Page 1 GSX-R750 9 9 5 0 0 - 3 7 1 3 0 - 0 1 E...
Page 2: General Information
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 compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.
Page 3: How To Use This Manual
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 4 Use engine coolant. wise specified. 99000-99032-11X (Except USA) Apply molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKI 99000-99001-SS5 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent grease. Apply or use brake fluid.
Page 5: Abbreviations Used In This Manual
ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Engine Control Module : Alternating Current Engine Control Unit (ECU) : Air Cleaner, Air Cleaner Box (FI Control Unit) : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp.
Page 6 : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor...
Page 7 WIRE COLOR : Black : Green :Pink : Blue : Gray : Red : Brown : Light blue : White : Dark green : Light green : Yellow : Dark gray : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer B/Lg...
Page 8: Table Of Contents
GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE................. 1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI GSX-R750K6 (’06-MODEL)............1- 4 SERIAL NUMBER LOCATION ..............1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION....... 1- 5 FUEL (FOR USA AND CANADA)............1- 5 FUEL (FOR OTHER COUNTRIES) ............1- 5 ENGINE OIL (FOR USA)................
Page 9: Warning/Caution/Note
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. ...
Page 10 GENERAL INFORMATION  * 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 and orientation.
Page 11: Suzuki Gsx-R750K6 ('06-Model)
GENERAL INFORMATION SUZUKI GSX-R750K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustrations and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.
Page 12: Fuel, Oil And Engine Coolant Recommendation
Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.
Page 13: Front Fork Oil
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
Page 14: Break-In Procedures
GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
Page 15: Information Labels
GENERAL INFORMATION INFORMATION LABELS GSX-R750 GSX-R750UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Fuel information label...
Page 16: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 040 mm (80.3 in) Overall width ................715 mm (28.1 in) Overall height ................1 125 mm (44.3 in) Wheelbase ................1 400 mm (55.1 in) Ground clearance..............130 mm (5.1 in) Seat height ................
Page 17: Chassis
1-10 GENERAL INFORMATION CHASSIS Front suspension ..............Inverted telescopic, coil spring, oil damped Rear suspension ..............Link type, coil spring, oil damped Front fork stroke..............120 mm (4.7 in) Rear wheel travel ..............130 mm (5.1 in) Steering angle................. 27° Caster ..................
Page 18 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ............ 2- 2 PERIODIC MAINTENANCE CHART............. 2- 2 LUBRICATION POINTS ................ 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ........2- 4 AIR CLEANER..................2- 4 SPARK PLUG..................2- 5 VALVE CLEARANCE................2- 7 ENGINE OIL AND OIL FILTER .............
Page 19: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. IMPORTANT (For E-28): The periodic maintenance intervals and service requirements have been estab- lished in accordance with EPA regulations.
Page 20: Lubrication Points
PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Brake pedal pivot and footrest pivot Clutch lever holder Footrest pivot and Side-stand pivot Drive chain gearshift lever pivot...
Page 21: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months). Replace every 18 000 km (11 000 miles, 36 months). •...
Page 22: Spark Plug
PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). Replace every 12 000 km (7 500 miles, 24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) •...
Page 23 PERIODIC MAINTENANCE SPARK PLUG GAP • Measure the spark plug gap with a thickness gauge. • Adjust the spark plug gap if necessary.  Spark plug gap: Standard: 0.7 – 0.8 mm (0.028 – 0.031 in)  09900-20803: Thickness gauge ELECTRODE’S CONDITION •...
Page 24: Valve Clearance
PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-14) • Disconnect the CMP sensor coupler 1. •...
Page 25 PERIODIC MAINTENANCE • Turn the crankshaft to bring the line A on the CKP sensor rotor to the rib B behind the clutch cover and also to bring the notches A on the left ends of both camshafts (Ex. and In.) to the positions as shown.
Page 26 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. (3-14) • Remove the tappet and shim by fingers or magnetic hand. •...
Page 27 2-10 PERIODIC MAINTENANCE (INTAKE SIDE)
Page 28 PERIODIC MAINTENANCE 2-11 (EXHAUST SIDE)
Page 29: Engine Oil And Oil Filter
2-12 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.
Page 30: Exhaust Control Valve
Oil and filter change : 2.5 L (2.6/2.2 US/Imp qt) Engine overhaul : 2.9 L (3.1/2.6 US/Imp qt)  ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
Page 31: Fuel Line
2-14 PERIODIC MAINTENANCE • Remove the under cowlings. (8-5) • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. FUEL LINE Inspect initially 6 000 km (4 000 miles, 12 months). • Inspect the fuel feed hose 1 for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.
Page 32: Throttle Valve Synchronization
PERIODIC MAINTENANCE 2-15 THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths). • Inspect the throttle valve synchronization periodically. (5-26) EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) Inspect every 12 000 km (7 500 miles, 24 months).
Page 33: Clutch
2-16 PERIODIC MAINTENANCE CLUTCH Inspect every 6 000 km (4 000 miles, 12 months). • Lift and support the fuel tank with its prop stay. (5-3) • Turn in the adjuster 1 all the way into the clutch lever assem- bly.
Page 34: Cooling System
PERIODIC MAINTENANCE 2-17 COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 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 reservoir.
Page 35 2-18 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •...
Page 36 PERIODIC MAINTENANCE 2-19 RADIATOR HOSES • Remove the under cowlings. (8-5) • Lift and support the fuel tank. (5-3) • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one.
Page 37: Drive Chain
2-20 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below.
Page 38 PERIODIC MAINTENANCE 2-21 • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the 1 2 3 19 20 21 service limit, the chain must be replaced.  Drive chain 20-pitch length: Service limit: 319.4 mm (12.57 in) ADJUSTING •...
Page 39 • After washing and drying the chain, oil it with a heavyweight motor oil.  * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is RK525ROZ5Y. Suzuki recommends to use this standard drive chain as a replacement.
Page 40: Brake
PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years.
Page 41 2-24 PERIODIC MAINTENANCE BRAKE PADS Front 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 the new ones. (8-65) ...
Page 42 PERIODIC MAINTENANCE 2-25 BRAKE LIGHT SWITCH • Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
Page 43 2-26 PERIODIC MAINTENANCE FRONT BRAKE (Master cylinder side) • Bleed air from the master cylinder in the same manner as front brake (caliper side).  Air bleeder valve: 6.0 N·m (0.6 kgf-m, 4.3 Ib-ft) NOTE: If air is trapped in the master cylinder, bleed air from the master cylinder first.
Page 44: Tires
PERIODIC MAINTENANCE 2-27 TIRES Inspect every 6 000 km (4 000 miles, 12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.
Page 45: Front Fork
2-28 PERIODIC MAINTENANCE FRONT FORK Inspect every 12 000 km (7 500 miles, 24 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. (8-18) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months).
Page 46: Exhaust Pipe Bolt And Nut
PERIODIC MAINTENANCE 2-29 EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque.
Page 47: Chassis Bolts And Nuts
2-30 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m...
Page 48 PERIODIC MAINTENANCE 2-31...
Page 49: Compression Pressure Check
2-32 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
Page 50: Oil Pressure Check
PERIODIC MAINTENANCE 2-33 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 100 – 400 kPa (1.0 – 4.0 kgf/cm , 14 – 57 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) If the oil pressure is lower or higher than the specification, the following causes may be considered.
Page 51: Sds Check
2-34 PERIODIC MAINTENANCE SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.
Page 52: Data At The Time Of Racing
PERIODIC MAINTENANCE 2-35 Data at 3 000 r/min under no load 3 000 r/min Check the manifold absolute pressure. XXX mmHg Data at the time of racing Throttle: Slowly open Throttle: Quick wide open Secondary throttle valve opens closes in according with the engine r/min.
Page 53 2-36 PERIODIC MAINTENANCE Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. Approx. XXX mmHg Data of secondary throttle valve operation at the time of starting Closes fully in approx. XX sec.
Page 54 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ..............3-10 ENGINE DISASSEMBLY ................3-14 ENGINE COMPONENTS INSPECTION AND SERVICE......3-27 CYLINDER HEAD COVER..............3-27 CMP SENSOR ..................
Page 55: Engine Components Removable With Engine In Place
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 INSTALLATION 11-7...
Page 56: Engine Removal And Installation
ENGINE 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 procedure. • Remove the under cowlings. (8-5) •...
Page 57 ENGINE RADIATOR • Disconnect the by-pass hose 1 and radiator inlet hose 2. • Disconnect the oil cooler outlet hose 3. • Disconnect the cooling fan coupler 4. • Remove the radiator mounting bolts. • Remove the radiator 5.  Be careful not to bent the radiator fins.
Page 58 ENGINE EXHAUST PIPE AND MUFFLER • Remove the EXCV cables along with the bracket 1. • Loosen the muffler connecting bolt. • Remove the HO2 sensor 2 (For E-02, 19). (4-107) • Remove the exhaust pipe bolts. • Remove the exhaust pipe. •...
Page 59 ENGINE • Disconnect the following couplers. 3 GP switch lead wire 4 CKP sensor lead wire 5 Ground lead wire 6 Starter motor lead wire 7 Speed sensor lead wire 8 ECT sensor • Disconnect the ignition coil/plug cap lead wire couplers. ...
Page 60 ENGINE ENGINE SPROCKET AND GEARSHIFT LEVER • Disengage the gearshift lever 1. • Remove the engine sprocket cover 2. • Remove the clutch push rod 3. • Remove the speed sensor rotor 4. • Remove the engine sprocket nut 5 and the washer 6. •...
Page 61 ENGINE • Remove the engine sprocket 0. ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolt A. • Loosen the engine mounting pinch bolt 1. • Remove the engine mounting bolt B.
Page 62 ENGINE • Remove the engine mounting nut 2. • Remove the engine mounting thrust adjuster lock-nut 3 with the special tool. • Loosen the engine mounting thrust adjuster 4 fully.  09940-14980: Engine mounting thrust adjuster socket wrench • Remove the engine mounting nut 5. •...
Page 63: Engine Installation
3-10 ENGINE 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 spacers 1. •...
Page 64 ENGINE 3-11  LENGTH ITEM N·m kgf-m lb-ft ITEM 40.0 1.77 16.5 2.17 Bolt 16.5 8.46 32.5 8.07 54.0 Spacer 30.5 1.20 Adjuster 1.57 a LH b RH...
Page 65 • Tighten the speed sensor rotor bolt 4 to the specified torque.  Speed sensor rotor bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the clutch push rod end.  99000-25010: SUZUKI SUPER GREASE “A”...
Page 66 ENGINE 3-13 • Tighten the muffler mounting bolts, exhaust pipe bolts and muffler connecting bolt to the specified torque.  Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
Page 67: Engine Disassembly
3-14 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 origi- nal positions. • Remove the spark plugs. (2-5) STARTER MOTOR •...
Page 68 ENGINE 3-15 • Turn the crankshaft to bring the line A on the CKP sensor rotor to the rib B behind the clutch cover and also to bring the cams to the position as shown. • Remove the cam chain tension adjuster 2. •...
Page 69 3-16 ENGINE CYLINDER HEAD • Remove the thermostat cover 1. • Remove the thermostat 2 and thermostat conector 3. THERMOSTAT INSPECTION (7-9) • Remove the ECT sensor 4. ECT SENSOR INSPECTION (7-7) • Remove the cylinder head bolts (M6) 5. •...
Page 70 ENGINE 3-17 • Hold the clutch housing with the special tool.  Do not damage the clutch plates by the special tool.  09920-53740: Clutch sleeve hub holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. •...
Page 71 3-18 ENGINE • Hold the clutch sleeve hub with the special tool.  09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the washers C, D and E from the clutch sleeve hub. • Remove the wave spring washers F and clutch lifter driven cam G.
Page 72 ENGINE 3-19 OIL PUMP DRIVE SPROCKET • Remove the spacer 1. • Remove the oil pump drive sprocket 2 and chain 3. • Remove the thrust washer 4. GEARSHIFT SYSTEM • With the snap ring 1 and washer removed, remove the gear- shift shaft assembly 2.
Page 73 3-20 ENGINE • Remove the shaft 4, bearing 5 and thrust washer 6. • Remove the generator cover. • Remove the dowel pins and gasket. • Remove the starter idle gear No. 2 7 and shaft 8. CAM CHAIN/CAM CHAIN TENSIONER/CAM CHAIN GUIDE •...
Page 74 ENGINE 3-21 GENERATOR ROTOR AND STARTER DRIVEN GEAR • Hold the generator rotor with the special tool.  09930-44520: Rotor holder • Remove the generator rotor bolt. • Install a bolt A of suitable size to the left end of crankshaft. SUITABLE BOLT A [M12, length: 28 –...
Page 75 3-22 ENGINE GEAR POSITION SWITCH • Remove the gear position switch 1. CRANKCASE BREATHER (PCV) COVER • Remove the crankcase breather cover 1. • Remove the gasket 2. OIL PRESSURE SWITCH • Remove the oil pressure switch 1. OIL FILTER •...
Page 76 ENGINE 3-23 OIL COOLER • Remove the oil cooler 1. OIL PAN • Remove the plate 1 and oil pan. • Remove the gasket. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL STRAINER • Remove the oil strainer 2. OIL PUMP •...
Page 77 3-24 ENGINE • Remove the upper crankcase bolts. • Remove the lower crankcase bolts (M8). • Remove the crankshaft journal bolts (M9). • Remove the lower crankcase assembly. • Remove the dowel pins and O-ring 2. BALANCER SHAFT • Remove the balancer shaft 1 and oil seal 2. COUNTERSHAFT •...
Page 78 ENGINE 3-25 • Remove the C-ring 6 and bearing pin 7. CRANKSHAFT • Loosen the conrod bearing cap bolts by using a 10 mm, 12-point socket wrench, and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap. •...
Page 79 3-26 ENGINE • Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the piston head.
Page 80: Engine Components Inspection And Service
ENGINE 3-27 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. CYLINDER HEAD COVER •...
Page 81: Crankcase Breather Reed Valve
3-28 ENGINE INSPECTION • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. CRANKCASE BREATHER REED VALVE REMOVAL • Remove the crankcase breather reed valve 1 from the crank- case breather cover.
Page 82: Camshaft
ENGINE 3-29 CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against let- ters “IN” (for intake). CAM WEAR • Check the camshaft for wear or damage. •...
Page 83: Camshaft Runout
3-30 ENGINE NOTE: Do not rotate the camshaft with the plastigauge in place. • Remove the camshaft holders, and read the width of the com- pressed plastigauge with envelope scale. • This measurement should be taken at the widest part. •...
Page 84: Cam Chain Tension Adjuster
ENGINE 3-31 CAM CHAIN TENSION ADJUSTER INSPECTION • Holding the cam chain tension adjuster as shown, compress the plunger by turning the adjuster body until the outer circlip A fits the groove B. NOTE: * Wipe off engine oil from the plunger head and thumb so that they may not to be slippery.
Page 85: Cam Chain Guide
3-32 ENGINE CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guide No. 1 and No. 2. • If they are worn or damaged, replace them with the new ones. CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY •...
Page 86 ENGINE 3-33 CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.
Page 87 3-34 ENGINE VALVE STEM DEFLECTION • Lift the valve about 10 mm from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one.
Page 88 ENGINE 3-35 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 °C – 150 °C (212 °F – 302 °F) with a hot plate.  Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.
Page 89 3-36 ENGINE • If the seat width W measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter.  Valve seat width W: Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) If the valve seat is out of specification, re-cut the seat.
Page 90 ENGINE 3-37 VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • Check the valve spring for proper strength by measuring its free length and also by the force required to compress it.
Page 91 3-38 ENGINE • Put on the valve spring retainer 2, and using the special tool 3, press down the spring, fit the cotter halves 4 to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.
Page 92: Clutch
ENGINE 3-39 • Apply SUZUKI SUPER GREASE “A” to the O-rings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the intake pipes. • Apply THREAD LOCK to the bolts.  99000-32050: THREAD LOCK “1342” CLUTCH CLUTCH DRIVE PLATE INSPECTION...
Page 93: Clutch Lifter
3-40 ENGINE CLUTCH SPRING INSPECTION • Measure the free length of each coil spring with a vernier cali- pers, and compare the length with the specified limit. • Replace all the springs if any spring is not within the limit. ...
Page 94 ENGINE 3-41 CLUTCH LIFTER PIN ADJUSTMENT NOTE: When adjusting the clutch lifter, it is not necessary to install the clutch onto the countershaft. • Assemble the following parts into the primary driven gear assembly. (3-90 to -93) * Clutch sleeve hub * Spring washer seat, Spring washer * Clutch drive plates, Clutch driven plates * Pressure plate...
Page 95: Oil Pump
3-42 ENGINE WAVE SPRING WASHER INSPECTION • Measure the free height H of each wave spring washer with a vernier calipers. • If each wave spring washer height H is not within the speci- fied limit, replace it with a new one. ...
Page 96 ENGINE 3-43 DISASSEMBLY • With holding the rotor with the special tool remove the starter clutch bolts.  09930-44520: Rotor holder • Remove the one way clutch 1 and guide 2 from the rotor. REASSEMBLY • When fitting the one way clutch 1 to the guide 2, position flange side A of one way clutch to the rotor side.
Page 97: Generator
3-44 ENGINE GENERATOR INSPECTION (9-10) REASSEMBLY • When installing the generator stator set bolts, tighten them to the specified torque.  Generator stator set bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) NOTE: Be sure to install the grommet 1 to the generator cover. WATER PUMP 7-11 GEARSHIFT SYSTEM...
Page 98: Oil Pressure Regulator
ENGINE 3-45 • Install the following parts to the gearshift shaft/gearshift arm as shown in the illustration. 1 Washer 5 Plate return spring 2 Snap ring 6 Washer 3 Gearshift shaft return spring 7 Screw 4 Gearshift cam drive plate OIL PRESSURE REGULATOR •...
Page 99: Transmission
3-46 ENGINE TRANSMISSION DRIVESHAFT REMOVAL (3-52) DISASSEMBLY Disassemble the countershaft and driveshaft. Pay attention to the following points: • Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2. • Slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, then remove the 2nd drive gear circlip 5.
Page 100 Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE “A” to it.  99000-25010: SUZUKI SUPER GREASE “A”...
Page 101 3-48 ENGINE TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft...
Page 102: Cylinder
ENGINE 3-49 CYLINDER CRANKCASE SERVICING (3-52) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set.
Page 103: Piston And Piston Ring
3-50 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. ...
Page 104: Piston Ring Groove Width
ENGINE 3-51 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 exceeds the limit, replace both the piston and piston rings.  09900-20803: Thickness gauge 09900-20205: Micrometer (0 –...
Page 105: Crankcase
3-52 ENGINE CRANKCASE DRIVESHAFT AND GEARSHIFT CAM Removal • Remove the screws. • Remove the gearshift fork shaft 1, gearshift cam 2 and gearshift forks 3. • Remove the spacer 4. • Remove the driveshaft left bearing dust seal 5. •...
Page 106 ENGINE 3-53 • Remove the driveshaft assembly 8. GEARSHIFT FORK-TO-GROOVE CLEARANCE • Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. • The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. ...
Page 107 3-54 ENGINE BEARING AND DUST SEAL Inspection • Inspect the gearshift cam bearing 1 for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Inspect the gearshift cam bearing 2, gearshift shaft bearings 3 (LH) and 4 (RH) for abnormal noise and smooth rotation while they are in the crankcase.
Page 108 ENGINE 3-55 • Inspect the driveshaft left bearing dust seal for wear and dam- age. • Replace the dust seal if there is anything unusual. Removal • Remove the gearshift cam bearing with the special tools.  09923-74511: Bearing remover 09930-30104: Sliding shaft ...
Page 109 • Install new oil seal with the special tool.  09913-70210: Bearing installer set (22) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the bearing with the special tool.
Page 110  99000-32050: THREAD LOCK “1342”  Bearing retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the dowel pin. • Apply SUZUKI SUPER GREASE “A” to the O-ring and fit the driveshaft left bearing case 6.  Replace the O-ring with a new one.
Page 111   Driveshaft left bearing case bolt: 12 N·m (1.2 kgf-m, 8.7 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip and O-ring. • Apply THREAD LOCK to the bolts and tighten them to the specified torque.
Page 112 ENGINE 3-59 • Remove the oil jet 2 (for transmission) from the lower crank- case. • Remove the oil jet 3 (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • Check the oil jets for clogging. •...
Page 113 3-60 ENGINE • Install the oil jet (for transmission). • Apply engine oil to the O-ring.  Use new O-ring to prevent oil pressure leakage. • Install the oil jet (for cam chain tension adjuster). PLUG Removal • Remove the oil gallery plugs 1 and 2. •...
Page 114 • Apply engine coolant to the O-rings of the water jacket plugs 5 and 6.  99000-99032-11X: SUZUKI COOLANT (Except USA) • Tighten each plug to the specified torque.  1 Oil gallery plug: 10 N·m (1.0 kgf-m, 7.0 lb-ft) 2 Oil gallery plug: 22 N·m (2.2 kgf-m, 16.0 lb-ft)
Page 115: Balancer Shaft
3-62 ENGINE BALANCER SHAFT DISASSEMBLY • Remove the balancer gear along with the dampers from the balancer shaft. INSPECTION • Inspect the damper for wear and damage, replace it if any defects are found. REASSEMBLY • Apply MOLYBDENUM OIL SOLUTION to each part. ...
Page 116 ENGINE 3-63 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge.  Balancer shaft journal oil clearance: Standard: 0.028 –...
Page 117 3-64 ENGINE INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part A first and press the other end.  Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.
Page 118: Crankshaft And Conrod
ENGINE 3-65 CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with V-blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. •...
Page 119 3-66 ENGINE CONROD-BIG END 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-BIG END BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown.
Page 120 ENGINE 3-67 • 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 Crank pin O.D. B Code Green Black Brown Conrod I.D A Black Brown...
Page 121 3-68 ENGINE  Crank pin O.D. Code O.D. specification 32.992 – 33.000 mm (1.2989 – 1.2992 in) 32.984 – 32.992 mm (1.2986 – 1.2989 in) 32.976 – 32.984 mm (1.2983 – 1.2986 in)  09900-20202: Micrometer (25 – 50 mm) ...
Page 122: Crankshaft Journal Bearing
ENGINE 3-69 CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and lower crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown.  09900-22301: Plastigauge  Never rotate the crankshaft when a piece of plasti- gauge is installed.
Page 123 3-70 ENGINE • Check the corresponding crankcase journal I.D. code number A, “A”, “B” or “C” which is stamped on the rear of upper crankcase. • Check the corresponding crankshaft journal O.D. code num- ber B, “A”, “B” or “C” which is stamped on the crankshaft. ...
Page 124 ENGINE 3-71  Crankshaft journal O.D. specification Code O.D. specification 31.994 – 32.000 mm (1.2596 – 1.2598 in) 31.988 – 31.994 mm (1.2594 – 1.2596 in) 31.982 – 31.988 mm (1.2591 – 1.2594 in)  09900-20202: Micrometer (25 – 50 mm) ...
Page 125: Crankshaft Thrust Bearing
3-72 ENGINE 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. L: Left-side thrust bearing R: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.
Page 126 ENGINE 3-73  Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.560 – 2.585 mm White 2.475 – 2.500 mm 0.060 – 0.110 mm (0.1008 – 0.1018 in) (12228-17E00-0F0) (0.0974 – 0.0984 in) (0.0024 –...
Page 127: Engine Reassembly
3-74 ENGINE 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 reas- sembling. •...
Page 128 ENGINE 3-75 • 1st ring 4 and 2nd ring 3 have letters “IR” and “R” marked on one side. Be sure to bring the marked side upward when fitting them to the piston. • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
Page 129 3-76 ENGINE • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent C of each piston head must be brought to the exhaust side.  Be careful not to damage the cylinder wall and piston jet by the conrod.
Page 130 ENGINE 3-77 • Set the crankshaft to the conrods and upper crankcase. • Apply engine oil to the crank pin and bearing surface.  Be sure to clean the conrod big end. • When fitting the conrod cap, make sure that I.D. code A on each conrod faces intake side.
Page 131 3-78 ENGINE • Insert the right and left thrust bearings with oil groove B fac- ing the crank web. NOTE: Right thrust bearing has green painting. BALANCER SHAFT • Install the thrust washers 1, 2 and oil seal 3. • Apply a MOLYBDENUM OIL SOLUTION to each balancer shaft journal and bearing lightly.
Page 132 ENGINE 3-79 • Turn the bearing to fit the bearing dowel pin in the position A. • Install the dowel pin and oil seal 3. • Install the gearshift shaft and fork 4, bushing 5 and retainer...
Page 133 • Install the dowel pins. • Install the dowel pins, O-ring 1 and cap 2.  Replace the O-ring with a new one. • Apply SUZUKI BOND to the mating surface of the lower crankcase.  99000-31110: SUZUKI BOND “1215” (or equivalent bond)
Page 134 ENGINE 3-81 • Tighten the crankshaft journal bolts (M9) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure in the following two steps.  Crankshaft journal bolt: (M9) Initial : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Final : 50°...
Page 135  Oil pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) OIL STRAINER AND OIL PRESSURE REGULATOR • Apply SUZUKI SUPER GREASE “A” to the O-rings and press in the oil strainer and oil pressure regulator to the crankcase.  99000-25010: SUZUKI SUPER GREASE “A”...
Page 136  99000-31140: 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 to the hole of thread end. OIL COOLER • Apply SUZUKI SUPER GREASE “A” to the O-ring and install the oil cooler.
Page 137 • Install the crankcase breather cover 2.  Crankcase breather cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) GEAR POSITION SWITCH • Apply SUZUKI SUPER GREASE “A” to the O-ring. NOTE: Align the gear position switch pin A with the gearshift cam hole ...
Page 138 ENGINE 3-85 WATER PUMP • Apply SUZUKI SUPER GREASE “A” to the O-ring.  Use a new O-ring to prevent oil leakage.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the water pump. NOTE: Set the water pump shaft end A to the oil pump shaft B as shown.
Page 139 3-86 ENGINE GENERATOR ROTOR AND STARTER DRIVEN GEAR • Degrease the tapered portion A of generator rotor and also the crankshaft B. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. • Install the generator rotor onto the crankshaft. •...
Page 140 STARTER IDLE GEAR • Install the starter idle gear No. 2 1 and shaft 2. • Apply SUZUKI BOND lightly to the mating surfaces A at the parting line between the upper and lower crankcases.  99000-31140: SUZUKI BOND “1207B”...
Page 141 • Install the starter idle gear No. 1 shaft 5, thrust washer 6, bearing 7, starter idle gear No. 1 8, washer 9, and spring washer 0. • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 142 ENGINE 3-89 • Install the gearshift cam stopper plate 5. NOTE: Align the gearshift cam pin B with the gearshift cam stopper plate hole C . • Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque. ...
Page 143 3-90 ENGINE • Install the oil pump drive sprocket 1 to the countershaft. NOTE: Teeth A on the sprocket must face the clutch side. • Pass the chain between the oil pump drive and driven sprock- ets. CLUTCH • Install the primary driven gear assembly 1. NOTE: * Before assembling the clutch, adjust the clutch lifter.
Page 144 ENGINE 3-91 • Install the clutch sleeve hub assembly onto the countershaft. • Install the washer 9 and spring washer 0. NOTE: * Before installing the washer 9 , visually inspect the washer surface for wear and damage. If necessary, replace it with a new one.
Page 145 3-92 ENGINE • Install the clutch push rod C into the countershaft. • Install the clutch push piece D, bearing E and thrust washer F to the countershaft. NOTE: Thrust washer F is located between the pressure plate and bearing E . •...
Page 146 ENGINE 3-93 *1: Direction of outside *2: Paint DRIVE PLATE: a No. 2 Drive plate ..1 pc. [Black paint/I.D. 111 mm (4.4 in)] b No. 1 Drive plate ..7 pcs. [Purple paint/I.D. 111 mm (4.4 in)] c No. 3 Drive plate ..1 pc. [NIL/I.D. 118 mm (4.6 in)] NOTE: No.3 drive plate can be distinguished by the inside diameter (I.D.).
Page 147 3-94 ENGINE CLUTCH COVER • Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown.  99000-31140: SUZUKI BOND “1207B” • Install new gasket 1 and dowel pin.  Use a new gasket to prevent oil leakage.
Page 148 ENGINE 3-95 • Place the cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Tighten the cylinder head bolts (M10) in the following four-step. Step 1: • Tighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagonally.
Page 149 3-96 ENGINE • Apply engine coolant to the O-ring. • Install the thermostat conector 3.  Use a new O-ring to prevent engine coolant leakage.  Thermostat conector bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the thermostat 4. NOTE: The jiggle valve A of thermostat faces upside.
Page 150 ENGINE 3-97 The camshafts are identified by the embossed letters. • Before replacing the camshafts on cylinder head, apply MOLYBDENUM OIL SOLUTION to their journals and cam faces. • Apply a MOLYBDENUM OIL SOLUTION to the camshaft jour- nal holders. ...
Page 151 3-98 ENGINE • Install the dowel pins. • Install O-rings 3 to the camshaft journal holders.  Replace the O-rings with new ones. • Install the camshaft journal holders. NOTE: * Each camshaft journal holder is identified with an embossed letter.
Page 152 ENGINE 3-99 • Tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque.  Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)  The camshaft journal holder bolts are made of a spe- cial material and much superior in strength, compared with other types of high strength bolts.
Page 153 3-100 ENGINE • Fit a new gasket 1.  Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster.  Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Turn the crankshaft approx. 180° counterclockwise to make 180˚...
Page 154 ENGINE 3-101 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Page 155  Replace the gaskets with new ones. • Install a new gasket to the cylinder head cover. • Apply SUZUKI BOND to the cam end cap points of the gasket as shown.  99000-31140: SUZUKI BOND “1207B” ...
Page 156 • Tighten the head cover bolts to the specified torque.  Head cover bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft) STARTER MOTOR • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 157 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING ..............4- 3 ELECTRICAL PARTS ................4- 3 FUSE....................... 4- 4 ECM/VARIOUS SENSORS ..............4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE......4- 6 USING THE MULTI-CIRCUIT TESTER..........4- 9 FI SYSTEM TECHNICAL FEATURES............4-10 INJECTION TIME (INJECTION VOLUME) ..........
Page 158 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION......4-75 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION ....... 4-77 “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION....4-80 “C41”...
Page 159: Precautions In Servicing
FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.
Page 160: Fuse
FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
Page 161 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.
Page 162: Electrical Circuit Inspection Procedure
FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
Page 163 FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
Page 164 FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
Page 165: Using The Multi-Circuit Tester
FI SYSTEM DIAGNOSIS USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
Page 166: Fi System Technical Features
4-10 FI SYSTEM DIAGNOSIS 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 intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 167: Compensation Of Injection Time (Volume)
FI SYSTEM DIAGNOSIS 4-11 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 When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (volume).
Page 168: Fi System Parts Location
4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A Throttle position sensor (TPS) B Secondary throttle position sensor (STPS) C Secondary throttle valve actuator (STVA) D Intake air pressure sensor (IAPS) E Exhaust control valve actuator (EXCVA) F HO2 sensor (For E-02, 19) G Crankshaft position sensor (CKPS) H Fuel pump relay (FP relay) I Fuel pump (FP)
Page 169 FI SYSTEM DIAGNOSIS 4-13 J Cooling fan relay K Cooling fan L Intake air temperature sensor (IATS) M PAIR control solenoid valve N Camshaft position sensor (CMPS) O Ignition coil (IG COIL) P Secondary fuel injector Q Primary fuel injector R Engine coolant temperature sensor (ECTS) S Speed sensor T Atmospheric pressure sensor (APS)
Page 170: Fi System Wiring Diagram
4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM...
Page 171: Ecm Terminal
FI SYSTEM DIAGNOSIS 4-15 ECM TERMINAL (Black) (Gray) ECM couplers TERMINAL TERMINAL CIRCUIT CIRCUIT STVA signal (STVA. 2A) STVA signal (STVA. 2B) STVA signal (STVA. 1A) STVA signal (STVA. 1B) EXCVA power (MO–) STP sensor signal (STP) Ignition switch signal EXCVA power (MO+) [For E-03, 28, 33] EXCVA position sensor (MPS)
Page 172 4-16 FI SYSTEM DIAGNOSIS (Black) (Gray) ECM couplers TERMINAL TERMINAL CIRCUIT CIRCUIT — — — — — — Tachometer — Fuel pump relay (FP Relay) — Immobilizer communication Immobilizer communication [For E-02, 19, 24] [For E-02, 19, 24] HO2 sensor heater (OXH) Mode select switch [For E-02, 19] Starter relay...
Page 173: Self-Diagnosis Function
FI SYSTEM DIAGNOSIS 4-17 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 provided.
Page 174: Dealer Mode
4-18 FI SYSTEM DIAGNOSIS 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. These affected devices are indicated in the code form.
Page 175 FI SYSTEM DIAGNOSIS 4-19 CODE MALFUNCTION PART REMARKS None No defective part Camshaft position sensor (CMPS) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air temperature sensor (IATS) Atmospheric pressure sensor (APS) Tip-over sensor (TOS) Ignition signal #1 (IG coil #1)
Page 176: Tps Adjustment
4-20 FI SYSTEM DIAGNOSIS TPS ADJUSTMENT 1. Adjust the engine rpm to 1 200 r/min. (2-14) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, remove the aircleaner box and lift up the throttle body.
Page 177: Fail-Safe Function
FI SYSTEM DIAGNOSIS 4-21 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY CMP sensor When camshaft position signal has...
Page 178 4-22 FI SYSTEM DIAGNOSIS STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY Secondary injection signal #1 Fuel-cut (secondary side) — “YES” #2, #3 & #4 cylinders can run. #2 Fuel-cut (secondary side) — “YES” #1, #3 & #4 cylinders can run. #3 Fuel-cut (secondary side) —...
Page 179: Fi System Troubleshooting
FI SYSTEM DIAGNOSIS 4-23 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 such as below will facilitate collecting information required for proper analysis and diagnosis.
Page 180: Visual Inspection
4-24 FI SYSTEM DIAGNOSIS MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (...
Page 181: Self-Diagnostic Procedures
FI SYSTEM DIAGNOSIS 4-25 SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.
Page 182: Use Of Sds Diagnostic Procedures
4-26 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSTIC PROCEDURES * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.
Page 183: Use Of Sds Diagnosis Reset Procedure
FI SYSTEM DIAGNOSIS 4-27 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
Page 184: Show Data When Trouble (Displaing Data At The Time Of Dtc)
4-28 FI SYSTEM DIAGNOSIS SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.
Page 185: Malfunction Code And Defective Condition
FI SYSTEM DIAGNOSIS 4-29 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.
Page 186 4-30 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated.
Page 187 FI SYSTEM DIAGNOSIS 4-31 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated.
Page 188 4-32 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM HO2 sensor HO2 sensor output voltage is not input HO2 sensor circuit open or (For E-02, to ECM during engine operation and shorted to ground running condition. (Sensor voltage <...
Page 189: C11" (P0340) Cmp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-33 “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CMP sensor and rotor tip •...
Page 190 4-34 FI SYSTEM DIAGNOSIS 6) Under this condition, if a suitable screwdriver touching the pick-up surface of the CMP sensor is moved, the tester read- ing voltage changes (0.8 V and less ↔ 4.3 V and more). Is the voltage OK? ECM couplers (Harness side) •...
Page 191: C12" (P0335) Ckp Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-35 “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip •...
Page 192 4-36 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground.  CKP sensor continuity: ∞ Ω (Infinity) (B – Ground) (G – Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.
Page 193 FI SYSTEM DIAGNOSIS 4-37 Is the voltage OK? ECM couplers (Harness side) • G/W or O/BI wire open or shorted to ground. (Black) (Gray) • Loose or poor contacts on the CKP sensor cou- pler or ECM coupler (terminal D or U). •...
Page 194: C13" (P0105-H/L) Iap Sensor Circuit Malfunction
4-38 FI SYSTEM DIAGNOSIS “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage < 4.85 V •...
Page 195 FI SYSTEM DIAGNOSIS 4-39 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the R wire A and B/Br wire B.
Page 196 4-40 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 7) Check the continuity between G/B wire C and terminal 9. 8) If OK, then check the continuity between B/Br wire B and ter- minal S.  IAPS lead wire continuity: Continuity () ...
Page 197 FI SYSTEM DIAGNOSIS 4-41 7) Disconnect the ECM coupler. 8) Check the continuity between R wire A and terminal A. 9) Also, check the continuity between G/B wire C and terminal  IAPS lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Gray) (Black)
Page 198 4-42 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 –...
Page 199 FI SYSTEM DIAGNOSIS 4-43 Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg) 3.1 – 3.6 2 000 2 001 2.8 – 3.4 5 000 1 524 5 001...
Page 200: C14" (P0120-H/L) Tp Sensor Circuit Malfunction
4-44 FI SYSTEM DIAGNOSIS “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •...
Page 201 FI SYSTEM DIAGNOSIS 4-45  TP sensor input voltage: 4.5 – 5.5 V (+ R – - Ground) (+ R – - B/Br)  09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? Go to Step 2. •...
Page 202 4-46 FI SYSTEM DIAGNOSIS Is the continuity OK? Go to Step 2. P/B wire shorted to VCC, or B/Br wire open 9) After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 1 (When indicating P0120-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank.
Page 203 FI SYSTEM DIAGNOSIS 4-47 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Install the test harness to the TP sensor. 4) Check the continuity between terminal A and ground.  TP sensor continuity: ∞ Ω (Infinity) (Terminal A –...
Page 204 4-48 FI SYSTEM DIAGNOSIS Step 3 1) Connect the TP sensor coupler 1 to the test harness. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the coupler (between + P/B and - B/Br) by turning the throttle grip. ...
Page 205: C15" (P0115-H/L) Ect Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-49 “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction 0.15 V Sensor voltage < 4.85 V •...
Page 206 4-50 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-H:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
Page 207 FI SYSTEM DIAGNOSIS 4-51 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 4) Disconnect the ECT sensor coupler.
Page 208 4-52 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance.  ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal)  09900-25008: Multi-circuit tester set ...
Page 209: C21" (P0110-H/L) Iat Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-53 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction 0.15 V Sensor voltage < 4.85 V •...
Page 210 4-54 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-H:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
Page 211 FI SYSTEM DIAGNOSIS 4-55 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
Page 212 4-56 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance.  IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Is the resistance OK? ECM couplers (Harness side) •...
Page 213: C22" (P1450-H/L) Ap Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-57 “C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE AP sensor voltage is not within the fol- • Clogged air passage with dust lowing range. • AP sensor circuit open or shorted to ground 0.5 V Sensor voltage <...
Page 214 4-58 FI SYSTEM DIAGNOSIS 4) Disconnect the AP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire and ground. 7) If OK, then measure the voltage at the R wire A and B/Br wire B.
Page 215 FI SYSTEM DIAGNOSIS 4-59 6) Disconnect the ECM coupler. 7) Check the continuity between G/Y wire C and terminal P. 8) If OK, then check the continuity between B/Br wire B and ter- minal S.  APS lead wire continuity: Continuity () ...
Page 216 4-60 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. 8) Check the continuity between R wire A and terminal A. 9) If OK, then check the continuity between G/Y wire C and ter- minal P.  APS lead wire continuity: Continuity () ...
Page 217 FI SYSTEM DIAGNOSIS 4-61 Step 3 1) Remove the AP sensor. 2) Connect the vacuum pump gauge to the vacuum port of the AP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 – 5.0 V) and connect - terminal to the ground terminal 2 and + terminal to the VCC terminal 3.
Page 218 4-62 FI SYSTEM DIAGNOSIS Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg) 3.1 – 3.6 2 000 2 001 2.8 – 3.4 5 000 1 524 5 001...
Page 219: C23" (P1651-H/L) To Sensor Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-63 “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON.
Page 220 4-64 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-H:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (8-8) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
Page 221 FI SYSTEM DIAGNOSIS 4-65 Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (8-8) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
Page 222: C24" (P0351), "C25" (P0352), "C26" (P0353) Or "C27" (P0354) Ignition System Malfunction
4-66 FI SYSTEM DIAGNOSIS Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage between B and B/Br wires. ...
Page 223: C28" (P1655) Stv Actuator Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-67 “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. •...
Page 224 4-68 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground.  STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between terminal A and terminal B) and (between terminal C and terminal ...
Page 225 FI SYSTEM DIAGNOSIS 4-69 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.
Page 226: C29" (P1654-H/L) Stp Sensor Circuit Malfunction
4-70 FI SYSTEM DIAGNOSIS “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is •...
Page 227 FI SYSTEM DIAGNOSIS 4-71 Step 1 (When indicating P1654-H:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
Page 228 4-72 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1654-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
Page 229 FI SYSTEM DIAGNOSIS 4-73 Step 2 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Disconnect the STP sensor coupler. 4) Check the continuity between each terminal and ground.  STP sensor continuity: ∞ Ω (Infinity) (Terminal –...
Page 230 4-74 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between + Y wire and - B wire) by turning the secondary throttle valve (close and open) with a finger.
Page 231: C31" (P0705) Gp Switch Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-75 “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short Switch voltage is not within the following range. • Gear Position switch malfunction Switch voltage >...
Page 232 4-76 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM couplers (Harness side) • P wire open or shorted to ground (Black) (Gray) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
Page 233: C32" (P0201), "C33" (P0202), "C34" (P0203) Or "C35" (P0204) Primary Fuel Injector Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-77 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short interrupted by 4 times or more continuously. •...
Page 234 4-78 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and ground.  Injector continuity: ∞ Ω (Infinity)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. Replace the injector with a new one.
Page 235 FI SYSTEM DIAGNOSIS 4-79 Is the voltage OK? ECM couplers (Harness side) • Gr/W wire open or shorted to ground, or poor h (Black) (Gray) connection (#1 cylinder side) • Gr/B wire open or shorted to ground, or poor g connection (#2 cylinder side) •...
Page 236: C36" (P1764), "C37" (P1765), "C38" (P1766) Or "C39" (P1767) Secondary Fuel Injector Circuit Malfunction
4-80 FI SYSTEM DIAGNOSIS “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Some failure exists in the fuel injector signal in a • Injector circuit open or short high load, high revolution condition. •...
Page 237 FI SYSTEM DIAGNOSIS 4-81 5) If OK, then check the continuity between each terminal and ground.  Injector continuity: ∞ Ω (Infinity)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. Replace the injector with a new one.
Page 238 4-82 FI SYSTEM DIAGNOSIS Is the voltage OK? ECM couplers (Harness side) • Lg wire open or shorted to ground, or poor x (Black) (Gray) connection (#1 cylinder side) • Lg/W wire open or shorted to ground, or poor w connection (#2 cylinder side) •...
Page 239: C41" (P0230-H/L) Fp Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-83 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump • Fuel pump relay circuit open or short although fuel pump relay is turned ON, • Fuel pump relay malfunction or voltage is applied to fuel pump, •...
Page 240 4-84 FI SYSTEM DIAGNOSIS Is the FP relay OK? ECM couplers (Harness side) • Y/B or O/W wire open or short or poor ] con- (Black) (Gray) nection • Y/R or R/Bl wire open, shorted or poor W con- nection •...
Page 241 FI SYSTEM DIAGNOSIS 4-85 Step 1 (When indicating P0230-L:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (5-7) Is the FP relay OK? ECM couplers (Harness side) •...
Page 242: C42" (P01650) Ig Switch Circuit Malfunction
4-86 FI SYSTEM DIAGNOSIS “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Ignition switch signal is not input to the ECM. • Ignition system circuit open or short • ECM malfunction When the ID agreement is not verified. •...
Page 243: C44" (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction (For E-02, 19)
FI SYSTEM DIAGNOSIS 4-87 “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (For E-02, 19) DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0130) to ECM during engine operation and •...
Page 244 4-88 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. 8) Check the continuity between W/G wire A and terminal B. 9) Also, check the continuity between B/Br wire B and terminal S.  HO2S lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set ...
Page 245 FI SYSTEM DIAGNOSIS 4-89 Is the voltage OK? ECM couplers (Harness side) • W/G wire or B/Br wire open or shorted to ground, or poor B or S connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •...
Page 246 4-90 FI SYSTEM DIAGNOSIS Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probe to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W (O/W) wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.
Page 247: C46" (P1657-H/L Or P1658) Excv Actuator Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-91 “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the • EXCVA maladjusted EXCV actuator. • EXCVA circuit open or short EXCVA position sensor voltage low or •...
Page 248 4-92 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-H:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (5-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
Page 249 FI SYSTEM DIAGNOSIS 4-93 Step 1 (When indicating P1657-L:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (5-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
Page 250 4-94 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1658:) 1) Turn the ignition switch OFF. 2) Remove the frame cover. (5-8) 3) Check the EXCVA motor coupler for loose or poor contacts. Is the contacting OK? Go to Step 6. Loose or poor contacts on the EXCV motor cou- pler 4) After repairing the trouble, clear the DTC using SDS tool.
Page 251 FI SYSTEM DIAGNOSIS 4-95 Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Y wire and ground.  Position sensor continuity: ∞ Ω (Infinity) 3) If OK, then measure the position sensor resistance. 4) Connect the position sensor coupler. 5) Set the EXCVA to adjustment position.
Page 252 4-96 FI SYSTEM DIAGNOSIS Step 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler. 3) Measure the position sensor output voltage at fully close posi- tion and fully open position. 4) Insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler.
Page 253 FI SYSTEM DIAGNOSIS 4-97 Step 5 1) If the position sensor output voltage is 0.5 V and less at fully close position, adjust the output voltage to specified by turn- ing out the No. 1 cable adjuster 1. 2) Repeat the above procedure (Step 4) until the out put voltage becomes specified value.
Page 254 4-98 FI SYSTEM DIAGNOSIS Step 6 1) Turn the ignition switch OFF. 2) Disconnect the motor lead wire coupler of the EXCVA. 3) Apply 12 V to the terminal and check the operation of EXCVA. 12 V 4) Then, swap the wires supplied 12 V and check the operation of EXCVA.
Page 255 FI SYSTEM DIAGNOSIS 4-99 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Exhaust valve operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the EXCVA, the function is normal.
Page 256: C49" (P1656) Pair Control Solenoid Valve Circuit Malfunction
4-100 FI SYSTEM DIAGNOSIS “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction •...
Page 257 FI SYSTEM DIAGNOSIS 4-101 Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground.  PAIR valve voltage: Battery voltage (+ O/W – - Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? ECM couplers (Harness side) •...
Page 258 4-102 FI SYSTEM DIAGNOSIS 4) Click each button 2. At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.
Page 259: C60" (P0480) Cooling Fan Relay Circuit Malfunction
FI SYSTEM DIAGNOSIS 4-103 “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short • ECM malfunction Engine stop Side-stand Ignition Cooling fan switch relay switch...
Page 260 4-104 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4) Click the operate button 2. At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal.
Page 261: Sensors
FI SYSTEM DIAGNOSIS 4-105 SENSORS CMP SENSOR INSPECTION The camshaft position sensor is installed on the cylinder head cover. (4-33) CMP SENSOR REMOVAL AND INSTALLATION • Remove the CMP sensor. (3-26) • Install the CMP sensor in the reverse order of removal. ...
Page 262: Ect Sensor Inspection
4-106 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the cylin- der head. (4-49) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor. (7-7) • Install the ECT sensor in the reverse order of removal. ...
Page 263: Stp Sensor Adjustment
FI SYSTEM DIAGNOSIS 4-107 STP SENSOR ADJUSTMENT • Adjust the STP sensor. (5-22) HO2 SENSOR INSPECTION (For E-02, 19) The heated oxygen sensor is installed to the exhaust pipe. (4-87) HO2 SENSOR REMOVAL AND INSTALLATION • Remove the right under cowling. (8-5) •...
Page 264 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM................5- 2 FUEL SYSTEM..................... 5- 3 FUEL TANK LIFT-UP ................5- 3 FUEL TANK REMOVAL................ 5- 4 FUEL TANK INSTALLATION ............... 5- 4 FUEL PRESSURE INSPECTION ............5- 4 FUEL PUMP INSPECTION ..............
Page 265: Fuel Delivery System
FUEL SYSTEM AND THROTTLE BODY 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 flows into the injector installed in the fuel delivery pipe.
Page 266: Fuel System
FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seats. (8-7 and -8) • Take out the fuel tank prop stay 1. • Remove the fuel tank bolt. • Lift and support the fuel tank with the fuel tank prop stay.
Page 267: Fuel Tank Removal
FUEL SYSTEM AND THROTTLE BODY FUEL TANK REMOVAL • Lift and support the fuel tank. (above) • Disconnect the fuel pump lead wire coupler 1. • Disconnect the fuel tank breather hose 2 and fuel tank drain hose 3. • Place a rag under the fuel feed hose 4 and disconnect the fuel feed hose.
Page 268: Fuel Pump Inspection
FUEL SYSTEM AND THROTTLE BODY • Install the special tools between the fuel tank and fuel delivery pipe.  09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77331: Oil pressure gauge 09915-74521: Oil pressure gauge hose Turn the ignition switch ON and check the fuel pressure. ...
Page 269: Fuel Discharge Amount Inspection
FUEL SYSTEM AND THROTTLE BODY FUEL DISCHARGE AMOUNT INSPECTION  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Lift and support the fuel tank. (5-3) • Turn the ignition switch OFF. • Disconnect the battery - lead wire. •...
Page 270: Fuel Pump Relay Inspection
FUEL SYSTEM AND THROTTLE BODY • Connect a proper lead wire to the fuel pump lead wire coupler (fuel pump side) and apply 12 V to the fuel pump (between Y/R wire and B/W wire) for 10 seconds and measure the amount of fuel discharged.
Page 271: Fuel Pump And Fuel Filter Removal
FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION  1 Fuel level gauge 5 Holder 2 Fuel pump case/Fuel filter cartridge 6 Fuel mesh filter ITEM N·m kgf-m lb-ft 3 Fuel pump 7 O-ring 4 Rubber cushion A Fuel pump mounting bolt...
Page 272 FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the fuel tank. (5-4) • Remove the fuel pump assembly 1 by removing its mounting bolts diagonally.  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the nuts. •...
Page 273: Fuel Mesh Filter Inspection And Cleaning
5-10 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel mesh filter 7. • Remove the fuel pump 8 from the fuel pump case/fuel filter cartridge 9. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.
Page 274 • Be sure to connect the wires to the proper terminals. A (Bl) ..+ terminal for fuel pump B (R)..+ terminal for fuel level gauge • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it.  99000-25010: SUZUKI SUPER GREASE “A”...
Page 275 5-12 FUEL SYSTEM AND THROTTLE BODY • When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers.  Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: Apply a small quantity of the THREAD LOCK to the thread por- tion of fuel pump mounting bolts.
Page 276: Throttle Body
FUEL SYSTEM AND THROTTLE BODY 5-13 THROTTLE BODY CONSTRUCTION Only for E-33 1 TP sensor 8 Fast idle adjusting screw 2 STP sensor 9 Throttle stop screw  3 STVA 0 Vacuum hose 4 Fuel delivery pipe A Fuel delivery pipe mounting screw ITEM N·m kgf-m lb-ft 5 O-ring...
Page 277: Air Cleaner Box Removal And Installation
5-14 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX REMOVAL AND INSTAL- LATION REMOVAL • Lift and support the fuel tank. (5-3) • Disconnect the fuel pump relay 1, cooling fan relay 2 and IAT sensor lead wire coupler 3. •...
Page 278: Throttle Body Removal
FUEL SYSTEM AND THROTTLE BODY 5-15 THROTTLE BODY REMOVAL • Remove the air cleaner box. (5-14) • Disconnect the throttle cables from their drum.  After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body.
Page 279: Throttle Body Disassembly
5-16 FUEL SYSTEM AND THROTTLE BODY • Remove the throttle body assembly. THROTTLE BODY DISASSEMBLY  Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. •...
Page 280 FUEL SYSTEM AND THROTTLE BODY 5-17 • Remove the TP sensor and STP sensor with the special tool.  09930-11950: Torx wrench NOTE: Prior to disassembly, mark the each sensor’s original position with a paint or scribe for accurate reinstallation. ...
Page 281: Throttle Body Cleaning
5-18 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CLEANING  Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
Page 282: Throttle Body Reassembly
* Apply thin coat of the engine oil to the O-ring. * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary.  99000-25010: SUZUKI SUPER GREASE “A”...
Page 283 5-20 FUEL SYSTEM AND THROTTLE BODY • Install the fuel injector 5 by pushing it straight to the delivery pipe 6. NOTE: Align the boss E of the injector with the groove F of the delivery pipe.  Never turn the injector while pushing it. •...
Page 284: Throttle Body Installation
FUEL SYSTEM AND THROTTLE BODY 5-21 THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector.
Page 285: Stp Sensor Adjustment
5-22 FUEL SYSTEM AND THROTTLE BODY STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor output voltage and adjust the STP sensor position as follows: • Remove the air cleaner box . (5-14) • Loosen the throttle body clamp screws at the intake pipe side. •...
Page 286: Fuel Injector Removal
FUEL SYSTEM AND THROTTLE BODY 5-23 FUEL INJECTOR REMOVAL • Remove the air cleaner box. (5-14) • With battery negative cable disconnected, disconnect the injector couplers. • Remove the fuel delivery pipe assemblies. (5-16) • Remove the primary and secondary fuel injectors #1, #2, #3 and #4.
Page 287: Fast Idle
5-24 FUEL SYSTEM AND THROTTLE BODY FAST IDLE The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.
Page 288 FUEL SYSTEM AND THROTTLE BODY 5-25 • Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened. Example: TP sensor output voltage with the STV fully open Minus TP sensor output voltage at idle is 0.030 V STV fully open 1.155 V Idle...
Page 289: Throttle Valve Synchronization
5-26 FUEL SYSTEM AND THROTTLE BODY THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. Step 1 • Lift and support the fuel tank. (5-3) • Start up the engine and run it in idling condition for warming up. •...
Page 290: Throttle Position Sensor (Tps) Setting
FUEL SYSTEM AND THROTTLE BODY 5-27 Step 3 • Turn in all the idle air screws to the complete close position. • Check for difference of vacuum between #1 and #2. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower.
Page 291 EXHAUST SYSTEM EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM..................6- 2 EXHAUST CONTROL SYSTEM ............6- 2 OPERATION..................6- 3 EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)..........6- 4 EXCVA REMOVAL................6- 4 EXCVA PULLEY INSPECTION............. 6- 5 EXCVA INSTALLATION ............... 6- 5 EXCVA INSPECTION................
Page 292: Exhaust System
EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exhaust control system (EXCS) consists of the exhaust control valve (EXCV), exhaust control valve actuator (EXCVA) and exhaust control valve cables (EXCV cables). EXCV is installed the exhaust pipes. EXCVA is mounted on the right side of the seat rail. The EXCV is oper- ated by the EXCVA via the cables.
Page 293: Operation
EXHAUST SYSTEM OPERATION The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then the ECM determines the EXCV opening angle based on the engine rpm and gear positions.
Page 294: Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)
EXHAUST SYSTEM EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA REMOVAL • Turn the ignition switch OFF. • Remove the frame cover. (8-8) • Connect the special tool (Mode select switch) to the dealer mode coupler. (4-18) •...
Page 295: Excva Pulley Inspection
EXHAUST SYSTEM • Hold the EXCVA pulley with an adjustable wrench, and loosen the pulley mounting bolt.  * When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged. * Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA.
Page 296: Excva Inspection
EXHAUST SYSTEM • Tighten the EXCVA mounting bolts to the specified torque.  EXCVA mounting bolt: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft) • Turn in the two cable adjusters fully. • Connect the No.1 cable 1 (01H0CL) and No.2 cable 2 (01H0OP) to the EXCVA pulley.
Page 297: Excv Cable Replacement
EXHAUST SYSTEM EXCV CABLE REPLACEMENT • Lift and support the fuel tank. (5-3) • Check the EXCVA to adjustment position. (6-4)  Before disconnecting the EXCV cables, be sure to set the EXCVA to the ADJUSTMENT setting position. • Disconnect the EXCV cables from the EXCVA pulley. (6-4) •...
Page 298: Excva Adjustment
EXHAUST SYSTEM • Connect the No.1 cable 1 and No.2 cable 2 to the EXCVA pulley. No. 1 cable • Loosen the lock-nut 9 and turn the No.2 cable adjuster 0 in or out until the thread length D becomes 11.0 – 12.0 mm (0.43 –...
Page 299 EXHAUST SYSTEM • To set the EXCV to fully close position, apply 12 V to A and B terminals. Battery + terminal–– A (Pink lead wire) terminal Battery - terminal–– B (Gray lead wire) terminal  To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully close position.
Page 300: Excv/Exhaust Pipe, Muffler Removal
6-10 EXHAUST SYSTEM Measure the position sensor output voltage at fully open posi- tion.  Position sensor output voltage EXCV is fully open: 3.7 output voltage 4.5 (V) (+ Yellow – - B/Br) If the measured voltage is more than specification, adjust the No.2 cable adjuster as follows: •...
Page 301 EXHAUST SYSTEM 6-11 • Loosen the exhaust pipe connector bolt 5. • Remove the muffler mounting bolts 6. • Loosen the exhaust pipe bolts 7. • Remove the muffler body A. • Remove the exhaust pipe bolts 7. • Remove the exhaust pipe B. NOTE: When an exhaust pipe separates, not to throw or drop, have by hand and remove carefully.
Page 302: Excv Inspection
6-12 EXHAUST SYSTEM EXCV INSPECTION • Turn the EXCV by hand and check that it moves smoothly. • If it does not move smoothly, replace the EXCV together with the exhaust pipe. • Decarbonize the EXCV if necessary.  * Do not attempt to disassemble the EXCV. * The EXCV is available only as the exhaust pipe assembly.
Page 303 EXHAUST SYSTEM 6-13 • Tighten the radiator mounting bolts to the specified torque.  Radiator mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the EXCV cables. (6-7)
Page 304 6-14 EXHAUST SYSTEM * When adjusting the No. 1 and No. 2 cables, the cable slots of EXCVA pulley must be located to adjustment position. * Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA.
Page 305 COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ..................7- 2 COOLING CIRCUIT ..................7- 3 COOLING CIRCUIT INSPECTION............7- 3 RADIATOR AND WATER HOSES .............. 7- 4 RADIATOR REMOVAL ................. 7- 4 RADIATOR CAP INSPECTION............. 7- 4 RADIATOR INSPECTION AND CLEANING.........
Page 306: Engine Coolant
COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).
Page 307: Cooling Circuit
COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT RESERVOIR THERMOSTAT CYLINDER HEAD ECT SENSOR TANK CYLINDER RADIATOR WATER PUMP Oil cooler COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the right under cowling. (8-5) •...
Page 308: Radiator And Water Hoses
COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowlings. (8-5) • Drain the engine coolant. (2-17) • Remove the radiator assembly. (3-4) • Remove the reservoir tank 1, cooling fan 2 from the radia- tor.
Page 309: Radiator Installation
COOLING AND LUBRICATION SYSTEM Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. RADIATOR INSTALLATION • Install the cooling fan.  Cooling fan mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) •...
Page 310: Cooling Fan
COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL (7-4) INSPECTION • Remove the right under cowling. (8-5) • Disconnect the cooling fan coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. •...
Page 311: Cooling Fan Relay Inspection
COOLING AND LUBRICATION SYSTEM COOLING FAN RELAY INSPECTION Cooling fan relay is located on the air cleaner box (left side one). • Lift and support the fuel tank. (8-3) • Remove the cooling fan relay 1. First check the insulation between A and B terminals with tester.
Page 312: Installation
COOLING AND LUBRICATION SYSTEM • If the ECT sensor ohmic value does not change in the propor- tion indicated, replace it with a new one.  Temperature sensor specification Temperature Standard resistance 20 °C (68 °F) Approx. 2.45 kΩ 50 °C (122 °F) Approx.
Page 313: Thermostat
COOLING AND LUBRICATION SYSTEM THERMOSTAT REMOVAL • Drain engine coolant. (2-17) • Lift and support the fuel tank. (5-3) • Place a rag under the thermostat cover. • Remove the thermostat cover 1. • Remove the thermostat 2. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner.
Page 314: Installation
7-10 COOLING AND LUBRICATION SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in).  Thermostat valve lift A Standard: 8.0 mm and over at 95 °C (0.31 in and over at 203 °F) •...
Page 315: Water Pump
COOLING AND LUBRICATION SYSTEM 7-11 WATER PUMP REMOVAL AND DISASSEMBLY NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer.
Page 316 7-12 COOLING AND LUBRICATION SYSTEM • Remove the mechanical seal ring 4 and rubber seal 5 from the impeller. • Remove the impeller shaft 6 and washer 7. • Remove the mechanical seal with the special tool.  09921-20240: Bearing remover set (12 mm) NOTE: If there is no abnormal condition, the mechanical seal removal is not necessary.
Page 317: Inspection
COOLING AND LUBRICATION SYSTEM 7-13 INSPECTION MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. • Replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. OIL SEAL •...
Page 318: Reassembly And Installation
 09913-70210: Bearing installer set (22) NOTE: The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip.  99000-25010: SUZUKI SUPER GREASE “A”...
Page 319 NOTE: * Apply engine coolant to the O-ring 6 . * Apply SUZUKI SUPER GREASE “A” to the O-ring 7 .  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Tighten the water pump cover screws to the specified torque.
Page 320 7-16 COOLING AND LUBRICATION SYSTEM • Install the water pump. NOTE: Set the water pump shaft end F to the oil pump shaft G as shown. • Tighten the water pump mounting bolts to the specified torque.  Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) •...
Page 321: Lubrication System
• Remove the oil cooler 1. INSTALLATION Install the oil cooler in the reverse order of removal. Pay atten- tion to the following points: • Apply SUZUKI SUPER GREASE “A” to the O-ring.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) ...
Page 322: Oil Pressure
7-18 COOLING AND LUBRICATION SYSTEM OIL PRESSURE 2-33 OIL FILTER 2-13 OIL PRESSURE REGULATOR 3-44 OIL STRAINER 3-44 OIL JET 3-58 OIL PUMP 3-41 OIL PRESSURE SWITCH 9-34...
Page 323: Oil Pressure Switch
COOLING AND LUBRICATION SYSTEM 7-19 ENGINE LUBRICATION SYSTEM CHART CAMSHAFT JOURNALS, INTAKE CAMSHAFT CAMFACES AND TAPPETS CAM CHAIN OIL JET (#8) EXHAUST CAMSHAFT TENSION ADJUSTER CAM DRIVE CHAIN CAMSHAFT JOURNALS, CAMSHAFT JOURNAL HOLDER B CAMFACES AND TAPPETS BALANCER SHAFT SUB GALLERY #2 BEARING #1 PISTON COOLING #2 PISTON COOLING...
Page 324: Engine Lubrication System
7-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM...
Page 325 COOLING AND LUBRICATION SYSTEM 7-21...
Page 326 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ..................8- 3 FASTENER REMOVAL AND INSTALLATION........8- 3 BODY COWLING COVER AND LOWER BRACKET COVER ..... 8- 5 INNER UNDER COWLING..............8- 5 UNDER COWLING ................8- 5 SCREEN ....................8- 6 BODY COWLING .................. 8- 6 AIR INTAKE PIPE .................
Page 327 CHASSIS CHASSIS CONTENTS REMOVAL ..................... 8-49 INSPECTION ..................8-51 REAR SHOCK ABSORBER SCRAPPING PROCEDURE ....8-51 INSTALLATION..................8-52 SUSPENSION SETTING ............... 8-53 REAR SUSPENSION ................... 8-54 CONSTRUCTION .................. 8-54 REMOVAL ..................... 8-55 INSPECTION ..................8-56 DISASSEMBLY ..................8-59 REASSEMBLY AND INSTALLATION ..........8-60 FINAL INSPECTION AND ADJUSTMENT ...........
Page 328: Exterior Parts
CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece 1. • Pull out the fastener a. Installation • Let the center piece stick out toward the head so that the pawls 2 close.
Page 329 CHASSIS Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. • Push in the head of center piece.
Page 330: Body Cowling Cover And Lower Bracket Cover
CHASSIS BODY COWLING COVER AND LOWER BRACKET COVER REMOVAL • Remove the body cowling cover 1 by removing the screws and fasteners. • Remove the lower bracket cover 2 by removing the bolts. INSTALLATION • Install the lower bracket cover and body cowling cover in the reverse order of removal.
Page 331: Screen
CHASSIS SCREEN REMOVAL • Remove the screen 1 by removing the screws. INSTALLATION • Install two nuts (middle ones) as shown. • Install the window screen. BODY COWLING REMOVAL • Remove the left and right under cowlings. (8-5) • Remove the screen. (Above) •...
Page 332: Air Intake Pipe
CHASSIS AIR INTAKE PIPE REMOVAL • Remove the body cowling. (8-6) • Remove the fasteners. • Remove the air intake pipes 1. (LH/RH) INSTALLATION • Install the air intake pipes in the reverse order of removal. COWLING BRACE REMOVAL • Remove the body cowling. (8-6) •...
Page 333: Rear Seat/Seat Tail Cover
CHASSIS REAR SEAT/SEAT TAIL COVER REMOVAL • Remove the rear seat (seat tail cover) using the ignition key. INSTALLATION • Insert the seat hook to the guide and push down the seat (seat tail cover) firmly until the seat (seat tail cover) snaps into the locked position.
Page 334: Front Wheel
CHASSIS FRONT WHEEL CONSTRUCTION  1 Brake disc 6 Front axle 2 Collar 7 Front wheel ITEM N·m kgf-m lb-ft 3 Dust seal A Front axle bolt 10.0 72.5 4 Bearing B Brake disc bolt 16.5 5 Spacer...
Page 335: Removal And Disassembly
8-10 CHASSIS REMOVAL AND DISASSEMBLY • Remove the brake calipers.  Do not operate the brake lever while removing the cal- ipers. • Loosen two axle pinch bolts 1 on the right front fork leg. • Remove the front axle bolt 2. •...
Page 336 CHASSIS 8-11 • Remove the brake discs, left and right. • Remove the dust seals on both sides with the special tool.  09913-50121: Oil seal remover  The removed dust seals must be replaced with new ones. • Remove the wheel bearings with the special tool. ...
Page 337: Inspection
8-12 CHASSIS INSPECTION TIRE INSPECTION (8-85) BRAKE DISC INSPECTION (8-70) AXLE SHAFT • Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.  09900-20607: Dial gauge (1/100) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) ...
Page 338: Reassembly And Installation
Right 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the wheel bearings.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 339 Clearance Spacer • Install the dust seal with the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lip.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) BRAKE DISC • Make sure that the brake disc is clean and free of any greasy matter.
Page 340 CHASSIS 8-15 • Install the collar 1 in the right side. WHEEL • Install the front wheel with the front axle and hand-tighten the front axle bolt temporarily.  The directional arrow on the tire should point to the wheel rotation, when remounting the wheel. BRAKE CALIPER •...
Page 341 8-16 CHASSIS • Tighten 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)
Page 342: Front Fork
CHASSIS 8-17 FRONT FORK CONSTRUCTION 1 Adjuster rod 9 Oil seal stopper ring 2 Spring retainer 0 Dust seal  3 Spacer A Inner tube 4 Spring A Front fork cap bolt ITEM N·m kgf-m lb-ft 5 Inner rod/Damper rod (cartridge) B Lock-nut 25.5 6 Outer tube...
Page 343: Removal And Disassembly
8-18 CHASSIS REMOVAL AND DISASSEMBLY • Remove the under cowling cover and the lower bracket cover. (8-5) • Remove the front wheel. (8-10) • Disconnect the brake hose from the brake hose guides at the front fender. • Remove the front fender. •...
Page 344 CHASSIS 8-19 • Remove the front fork cap bolt from the inner rod by loosening the lock nut. • Compress the fork spring with the special tool and remove the special tool. • Remove the front fork cap bolt 5, adjuster rod 6, spring retainer 7, spacer 8 and spring 9.
Page 345 8-20 CHASSIS • Remove the damper rod bolt with the special tool and a hexa- gon wrench.  09940-30221: Front fork assembling tool • Remove the inner rod/damper rod (cartridge) B.  Do not disassemble the inner rod/damper rod (car- tridge).
Page 346: Inspection
CHASSIS 8-21 • Remove the oil seal E with the special tool.  09913-50121: Oil seal remover  The removed oil seal must be replaced with a new one. • Remove the oil seal retainer F. INSPECTION INNER AND OUTER TUBES •...
Page 347: Reassembly
8-22 CHASSIS DAMPER ROD • Move the inner rod by hand to examine it for smoothness. • If any defects are found, replace inner rod/damper rod (car- tridge) with a new one. REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL •...
Page 348 • Place the front fork vertically without spring. • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube.  Capacity (each leg): 408 ml (13.8/14.4 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 or an equivalent fork oil...
Page 349 8-24 CHASSIS • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.  09940-52841: Inner rod holder NOTE: Refill front fork oil up to the top of the outer tube so that bubbles are visible while bleeding air.
Page 350 CHASSIS 8-25 • Insert the adjuster rod to the front fork cap bolt. • Apply fork oil to the O-ring.  The removed O-ring must be replaced with a new one. • Be sure to check or adjust the height D of the rebound damp- ing force adjuster as follows.
Page 351: Installation
8-26 CHASSIS INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Set the upper surface of the outer tube height A at 5.0 mm (0.196 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts 1 to the specified torque.
Page 352: Suspension Setting
CHASSIS 8-27 SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT Turn the damping force adjuster 1 counterclockwise fully. It is at softest position and turn it out to standard setting position. ...
Page 353: Steering Damper
8-28 CHASSIS STEERING DAMPER CONSTRUCTION  1 Steering damper Convex curve side of the washer 2 Dust seal faces down side. ITEM N·m kgf-m lb-ft 3 Steering stem head nut A Damper rod bolt 16.5 B Damper rod nut 65.0...
Page 354: Removal
Do not remove the bolt A. INSTALLATION Install the steering damper in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the bearings and dust seals.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 355: Steering
8-30 CHASSIS STEERING CONSTRUCTION  1 Steering stem upper bracket 8 Steering stem lower bracket 2 Handlebars A Steering stem head nut ITEM N·m kgf-m lb-ft 3 Handlebar balancer B Steering stem lock-nut 65.0 4 Steering stem nut C Front fork upper clamp bolt 58.0 5 Dust seal cover D Handlebar clamp bolt...
Page 356: Removal
CHASSIS 8-31 REMOVAL • Remove the under cowling. (8-5) • Support the motorcycle with a jack or a wooden block.  Do not work by using side stand. Do not support the motorcycle with exhaust pipe. Make sure that the motorcycle is supported securely.
Page 357: Inspection And Disassembly
8-32 CHASSIS • Remove the dust seal cover 1, dust seal 2, steering stem upper bearing inner race 3 and bearing 4. 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...
Page 358: Reassembly
INSTALLATION Install the steering stem in the reverse order of removal. Pay attention to the following points: BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings and bearing races.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the lower bearing to the steering stem lower bracket.
Page 359 8-34 CHASSIS • Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will be 1/4 – 1/2 turn seated properly. • Loosen the stem nut by 1/4 – 1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle.
Page 360: Steering Tension Adjustment
CHASSIS 8-35 STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). •...
Page 361: Handlebars
8-36 CHASSIS HANDLEBARS CONSTRUCTION 1 Left handle grip 5 Handlebar (RH)  2 Right handle throttle grip 6 Handlebar (LH) 3 Right handle switch 7 Handle balancer ITEM N·m kgf-m lb-ft 4 Left handle switch A Handlebar clamp bolt 16.5 REMOVAL •...
Page 362: Installation
CHASSIS 8-37 • Remove the left handle switch 5 and disconnect the clutch lever switch lead wire. • Remove the handle balancer 6. • Remove the left handle grip 7. • Disconnect the clutch cable 8. • Remove the clutch lever holder 9. •...
Page 363 8-38 CHASSIS • Insert the protrusion A of the handlebars into the hole B of the steering stem upper bracket. • Tighten the front fork upper clamp bolts 1 and handlebar clamp bolts 2 to the specified torque.  Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •...
Page 364 CHASSIS 8-39 • Apply the SUZUKI SUPER GREASE “A” to the throttle cables and cable drum.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • When remounting the right and left handle switches, engage the stopper with the handlebar hole.
Page 365: Rear Wheel
8-40 CHASSIS REAR WHEEL CONSTRUCTION 1 Rear axle 0 Sprocket mounting drum 2 Brake disc A Sprocket 3 Collar B Bearing 4 Dust seal C Dust seal  5 Rear wheel D Collar 6 Spacer A Brake disc bolt ITEM N·m kgf-m lb-ft...
Page 366: Removal
CHASSIS 8-41 REMOVAL • Remove the cotter pin. (For E-03, 28, 33) • Loosen the axle nut 1. • Remove the under cowling. (8-5) • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. •...
Page 367: Inspection And Disassembly
8-42 CHASSIS • Remove the dust seal with the special tool.  09913-50121: Oil seal remover  The removed dust seal must be replaced with a new one. • Remove the dust seal with the special tool.  09913-50121: Oil seal remover ...
Page 368 CHASSIS 8-43 SPROCKET • Inspect the sprocket teeth for wear. • If they are worn as shown, replace the two sprockets and drive chain as a set. A Normal wear B Excessive wear BEARINGS • Inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place.
Page 369: Reassembly And Installation
8-44 CHASSIS REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 93 N·m 35 N·m (9.3 kgf-m, 67.5 lb-ft) (3.5 kgf-m, 25.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) E-02, 19, 24 E-03, 28, 33...
Page 370 CHASSIS 8-45 BEARINGS • Apply SUZUKI SUPER GREASE “A” to the bearings before installing.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) • Install the new bearing to the sprocket mounting drum with the special tool.  09913-70210: Bearing installer set •...
Page 371 DUST SEALS • Install the new dust seal with the special tool.  09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the dust seal lip before assembling rear wheel.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) REAR SPROCKET AND SPROCKET MOUNTING DRUM •...
Page 372 CHASSIS 8-47 BRAKE DISC • Apply THREAD LOCK to the disc bolts and tighten them to the specified torque. NOTE: Make sure that the brake disc is clean and free of any greasy matter.  99000-32130: THREAD LOCK SUPER “1360” ...
Page 373: Rear Shock Absorber
8-48 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION  Rear shock absorber mount- 1 Rear shock absorber ing bolt/nut ITEM N·m kgf-m lb-ft Rear shock absorber bracket 36.0 2 Rear shock absorber bracket 11.5 83.0...
Page 374: Removal
CHASSIS 8-49 REMOVAL • Remove the front seat. (8-5) • Remove the fuel tank. (5-4) • Disconnect the HO2 sensor lead wire coupler. (4-107) • Remove the under cowling. (8-5) • Remove the exhaust muffler. (6-10) • Loosen the axle nut. •...
Page 375 8-50 CHASSIS • Remove the brake fluid reservoir mounting bolt. • Loosen the rear shock absorber bracket. • Remove the rear shock absorber upper and lower mounting bolts and nuts. • Remove the rear shock absorber.
Page 376: Inspection
CHASSIS 8-51 INSPECTION Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one.  Do not attempt to disassemble the rear shock absorber unit. It is unserviceable. REAR SHOCK ABSORBER SCRAPPING PROCEDURE ...
Page 377: Installation
8-52 CHASSIS • Press the valve with a screwdriver to bleed out the nitrogen gas.  * Releasing high pressure gas from the rear shock absorber unit can be hazardous. Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit.
Page 378: Suspension Setting
CHASSIS 8-53 SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The set length 176.4 mm (6.94 in) provides the maximum spring pre-load. The set length 186.4 mm (7.34 in) provides the minimum spring pre-load.
Page 379: Rear Suspension
8-54 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 0 Plate  2 Rear cushion rod Rear shock absorber mounting 3 Rear cushion lever bolt/nut ITEM N·m kgf-m lb-ft 4 Spacer B Rear cushion lever bolt/nut 36.0 5 Bearing C Rear cushion rod bolt/nut 71.0 6 Chain cover D Swingarm pivot shaft...
Page 380: Removal
CHASSIS 8-55 REMOVAL • Cut the drive chain. (8-89 and -90) NOTE: It is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • Remove the rear shock absorber. (8-49 and -50) • Remove the cushion lever mounting bolt/nut 1. •...
Page 381: Inspection
8-56 CHASSIS • Remove the plate 0. INSPECTION SWINGARM PIVOT SHAFT • Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit.  Swingarm pivot shaft runout: Service limit: 0.3 mm (0.01 in) ...
Page 382 CHASSIS 8-57 SWINGARM • Inspect the swingarm for damage. If any damages are found, replace the swingarm with a new one. CUSHION ROD • Inspect the cushion rod for damage and distortion. • If any defects are found, replace the cushion rod with a new one.
Page 383 8-58 CHASSIS SWINGARM BEARING • Insert the spacer into bearing and check the play when mov- ing the spacer up and down. • If excessive play is noted, replace the bearing with a new one. CUSHION ROD BEARING • Insert the spacer into bearing and check the play when mov- ing the spacer up and down.
Page 384: Disassembly
CHASSIS 8-59 DISASSEMBLY SWINGARM BEARING • Draw out the swingarm pivot bearings with the special tool.  09921-20240: Bearing remover set ( 28 mm)  The removed bearings must be replaced with new ones. • Remove the center spacer. CUSHION ROD BEARING •...
Page 385: Reassembly And Installation
115 N·m (11.5 kgf-m, 83.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 1 mm (0.04 in) 1 mm (0.04 in) Apply SUZUKI SUPER GREASE “A” 78 N·m to the bearings, washers and dust seals. (7.8 kgf-m, 56.5 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft)
Page 386 • Press the bearings into the cushion lever with the special tool.  09924-84521: Bearing installer set NOTE: When installing the bearing, stamped mark on the bearing must face outside. • Apply SUZUKI SUPER GREASE “A” to the bearings, spacers.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease)
Page 387 8-62 CHASSIS • Remount the plate 1. • Remount the chain cases 2 chain buffer 3 and rear fender (lower) 4. SWINGARM PIVOT THRUST CLEARANCE ADJUSTMENT Adjust swingarm pivot thrust clearance in the following procedure. • Insert the swingarm pivot shaft and tighten to the specified torque.
Page 388: Final Inspection And Adjustment
CHASSIS 8-63 SHOCK ABSORBER, CUSHION LEVER AND CUSHION ROD MOUNTING BOLT/NUT • Install the cushion lever. • Tighten the cushion lever mounting nut 1 to the specified torque.  Cushion lever mounting nut: 98 N·m (9.8 kgf-m, 71.0 lb-ft) • Install the cushion rod. •...
Page 389: Front Brake
8-64 CHASSIS FRONT BRAKE CONSTRUCTION  1 Brake lever A Master cylinder mounting bolt 2 Dust boot B Brake hose union bolt ITEM N·m kgf-m lb-ft 3 Piston set C Caliper mounting bolt 4 Piston seal D Caliper air bleeder valve 16.5 5 Dust seal E Caliper housing bolt...
Page 390: Brake Pad Replacement
CHASSIS 8-65  * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
Page 391: Brake Fluid Replacement
8-66 CHASSIS • Install the spring to the caliper, bring its wider side of pawl A facing top. • Install the new brake pads. • Install the brake caliper. • Tighten each bolt to the specified torque.  Pad mounting pin 1: 15 N·m (1.5 kgf-m, 11.0 lb-ft) Front brake caliper mounting bolt 2: 35 N·m (3.5 kgf-m, 25.5 lb-ft) NOTE:...
Page 392: Caliper Removal
CHASSIS 8-67 CALIPER REMOVAL • Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta- cle. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid.
Page 393: Caliper Inspection
8-68 CHASSIS • Remove the dust seals 4 and piston seals 5.  Avoid reusing 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.
Page 394: Caliper Installation
CHASSIS 8-69 PISTON SEAL • Install the piston seals as shown in the illustration. Dust seal Caliper body Piston seal O-RING • Install the new O-ring 1 and reassemble caliper halves.  Replace the O-ring with a new one. • Temporarily tighten the air bleeder valve 2. •...
Page 395: Brake Disc Inspection
8-70 CHASSIS BRAKE DISC INSPECTION • Visually check the brake disc for damage or cracks. • Measure the thickness with a micrometer. • Replace the disc if the thickness is less than the service limit or if damage is found. ...
Page 396: Master Cylinder Removal And Disassembly
CHASSIS 8-71 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain the brake fluid. (8-66) • Disconnect the front brake light switch lead wires 1. • Place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose.
Page 397: Master Cylinder Inspection
8-72 CHASSIS • Remove the dust boot 9 push rod 0 and snap ring A. • Remove the following parts. B Secondary cup C Piston D Primary cup E Return spring F Return spring guide G Air bleeder valve • Remove the dust rubber H and snap ring I. •...
Page 398: Master Cylinder Reassembly
 Specification and classification: DOT 4 • Install the O-ring to the brake hose connector.  Use a new O-ring to prevent the fluid leakage. • Apply SUZUKI SILICONE GREASE to the push rod.  99500-25100: SUZUKI SILICONE GREASE...
Page 399: Master Cylinder Installation
8-74 CHASSIS • Apply SUZUKI SILICONE GREASE to the brake lever pivot bolt.  99000-25100: SUZUKI SILICONE GREASE  Brake lever pivot bolt: 1 N·m (0.1 kgf-m, 0.7 lb-ft) Brake lever lock-nut: 6 N·m (0.6 kgf-m, 4.5 lb-ft) • Align the convex part A of brake light switch with the hole B of master cylinder when installing the brake light switch.
Page 400: Rear Brake
CHASSIS 8-75 REAR BRAKE CONSTRUCTION  1 Brake pedal A Caliper air bleeder valve 2 Piston/Cup set B Brake hose union bolt ITEM N·m kgf-m lb-ft 3 Reservoir hose C Brake caliper mounting bolt 0.75 4 Brake hose D Brake master cylinder mounting bolt 16.5 5 Brake pad E Brake master cylinder rod lock-nut...
Page 401: Brake Pad Replacement
8-76 CHASSIS  * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.
Page 402: Brake Fluid Replacement
CHASSIS 8-77 BRAKE FLUID REPLACEMENT • Remove the brake fluid reservoir mounting bolt 1. • Place a rag underneath the brake fluid reservoir to catch any split brake fluid. Remove the brake fluid reservoir cap 2. • Replace the brake fluid in the same manner as the front brake.
Page 403 8-78 CHASSIS • Remove the brake pad spring. • Remove the caliper air bleeder valve 4. • Remove the spacer 5 and rubber boot 6 from the caliper. • Place a rag over the piston to prevent it from popping out and then force out the pistons using compressed air.
Page 404: Caliper Inspection
CHASSIS 8-79 CALIPER INSPECTION BRAKE CALIPER AND BRAKE CALIPER PISTON • Inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. • Inspect the brake caliper piston surface for any scratches and other damage.
Page 405: Caliper Reassembly
Caliper body Piston seal SLIDING PIN • Install the rubber boot 1. • Apply SUZUKI SILICONE GREASE to the inside of the boot.  99000-25100: SUZUKI SILICONE GREASE • Install the spacer 2. • Install the caliper air bleeder valve.
Page 406: Caliper Installation
CHASSIS 8-81 CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Tighten each bolt to the specified torque.  Brake hose union bolt 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Brake caliper mounting bolt 2: 17 N·m (1.7 kgf-m, 12.5 lb-ft) Brake caliper pin bolt 3: 32 N·m (3.2 kgf-m, 23.0 lb-ft) •...
Page 407 8-82 CHASSIS • Remove the reservoir cap 7, insulator 8, diaphragm 9 and reservoir tank 0. • Remove the snap ring A with the special tool.  09900-06108: Snap ring pliers • Remove the connector B. • Remove the O-ring C. ...
Page 408: Master Cylinder Inspection
* Do not wipe the components with a rag. * Apply brake fluid to the cylinder bore and all the component to be inserted into the bore.  Specification and classification: DOT 4 • Apply SUZUKI SILICONE GREASE to the push rod end.  99000-25100: SUZUKI SILICONE GREASE...
Page 409: Master Cylinder Installation
8-84 CHASSIS MASTER CYLINDER INSTALLATION Install the master cylinder in the reverse order of removal. Pay attention to the following points: • Apply THREAD LOCK to the master cylinder mounting bolts.  99000-32110: THREAD LOCK SUPER “1322” (or equivalent thread lock) •...
Page 410: Tire And Wheel
CHASSIS 8-85 TIRE AND WHEEL TIRE REMOVAL The most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
Page 411: Valve Inspection
8-86 CHASSIS VALVE INSPECTION • Inspect the valve after the tire is removed from the rim. • Replace the valve with a new one if the seal A rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.
Page 412: Tire Installation
CHASSIS 8-87 TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points.  * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant.
Page 413: Balancer Weight Installation
8-88 CHASSIS • In this condition, check the “rim line” B cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.
Page 414: Drive Chain
CHASSIS 8-89 DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain.  09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool.
Page 415: Drive Chain Connecting
8-90 CHASSIS • Place the drive chain link being disjointed on the holder part 8 of the tool. • Turn in both the adjuster bolt 6 and pressure bolt “A” 3 so that each of their end hole fits over the chain joint pin properly. •...
Page 416 CHASSIS 8-91 • 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, its stamp mark must face the joint plate holder 3 side. •...
Page 417 8-92 CHASSIS • Stake the joint pin by turning (approximately 7/8 turn) the pressure 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) ...
Page 418 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................. 9- 3 CONNECTOR ..................9- 3 COUPLER....................9- 3 CLAMP ....................9- 3 FUSE...................... 9- 3 SEMI-CONDUCTOR EQUIPPED PART ..........9- 4 BATTERY ....................9- 4 CONNECTING THE BATTERY............. 9- 4 WIRING PROCEDURE................
Page 419 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS TURN SIGNAL/SIDE-STAND RELAY ..........9-37 STARTER RELAY ................. 9-37 FUEL PUMP RELAY ................9-37 COOLING FAN RELAY................. 9-37 IGNITION SWITCH REMOVAL ............. 9-38 IGNITION SWITCH INSTALLATION............. 9-38 SWITCHES INSPECTION ..............9-39 BATTERY ....................9-40 SPECIFICATIONS ................. 9-40 INITIAL CHARGING ................
Page 420: Cautions In Servicing
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 Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.
Page 421: Semi-Conductor Equipped Part
ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •...
Page 422: Using The Multi-Circuit Tester
ELECTRICAL SYSTEM USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •...
Page 423: Location Of Electrical Components
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Fuel pump relay (5-7) 9 Fuel pump (5-8) 2 IAT sensor (4-53) 0 Regulator/Rectifier 3 Cooling fan relay (7-7) A Oil pressure switch 4 PAIR control solenoid valve (11-7) B Generator 5 CMP sensor (4-33) C Speed sensor 6 Ignition coil (No.1, 2, 3, 4) D GP switch...
Page 424 ELECTRICAL SYSTEM 1 Battery 0 STP sensor (4-70) 2 AP sensor (4-57) A TP sensor (4-44) 3 Mode selection switch coupler (4-18) B IAP sensor (4-38) 4 Fuse Box C Starter relay/Main fuse 5 ECM (Engine Control Module) D Turn signal/Side-stand relay 6 Secondary fuel injector (4-80) E EXCVA (6-4) 7 Primary fuel injector (4-77)
Page 425: Charging System
ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier IG. switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (9-9) Is the battery for current leaks OK? Go to Step 3.
Page 426: Inspection
ELECTRICAL SYSTEM Step 5 1) Measure the generator no-load performance. (9-11) Is the generator no-load performance OK? Go to Step 6. Faulty generator Step 6 1) Inspect the regulator/rectifier. (9-11) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier Step 7 1) Inspect wirings.
Page 427 9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. (8-7) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the + and - battery termi- nals using the multi-circuit tester.
Page 428 ELECTRICAL SYSTEM 9-11 GENERATOR NO-LOAD PERFORMANCE • Lift and support the fuel tank. (5-3) • Disconnect the generator coupler. • Start the engine and keep it running at 5 000 r/min. • Using the multi-circuit tester, measure the voltage between three lead wires.
Page 429: Starter System And Side-Stand/Ignition Interlock System
9-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To Ignition coil Starter motor GP switch Fuse (10 A) (Neutral) Battery Starter relay Starter Turn signal/ button side-stand relay Clutch switch side-stand switch TROUBLESHOOTING Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.
Page 430: Starter Motor Removal
ELECTRICAL SYSTEM 9-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and B/Y -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch •...
Page 431: Starter Motor Disassembly
9-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration.  1 O-ring 4 Armature 2 Housing end (inside) 5 Housing end (outside) ITEM N·m kgf-m lb-ft 3 Starter motor case A Lead wire mounting bolt STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness...
Page 432: Starter Motor Reassembly
STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.  99000-25010: SUZUKI SUPER GREASE “A” (or equivalent grease) •...
Page 433: Starter Relay Inspection
9-16 ELECTRICAL SYSTEM • Tighten the starter motor lead wire mounting bolt to the speci- fied torque.  Lead wire mounting bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft) STARTER RELAY INSPECTION • Remove the front seat. (8-7) • Disconnect the battery - lead wire from the battery. •...
Page 434: Side Stand/Ignition Interlock System Parts Inspection
ELECTRICAL SYSTEM 9-17 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH The side-stand switch coupler is located above the crankcase.
Page 435 9-18 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Remove the front seat. • Disconnect the battery - lead wire from the battery. • Lift and support the fuel tank. (5-3) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmis- sion in “NEUTRAL”.
Page 436 ELECTRICAL SYSTEM 9-19 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the front seat.(8-7) • Disconnect the battery - lead wire from the battery. • Remove the frame cover. (8-8) •...
Page 437: Ignition System
9-20 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Side- stand Power source relay circuit Fuse sensor Waveform arrangement Ignition circuit switch Fuse Waveform arrangement sensor circuit Battery sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 14 500 r/min, this circuit cuts off fuel at the fuel injector.
Page 438: Immobilizer (Except For E-03, 28, 33)
ELECTRICAL SYSTEM 9-21 IMMOBILIZER (Except for E-03, 28, 33) DESCRIPTION The immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start. Indicator light Immobi-antenna Indicator light...
Page 439 9-22 ELECTRICAL SYSTEM Operation When the ignition switch is turned ON with the engine stop switch in ON, the immobi-antenna and ECM are powered ON. The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID.
Page 440: Troubleshooting
ELECTRICAL SYSTEM 9-23 TROUBLESHOOTING No spark or poor spark NOTE: Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.
Page 441 9-24 ELECTRICAL SYSTEM Step 5 1) Inspect the ignition coil/plug caps. (9-26) Is the ignition coil/plug cap OK? Go to Step 6. • Poor connection of the ignition coil/plug cap(-s). • Faulty ignition coil/plug cap(-s). Step 6 1) Measure the CKP sensor peak voltage and its resistance. (9-27 to -28) NOTE: The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.
Page 442: Inspection
ELECTRICAL SYSTEM 9-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. (5-14) • Disconnect all the ignition coil/plug cap lead wire couplers before removing the ignition coil/plug caps. • Remove all of the ignition coil/plug caps. ...
Page 443 9-26 ELECTRICAL SYSTEM NOTE: Use the special tool, to prevent the rubber of the water proof coupler from damage. • Shift the transmission into neutral and turn ignition switch “ON”. • Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage.
Page 444 ELECTRICAL SYSTEM 9-27 CKP SENSOR PEAK VOLTAGE • Remove the front seat. (8-7) NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Disconnect the both couplers 1. • Connect the multi-circuit tester with peak volt adaptor as fol- lows.
Page 445 9-28 ELECTRICAL SYSTEM If the peak voltage is lower than the standard range, check the peak voltage at the CKP sensor lead wire coupler. Black • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) • Disconnect the CKP sensor lead wire coupler and connect the multi-circuit tester with the peak volt adaptor.
Page 446: Combination Meter
ELECTRICAL SYSTEM 9-29 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 of high response compared to those currently in use because of this composition. The rpm pointer is driven by the stepping motor.
Page 447: Removal And Disassembly
9-30 ELECTRICAL SYSTEM REMOVAL AND DISASSEMBLY • Remove the screw 1. • With the hooked parts 2 of the combination meter pulled from the headlight housing, disconnect the combination meter lead wire coupler. • Remove the combination meter.  When disconnecting and reconnecting the combina- tion meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
Page 448: Inspection
ELECTRICAL SYSTEM 9-31 INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights [FI light, Fuel level indicator light, Engine RPM indicator light and immobilizer indi- cator light (For E-02, 19, 24)] immediately after turning the ignition switch on. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.
Page 449 9-32 ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection (7-7) • Remove the front seat.(8-7) • Lift and support the fuel tank. (5-3) • Disconnect the ECT sensor coupler 1.  When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
Page 450 ELECTRICAL SYSTEM 9-33 FUEL LEVEL GAUGE INSPECTION • Remove the fuel pump assembly. (5-9) • Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. Float position Resistance 182 ±...
Page 451 9-34 ELECTRICAL SYSTEM SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. SPEED SENSOR •...
Page 452: Lamps
ELECTRICAL SYSTEM 9-35 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 55 W H7 1 12 V 65 W H9 2 POSITION LIGHT 3 12 V 5 W × 2 BRAKE LIGHT/TAILLIGHT: LED LICENCE PLATE LIGHT 4 12 V 5 W TURN SIGNAL LIGHT 5 12 V 21 W ×...
Page 453 9-36 ELECTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. NOTE: * Use a screw driver + for adjuster A and B . * To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. A: Horizontal adjuster B: Vertical adjuster To adjust the beam horizontally: •...
Page 454: Relays
ELECTRICAL SYSTEM 9-37 RELAYS 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 operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
Page 455: Ignition Switch Removal
9-38 ELECTRICAL SYSTEM IGNITION SWITCH REMOVAL • Remove the air cleaner box. (5-14) • Disconnect the ignition switch lead wire coupler (Green) 1. • Disconnect the immobilizer lead wire coupler (Black) 2. (For E-02, 19, 24) • Remove the cable guide 3. •...
Page 456: Switches Inspection
ELECTRICAL SYSTEM 9-39 SWITCHES INSPECTION 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. PUSH HAZARD SWITCH HORN BUTTON Color Position Color B/Bl (OFF) Position (ON) PUSH...
Page 457: Battery
9-40 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YT12A-BS Capacity 12V,36kC (8Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes A.
Page 458 ELECTRICAL SYSTEM 9-41 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container 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 bat- tery.
Page 459: Servicing
9-42 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Page 460 SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION..10- 2 ENGINE ....................10- 6 RADIATOR (COOLING SYSTEM) ............10-12 CHASSIS ..................... 10-13 BRAKES ....................10-14 ELECTRICAL ..................10-15 BATTERY .................... 10-16 WIRING HARNESS, CABLE AND HOSE ROUTING........
Page 461: Troubleshooting
10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.
Page 462 SERVICING INFORMATION 10-3 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated.
Page 463 10-4 SERVICING INFORMATION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated. Sensor voltage is higher than specified STP sensor circuit shorted to value.
Page 464 SERVICING INFORMATION 10-5 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM HO2 sensor HO2 sensor output voltage is not input HO2 sensor circuit open or (For E-02, to ECM during engine operation and shorted to ground running condition. (Sensor voltage < 0.55 V) P0130 In other than the above value, C44 (P0130) is indicated.
Page 465: Engine
10-6 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of adjustment Adjust. 2. Worn valve guides or poor seating of valves Repair or replace. 3.
Page 466 SERVICING INFORMATION 10-7 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace.
Page 467 10-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace.
Page 468 SERVICING INFORMATION 10-9 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust.
Page 469 10-10 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinders Replace.
Page 470 SERVICING INFORMATION 10-11 Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts 1. Heavy carbon deposit on piston crowns Clean. 2. Not enough oil in the engine Add oil. 3. Defective oil pump or clogged oil circuit Replace or clean.
Page 471: Radiator (Cooling System)
10-12 SERVICING INFORMATION RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats 1. Not enough engine coolant Add coolant. 2. Radiator core clogged with dirt or scale Clean. 3. Faulty cooling fan Repair or replace. 4. Defective cooling fan relay, or open- or short- Repair or replace.
Page 472: Chassis
SERVICING INFORMATION 10-13 CHASSIS Complaint Symptom and possible causes Remedy Heavy steering 1. Overtightened steering stem nut Adjust. 2. Broken bearing in steering stem Replace. 3. Distorted steering stem Replace. 4. Not enough pressure in tires Adjust. Wobbly handlebars 1. Loss of balance between right and left front forks Adjust.
Page 473: Brakes
10-14 SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system Repair or replace. power 2. Worn pads Replace. 3. Oil adhesion of engaging surface of pads/shoe Clean disc and pads. 4.
Page 474: Electrical
SERVICING INFORMATION 10-15 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective spark plugs Replace. 3. Defective CMP sensor Replace. 4. Defective CKP sensor Replace. 5. Defective ECM Replace. 6. Defective TO sensor Replace.
Page 475: Battery
10-16 SERVICING INFORMATION 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 Battery runs down...
Page 476: Wiring Harness, Cable And Hose Routing
SERVICING INFORMATION 10-17 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Wiring harness Brake light switch HO2 sensor (E-02, 19) Wiring harness Starter motor lead wire Clamp 1 Integrated clamp 8 Protector 2 Cooling fan relay *1 To ECT sensor 3 Fuel pump relay *2 Cut the tip after clamping.
Page 477 10-18 SERVICING INFORMATION 6 N·m Guide (0.6 kgf-m, 4.5 lb-ft) Handlebar switch (RH) Iginition switch Clamp Wiring harness Battery - lead wire Wiring harness Position light (LH) Turn signal light (RH) Clamp 1 Rear combination light 8 Brake light switch 2 EXCVA 9 Horn 3 AP sensor...
Page 478 SERVICING INFORMATION 10-19 6 N·m (0.6 kgf-m, 4.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) 5 N·m (0.5 kgf-m, 3.5 lb-ft) 11 N·m (1.1 kgf-m, 8.0 lb-ft) 7 N·m (0.7 kgf-m, 5.0 lb-ft) 14 N·m (1.4 kgf-m, 10 lb-ft) 1 Battery - lead wire *1 Fix the clamp in parallel with the cover surface.
Page 479: Ho2 Sensor Harness Routing (For E-02, 19)
10-20 SERVICING INFORMATION HO2 SENSOR HARNESS ROUTING (For E-02, 19) 48 N·m (4.8 kgf-m, 34.5 lb-ft) 1 HO2 sensor Clamp the HO2 sensor lead wire so as not to over- 2 Clutch cable lap the oil inspection window. 3 Oil pan Pass the HO2 sensor lead wire through between 4 Under cowling the frame and engine.
Page 480: Cable Routing
SERVICING INFORMATION 10-21 CABLE ROUTING 0 mm 0 mm 0 mm 1 Clutch cable *1 Clutch cable must be clamped on the grommet. 2 Throttle cable No.1 *2 Pass the throttle cables above the clutch cable. 3 Throttle cable No.2 *3 Pass the throttle cable No.2 outer from No.1.
Page 481: Fuel Tank Hose Routing
10-22 SERVICING INFORMATION FUEL TANK HOSE ROUTING Pass the fuel tank drain hose and breather hose 1 Fuel tank water drain hose through behind the PCV hose. Set the fuel tank drain hose and breather hose with 2 Fuel tank breather hose lengthwise backward.
Page 482: Cooling System Hose Routing
SERVICING INFORMATION 10-23 COOLING SYSTEM HOSE ROUTING 90˚ 90˚ 90˚ 1 Reservoir tank overflow hose *1 Clamp should face downward. 2 Reservoir tank inlet hose *2 Clamp should face right side. 3 Oil cooler outlet hose *3 Yellow marking 4 Clearance *4 White marking 5 Radiator inlet hose *5 Clamp should face backward.
Page 483: Front Brake Hose Routing
10-24 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING 1 – 2 mm (0.04 – 0.08 in) 14˚ 42˚ 42˚ 1 Brake hose guide *4 Clamp the brake hose firmly. After positioning the clamp with stopper, tighten *1 Clamp should face downward. the clamp bolt.
Page 484: Rear Brake Hose Routing
SERVICING INFORMATION 10-25 REAR BRAKE HOSE ROUTING 28˚ 23 N . m 2.3 kgf-m 16.5 lb-ft 28˚ 28˚ 23 N . m 2.3 kgf-m 16.5 lb-ft 1 Rear brake hose *2 Pass the reservoir hose above the brake hose. 2 Brake fluid reservoir hose *3 Position the brake union with the stopper before tightening.
Page 485: Fuel Tank Installation
10-26 SERVICING INFORMATION FUEL TANK INSTALLATION 1 Velcro fastening 4 Fuel tank side cushion 2 Frame cover cushion Apply adhesive agent. 3 Fuel tank front cover (equivalent to ARONALPHA 201) COWLING INSTALLATION...
Page 486: Frame Cover Installation
SERVICING INFORMATION 10-27 Intake cover (RH) To head light Air intake pipe (RH) Side cowling (LH) Under cowling cover (RH) Intake cover (LH) To frame Air intakepipe (LH) To oil pan Wind screen Under cowling cover (LH) Side cowling (RH) Under cowling (LH) headlight Heat shield...
Page 487: Seat Lock Cable Routing
10-28 SERVICING INFORMATION SEAT LOCK CABLE ROUTING REAR FENDER INSTALLATION...
Page 488 SERVICING INFORMATION 10-29 1 Seat rail 4 Rear fender (rear) 2 Rear fender (front) 5 Rear fender (lower) 3 Rear fender cover (front) 6 Swingarm...
Page 489: Side-Stand Installation
10-30 SERVICING INFORMATION SIDE-STAND INSTALLATION 40 N·m (4.0 kgf-m, 29.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 1 Side-stand spring No.1 2 Side-stand spring No.2 UNDER COWLING CUSHION RUBBER/HEAT SHIELD INSTALLATION Max. 3 mm (0.12 in) 2 mm (0.08 in)
Page 490: Front Footrest Installation
SERVICING INFORMATION 10-31 FRONT FOOTREST INSTALLATION 18 N . m (1.8 kgf-m, 13.0 lb-ft) 18 N . m (1.8 kgf-m, 13.0 lb-ft) 10 N . m (1.0 kgf-m, 7.0 lb-ft) 46 N . m (4.6 kgf-m, 33.5 lb-ft) 23 N·m 23 N·m (2.3 kgf-m, 16.5 lb-ft) (2.3 kgf-m, 16.5 lb-ft)
Page 491: Rear View Mirror Installation
10-32 SERVICING INFORMATION REAR VIEW MIRROR INSTALLATION 1 Body cowling 5 Turn signal lead wire coupler 2 Cowling brace 6 Mirror cover 3 Cushion 7 Mirror body Locate the turn signal lead wire coupler 5 4 Turn signal lead wire between the mirror cover 6 and mirror body 7.
Page 492: Special Tools
SERVICING INFORMATION 10-33 SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-06107 09900-06108 Hexagon socket 09900-20102 Micrometer Snap ring pliers Snap ring pliers (24 mm) Vernier calipers (25 – 50 mm) 09900-20203 09900-20205 09900-20602 09900-20605 Micrometer Micrometer 09900-20508 Dial gauge Dial calipers (50 – 75 mm) (0 –...
Page 493 10-34 SERVICING INFORMATION 09910-20115 09913-10750 09913-50121 09913-70210 09915-40610 Conrod stopper Adapter Oil seal remover Bearing installer set Oil filter wrench 09915-64512 09915-74521 09915-74540 09915-77331 Compression gauge Oil pressure gauge Oil pressure gauge Meter 09916-10911 hose attachment (for high pressure) Valve lapper set 09916-14530 09916-20640 09916-33210...
Page 494 SERVICING INFORMATION 10-35 09917-47011 09920-34830 09920-53740 Vacuum pump 09919-28610 Starter clutch Clutch sleeve hub 09921-20210 gauge Sleeve protector holder holder Bearing remover 09922-22711 09921-20240 Drive chain cutting 09923-74511 09924-84510 09924-84521 Bearing remover set and joining tool Bearing remover Bearing installer set Bearing installer set 09925-18011 Steering bearing...
Page 495 10-36 SERVICING INFORMATION 09940-30221 09940-40211 09940-40220 09940-14940 09940-14990 Front fork assem- Fuel pressure Fuel pressure gauge Swingarm pivot Engine mounting bling tool gauge adaptor hose attachment thrust adjuster thrust adjuster socket wrench socket wrench 09940-52841 09940-52861 09940-94922 09940-94930 Front fork inner Front fork oil seal 09940-92720 Front fork spring...
Page 496: Tightening Torque
SERVICING INFORMATION 10-37 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Exhaust pipe bolt 16.5 Muffler connecting bolt 16.5 Muffler mounting bolt 16.5 Speed sensor rotor bolt 18.0 Speed sensor bolt 0.45 Engine sprocket nut 11.5 83.0 Engine mounting bolt (Cylinder) 39.8 Engine mounting nut (Crankcase) 54.0...
Page 497: Fi System And Intake Air System
10-38 SERVICING INFORMATION ITEM N·m kgf-m lb-ft Crankcase bolt (Initial) (M: 6) (Final) (Initial) 11.0 (M: 8) (Final) 19.0 Crankcase bolt (Inner hexagon) (Initial) 11.0 (M: 8) (Final) 16.0 Crankshaft journal bolt (M: 9) 16.0 Oil gallery plug (M: 6) (M: 10) 13.0 (M: 12)
Page 498: Chassis
SERVICING INFORMATION 10-39 CHASSIS N·m kgf-m lb-ft ITEM Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt and nut 16.5 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 14.5 Front fork damper rod bolt...
Page 499: Tightening Torque Chart
10-40 SERVICING INFORMATION N·m kgf-m lb-ft ITEM Seat rail bolt 36.0 Rear view mirror nut TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7”...
Page 500: Service Data
SERVICING INFORMATION 10-41 SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 29.0 — (1.14) 23.0 — (0.91) Valve clearance (when cold) 0.08 – 0.18 — (0.0031 – 0.0071) 0.18 – 0.28 — (0.0071 – 0.0110) Valve guide to valve stem 0.010 –...
Page 501 10-42 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 000 kPa (13 – 17 kgf/cm², 185 – 242 psi) (10 kgf/cm , 142 psi) Compression pressure difference 200 kPa —...
Page 502 SERVICING INFORMATION 10-43 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5909 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 –...
Page 503 10-44 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/2 turn back — Drive plate thickness 2.72 – 2.88 2.42 No. 1, 2 and 3 (0.107 – 0.113) (0.095) Drive plate claw width 13.85 –...
Page 504 SERVICING INFORMATION 10-45 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 82 °C (180 °F) — ature Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) — ECT sensor resistance 20 °C Approx.
Page 505 10-46 SERVICING INFORMATION FI SENSORS ITEM SPECIFICATION NOTE 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.28 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.7 V at idle speed TP sensor input voltage 4.5 –...
Page 506 SERVICING INFORMATION 10-47 THROTTLE BODY ITEM SPECIFICATION Bore size 42 mm I.D. No. 02H1 (For E-33), 02H0 (For the others) Idle r/min 1 200 ± 100 r/min Fast idle r/min 1 500 – 2 000 r/min (When cold engine) Throttle cable play 2.0 –...
Page 507 10-48 SERVICING INFORMATION WATTAGE Unit: W STANDARD/SPECIFICATION ITEM E-03, 28, 33 Others ← Headlight ← ← Position/Parking light 5 × 2 ← Brake light/Taillight ← Turn signal light 21 × 4 ← License plate light ← Combination meter light ← Turn signal indicator light ←...
Page 508 SERVICING INFORMATION 10-49 ITEM STANDARD LIMIT Wheel rim runout Axial — (0.08) Radial — (0.08) Wheel rim size Front 17 M/C × MT 3.50 — Rear 17 M/C × MT 5.50 — Wheel axle runout 0.25 Front — (0.010) 0.25 Rear —...
Page 509 (10.22) Front fork oil level (without spring, — outer tube fully compressed) (4.41) Front fork oil type SUZUKI FORK OIL SS-05 or equivalent fork oil — Front fork oil capacity (each leg) 408 ml — (13.8/14.4 US/Imp oz) Front fork inner tube O.D.
Page 510 EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ...............11- 2 FUEL INJECTION SYSTEM..............11- 2 CRANKCASE EMISSION CONTROL SYSTEM........11- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) .....11- 4 NOISE EMISSION CONTROL SYSTEM..........11- 5 PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION ..........11- 6 PAIR HOSES..................11- 6 PAIR REED VALVE ................11- 6...
Page 511: Emission Control Systems
EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM GSX-R750 motocycles are equipped with a fuel injection system for emission level control. This fuel injec- tion system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With a view to reducing CO, NOX and HC, all of the fuel injection volumes are stringently controlled with the programmed injection maps in the ECM by varying engine conditions.
Page 512: Crankcase Emission Control System
EMISSION CONTROL INFORMATION 11-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.
Page 513: Exhaust Emission Control System (Pair System)
11-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system, exhaust control system and three-way catalyst system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve.
Page 514: Noise Emission Control System
EMISSION CONTROL INFORMATION 11-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.
Page 515: Pair (Air Supply) System And Emission Control System Inspection
11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses is securely connected. PAIR REED VALVE • Remove the cylinder head cover. (3-14) •...
Page 516: Pair Control Solenoid Valve
EMISSION CONTROL INFORMATION 11-7 PAIR CONTROL SOLENOID VALVE • Remove the air cleaner box. (5-14) • Disconnect the PAIR control solenoid valve lead wire coupler 1 and PAIR hoses. • Remove the PAIR control solenoid valve 2. • Check that air flows through the air inlet port to the air outlet port.
Page 517: Pair (Air Supply) System Hose Routing
11-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Approx. 0˚ Approx. 0˚ Approx. 0˚ 1 PAIR control solenoid valve *1 White marking 2 PAIR reed valve *2 Yellow marking (Opposite side)
Page 518: Ho2 Sensor Inspection (For E-02, 19)
EMISSION CONTROL INFORMATION 11-9 HO2 SENSOR INSPECTION (For E-02, 19) The HO2 sensor coupler 1 is located under the fuel tank. • Inspect the HO2 sensor and its circuit referring to flow table of the malfunction code C44 (P0130/P0135). • Check the resistance between the terminals of the HO2 sen- sor.
Page 519 WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. IGNITION IGNITION IGNITION IGNITION COIL #4 PAIR CONTROL COIL #1 COIL #2 COIL #3 SOLENOID HANDLEBAR SWITCH (R) ENGINE STOP FRONT BRAKE STARTER SIDE-STAND : TURN SIGNAL INDICATOR LIGHT SWITCH SWITCH BUTTON...
Page 520 E-03, 28, 33 IGNITION IGNITION IGNITION IGNITION COIL #4 PAIR CONTROL COIL #1 COIL #2 COIL #3 SOLENOID HANDLEBAR SWITCH (R) ENGINE STOP STARTER FRONT BRAKE : TURN SIGNAL INDICATOR LIGHT SIDE-STAND SWITCH BUTTON SWITCH SWITCH : HI BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT PUSH FREE...
Page 521 Prepared by December, 2005 Part No. 99500-37130-01E Printed in Japan...
Page 522 Printed in Japan...

This manual is also suitable for:

Gsx-r600 2006 Gsx-r600 2007 2007 gsxr 600 2006 gsxr 600

Suzuki GSX-R750 Service Manual

General Information 1

Periodic Maintenance

Engine

Fi System Diagnosis

Fuel System and Throttle Body

Exhaust System

Cooling and Lubrication System

Chassis

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki GSX-R750