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.
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.
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.
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...
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...
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...
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.
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.
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.
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.
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...
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 ..............
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 ................
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...
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.
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...
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). •...
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) •...
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.
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.
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) •...
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 •...
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. •...
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.
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.
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.
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: •...
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.
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.
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. •...
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.
* 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.
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.
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.
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.
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).
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...
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).
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 .
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...
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.
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 ..................
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...
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.
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.
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 •...
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. •...
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.
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. •...
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. •...
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.
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. •...
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...
! 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.
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 .
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...
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 •...
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. •...
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.
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. •...
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.
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. •...
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.
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 •...
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.
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 •...
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 •...
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.
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.
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 •...
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...
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 &...
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 •...
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.
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. •...
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.
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.
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.
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.
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°...
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.
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.
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)
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. •...
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.
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 •...
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 •...
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.
* 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.
ENGINE 3-49 TRANSMISSION PARTS LOCATION...
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.
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 –...
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 –...
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.
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. •...
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.
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.
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. •...
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.
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.
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. •...
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.
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 –...
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.
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.
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.
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 –...
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. •...
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. •...
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. •...
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-...
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.
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 .
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.
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.
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 .
• 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 •...
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”...
• 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.
• 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)
[ 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.
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.
• 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.
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.
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”...
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.
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.
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 •...
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) ...
! 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”...
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.
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 .
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.
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.
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.
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. •...
• 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”...
! 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)
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 ..................
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 ......
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.
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 •...
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.
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 •...
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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...
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.
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.
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.
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.
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. •...
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. •...
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 •...
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.
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.
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...
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 •...
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 •...
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 <...
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.
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.
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 •...
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.
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.
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 •...
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.
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. •...
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 •...
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.
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.
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.
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) •...
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. •...
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.
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 ..
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...
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 .
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 •...
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.
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. •...
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.
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.
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. •...
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.
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...
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. •...
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 .
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.
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 .
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...
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 •...
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...
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.
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 •...
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.
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 •...
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 •...
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) •...
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.
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)
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. •...
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. •...
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 •...
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. •...
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. •...
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) •...
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.
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.
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) •...
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.
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.
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 •...
[ 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”...
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.
* 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) •...
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........
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 ........
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...
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. •...
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. •...
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.
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) •...
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. •...
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. •...
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.
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.
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 .
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.
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.
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 .
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. •...
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.
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.
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.
• 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.
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...
[ 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)
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.
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.
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.
• 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”...
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...
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. •...
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.
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 •...
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 .
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 •...
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.
• 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)
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. •...
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...
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. •...
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 .
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.
• 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.
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 .
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. •...
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.
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)
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...
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 .
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. •...
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.
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.
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.
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 .
• 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”...
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.
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.
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...
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.
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.
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.
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 .
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.
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 •...
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 .
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...
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.
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.
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.
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.
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.
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.
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.
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. •...
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.
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. •...
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. •...
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.
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.
• 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.
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...
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.
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.
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”.
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) •...
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.
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.
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.
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.
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...
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...
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)
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. •...
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.
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 <...
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.
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.
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.
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 •...
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.
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) –...
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...
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.
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.
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.
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.
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.
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.
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.
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.
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...
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 •...
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...
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. •...
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.
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...
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.
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.
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.
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 ......
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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...
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...
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 .
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...
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...
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 –...
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) ———...
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.
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 –...
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 ←...
(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) ———...
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-...
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 ......
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...
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.
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...
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. •...
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 ........
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 –...
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 ←...
(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)
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-...
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. •...
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 09915-7