 50 N . m (5.0 kgf . m, 36.2 lb-ft) 40 N . m (4.0 kgf . m, 28.9 lb-ft) GEARSHIFT PEDAL SET-UP Footrest 52 – 62 mm (2.05 – 2.44 in)
Page 400: Special Tools
SERVICING INFORMATION 8-27 SPECIAL TOOLS 09900-20101 09900-20202 09900-06104 09900-06107 09900-06108 09900-20102 Micrometer Snap ring pliers Snap ring pliers Snap ring pliers Vernier calipers (25–50 mm) 09900-20204 09900-20205 09900-20602 09900-20605 Micrometer Micrometer 09900-20508 Dial gauge Dial calipers (75–100 mm) (0–25 mm) Cylinder gauge set (1/1000 mm, 1 mm) (1/100 mm, 10–34 mm)
Page 401 8-28 SERVICING INFORMATION 09915-74520 09915-74540 09916-14510 09915-77330 09916-10911 Oil pressure gauge Oil pressure gauge Valve spring Meter Valve lapper set hose adaptor compressor (for high pressure) 09916-14521 09916-20630 09916-20650 Valve spring compressor 09916-21111 Valve seat cutter head Solid pilot 09916-34542 attachment Valve seat cutter set (N-126)
Page 402 SERVICING INFORMATION 8-29 09940-14911 09930-30450 09930-11960 09930-44520 09930-82710 Steering stem nut Rotor remover Torx wrench Rotor holder Mode selection switch wrench 09940-30221 09940-14960 09940-14990 09940-40211 09940-14970 Front fork assembling Steering nut wrench Engine mounting thrust Fuel pressure gauge Swingarm pivot shaft tool adjuster socket wrench adaptor...
Page 403: Tightening Torque
8-30 SERVICING INFORMATION TIGHTENING TORQUE ENGINE N . m kgf . m ITEM lb-ft Exhaust pipe bolt 16.5 Muffler mounting nut 16.5 Speed sensor rotor bolt 14.4 Engine sprocket nut 11.5 83.2 Engine mounting bolt and nut (M:12) 54.0 (M:10) 39.8 Engine mounting thrust adjuster Engine mounting thrust adjuster lock nut...
Page 404 SERVICING INFORMATION 8-31 N . m kgf . m lb-ft ITEM Piston cooling oil jet bolt Oil pump mounting bolt Conrod bearing cap bolt (Initial) 11.0 (Final) 90° (µ turn) Bearing retainer screw Breather cover bolt Oil strainer bolt Oil pan bolt Oil cooler bolt FI SYSTEM AND INTAKE AIR SYSTEM N .
Page 405 8-32 SERVICING INFORMATION CHASSIS N . m kgf . m ITEM lb-ft Steering stem head nut 65.0 Steering stem lock nut 58.0 Steering damper bolt and nut 16.6 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 25.5 Front fork inner rod lock nut...
Page 406 SERVICING INFORMATION 8-33 TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt N . m kgf . m N . m kgf . m A (mm) lb-ft lb-ft 0.15...
Page 407: Service Data
8-34 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STD/SPEC. LIMIT ——— Valve diam. (1.14) ——— (0.94) 0.10 – 0.20 Valve clearance ——— (0.004 – 0.008) (when cold) 0.20 – 0.30 ——— (0.008 – 0.012) Valve guide to valve stem 0.010 –...
Page 408 SERVICING INFORMATION 8-35 ITEM STD/SPEC. LIMIT Camshaft journal O.D. 23.959 – 23.980 IN. & EX. ——— (0.9433 – 0.9441) Camshaft runout 0.10 ——— (0.004) Cam chain pin (at arrow “3”) ——— 14th pin Cylinder head distortion 0.20 ——— (0.008) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STD/SPEC.
Page 409 8-36 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STD/SPEC. LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5921) (0.5910 – 0.5913) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –...
Page 410 SERVICING INFORMATION 8-37 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STD/SPEC. LIMIT 1.857 (78/42) ——— Primary reduction ratio 2.470 (42/17) ——— Final reduction ratio 2.785 (39/14) ——— Gear ratios 2.052 (39/19) ——— 1.681 (37/22) ——— 1.450 (29/20) ———...
Page 411 8-38 SERVICING INFORMATION ITEM STD/SPEC. LIMIT Use an antifreeze/coolant compatible with alumi- Engine coolant type num radiator, mixed with distilled water only, at ——— the ratio of 50:50. Reserve Approx. 250 ml Engine coolant ——— tank side (0.3/0.2 US/Imp qt) Engine Approx.
Page 412 SERVICING INFORMATION 8-39 THROTTLE BODY ITEM STD/SPEC. Bore size 42 mm I.D. No. 35 F1 (For E-33), 35 F0 (For the others) Idle r/min. 1 200 ± 100 r/min. Fast idle r/min. 3 500 r/min. (After warming up) Throttle cable play 2.0 –...
Page 413 8-40 SERVICING INFORMATION WATTAGE STD/SPEC. ITEM E-03, -24, -28, -33 E-02, -19 ← 55 + 55 W Headlight ← 55 W ——— Parking or position light ← 21/5 W × 2 Brake light / Taillight ← 21 W × 4 Turn signal light ←...
Page 414 (9.831) Front fork oil level (without spring, ——— outer tube fully compressed) (4.06) Front fork oil type SUZUKI Fork oil SS-08 (#10) or an equivalent fork oil ——— Front fork oil capacity (each leg) 473 ml ——— (16.0/16.7 US/Imp oz) ———...
Page 415 8-42 SERVICING INFORMATION ITEM STD/SPEC. LIMIT Rear wheel travel ——— (5.1) Swingarm pivot shaft runout ——— (0.01) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane R + M Gasoline containing MTBE (Methyl Tertiary Butyl Ether), E-03, -33 less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is per-...
Page 416: Emission
EMISSION CONTROL INFORMATION 9-1 EMISSION CONTROL INFORMATION CONTENTS FUEL INJECTION SYSTEM ............. 9- 2 EVAPORATIVE EMISSION CONTROL SYSTEM ......9- 2 CANISTER HOSE ROUTING ............9- 3 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION ..9- 4 PAIR (AIR SUPPLY) SYSTEM DIAGRAM........9- 5 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ......
Page 417: Fuel Injection System
9-2 EMISSION CONTOROL INFORMATION FUEL INJECTION SYSTEM GSX-R750 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. EVAPORATIVE EMISSION CONTROL SYSTEM...
Page 418: Canister Hose Routing
EMISSION CONTROL INFORMATION 9-3 CANISTER HOSE ROUTING (Only for E-33)
Page 419: Evaporative Emission Control System Inspection
9-4 EMISSION CONTOROL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the seats and frame cover. • Remove the fuel tank. (4-51) HOSES Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. CANISTER Inspect the canister for damage to the body.
Page 420: Pair (Air Supply) System Diagram
EMISSION CONTROL INFORMATION 9-5 PAIR (AIR SUPPLY) SYSTEM DIAGRAM Air cleaner box PAIR control valve Throttle body PAIR reed valve FRESH AIR EXHAUST GAS NEGATIVE PRESSURE PAIR control valve OPEN CLOSE...
Page 421: Pair (Air Supply) System Hose Routing
9-6 EMISSION CONTOROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR valve vacuum hose (530 mm) To throttle body (N0.4 cylinder) PAIR valve hose R (50 mm) PAIR cleaner hose PAIR valve 10 N . m (1.0 kgf . m, 7.5 lb-ft) Matching mark PAIR valve hose L (30 mm) PAIR reed valve...
Page 422: Pair (Air Supply) System Inspection
EMISSION CONTROL INFORMATION 9-7 PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES • Inspect the hoses for wear or damage. • Inspect that the hoses and pipes are securely connected. PAIR REED VAVLE • Remove the PAIR valve cover. • Inspect the reed valve for the carbon deposit. •...
Page 423: Gsx-R750K1 ('01-Model)
GSX-R750K1 (’01-MODEL) 10-1 GSX-R750K1 (’01-MODEL) This chapter describes service data, service specifications and servicing procedures which differ from those of the GSX-R750Y (’00-model). CONTENTS SPECIFICATIONS ................10- 2 SERVICE DATA ................. 10- 3 CLUTCH ................... 10-12 CLUTCH REASSEMBLY ............... 10-12 CLUTCH DRIVE PLATES INSPECTION ........
Page 424: Specifications
10-2 GSX-R750K1 (’01-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 040 mm (80.3 in) Overall width ................715 mm (28.1 in) Overall height ................1 135 mm (44.7 in) Wheelbase ................1 410 mm (55.5 in) Ground clearance ..............130 mm ( 5.1 in) Seat height ................
Page 425: Service Data
GSX-R750K1 (’01-MODEL) 10-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STD/SPEC. LIMIT Valve diam. ——— (1.14) ——— (0.94) Valve clearance (when cold) 0.10 – 0.20 ——— (0.004 – 0.008) 0.20 – 0.30 ——— (0.008 – 0.012) Valve guide to valve stem 0.010 –...
Page 426 10-4 GSX-R750K1 (’01-MODEL) ITEM STD/SPEC. LIMIT Camshaft journal O.D. 23.959 – 23.980 IN. & EX. ——— (0.9433 – 0.9441) Camshaft runout 0.10 ——— (0.004) Cam chain pin (at arrow “3”) 14th pin ——— Cylinder head distortion 0.20 ——— (0.008) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STD/SPEC.
Page 427: Clutch
GSX-R750K1 (’01-MODEL) 10-5 CONROD + CRANKSHAFT Unit: mm (in) ITEM STD/SPEC. LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5910 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –...
Page 428 10-6 GSX-R750K1 (’01-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STD/SPEC. LIMIT Primary reduction ratio 1.857 (78/42) ——— Final reduction ratio 2.470 (42/17) ——— Gear ratios 2.785 (39/14) ——— 2.052 (39/19) ——— 1.681 (37/22) ——— 1.450 (29/20) ———...
Page 429 GSX-R750K1 (’01-MODEL) 10-7 INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM STD/SPEC. NOTE 11 – 16 Ω at 20°C (68°F) Injector resistance Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec. Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm , 43 psi) set pressure FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR...
Page 430 10-8 GSX-R750K1 (’01-MODEL) THROTTLE BODY ITEM STD/SPEC. Bore size 42 mm I.D. No. 35 F1 (For E-33), 35 F0 (For the others) Idle r/min. 1 200 ± 100 r/min. Fast idle r/min. 3 500 r/min. (After warming up) Throttle cable play 2.0 –...
Page 431 GSX-R750K1 (’01-MODEL) 10-9 WATTAGE STD/SPEC. ITEM E-03, 24, 28, 33 The others ← Headlight 55 + 55 W ← 55 W Parking or position light ——— ← Brake light/Taillight 21/5 W × 2 ← Turn signal light 21 W × 4 ←...
Page 432 (9.61) Front fork oil level (without spring, ——— outer tube fully compressed) (4.06) Front fork oil type SUZUKI Fork oil SS-08 (#10) or an equivalent fork oil ——— Front fork oil capacity (each leg) 473 ml ——— (16.0/16.7 US/Imp oz)
Page 433 GSX-R750K1 (’01-MODEL) 10-11 ITEM STD/SPEC. LIMIT Rear wheel travel ——— (5.1) Swingarm pivot shaft runout ——— (0.01) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump R + M octane ( Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
Page 434: Clutch Reassembly
10-12 GSX-R750K1 (’01-MODEL) CLUTCH CLUTCH REASSEMBLY Direction of outside DRIVE PLATE: A No.1 Drive Plate ........8 pcs. B No.2 Drive Plate ........1 pc. C No.3 Drive Plate ........1 pc. DRIVE PLATE: a No.1 Driven Plate ........6 – 8 pcs. b No.2 Driven Plate ........
Page 435: Clutch Drive Plates Inspection
GSX-R750K1 (’01-MODEL) 10-13 CLUTCH DRIVE PLATES INSPECTION NOTE: * Wipe off engine oil from the clutch drive plates with a clean rag. * Clutch drive plate No.1: Purple paint No.2: Green paint No.3: Dampers on claws • Measure the drive plates with a vernier calipers. •...
Page 436: Fuel Pressure Inspection
10-14 GSX-R750K1 (’01-MODEL) FUEL PRESSURE INSPECTION • Lift and support the fuel tank with its prop stay. • Place a rag under the fuel feed hose. • Remove the fuel feed hose 1 and install the special tools be- tween the fuel tank and fuel delivery pipe. [ 09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77330: Oil pressure gauge...
Page 437: Throttle Stop Screw
GSX-R750K1 (’01-MODEL) 10-15 THROTTLE STOP SCREW The throttle stop screw A is installed on the No.1 throttle body. • Remove the front seat. • Lift and support the fuel tank. • Ajust the engine idle speed. (2-15) AP SENSOR The AP sensor B (Atmospheric pressure sensor) is located over the ECM.
Page 438: Engine Mounting Bolt And Nut
10-16 GSX-R750K1 (’01-MODEL) ENGINE MOUNTING BOLT AND NUT Left Right LENGTH N . m kgf . m ITEM ITEM lb-ft 1.77 39.8 Bolt 2.17 54.0 8.46 16.5 Spacer 30.5 1.20 32.5 Adjuster 1.57...
Page 439: Canister Hose Routing (For E-33)
GSX-R750K1 (’01-MODEL) 10-17 CANISTER HOSE ROUTING (FOR E-33)
Page 440: Gsx-R750K2 ('02-Model)
• Any differences between the GSX-R750K1 (’01-model) and GSX-R750K2 (’02-model) in specifications and service data are indicated with an asterisk mark (*). • Please refer to the GSX-R750 Service Manual for details which are not given in this manual. CONTENTS SPECIFICATIONS ................
Page 441: Specifications
11-2 GSX-R750K2 (’02-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 040 mm (80.3 in) Overall width ..............715 mm (28.1 in) Overall height ..............1 135 mm (44.7 in) Wheelbase ..............1 410 mm (55.5 in) Ground clearance ............130 mm (5.1 in) Seat height ..............
Page 442 GSX-R750K2 (’02-MODEL) 11-3 CHASSIS Front suspension ............Inverted telescopic, coil spring, spring pre-load fully adjustable, rebound and compression damping force fully adjustable. Rear suspension ............Link type system, gas/oil damped, coil spring, spring pre-road fully adjustable, rebound and com- pression damping force fully adjustable. Caster ................
Page 443: Engine
11-4 GSX-R750K2 (’02-MODEL) ENGINE CLUTCH The spring washer 1 and its seat 2 have been equipped and No. 3 Drive plate 3 has been changed as follows. No. 3 Drive plate A: 8.5 mm (0.33 in) Part No.: 21440 -39F00 K2-MODEL TIGHTENING TORQUE FOR CAM CHAIN TENSION ADJUSTER CAP...
Page 444: Fi System And Intake Air System
GSX-R750K2 (’02-MODEL) 11-5 FI SYSTEM AND INTAKE AIR SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT ––––––––––– Camshaft position The signal does not reach ECM for more than 4 sec. after re- sensor ceiving the starter signal.
Page 445 11-6 GSX-R750K2 (’02-MODEL) Secondary throttle When no actuator control signal is supplied from the ECM or valve actuator communication signal does not reach ECM or operation voltage does not reach STVA motor, c28 is indicated. STVA can not operate. STVA lead wire/coupler. The sensor should produce following voltage.
Page 446: C28" Stv Actuator Circuit Malfunction
GSX-R750K2 (’02-MODEL) 11-7 “C28” STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction. ECM does not receive communication signal from • STVA circuit open or short. the STVA. • STVA motor malfunction. INSPECTION •...
Page 447: C29" Stp Sensor Circuit Malfunction
11-8 GSX-R750K2 (’02-MODEL) “C29” STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. • STP sensor maladjusted. Difference between actual throttle opening and • STP sensor circuit open or short. opening calculated by ECM in larger than specified •...
Page 448 GSX-R750K2 (’02-MODEL) 11-9 Turn the ignision switch OFF. Connect the STP sensor coupler. Insert the copper wires to the lead wire coupler. Disconnect the STVA lead wire coupler 1. Turn the ignition switch ON. Measure the STP sensor output voltage at the coupler (be- tween Yellow and Black wires) by turning the secondary throttle valve (close and open) with a finger.
Page 449: Fuel Pump
11-10 GSX-R750K2 (’02-MODEL) FUEL PUMP CONSTRUCTION N . m Kgf . m ITEM lb-ft 1 Fuel pressure regulator 2 O-ring 3 Fuel pump case/Fuel filter cartridge (For high pressure) 4 Thermistor 5 Fuel pump 6 Fuel mesh filter (For low pressure) REASSEMBLY •...
Page 450 GSX-R750K2 (’02-MODEL) 11-11 • Be sure to connecft the wires to the proper terminals. A ....+ terminal for fuel pump B ....For thermistor C ....- terminal for fuel pump Pass through the wires behind the thermistor.
Page 451: Throttle Body
11-12 GSX-R750K2 (’02-MODEL) THROTTLE BODY CONSTRUCTION 1 Vacuum hose 2 TP sensor 3 STP sensor 4 Throttle body (Nos. 3, 4) 5 Throttle body (Nos. 1, 2) 6 Synchronizing screw 7 Stay plate 8 Fast idle adjusting screw 9 Throttle stop screw 0 Fuel delivery pipe A O-ring B Dust seal...
Page 452 GSX-R750K2 (’02-MODEL) 11-13 THROTTLE BODY REMOVAL • Lift and support the fuel tank with its prop stay. • Disconnect the IAT sensor coupler 1 and PAIR hose 2. • Disconnect the IAP sensor coupler 3 and vacuum hose 4. • Disconnect the crankcase breather hose 5. •...
Page 453 11-14 GSX-R750K2 (’02-MODEL) • Disconnect the throttle cables from their drum. • Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank. • Disconnect the vacuum hose 1 from the PAIR valve. •...
Page 454 GSX-R750K2 (’02-MODEL) 11-15 THROTTLE BODY DISASSEMBLY • Disconnect the following parts. 1 Fuel feed hose 2 Vacuum hose 3 Vacuum hose 4 Purge hose (Only for E-33) • Disconnect the lead wire couplers. • Remove the fuel delivery pipe assembly 5 by removing its mounting screws.
Page 455 11-16 GSX-R750K2 (’02-MODEL) • Remove the nut 1. • Separate the throttle body assembly to a pair of two bodies (Nos. 1 . 2 and Nos. 3 . 4) by removing their connecting bolts. NOTE: Be careful not to lose the springs. Never remove the secondary throttle valve and throttle valve.
Page 456 GSX-R750K2 (’02-MODEL) 11-17 THROTTLE BODY CLEANING " Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
Page 457 11-18 GSX-R750K2 (’02-MODEL) • Install the stay plate 1. • Place the throttle body assembly on the surface plate and tighten the connecting bolts. ! Throttle body connecting bolt: 6 N . m (0.6 kgf . m, 4.5 lb-ft) • Install the fast idle link levers properly. •...
Page 458 GSX-R750K2 (’02-MODEL) 11-19 White color T PS and STPS resemble each other very closely in external appearance. Make sure to check the color of coupler before installing. STVA STPS 3.5 N . m (0.35 kgf . m, 2.5 lb-ft) 6 N . m (0.6 kgf .
Page 459 11-20 GSX-R750K2 (’02-MODEL) • Assemble the fuel delivery pipes. • Install the fuel delivery pipe assembly to the throttle body as- sembly. Never turn the fuel injectors while installing them. • Tighten the fuel delivery pipe mounting screws. ! Fuel delivery pipe mounting screw: 3.5 N . m (0.35 kgf .
Page 460 GSX-R750K2 (’02-MODEL) 11-21 THROTTLE BODY CLAMP POSITION Forward 25˚ ± 10˚ 10˚ ± 10˚ 10˚ ± 10˚ VIEW OF TOP STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor positioning as follows: •...
Page 461 11-22 GSX-R750K2 (’02-MODEL) THROTTLE POSITION SENSOR ADJUSTMENT 1. Adjust the engine rpm to 1 200 rpm. 2. Stop the engine and connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, loosen the screws and turn the throttle position sensor and bring the line to middle.
Page 462: Throttle Valve Synchronization
GSX-R750K2 (’02-MODEL) 11-23 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH GAUGE • Lift and support the fuel tank. • Start up the engine and run it in idling condition for warming up. •...
Page 463 11-24 GSX-R750K2 (’02-MODEL) • Remove the vacuum hose 1 from the No. 1 throttle body. • Connect one of the four rubber hoses of the vacuum balancer gauge to the nipple 2 on the No.1 throttle body. [ 09913-13121: Vacuum balancer gauge •...
Page 464 GSX-R750K2 (’02-MODEL) 11-25 THROTTLE VALVE SYNCHRONIZATION • Remove the PAIR vacuum hose 1 and connect a proper rub- ber cap to the nipple. • To synchronize throttle valves, remove the respective vacuum hoses 2 from each vacuum nipple and connect the vacuum balancer gauge hoses to the vacuum nipples respectively.
Page 465: Chassis
• Tighten the front axle to the specified torque. ! Front axle: 100 N . m (10.0 kgf . m, 72.5 lb-ft) SWINGARM PIVOT BOSS REMOVAL • Remove the swingarm. (6-52 of the GSX-R750 Service Manual) • Remove the swingarm pivot boss nut. NOTE: Remove the swingarm pivot boss when only replacing it.
Page 466 GSX-R750K2 (’02-MODEL) 11-27 INSTALLATION • Set the swingarm pivot boss by its set screws. • Tighten the swingarm boss nut to the specified torque. ! Swingarm pivot boss nut: 65 N . m (6.5 kgf . m, 47.0 lb-ft) 15 N . m 1.5 kgf .
Page 467: Torque Link
11-28 GSX-R750K2 (’02-MODEL) TORQUE LINK Front side of the torque link washer has been eliminated. In accor- dance with this elimination, the torque link mounting bolt has been changed. K2-model 19 mm (0.7 in) 34.5 mm (1.36 in)
Page 468: Servicing Information
GSX-R750K2 (’02-MODEL) 11-29 SERVICING INFORMATION WIRE HARNESS ROUTING...
Page 469 11-30 GSX-R750K2 (’02-MODEL) Clamp Wire harness Fix the wire harness Regulator/ clamp to the frame. rectifier Pass the neutral switch lead wire behind the bypass Clamp hose and breather hose. Wiring harness To the Fan motor fuel pump Wire harness Rear turn signal light (L) Clamp...
Page 470 GSX-R750K2 (’02-MODEL) 11-31...
Page 471: Cooling System Hose Routing
11-32 GSX-R750K2 (’02-MODEL) COOLING SYSTEM HOSE ROUTING...
Page 472: Front Brake Hose Routing
GSX-R750K2 (’02-MODEL) 11-33 FRONT BRAKE HOSE ROUTING...
Page 473: Rear Brake Hose Routing
11-34 GSX-R750K2 (’02-MODEL) REAR BRAKE HOSE ROUTING...
Page 474: Canister Hose Routing (Only For E-33)
GSX-R750K2 (’02-MODEL) 11-35 CANISTER HOSE ROUTING (Only for E-33)
Page 475: Service Data
11-36 GSX-R750K2 (’02-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STD/SPEC. LIMIT Valve diam. ——— (1.14) ——— (0.94) Valve clearance (when cold) 0.10 – 0.20 ——— (0.004 – 0.008) 0.20 – 0.30 ——— (0.008 – 0.012) Valve guide to valve stem 0.010 –...
Page 476 GSX-R750K2 (’02-MODEL) 11-37 ITEM STD/SPEC. LIMIT Camshaft journal O.D. 23.959 – 23.980 IN. & EX. ——— (0.9433 – 0.9441) Camshaft runout 0.10 ——— (0.004) Cam chain pin (at arrow “3”) 14th pin ——— Cylinder head distortion 0.20 ——— (0.008) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STD/SPEC.
Page 477 11-38 GSX-R750K2 (’02-MODEL) CONROD + CRANKSHAFT Unit: mm (in) ITEM STD/SPEC. LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5910 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –...
Page 478 GSX-R750K2 (’02-MODEL) 11-39 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STD/SPEC. LIMIT Primary reduction ratio 1.857 (78/42) ——— Final reduction ratio 2.470 (42/17) ——— Gear ratios 2.785 (39/14) ——— 2.052 (39/19) ——— 1.681 (37/22) ——— 1.450 (29/20) ———...
Page 479 11-40 GSX-R750K2 (’02-MODEL) INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM STD/SPEC. NOTE 11 – 16 Ω at 20°C (68°F) Injector resistance Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec. Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm , 43 psi) set pressure FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR...
Page 480 GSX-R750K2 (’02-MODEL) 11-41 THROTTLE BODY ITEM STD/SPEC. Bore size 42 mm I.D. No. * 35 F3 (For E-33), 35 F2 (The others) Idle r/min. 1 200 ± 100 r/min. + 200 Fast idle r/min. *1 800 r/min. (When engine is cold) –...
Page 481 11-42 GSX-R750K2 (’02-MODEL) WATTAGE STD/SPEC. ITEM E-03, 24, 28, 33 The others Headlight * 60 W × 2 55 + 55 W * 55 W × 2 55 W Parking or position light ——— ← Brake light/Taillight 21/5 W × 2 ←...
Page 482 (9.61) Front fork oil level (without spring, ——— outer tube fully compressed) (4.06) Front fork oil type SUZUKI Fork oil SS-08 (#10) or an equivalent fork oil ——— Front fork oil capacity (each leg) 473 ml ——— (16.0/16.7 US/Imp oz)
Page 483 11-44 GSX-R750K2 (’02-MODEL) ITEM STD/SPEC. LIMIT Rear wheel travel ——— (5.1) Swingarm pivot shaft runout ——— (0.01) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 90 pump R + M octane ( Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
Page 484: Wiring Diagram
WIRING DIAGRAM FI SYSTEM WIRING DIAGRAM WIRE COLOR : Black : Blue : Brown Dbr : Dark brown : Dark green : Green : Gray Lbl : Light blue : Light green : Orange : Pink : Red : Violet : White : Yellow B/Bl : Black with Blue tracer...
Page 485 WIRING DIAGRAM (Y-MODEL) FOR E-03, 28, 33 HANDLE SWITCH (R) T: TURN SIGNAL INDICATOR LIGHT FRONT B: HIGH BEAM INDICATOR LIGHT ENGINE BRAKE N: NEUTRAL INDICATOR LIGHT STOP STARTER LIGHT F: FUEL INDICATOR LIGHT OIL: OIL PRESSURE/ENGINE COOLANT IGNITION COIL/PLUG CAP PUSH TEMP./FI INDICATOR LIGHT SIDE-STAND...
Page 486 FOR E-24 (Y-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT ENGINE BRAKE B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT F: FUEL INDICATOR LIGHT IGNITION COIL/PLUG CAP PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH SPEEDOMETER...
Page 487 FOR E-02, 19 (Y-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT ENGINE BRAKE LIGHTING B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT F: FUEL INDICATOR LIGHT IGNITION COIL/PLUG CAP PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH...
Page 488 WIRING DIAGRAM (K1-MODEL) FOR E-03, 28, 33 HANDLE SWITCH (R) T: TURN SIGNAL INDICATOR LIGHT FRONT B: HIGH BEAM INDICATOR LIGHT ENGINE BRAKE N: NEUTRAL INDICATOR LIGHT STOP STARTER LIGHT F: FUEL INDICATOR LIGHT OIL: OIL PRESSURE/ENGINE COOLANT IGNITION COIL/PLUG CAP PUSH TEMP./FI INDICATOR LIGHT SIDE-STAND...
Page 489 FOR E-24 (K1-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT ENGINE BRAKE B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT F: FUEL INDICATOR LIGHT IGNITION COIL/PLUG CAP PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH SPEEDOMETER...
Page 490 THE OTHERS (K1-MODEL) HANDLE SWITCH (R) FRONT T: TURN SIGNAL INDICATOR LIGHT LIGHTING ENGINE BRAKE B: HIGH BEAM INDICATOR LIGHT STOP STARTER LIGHT N: NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP F: FUEL INDICATOR LIGHT PUSH OIL: OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SIDE-STAND SWITCH SPEEDOMETER...
Page 491 STARTER SIDE-STAND WIRING DIAGRAM (K2-MODEL) BUTTON SWITCH FI SYSTEM WIRING DIAGRAM SIDE-STAND RELAY BATTERY MAIN SWITCH ENGINE STOP IGNITION COIL SWITCH FUEL PUMP STARTER MAIN RELAY RELAY FUSE IG 2 IG 3 IG 4 IG 1 SWITCH FUEL PUMP 10A 15A 15A W/Bl Gr/W Gr/B...
Page 492 FOR E-02, 19, 54 (K2-MODEL) HANDLE SWITCH (R) FRONT ENGINE BRAKE STOP LIGHT SIDE STAND : TURN SIGNAL INDICATOR LIGHT SWITCH LIGHTING : HIGH BEAM INDICATOR LIGHT SWITCH : NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP STARTER : FUEL INDICATOR LIGHT : OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SPEEDOMETER...
Page 493 FOR E-24 (K2-MODEL) HANDLE SWITCH (R) FRONT ENGINE BRAKE STOP LIGHT SIDE STAND : TURN SIGNAL INDICATOR LIGHT SWITCH : HIGH BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP STARTER : FUEL INDICATOR LIGHT : OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SPEEDOMETER IGNITION...
Page 494 FOR E-03, 28, 33 (K2-MODEL) HANDLE SWITCH (R) FRONT ENGINE BRAKE STOP LIGHT SIDE STAND : TURN SIGNAL INDICATOR LIGHT SWITCH : HIGH BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT IGNITION COIL/PLUG CAP STARTER : FUEL INDICATOR LIGHT : OIL PRESSURE/ENGINE COOLANT TEMP./FI INDICATOR LIGHT SPEEDOMETER IGNITION...
Page 495 Prepared by 3rd Ed. August, 2002 1st Ed. February, 2000 Part No. 99500-37112-03E Printed in Japan...

This manual is also suitable for:

Gsx-r750ud Gsx-r750uf Gsx-r750y 2000 Gsx-r750k2 2002 Gsx-r750k3 2003 Gsx-r750k1 2001

Suzuki GSX-R750 Service Manual

Foreword Group Index

General Information 1

Periodic Maintenance

Engine

Fi System and Intake Air System

Cooling and Lubrication System

Chassis

Electrical System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki GSX-R750