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   Summary of Contents for Suzuki GSX-R750

  • Page 3

    FOREWORD This manual contains an introductory description on the SUZUKI GSX-R750 and procedures for its inspection/ser- vice and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........

  • Page 7

    Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...

  • Page 8

    CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner...

  • Page 9

    Precautions: 00-2 • Never reuse a circlip. When installing a • Inspect each terminal for corrosion and new circlip, take care not to expand the contamination. The terminals must be clean and free end gap larger than required to slip the of any foreign material which could impede proper circlip over the shaft.

  • Page 10

    00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse is blown, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.

  • Page 11

    Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.

  • Page 12

    00-5 Precautions: 2) Check each connector/coupler at both ends of the Continuity check circuit being checked for loose connection. Also 1) Measure resistance across coupler “B” (between “A” check for condition of the coupler lock if equipped. and “C” in figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals “A”...

  • Page 13

    Precautions: 00-6 3) Also, if measured values are as listed following, a Short circuit check (Wire harness to ground) resistance (abnormality) exists which causes the 1) Disconnect the negative (–) cable from the battery. voltage drop in the circuit between terminals “A” and 2) Disconnect the connectors/couplers at both ends of “B”.

  • Page 14

    : 09900–25008 (Multi-circuit tester set) I705H1000009-02 “D”: To other parts Using The Multi-Circuit Testers • Use the Suzuki multi-circuit tester set. • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi-circuit tester set)

  • Page 15: General Information

    Spark Plug Inspection and Cleaning ....0B-9 Symbols .............. 0A-1 Fuel Line Inspection ..........0B-10 Abbreviations ............0A-1 Evaporative Emission Control System SAE-to-Former SUZUKI Term ......0A-2 Inspection (E-33 only) ........0B-10 Vehicle Side View ..........0A-3 Engine Oil and Filter Replacement ....0B-10 Vehicle Identification Number ......0A-4 Throttle Cable Play Inspection and Fuel and Oil Recommendation ......

  • Page 16

    Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.

  • Page 17

    J1930 terms and abbreviations which may be used in GND: Ground this manual in compliance with SAE recommendations, GP Switch: Gear Position Switch as well as their former SUZUKI names. Ex. SAE term (Abbreviation): Former SUZUKI term HC: Hydrocarbons HO2 sensor: Heated Oxygen Sensor (HO2S)

  • Page 18

    Gauge motorcycles may exist depending on the Fuel Pump (FP): Fuel Pump (FP) markets. Generator (GEN): Generator SUZUKI GSX-R750 (2008-model) Ground (GND): Ground (GND, GRD) Right Side Hydrocarbons (HC): Hydrocarbons Heated Oxygen Sensor (HO2S): Heated Oxygen Sensor (HO2S), O2 sensor Ignition Control Module (ICM): —...

  • Page 19

    Use of SF/SG or SH/SJ in API with MA in JASO. spare parts. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.

  • Page 20

    2) Upon reaching an odometer reading of 1 600 km (1 Suzuki recommends the use of SUZUKI COOLANT anti- 000 miles) you can subject the motorcycle to full freeze/engine coolant. If this is not available, use an throttle operation.

  • Page 21

    General Information: 0A-6 Country and Area Codes B838H20101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX-R750 K8 (E-02) U.K. JS1CW111100100001 – GSX-R750 K8 (E-19) E.U. JS1CW111100100001 – GSX-R750U2 K8 (E-19) E.U.

  • Page 22

    0A-7 General Information: Warning, Caution and Information Labels Location B838H20101011 7, 9 1 (E-03, 33) 1 (E-24), 2 19, 21 10, 11 14, 15, 16, 17 12, 13 I838H1010001-01 1. Noise label (For E-03, 24, 33) 15. General warning label (French) (For GSX-R750UF E-19) 2.

  • Page 23: Component Location, Electrical Components Location

    General Information: 0A-8 Component Location Electrical Components Location B838H20103001 I837H1010006-03 1. EXCV actuator 9. CMP sensor 17. Fuel pump relay 2. IAP sensor 10. PAIR control solenoid valve 18. Cooling fan relay 3. TP sensor 11. Starter relay/Main fuse 19. AP sensor 4.

  • Page 24

    0A-9 General Information: I837H1010007-03 25. IAT sensor 31. Head light relay 37. Oil pressure switch 26. ISC valve 32. Turn signal/Side-stand relay 38. Generator 27. Secondary fuel injector 33. Steering damper solenoid valve 39. GP switch 28. Primary fuel injector 34.

  • Page 25: Specifications

    General Information: 0A-10 Specifications Specifications B838H20107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 040 mm (80.3 in) Overall width 715 mm (28.1 in) Overall height 1 125 mm (44.3 in) Wheelbase 1 405 mm (55.3 in) Ground clearance...

  • Page 26: Front Suspension

    0A-11 General Information: Chassis Item Specification Remark Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 120 mm (4.7 in) Rear wheel travel 130 mm (5.1 in) Caster 23° 45’ Tail 97 mm (3.8 in) Steering angle...

  • Page 27

    General Information: 0A-12 Special Tools and Equipment Special Tool B838H20108001 09900–06104 09900–06107 09900–06108 09900–18740 09900–20102 Snap ring pliers Snap ring pliers Snap ring pliers Hexagon socket (24 Vernier calipers (1/20 mm, 200 mm) 09900–20202 09900–20203 09900–20205 09900–20530 09900–20602 Micrometer (1/100 Micrometer (1/100 Micrometer (0 –...

  • Page 28

    0A-13 General Information: 09913–50121 09913–70210 09915–40610 09915–64512 09915–74521 Oil seal remover Bearing installer set Oil filter wrench Compression gauge Oil pressure gauge hose 09915–74540 09915–77331 09916–10911 09916–14510 09916–14522 Oil pressure gauge Meter (for high Valve lapper set Valve spring Valve spring attachment pressure) compressor...

  • Page 29

    General Information: 0A-14 09924–84521 09925–18011 09930–10121 09930–11920 09930–11940 Bearing installer set Steering bearing Spark plug wrench set Torx bit (JT40H) Bit holder installer 09930–11950 09930–30104 09930–34980 09930–44520 09930–44530 Torx wrench Rotor remover slide Rotor remover Rotor holder Rotor holder shaft 09930–82720 09940–14911 09940–14940...

  • Page 30

    0A-15 General Information: 09944–28321 99565–01010–015 Hexagon socket (19 CD-ROM Ver.15...

  • Page 31: Maintenance And Lubrication, Scheduled Maintenance

    Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B838H20200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.

  • Page 32

    0B-2 Maintenance and Lubrication: Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months — Brake fluid Replace every 2 years. — Brake hoses Replace every 4 years. Tires —...

  • Page 33

    Maintenance and Lubrication: 0B-3 Repair Instructions Air Cleaner Element Replacement 3) Drain water from the air cleaner box by removing the B838H20206001 drain plug (1). Replace air cleaner element Every 18 000 km (11 000 miles, 36 months) Refer to “Air Cleaner Element Removal and Installation in Section 1D (Page 1D-6)”.

  • Page 34: Exterior Parts

    0B-4 Maintenance and Lubrication: Exhaust Control Valve Inspection Valve Clearance Inspection and Adjustment B838H20206004 B838H20206005 Inspect exhaust control valve Inspect valve clearance Initially at 1 000 km (600 miles, 2 months) and every Initially every 24 000 km (14 500 miles, 48 months) 12 000 km (7 500 miles, 24 months) thereafter Inspection Inspect exhaust control valve as follows:...

  • Page 35

    Maintenance and Lubrication: 0B-5 4) Remove the valve timing inspection cap (1). 5) Turn the crankshaft to bring the line “C” on the CKP sensor rotor to the rib “D” behind the clutch cover and also to bring the notches “E” on the left ends of both camshafts (EX and IN) to the positions as shown.

  • Page 36

    0B-6 Maintenance and Lubrication: 7) Turn the crankshaft 360 degrees (one rotation) to 3) Check the figures printed on the shim. These figures bring the line on the CKP sensor rotor to the rib indicate the thickness of the shim, as illustrated. behind the clutch cover and also to bring the notches “E”...

  • Page 37

    Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I837H1020015-02...

  • Page 38

    0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I837H1020016-02...

  • Page 39

    Maintenance and Lubrication: 0B-9 6) Install the camshafts and cam chain tension adjuster. Spark Plug Gap Refer to “Engine Top Side Assembly in Section 1D 1) Remove the spark plugs. Refer to “Ignition Coil / (Page 1D-27)”. Plug Cap and Spark Plug Removal and Installation in 7) Rotate the engine so that the tappet is depressed Section 1H (Page 1H-6)”.

  • Page 40

    0B-10 Maintenance and Lubrication: Fuel Line Inspection Engine Oil Replacement B838H20206008 1) Place the motorcycle on the side-stand. Inspect fuel line 2) Place an oil pan below the engine, and drain engine Every 6 000 km (4 000 miles, 12 months) oil by removing the oil drain plug (1) and filler cap (2).

  • Page 41

    (thread diameter and pitch), filtering performance and durability I815H1020023-01 which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki Oil Level Inspection automobile oil filter on this motorcycle. 1) Place the motorcycle on the side-stand.

  • Page 42

    0B-12 Maintenance and Lubrication: Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization B838H20206011 B838H20206013 Inspect throttle cable play Inspect throttle valve synchronization Initially at 1 000 km (600 miles, 2 months) and every Initially at 1 000 km (600 miles, 2 months) (E-33 only) 6 000 km (4 000 miles, 12 months) thereafter and every 12 000 km (7 500 miles, 24 months) Inspect and adjust the throttle cable play “a”...

  • Page 43

    Maintenance and Lubrication: 0B-13 Engine Coolant Change Air Bleeding From the Cooling Circuit Refer to “Engine Coolant Description in Section 1F 1) Remove the right under cowling. Refer to “Exterior (Page 1F-1)”. Parts Removal and Installation in Section 9D (Page 9D-11)”. WARNING 2) Add engine coolant up to the radiator inlet.

  • Page 44

    0B-14 Maintenance and Lubrication: Clutch Cable Play Inspection and Adjustment 5) Loosen the lock-nut (5) and turn out the adjusting B838H20206015 screw (6) two or three rotations. Inspect clutch cable play 6) From that position, slowly turn in the adjusting screw Every 6 000 km (4 000 miles, 12 months) (6) until resistance is felt.

  • Page 45

    Maintenance and Lubrication: 0B-15 Drive Chain Inspection and Adjustment Drive Chain Length Inspection B838H20206016 1) Loosen the axle nut (1). Inspect drive chain 2) Loosen the left and right chain adjuster lock-nuts (2). Initially at 1 000 km (600 miles, 2 months) and every 3) Give tension to the drive chain fully by turning both 6 000 km (4 000 miles, 12 months) thereafter chain adjuster bolts (3).

  • Page 46

    “drive chain oil”. Such oil can damage the I838H1020003-01 O-rings. • The standard drive chain is a RK 525ROZ5Y. SUZUKI recommends to use this standard drive chain as a replacement. “a” I649G1020036-02 5) After adjusting the drive chain, tighten the axle nut (1) to the specified torque.

  • Page 47

    Maintenance and Lubrication: 0B-17 Brake System Inspection B838H20206018 Inspect brake system Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect brake hose and brake fluid “A” Every 6 000 km (4 000 miles, 12 months) WARNING •...

  • Page 48

    0B-18 Maintenance and Lubrication: Front and Rear Brake Hose Inspection 4) Tighten the lock-nut (1) securely. Inspect the brake hoses and hose joints for crack, Tightening torque damage or brake oil leakage. If any defects are found, Rear master cylinder rod lock-nut (a): 18 N·m ( replace the brake hose with a new one.

  • Page 49

    Maintenance and Lubrication: 0B-19 Tire Inspection CAUTION B838H20206019 The standard tire fitted on this motorcycle is Inspect tire 120/70 ZR17 M/C (58W) for front and 180/55 Every 6 000 km (4 000 miles, 12 months) ZR17 M/C (73W) for rear. The use of tires Tire Tread Condition other than those specified may cause Operating the motorcycle with excessively worn tires will...

  • Page 50

    0B-20 Maintenance and Lubrication: Chassis Bolt and Nut Inspection Front Fork Inspection B838H20206021 B838H20206023 Inspect front fork Tighten chassis bolt and nut Every 12 000 km (7 500 miles, 24 months) Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes.

  • Page 51

    Maintenance and Lubrication: 0B-21 I837H1020052-01 I837H1020055-01 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Rear shock absorber bracket nut 115 N⋅m (11.5 kgf-m, 83.0 lb-ft) Front axle bolt 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) Rear shock absorber mounting bolt/nut 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) Front axle pinch bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Front brake disc bolt 18 N⋅m (1.8 kgf-m, 13.0 lb-ft)

  • Page 52

    0B-22 Maintenance and Lubrication: Compression Pressure Check B838H20206024 Refer to “Compression Pressure Check in Section 1D (Page 1D-3)”. Oil Pressure Check B838H20206025 Refer to “Oil Pressure Check in Section 1E (Page 1E- 5)”. SDS Check B838H20206026 Refer to “SDS Check in Section 1A (Page 1A-17)”. I837H1020058-01 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Brake caliper air bleeder valve 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft)

  • Page 53

    Maintenance and Lubrication: 0B-23 Special Tools and Equipment Recommended Service Material B838H20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-17) NOTE Required service material is also described in the following. “Lubrication Points (Page 0B-2)”...

  • Page 54: Service Data

    0C-1 Service Data: Service Data General Information Specifications Service Data B838H20307001 Valve + Guide Unit: mm (in) Item Standard Limit 29.0 (1.14) — Valve diam. 23.0 (0.91) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...

  • Page 55

    Service Data: 0C-2 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 300 – 1 700 kPa (13 – 17 kgf/cm , 185 – 242 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —...

  • Page 56

    0C-3 Service Data: Balancer Unit: mm (in) Item Standard Limit Balancer shaft journal oil clearance 0.028 – 0.052 (0.0011 – 0.0020) 0.080 (0.0031) Balancer shaft journal O.D. 22.976 – 22.992 (0.9046 – 0.9052) — Oil Pump Item Standard Limit Oil pressure (at 60 °C, 140 °F) 100 –...

  • Page 57

    Service Data: 0C-4 Thermostat + Radiator + Fan + Coolant Item Standard/Specification Note Thermostat valve opening Approx. 82 °C (180 °F) — temperature Over 8 mm (0.31 in) and at 95 °C (203 °F) Thermostat valve lift — 20 °C Approx.

  • Page 58

    0C-5 Service Data: FI Sensors Item Standard/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 59

    Service Data: 0C-6 Throttle Body Item Specification Bore size 42 mm (1.65 in) I.D. No. 38H1 (For E-33), 38H0 (For the others) 1 200 ± 100 r/min Idle r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) Electrical Unit: mm Item...

  • Page 60

    0C-7 Service Data: Wattage Unit: W Specification Item E-02, 19, 24 The other countries ← 60 x 2 Headlight ← ← Position light ← Brake light/Taillight ← Turn signal light 21 x 4 ← License plate light ← Combination meter light ←...

  • Page 61

    Front fork oil level (Without spring, 115 (4.5) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 418 ml (14.1/14.7 US/lmp oz) — Front fork inner tube O.D 41 (1.6)

  • Page 62

    0C-9 Service Data: Tightening Torque List B838H20307002 Engine Item N⋅m kgf-m lb-ft Exhaust pipe bolt 16.5 Exhaust pipe mounting bolt 16.5 Exhaust pipe bracket bolt 18.0 Muffler connecting bolt 16.5 Muffler cover bolt 0.55 Muffler mounting bolt 18.0 Speed sensor rotor bolt 18.0 Speed sensor bolt 0.45...

  • Page 63

    Service Data: 0C-10 Item N⋅m kgf-m lb-ft Breather cover bolt Oil pan bolt Oil cooler mounting bolt Driveshaft bearing case bolt (LH and RH) Gearshift arm stopper 13.5 Gearshift cam stopper bolt Gearshift cam stopper plate bolt Driveshaft retainer bolt Gearshift cam bearing retainer screw Starter motor mounting bolt Starter motor lead wire mounting nut...

  • Page 64

    0C-11 Service Data: Chassis Item N⋅m kgf-m lb-ft Steering stem head nut 65.0 Steering stem lock-nut 65.0 Steering damper bolt 16.5 Steering damper 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...

  • Page 65

    Service Data: 0C-12 Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lb-ft N⋅m kgf-m lb-ft 0.15 0.23 0.45 0.55...

  • Page 66

    0C-13 Service Data:...

  • Page 67: Engine General Information And Diagnosis

    Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Precautions............. 1-1 Malfunction............1A-78 Precautions for Engine.......... 1-1 DTC “C28” (P1655): Secondary Throttle Engine General Information and Valve Actuator (STVA) Malfunction....1A-78 DTC “C29”...

  • Page 68: Engine Mechanical

    1-ii Table of Contents Emission Control Devices ...... 1B-1 ECT Sensor Inspection ........1C-5 IAT Sensor Removal and Installation....1C-5 Precautions............1B-1 IAT Sensor Inspection.........1C-6 Precautions for Emission Control Devices ..1B-1 AP Sensor Inspection..........1C-6 General Description ..........1B-1 AP Sensor Removal and Installation....1C-6 Fuel Injection System Description.......

  • Page 69: Engine Lubrication System

    Table of Contents 1-iii Cam Chain Guide / Cam Chain Tensioner Oil Pump Inspection ..........1E-13 Removal and Installation.........1D-37 Oil Pump Drive Gear Removal and Cam Chain Guide Inspection ......1D-37 Installation ............1E-13 Cam Chain Tensioner Inspection......1D-37 Specifications .............1E-14 Cylinder Head Disassembly and Assembly ..1D-38 Service Data............1E-14 Cylinder Head Related Parts Inspection ...1D-42 Tightening Torque Specifications......1E-15...

  • Page 70: Starting System

    1-iv Table of Contents Diagnostic Information and Procedures... 1G-4 Starter Motor Will Not Run ........1I-2 Fuel System Diagnosis ........1G-4 Starter Motor Runs But Does Not Crank The Engine ..............1I-2 Repair Instructions ..........1G-5 Fuel Pressure Inspection ........1G-5 Repair Instructions ..........

  • Page 71

    Table of Contents 1-v Exhaust System Components......1K-5 Exhaust System Inspection.......1K-14 EXCV Cable Removal and Installation....1K-6 Specifications .............1K-14 EXCVA Removal and Installation ....... 1K-7 Service Data............1K-14 EXCVA Inspection ..........1K-9 Tightening Torque Specifications......1K-15 EXCVA Pulley Inspection........1K-9 Special Tools and Equipment ......1K-15 EXCVA Adjustment ..........

  • Page 72

    1-1 Precautions: Precautions Engine Precautions Precautions for Engine B838H21000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.

  • Page 73

    Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine General Description Injection Timing Description B838H21101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.

  • Page 74

    1A-2 Engine General Information and Diagnosis: Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions When atmospheric pressure is low, the sensor sends the signal to ATMOSPHERIC PRESSURE SENSOR SIGNAL the ECM and reduce the injection time (volume).

  • Page 75

    Engine General Information and Diagnosis: 1A-3 Self-Diagnosis Function B838H21101002 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 indicator light). To check the function of the individual FI system devices, the dealer mode is provided.

  • Page 76

    1A-4 Engine General Information and Diagnosis: Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices.

  • Page 77

    Engine General Information and Diagnosis: 1A-5 Combination meter Cooling fan Cooling fan relay motor 15 A Br/Y Y/Bl R/Bl *1 Immobilizer *2 Ignition switch 23 11 42 Fuel 64*1 Lg/W pump 64*2 Lg/G Speed sensor 53*1 Lg/Bl O/Bl 65*1 Gr/W Gr/B Gr/Y Gr/R...

  • Page 78

    1A-6 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B838H21102002 I837H1110004-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT EXCVA power (MO+) ISC valve signal (ISC, 2A) Speed sensor signal ISC valve signal (ISC, 1B) STVA signal (STVA, 2A) ISC valve signal (ISC, 1A) STVA signal (STVA, 1A) Fuel pump relay (FP relay) —...

  • Page 79: Fi System Parts Location

    Engine General Information and Diagnosis: 1A-7 Component Location FI System Parts Location B838H21103001 “L” “I” “K” “C” “A” “J” “F” “H” “G” I837H1110126-01 “A”: ECM “E”: Intake air pressure sensor (IAPS) “I”: Fuel pump relay (FP relay) “B”: Throttle position sensor (TPS) “F”: Exhaust control valve actuator (EXCVA) “J”: Fuel pump (FP) “C”: Secondary throttle position sensor (STPS)

  • Page 80

    1A-8 Engine General Information and Diagnosis: “M” “O” “S” “A” “P” “T” “Z” “W” “N” “U” “X” “V” I837H1110127-01 “A”: ECM “Q”: Camshaft position sensor (CMPS) “V”: Speed sensor “M”: Cooling fan relay “R”: Ignition coil (IG coil) “W”: Atmospheric pressure sensor (APS) “N”: Cooling fan “S”: Secondary fuel injector “X”: Gear position switch (GP switch)

  • Page 81

    Engine General Information and Diagnosis: 1A-9 Diagnostic Information and Procedures Engine Symptom Diagnosis B838H21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guide or poor seating of Repair or replace.

  • Page 82

    1A-10 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensor or circuit. Repair or replace. (Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace.

  • Page 83

    Engine General Information and Diagnosis: 1A-11 Condition Possible cause Correction / Reference Item Noisy engine (Noise Too much play on pump shaft bearing. Replace. seems to come from Worn or damaged impeller shaft. Replace. water pump) Worn or damaged mechanical seal. Replace.

  • Page 84

    1A-12 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP switch. Replace.

  • Page 85

    Engine General Information and Diagnosis: 1A-13 Self-Diagnostic Procedures 5) Check the DTC to determine the malfunction part. B838H21104002 Refer to “DTC Table (Page 1A-21)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select switch) • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming DTC (Diagnostic Trouble Code)

  • Page 86

    1A-14 Engine General Information and Diagnosis: Use of SDS NOTE • Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

  • Page 87

    Engine General Information and Diagnosis: 1A-15 5) Check the DTC to determine the malfunction part. 4) The previous malfunction history code (Past DTC) Refer to “DTC Table (Page 1A-21)”. still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS tool. NOTE 5) Click “Clear”...

  • Page 88

    1A-16 Engine General Information and Diagnosis: Show Data When Trouble (Displaying Data at the Time of DTC) B838H21104004 Use of SDS 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.

  • Page 89

    Engine General Information and Diagnosis: 1A-17 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110270-01 SDS Check B838H21104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user.

  • Page 90

    1A-18 Engine General Information and Diagnosis: Sample Data sampled from cold starting through warm-up Check the engine r/min. XXX r/min Check the engine coolant temperature. XX ˚C Check the manifold absolute pressure. XXX kPa I837H1110131-01 Data at 3 000 r/min under no load Approx.

  • Page 91

    Engine General Information and Diagnosis: 1A-19 Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens closes in according with the throttle valve opening PAIR control solenoid valve OFF in according with the throttle valve opens closes I823H1110210-02 Data of intake negative pressure during idling (100 °C)

  • Page 92

    1A-20 Engine General Information and Diagnosis: Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XXX kPa I837H1110134-01...

  • Page 93

    Engine General Information and Diagnosis: 1A-21 Example of Trouble Three data; value 3 (current data 3), value 1 (past data 1) and value 2 (past data 2); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.

  • Page 94

    1A-22 Engine General Information and Diagnosis: Code Malfunction Part Remarks C25 (P0352) Ignition signal #2 (IG coil #2) For #2 cylinder (Page 1A-78) C26 (P0353) Ignition signal #3 (IG coil #3) For #3 cylinder (Page 1A-78) C27 (P0354) Ignition signal #4 (IG coil #4) For #4 cylinder (Page 1A-78) C28 (P1655)

  • Page 95

    Engine General Information and Diagnosis: 1A-23 Fail-Safe Function Table B838H21104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item Fail-Safe Mode Starting Ability Running Ability When camshaft position signal has failed...

  • Page 96

    1A-24 Engine General Information and Diagnosis: Item Fail-Safe Mode Starting Ability Running Ability EVAP system purge control ECM stops controlling EVAP system purge “YES” “YES” solenoid valve (E-33 only) control solenoid valve. ECM stops controlling steering damper Vehicle speed sensor “YES”...

  • Page 97

    Engine General Information and Diagnosis: 1A-25 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair / Cloudy / Rain / Snow / Always / Other Cold ( °C / °F) / Temperature Hot / Warm / Cool / Always Frequency Always / Sometimes ( times / day, month) / Only once...

  • Page 98

    1A-26 Engine General Information and Diagnosis: Malfunction Code and Defective Condition Table B838H21104009 Malfunction Detected Item Detected Failure Condition Check For Code NO FAULT — — CMP sensor wiring and The signal does not reach ECM for 3 sec. or mechanical parts CMP sensor P0340...

  • Page 99

    Engine General Information and Diagnosis: 1A-27 Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned TO sensor, lead wire/coupler 0.2 V ≤ Sensor voltage < 4.8 V connection In other than the above value, C23 (P1651) is TO sensor...

  • Page 100

    1A-28 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code No voltage is applied to the fuel pump, Fuel pump relay, lead wire/ although fuel pump relay is turned ON, or coupler connection, power voltage is applied to fuel pump although fuel source to fuel pump relay and pump relay is turned OFF.

  • Page 101

    Engine General Information and Diagnosis: 1A-29 Malfunction Detected Item Detected Failure Condition Check For Code Speedometer does not receive signal from the vehicle speed sensor for more than 6 sec. when the motorcycle is running. Speed sensor and ECM does not receive signal from the vehicle speedometer wiring/coupler Vehicle speed sensor P0500...

  • Page 102

    1A-30 Engine General Information and Diagnosis: DTC “C11” (P0340): CMP Sensor Circuit Malfunction B838H21104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • CMP sensor circuit open or short. receiving the starter signal.

  • Page 103

    Engine General Information and Diagnosis: 1A-31 Step Action 1) Turn the ignition switch OFF. • B/Y, R or B/Br wire • Inspect that metal open or shorted to particles or foreign 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 104

    1A-32 Engine General Information and Diagnosis: Step Action 5) Connect 3 new 1.5 V batteries in series, 1 kΩ resistor • B/Y, R or B/Br wire • Inspect that metal and the multi-circuit tester as shown in the figure. open or shorted to particles or foreign ground.

  • Page 105

    Engine General Information and Diagnosis: 1A-33 DTC “C12” (P0335): CKP Sensor Circuit Malfunction B838H21104011 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.

  • Page 106

    1A-34 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Check the CKP sensor coupler (1) for loose or poor contacts.

  • Page 107

    Engine General Information and Diagnosis: 1A-35 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi-circuit tester set) CKP sensor continuity ∞...

  • Page 108

    1A-36 Engine General Information and Diagnosis: DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B838H21104012 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.

  • Page 109

    Engine General Information and Diagnosis: 1A-37 C13 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.

  • Page 110

    1A-38 Engine General Information and Diagnosis: P0105-H for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 111

    Engine General Information and Diagnosis: 1A-39 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. G/B wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the G/B wire and terminal “19”.

  • Page 112

    1A-40 Engine General Information and Diagnosis: P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/B wire open, G/ B wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 113

    Engine General Information and Diagnosis: 1A-41 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/B wire open, G/ and Installation in Section 1C (Page 1C-1)”. B wire shorted to ground. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the R wire and terminal “7”.

  • Page 114

    1A-42 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler. Go to Step 3. • Loose or poor contacts on the ECM 2) Turn the ignition switch OFF. coupler. 3) Lift and support the fuel tank. Refer to “Fuel Tank •...

  • Page 115

    Engine General Information and Diagnosis: 1A-43 Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum hose for crack or 2) Connect the ECM coupler and IAP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •...

  • Page 116

    1A-44 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor. Refer to “IAP Sensor Removal ground, or poor “19”, IAP sensor with a new and Installation in Section 1C (Page 1C-3)”.

  • Page 117

    Engine General Information and Diagnosis: 1A-45 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B838H21104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...

  • Page 118

    1A-46 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.

  • Page 119

    Engine General Information and Diagnosis: 1A-47 P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. P/B wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 120

    1A-48 Engine General Information and Diagnosis: Step Action 7) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. P/B wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 8) Check the continuity between the P/B wire and terminal “6”.

  • Page 121

    Engine General Information and Diagnosis: 1A-49 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and P/B wire open, or P/B wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 122

    1A-50 Engine General Information and Diagnosis: Step Action 7) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and P/B wire open, or and Installation in Section 1C (Page 1C-1)”. P/B wire shorted to ground. 8) Check the continuity between the P/B wire and terminal “6”.

  • Page 123

    Engine General Information and Diagnosis: 1A-51 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the special tool between the TP sensor and its ground, or poor “6”, sensor with a new one.

  • Page 124

    1A-52 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B838H21104014 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤...

  • Page 125

    Engine General Information and Diagnosis: 1A-53 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.

  • Page 126

    1A-54 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Check the ECT sensor coupler (1) for loose or poor contacts.

  • Page 127

    Engine General Information and Diagnosis: 1A-55 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. •...

  • Page 128

    1A-56 Engine General Information and Diagnosis: Step Action 9) Measure the output voltage between the B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...

  • Page 129

    Engine General Information and Diagnosis: 1A-57 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B838H21104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤...

  • Page 130

    1A-58 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.

  • Page 131

    Engine General Information and Diagnosis: 1A-59 P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 132

    1A-60 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. •...

  • Page 133

    Engine General Information and Diagnosis: 1A-61 Step Action 10) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...

  • Page 134

    1A-62 Engine General Information and Diagnosis: DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction B838H21104016 Detected Condition and Possible Cause Detected Condition Possible Cause AP sensor voltage is not within the • Clogged vacuum passage with dust. following range. • AP sensor circuit open or shorted to ground. 0.5 V ≤...

  • Page 135

    Engine General Information and Diagnosis: 1A-63 C22 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the front seat. Refer to “Exterior Parts Removal coupler.

  • Page 136

    1A-64 Engine General Information and Diagnosis: P1450-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. G/Y wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.

  • Page 137

    Engine General Information and Diagnosis: 1A-65 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. G/Y wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the G/Y wire and terminal “20”.

  • Page 138

    1A-66 Engine General Information and Diagnosis: P1450-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/Y wire open, G/ Y wire shorted to 2) Remove the front seat. Refer to “Exterior Parts Removal ground.

  • Page 139

    Engine General Information and Diagnosis: 1A-67 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R and G/Y wire open, G/ and Installation in Section 1C (Page 1C-1)”. Y wire shorted to ground. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the R wire and terminal “7”.

  • Page 140

    1A-68 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the front seat. Refer to “Exterior Parts Removal coupler. and Installation in Section 9D (Page 9D-11)”. •...

  • Page 141

    Engine General Information and Diagnosis: 1A-69 Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Check the vacuum port for crack or 2) Connect the ECM coupler and AP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •...

  • Page 142

    1A-70 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/Y, R or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the AP sensor. Refer to “AP Sensor Removal ground, or poor “7”, AP sensor with a new and Installation in Section 1C (Page 1C-6)”.

  • Page 143

    Engine General Information and Diagnosis: 1A-71 DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B838H21104017 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...

  • Page 144

    1A-72 Engine General Information and Diagnosis: C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the front seat. Refer to “Exterior Parts Removal “TO Sensor Removal and Installation in Section 9D (Page 9D-11)”.

  • Page 145

    Engine General Information and Diagnosis: 1A-73 P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.

  • Page 146

    1A-74 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. B wire shorted to VCC, and Installation in Section 1C (Page 1C-1)”. or B/Br wire open. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the B wire and terminal “31”.

  • Page 147

    Engine General Information and Diagnosis: 1A-75 P1651-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or B wire open, or B wire shorted to ground. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.

  • Page 148

    1A-76 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or B wire open, or B and Installation in Section 1C (Page 1C-1)”. wire shorted to ground. 7) Insert the needle pointed probes to the lead wire coupler. 8) Check the continuity between the R wire and terminal “7”.

  • Page 149

    Engine General Information and Diagnosis: 1A-77 Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Insert the needle pointed probes to the lead wire coupler. ground, or poor “7”, coupler.

  • Page 150

    1A-78 Engine General Information and Diagnosis: DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B838H21104018 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-5)” for details. DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction B838H21104019 Detected Condition and Possible Cause Detected Condition...

  • Page 151

    Engine General Information and Diagnosis: 1A-79 Step Action 1) Lift and support the fuel tank. Refer to “Fuel Tank Go to Step 2. • Loose or poor Removal and Installation in Section 1G (Page 1G-9)”. contacts on the STVA coupler. 2) Remove the air cleaner box.

  • Page 152

    1A-80 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Lg, P/W, G and W/ • Loose or poor B wire open or contacts on the ECM 2) Disconnect the STVA lead wire coupler. shorted to ground, or coupler.

  • Page 153

    Engine General Information and Diagnosis: 1A-81 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). I837H1110136-01 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.

  • Page 154

    1A-82 Engine General Information and Diagnosis: DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B838H21104020 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •...

  • Page 155

    Engine General Information and Diagnosis: 1A-83 C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.

  • Page 156

    1A-84 Engine General Information and Diagnosis: P1654-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. Y/W wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 157

    Engine General Information and Diagnosis: 1A-85 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 3. Y/W wire shorted to and Installation in Section 1C (Page 1C-1)”. VCC, or B/Br wire open. 7) Check the continuity between the Y/W wire and terminal “18”.

  • Page 158

    1A-86 Engine General Information and Diagnosis: P1654-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or Y/W wire open, or Y/W wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 159

    Engine General Information and Diagnosis: 1A-87 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. R or Y/W wire open, or and Installation in Section 1C (Page 1C-1)”. Y/W wire shorted to ground. 7) Check the continuity between the Y/W wire and terminal “18”.

  • Page 160

    1A-88 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM coupler and STP sensor coupler. ground, or poor “7”, STP sensor with a new 3) Disconnect the STVA lead wire coupler.

  • Page 161

    Engine General Information and Diagnosis: 1A-89 DTC “C31” (P0705): GP Switch Circuit Malfunction B838H21104021 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • GP switch circuit open or short. GP switch voltage is not within the following range. •...

  • Page 162

    1A-90 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • P wire open or • P or B/W wire open, shorted to ground. or P wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 163

    Engine General Information and Diagnosis: 1A-91 DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction B838H21104022 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is •...

  • Page 164

    1A-92 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 165

    Engine General Information and Diagnosis: 1A-93 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-11)”.

  • Page 166

    1A-94 Engine General Information and Diagnosis: DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction B838H21104023 Detected Condition and Possible Cause Detected Condition Possible Cause Some failure exists in the fuel injector signal in a high •...

  • Page 167

    Engine General Information and Diagnosis: 1A-95 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 168

    1A-96 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-11)”.

  • Page 169

    Engine General Information and Diagnosis: 1A-97 DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B838H21104024 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground. C40/P0505 unusual.

  • Page 170

    1A-98 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Bl, Y, G or Br wire open. 2) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-7)”. 3) Check the ISC valve coupler (1) for loose or poor contacts.

  • Page 171

    Engine General Information and Diagnosis: 1A-99 Step Action 1) Check the continuity between each ISC valve terminal If wire is OK, Replace the ISC valve and ground. intermittent trouble or with a new one. Refer to faulty ECM. “Throttle Body Removal Special tool and Installation in (A): 09900–25008 (Multi-circuit tester set)

  • Page 172

    1A-100 Engine General Information and Diagnosis: ACTIVE CONTROL INSPECTION (ISC RPM Check 2 CONTROL) 1) Click the button (4) and decrease the “Spec” (2) to 1 Check 1 100 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation 2) Check that the “Desired idle speed”...

  • Page 173

    Engine General Information and Diagnosis: 1A-101 Check 4 1) Click the button (6) and increase the “Spec” (2) to 1 900 rpm. 2) Check that the “Desired idle speed” (3) is approx. 1 900 rpm. 3) Check that the “Engine speed” (7) is close to 1 900 I837H1110087-01 If the ISC valve does not function properly, inspect the rpm.

  • Page 174

    1A-102 Engine General Information and Diagnosis: Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”.

  • Page 175

    Engine General Information and Diagnosis: 1A-103 P0230-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. • Y/B wire shorted to Replace the FP relay power source. with a new one. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”.

  • Page 176

    1A-104 Engine General Information and Diagnosis: DTC “C41” (P2505): ECM Power Input Signal Malfunction B838H21104026 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the ECM. • Lead wire/coupler connection of ECM terminal to fuel fuse.

  • Page 177

    Engine General Information and Diagnosis: 1A-105 Step Action 1) Turn the ignition switch OFF. • Fuel pump relay Open or short circuit in circuit malfunction. the R/Bl wire. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”. Refer to “DTC “C41”...

  • Page 178

    1A-106 Engine General Information and Diagnosis: DTC “C42” (P1650): IG Switch Circuit Malfunction B838H21104027 Detected Condition and Possible Cause Detected Condition Possible Cause Ignition switch signal is not input to the ECM. • Ignition system circuit open or short. • ECM malfunction. When the ID agreement is not verified.

  • Page 179

    Engine General Information and Diagnosis: 1A-107 Troubleshooting (When Indicating C44/P0130:) CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent terminal damage. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”.

  • Page 180

    1A-108 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. W/G wire shorted to the and Installation in Section 1C (Page 1C-1)”. power source, or W/G or B/Br wire open. 7) Check the continuity between the W/G wire and terminal “34”.

  • Page 181

    Engine General Information and Diagnosis: 1A-109 Step Action 1) Connect the ECM coupler and HO2 sensor coupler. • W/G or B/Br wire Replace the HO2 open or shorted to sensor with a new one. 2) Warm up the engine enough. the power source, or Refer to “HO2 Sensor 3) Insert the needle pointed probes to the lead wire coupler.

  • Page 182

    1A-110 Engine General Information and Diagnosis: Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.

  • Page 183

    Engine General Information and Diagnosis: 1A-111 Step Action 1) Connect the HO2 sensor coupler. • O/W or W/B wire • Open or short circuit open or shorted to in the W/B wire or O/ 2) Insert the needle pointed probes to the lead wire coupler. ground, or poor “41”...

  • Page 184

    1A-112 Engine General Information and Diagnosis: DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction B838H21104029 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 185

    Engine General Information and Diagnosis: 1A-113 C46 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Go to Step 6. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Check the EXCVA position sensor coupler (1) and EXCVA motor coupler (2) for loose or poor contacts.

  • Page 186

    1A-114 Engine General Information and Diagnosis: P1657-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 4. Y wire shorted to VCC, or B/Br wire open. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 187

    Engine General Information and Diagnosis: 1A-115 Step Action 6) Disconnect the ECM coupler. Go to Step 4. Y wire shorted to VCC, or B/Br wire open. 7) Check the continuity between Y wire and terminal “14”. 8) Also, check the continuity between B/Br wire and terminal “35”.

  • Page 188

    1A-116 Engine General Information and Diagnosis: P1657-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2 and go to R or Y wire open, or Y Step 4. wire shorted to ground. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 189

    Engine General Information and Diagnosis: 1A-117 Step Action 7) Disconnect the ECM coupler. Go to Step 2 and go to R or Y wire open, or Y Step 4. wire shorted to ground. 8) Check the continuity between Y wire and terminal “14”. 9) Also, check the continuity between R wire and terminal “7”.

  • Page 190

    1A-118 Engine General Information and Diagnosis: P1658 (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 6. Loose or poor contacts on the EXCV motor 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.

  • Page 191

    Engine General Information and Diagnosis: 1A-119 Step Action 5) Turn the ignition switch ON. Go to Step 3. • Loose or poor contacts on the ECM 6) Measure the voltage between the R wire and ground. coupler (terminal “7” 7) If OK, then measure the voltage between the R wire and or “35”).

  • Page 192

    1A-120 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 4. Replace the EXCVA with a new one. 2) Check the continuity between Y wire and ground. Special tool (A): 09900–25008 (Multi-circuit tester set) EXCVA position sensor continuity ∞...

  • Page 193

    Engine General Information and Diagnosis: 1A-121 Step Action 1) Turn the ignition switch OFF. Replace the ECM with a Go to Step 5. known good one, and 2) Connect the EXCVA position sensor coupler (1). inspect it again. 3) Disconnect the EXCVA motor coupler (2). 4) Measure the EXCVA position sensor output voltage at EXCV fully closed position and fully opened position.

  • Page 194

    1A-122 Engine General Information and Diagnosis: Step Action 8) Then, to set the EXCV to fully opened position, apply 12 Replace the ECM with a Go to Step 5. V to the terminals oppositely. known good one, and Positive wire – Gr wire terminal inspect it again.

  • Page 195

    Engine General Information and Diagnosis: 1A-123 Step Action 1) If the EXCVA position sensor output voltage is 0.5 V and Replace the ECM with a Replace the EXCVA less at EXCV fully closed position, adjust the output known good one, and with a new one.

  • Page 196

    1A-124 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • Loose or poor • Replace the EXCVA contacts on the with a new one. 2) Disconnect the EXCVA motor coupler (1). EXCVA or ECM • Inspect that the coupler (terminal “13”...

  • Page 197

    Engine General Information and Diagnosis: 1A-125 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). I837H1110164-01 4) Click each button (2). At this time, if an operation sound is heard from the EXCVA, the function is normal.

  • Page 198

    1A-126 Engine General Information and Diagnosis: DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B838H21104030 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve voltage is not input to ECM. • PAIR control solenoid valve circuit open or short. •...

  • Page 199

    Engine General Information and Diagnosis: 1A-127 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the PAIR control solenoid valve 2) Remove the air cleaner box. Refer to “Air Cleaner Box with a new one. Refer to Removal and Installation in Section 1D (Page 1D-7)”.

  • Page 200

    1A-128 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • W/G wire open or Open or short circuit in shorted to ground, or the O/W wire. 2) Measure the voltage between the O/W wire and ground. poor “55”...

  • Page 201

    Engine General Information and Diagnosis: 1A-129 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B838H21104031 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •...

  • Page 202

    1A-130 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • O/W and G/R wire Replace the cooling fan open or shorted to relay with a new one. 2) Remove the front seat. Refer to “Exterior Parts Removal ground, or poor “42”...

  • Page 203

    Engine General Information and Diagnosis: 1A-131 4) Click the “Operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. NOTE The cooling fan relay and cooling fan motor inspection is operational at any engine coolant temperature until reaching 100 °C (212 °F).

  • Page 204

    1A-132 Engine General Information and Diagnosis: DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) B838H21104032 Detected Condition and Possible Cause Detected Condition Possible Cause EVAP system purge control valve voltage is not input to • EVAP system purge control valve circuit open or short. ECM.

  • Page 205

    Engine General Information and Diagnosis: 1A-133 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the EVAP system purge control 2) Lift and support the fuel tank. Refer to “Fuel Tank with a new one. Refer to Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 206

    1A-134 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • Dbr wire open or Open or short circuit in shorted to ground, or the O/W wire. 2) Measure the voltage between the O/W wire and ground. poor “61”...

  • Page 207

    Engine General Information and Diagnosis: 1A-135 DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction B838H21104033 Detected Condition and Possible Cause Detected Condition Possible Cause Speedometer does not receive signal from the vehicle • Speed sensor circuit open or short. speed sensor for more than 6 sec. when the motorcycle is •...

  • Page 208

    1A-136 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • P wire open or • Inspect that metal shorted to ground. particles or foreign 2) Lift and support the fuel tank. Refer to “Fuel Tank material stuck on the Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 209

    Engine General Information and Diagnosis: 1A-137 Step Action 5) Under this condition, if a suitable screwdriver touching • P wire open or • Inspect that metal the pick-up surface of the speed sensor is moved, the shorted to ground. particles or foreign tester reading voltage changes (0 V →...

  • Page 210

    1A-138 Engine General Information and Diagnosis: DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction B838H21104034 Detected Condition and Possible Cause Detected Condition Possible Cause Steering damper control current does not flow to • Steering damper solenoid valve circuit the solenoid valve. With IG turned ON, ECM interrupter element shorted.

  • Page 211

    Engine General Information and Diagnosis: 1A-139 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the steering damper with a new one. 2) Check the steering damper solenoid valve coupler (1) for loose or poor contacts. If OK, then measure the steering damper solenoid valve resistance.

  • Page 212

    1A-140 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • W wire shorted to • Low battery voltage VCC, or poor “26” or fuse is blown. 2) Measure the voltage between W wire and ground. connection failure.

  • Page 213

    Engine General Information and Diagnosis: 1A-141 Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Raise the front wheel off the ground. 3) Turn the ignition switch ON. 4) Click “Steering damper solenoid operating control” (1). I837H1110123-03 5) Click each button (2) ON/OFF while turning the handlebars left and right.

  • Page 214

    1A-142 Engine General Information and Diagnosis: Specifications Service Data B838H21107001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.28 V and more...

  • Page 215

    Engine General Information and Diagnosis: 1A-143 Special Tools and Equipment Special Tool B838H21108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-32) / (Page 1A-109) / (Page 1A-34) / (Page 1A-111) / (Page 1A-35) / (Page 1A-115) / (Page 1A-110) / (Page 1A-117) / (Page 1A-111) /...

  • Page 216

    1A-144 Engine General Information and Diagnosis: 09917–47011 09930–82720 Vacuum pump gauge Mode select switch (Page 1A-44) / (Page 1A-4) / (Page 1A- (Page 1A-70) 13) / (Page 1A-13) 99565–01010–015 CD-ROM Ver.15 (Page 1A-14) / (Page 1A-17)

  • Page 217

    Fuel Injection System Description B838H21201001 GSX-R750 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.

  • Page 218

    1B-2 Emission Control Devices: Crankcase Emission Control System Description B838H21201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.

  • Page 219

    Emission Control Devices: 1B-3 Exhaust Emission Control System Description B838H21201003 The exhaust emission control system is composed of the PAIR system, exhaust control system, HO2 sensor, three- way catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve.

  • Page 220

    1B-4 Emission Control Devices: Noise Emission Control System Description B838H21201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: • The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or •...

  • Page 221

    Emission Control Devices: 1B-5 Schematic and Routing Diagram PAIR System Hose Routing Diagram B838H21202001 “a” “C” “A” “D” “A” “ b” “ b” “b” “B” I837H1120044-03 1. PAIR control solenoid valve “B”: Yellow marking “a”: 45° 2. PAIR reed valve “C”: Face the clamp end rearward.

  • Page 222

    1B-6 Emission Control Devices: EVAP Canister Hose Routing Diagram (Only for E-33) B838H21202002 “C” “A” “B” “F” “E” “D” “ a ” “G” “A” “H” “I” I837H1120045-02 1. EVAP system purge control solenoid valve 7. Seat rail “E”: Clamp the hoses and battery (+) lead wire at this part. 2.

  • Page 223

    Emission Control Devices: 1B-7 Repair Instructions Heated Oxygen Sensor (HO2S) Removal and Installation Install the HO2 sensor in the reverse order of removal. Installation B838H21206001 Pay attention to the following points: Removal CAUTION WARNING Do not apply oil or other materials to the Do not remove the HO2 sensor while it is hot.

  • Page 224

    1B-8 Emission Control Devices: 6) Disconnect the CMP sensor coupler (2) and remove 11) Remove the cylinder head cover. Refer to “Engine the cylinder head cover shield (3). Top Side Disassembly in Section 1D (Page 1D-25)”. 12) Remove the PAIR reed valves (7) with the gaskets. I837H1120004-02 7) Remove the radiator mounting bolts.

  • Page 225

    Emission Control Devices: 1B-9 PAIR Control Solenoid Valve Removal and 3) Inspect the PAIR hoses for wear or damage. If it is worn or damaged, replace the PAIR hose with a new Installation B838H21206004 one. Refer to “PAIR System Hose Routing Diagram (Page 1B-5)”.

  • Page 226

    1B-10 Emission Control Devices: PAIR Control Solenoid Valve 4) Check the resistance between the terminals of the PAIR control solenoid valve. NOTE Special tool PAIR control solenoid valve can be checked (A): 09900–25008 (Multi-circuit tester set) without removing it from the motorcycle. Refer to “DTC “C49”...

  • Page 227

    Emission Control Devices: 1B-11 Crankcase Breather (PCV) Hose / Reed Valve / 8) Remove the EXCVA (4). Cover Removal and Installation B838H21206007 Removal 1) Lift and support the fuel tank with the prop stay. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 228

    1B-12 Emission Control Devices: Crankcase Breather (PCV) Cover Inspection Evaporative Emission Control System Removal B838H21206008 and Installation (Only for E-33) Inspect the crankcase breather (PCV) cover in the B838H21206010 following procedures: Hose Removal 1) Remove the crankcase breather (PCV) cover. Refer to “Crankcase Breather (PCV) Hose / Reed Valve / 1) Lift and support the fuel tank.

  • Page 229

    Emission Control Devices: 1B-13 EVAP System Purge Control Solenoid Valve Fuel Shut-off Valve Removal Removal 1) Lift and support the fuel tank with the prop stay. 1) Remove the front seat. Refer to “Exterior Parts Refer to “Fuel Tank Removal and Installation in Removal and Installation in Section 9D (Page 9D- Section 1G (Page 1G-9)”.

  • Page 230

    1B-14 Emission Control Devices: 9) Remove the rear fender (rear) plate (6) and rear 13) Disconnect the surge hose (10). fender (rear) (7). I837H1120038-02 14) Move the rear fender (front) backward. I837H1120034-02 10) Remove the rear fender (front) cover (8). 15) Disconnect the surge hose (11).

  • Page 231

    Emission Control Devices: 1B-15 • Clamp the EVAP hoses at white taping point. EVAP System Purge Control Solenoid Valve NOTE EVAP system purge control solenoid valve can be checked without removing it from the motorcycle. Refer to “DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) in Section 1A (Page 1A-132)”.

  • Page 232

    1B-16 Emission Control Devices: 3) Check the resistance between the terminals of the 1) When air is blown into the fuel shut-off valve with its EVAP system purge control solenoid valve. If the side “A” positioned upward, the air can pass through resistance is not within the standard range, replace to the canister side.

  • Page 233

    Emission Control Devices: 1B-17 Specifications Service Data B838H21207001 FI sensors Item Specification Note 0.4 V and less at idle speed HO2 sensor output voltage 0.6 V and more at 5 000 r/min 6.7 – 9.5 Ω at 23 °C (73 °F) HO2 sensor heater resistance PAIR control solenoid valve 20 –...

  • Page 234

    1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B838H21300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B838H21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

  • Page 235

    Engine Electrical Devices: 1C-2 CMP Sensor Inspection 5) Move the radiator forward. B838H21306002 6) Remove the front engine cover (3). Refer to “DTC “C11” (P0340): CMP Sensor Circuit 7) Disconnect the horn couplers (4). Malfunction in Section 1A (Page 1A-30)”. 8) Remove the horn (5).

  • Page 236

    1C-3 Engine Electrical Devices: Installation IAP Sensor Inspection B838H21306006 Install the CMP sensor in the reverse order of removal. Refer to “DTC “C13” (P0105-H/L): IAP Sensor Circuit Pay attention to the following points: Malfunction in Section 1A (Page 1A-36)”. CAUTION IAP Sensor Removal and Installation When installing the CMP sensor, make sure B838H21306007...

  • Page 237

    Engine Electrical Devices: 1C-4 2) Remove the TP sensor (1) with the special tool. 5) If the TP sensor adjustment is necessary, remove the right under cowling. Refer to “Exterior Parts Special tool Removal and Installation in Section 9D (Page 9D- : 09930–11950 (Torx wrench) 11)”.

  • Page 238

    1C-5 Engine Electrical Devices: Installation Special tool Install the ECT sensor in the reverse order of removal. (A): 09900–25008 (Multi-circuit tester set) Pay attention to the following points: Tester knob indication • Tighten the ECT sensor (1) to the specified torque. Resistance (Ω) CAUTION ECT sensor specification...

  • Page 239

    Engine Electrical Devices: 1C-6 Installation AP Sensor Removal and Installation B838H21306016 Install the IAT sensor in the reverse order of removal. Removal Pay attention to the following point: 1) Remove the front seat. Refer to “Exterior Parts • Tighten the IAT sensor screw (1) to the specified Removal and Installation in Section 9D (Page 9D- torque.

  • Page 240

    1C-7 Engine Electrical Devices: Installation 5) Close the secondary throttle valve by finger and Install the TO sensor in the reverse order of removal. measure the STP sensor output voltage. Pay attention to the following point: Special tool • When installing the TO sensor, bring the “UP” letters (A): 09900–25008 (Multi-circuit tester set) upward.

  • Page 241

    Engine Electrical Devices: 1C-8 8) Tighten the STP sensor mounting screw to the STV Actuator Inspection B838H21306022 specified torque. Refer to “DTC “C28” (P1655): Secondary Throttle Valve Tightening torque Actuator (STVA) Malfunction in Section 1A (Page 1A- STP sensor mounting screw: 3.5 N·m (0.35 kgf- 78)”.

  • Page 242

    1C-9 Engine Electrical Devices: ISC Valve Preset and Opening Initialization NOTE B838H21306026 The leaned value of the ISC valve is set at When removing or replacing the ISC valve, set the ISC Preset position. valve to the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool.

  • Page 243

    Engine Electrical Devices: 1C-10 Specifications Service Data B838H21307001 FI Sensors Item Standard/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.

  • Page 244

    1C-11 Engine Electrical Devices: Special Tools and Equipment Special Tool B838H21308001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1C-5) / (Page 1C- (Page 1C-7) 09930–11950 09930–82720 Torx wrench Mode select switch (Page 1C-4) / (Page 1C- (Page 1C-4) 4) / (Page 1C-7) / (Page 1C-8)

  • Page 245

    Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B838H21402001 I837H1140299-01...

  • Page 246

    1D-2 Engine Mechanical: Throttle Cable Routing Diagram B838H21402002 “A” “ a ” “B” “ a ” “ a ” “C” I837H1140300-01 1. Throttle cable No. 1 6. Throttle cable guide No. 2 2. Throttle cable No. 2 “A”: Pass the throttle cables to the front of brake hose. 3.

  • Page 247

    Engine Mechanical: 1D-3 Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B838H21404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-9)”. Compression Pressure Check B838H21404002 The compression pressure reading of a cylinder is a good indicator of its internal condition.

  • Page 248

    1D-4 Engine Mechanical: Repair Instructions Engine Components Removable with the Engine in Place B838H21406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal...

  • Page 249

    Engine Mechanical: 1D-5 Engine Right Side Item Removal Inspection Installation Refer to “Exhaust Pipe / Refer to “Exhaust Pipe / Refer to “Exhaust System Muffler Removal and Muffler Removal and Exhaust pipes/Muffler Inspection in Section 1K Installation in Section 1K Installation in Section 1K (Page 1K-14)”.

  • Page 250

    1D-6 Engine Mechanical: Engine Left Side Item Removal Inspection Installation Refer to “Speed Sensor Refer to “Speed Sensor Refer to “Speed Sensor Speed sensor Removal and Installation in Inspection in Section 9C Removal and Installation in Section 9C (Page 9C-5)”. (Page 9C-6)”.

  • Page 251

    Engine Mechanical: 1D-7 Air Cleaner Box Removal and Installation 7) Disconnect the PAIR hose (6). B838H21406003 Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 9)”. 2) Remove the air cleaner box mounting bolt (1). I837H1140291-01 8) Remove the air cleaner box.

  • Page 252

    1D-8 Engine Mechanical: Throttle Body Components B838H21406008 I837H1140292-02 1. Fuel delivery pipe 5. STP sensor 9. ISC valve [A]: For E-33 only 2. Fuel delivery pipe T-joint 6. Secondary fuel injector 10. Air screw : 3.5 Nm (0.35 kgf-m, 2.5 lb-ft) 3.

  • Page 253

    Engine Mechanical: 1D-9 Throttle Body Construction B838H21406009 “B” “A” “E” “3” “C” “5” “1” “2” “4” “D” “F” I838H1140001-02 1. Intake pipe 6. ISC valve hose “E”: Evenly tighten the bolts in the order of “1” to “5”. 2. Air cleaner outlet tube “A”: Face the clamp end backward.

  • Page 254

    1D-10 Engine Mechanical: Throttle Body Removal and Installation 5) Disconnect the STP sensor lead wire coupler (2), B838H21406010 IAP sensor lead wire coupler (3) and STVA lead wire Removal coupler (4). 1) Remove the under cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

  • Page 255

    Engine Mechanical: 1D-11 11) Disconnect the purge hose from the EVAP system • Connect the throttle pulling cable (3) and throttle purge control solenoid valve (8). (E-33 only) returning cable (4) to the throttle cable drum. “ a ” “ a ” I837H1140013-01 I837H1140016-01 12) Disconnect the TP sensor lead wire coupler (9).

  • Page 256

    1D-12 Engine Mechanical: 4) Remove the fuel delivery pipe assembly (6). 7) Remove the ISC valve hoses (10) and ISC valve (11). CAUTION Be careful not to twist the fuel delivery pipe T-joint (7) when removing the fuel delivery pipes, or joint part “A” of the fuel delivery pipe get damage.

  • Page 257

    • Align the secondary throttle shaft end “A” with the groove “B” of the STP sensor. • Apply grease to the secondary throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1140024-01 Special tool CAUTION : 09930–11950 (Torx wrench)

  • Page 258

    • Align the throttle shaft end “C” with the groove “D” of the TP sensor. • Apply grease to the throttle shaft end “C” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool : 09930–11950 (Torx wrench)

  • Page 259

    Engine Mechanical: 1D-15 • Assemble the fuel delivery pipes as shown in the • Install the fuel delivery pipe assembly to the throttle figure. body. • Tighten the fuel delivery pipe mounting screws (7) to CAUTION the specified torque. Be careful not to twist the fuel delivery pipe Tightening torque T-joint when installing the fuel delivery pipes, Fuel delivery pipe mounting screw (b): 3.5 N·m (...

  • Page 260

    1D-16 Engine Mechanical: Inspection 5) Disconnect the respective vacuum hoses (1) from Check following items for any defects or clogging. each vacuum nipple on the throttle body. Replace the damaged part if necessary. • O-rings • Throttle valves • Secondary throttle valves •...

  • Page 261

    Engine Mechanical: 1D-17 11) Click “Active control”. 15) Equalize the vacuum of the cylinders by turning each air screw (6) and keep it running at idling speed. 12) Click “ISC air volume control” (4). NOTE Always set the engine rpm at idle rpm. I837H1140294-02 13) Click “ON”...

  • Page 262

    1D-18 Engine Mechanical: ISC Valve Reset NOTE B838H21406015 The learned value of the ISC valve is set at When removing or replacing the throttle body assembly, RESET position. reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tools.

  • Page 263

    Engine Mechanical: 1D-19 5) Click the “Reset” button (2) to clear the TP learned 2) Disconnect the battery (–) lead wire (1). value. I837H1140247-01 3) Jack up the motorcycle and fix it for safety. 4) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”.

  • Page 264

    1D-20 Engine Mechanical: 11) Remove the oil cooler outlet hose (5). 17) Disconnect the GP switch lead wire coupler (13), ground lead wire coupler (14) and CKP sensor lead wire coupler (15). I837H1140286-01 12) Remove the muffler (6) and exhaust pipes (7) along with the HO2 sensor.

  • Page 265

    Engine Mechanical: 1D-21 20) Disconnect the CMP sensor lead wire coupler (23), 24) Remove the engine sprocket cover (30). PAIR solenoid valve lead wire coupler (24) and PAIR solenoid valve hose (25). I837H1140257-02 25) Remove the clutch push rod (31). I837H1140254-01 21) Remove the PAIR solenoid valve (26).

  • Page 266

    1D-22 Engine Mechanical: 30) Remove the engine mounting bolt (35). 36) Loosen the engine mounting thrust adjuster (41) fully. Special tool (A): 09940–14980 (Rotor remover) NOTE Do not remove the engine mounting bolts at this stage. I837H1140261-02 31) Remove the engine mounting nut (36). 32) Remove the engine mounting thrust adjuster lock- nut (37) with the special tool.

  • Page 267

    Engine Mechanical: 1D-23 Engine Assembly Installation • Tighten the engine mounting thrust adjuster lock-nuts B838H21406018 (3) and (4) to the specified torque with the special tool. Install the engine in the reverse order of engine removal. Tightening torque Pay attention to the following points: Engine mounting thrust adjuster lock-nut (b): 45 •...

  • Page 268

    1D-24 Engine Mechanical: • Tighten the engine mounting pinch bolt to the specified torque, as shown in the following illustration. “ b ” “ a ” 2 “ e ” “ c” “ f ” “ f ” “ d ” I837H1140274-03 1.

  • Page 269

    Engine Mechanical: 1D-25 • Install the engine sprocket. Refer to “Engine Sprocket Engine Top Side Disassembly B838H21406019 Removal and Installation in Section 3A (Page 3A-2)”. It is unnecessary to remove the engine assembly from • Install the exhaust pipe assembly and muffler. Refer to the frame when servicing the cylinder head cover and “Exhaust Pipe / Muffler Removal and Installation in camshafts.

  • Page 270

    1D-26 Engine Mechanical: Camshafts 3) Remove the cam chain tension adjuster (2). 1) Remove the valve timing inspection cap (1). I838H1140006-01 4) Remove the gasket (3). I837H1140201-01 2) 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.

  • Page 271

    Engine Mechanical: 1D-27 7) Remove the dowel pins. 4) Remove the cylinder head. 8) Remove the intake camshaft (6) and exhaust 5) Remove the dowel pins (3) and cylinder head gasket camshaft (7). (4). I837H1140208-01 I837H1140211-01 Cylinder Head Engine Top Side Assembly B838H21406020 NOTE Assemble the engine top side in the reverse order of...

  • Page 272

    1D-28 Engine Mechanical: • Tighten the cylinder head bolts (M10) to the specified Camshaft torque with a torque wrench sequentially and • The cam shafts are identified by the embossed letters. diagonally. IN: Intake camshaft • Additionally tighten the cylinder head bolts with the EX: Exhaust camshaft specified angles diagonally using an angular torque •...

  • Page 273

    Engine Mechanical: 1D-29 • Pull the cam chain lightly. • Bind the cam chain and the sprocket with a proper clamp (2) to prevent the cam chain disengagement • Turn the exhaust camshaft so that the arrow is aligned while installing the camshaft journal holders. with the gasket surface of the cylinder head.

  • Page 274

    1D-30 Engine Mechanical: • Apply engine oil to journals and cam faces. I837H1140226-02 I837H1140223-02 Embossed letter Cylinder • Install the dowel pins. No. 1 and No. 2 No. 3 and No. 4 • Install the cam chain guide No. 2 (4). •...

  • Page 275

    Engine Mechanical: 1D-31 I837H1140228-01 • Remove the clamps. • Fit a new gasket (1). CAUTION Use a new gasket to prevent oil leakage. I837H1140229-01 Cam Chain Tension Adjuster • Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the I837H1140230-01 adjuster body until the outer circlip “A”...

  • Page 276

    1D-32 Engine Mechanical: • Rotate the crankshaft (some turns) and recheck the NOTE valve timing. The cam chain tension adjuster can be serviced with the engine installed in the CAUTION frame. • Make sure that the adjuster works properly • Tighten the cam chain tension adjuster service cap (6) by checking no slack at point “C”.

  • Page 277

    • Install a new gasket to the cylinder head cover. • Apply bond to the cam end cap points of the gasket as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) CAUTION Use a new gasket to prevent oil leakage.

  • Page 278

    1D-34 Engine Mechanical: Camshaft Inspection Camshaft Runout B838H21406021 Measure the runout using the dial gauge. Replace the Refer to “Engine Top Side Disassembly (Page 1D-25)”. camshaft if the runout exceeds the limit. Refer to “Engine Top Side Assembly (Page 1D-27)”. Special tool (A): 09900–20607 (Dial gauge (1/100 mm, 10 Camshaft Identification...

  • Page 279

    Engine Mechanical: 1D-35 4) Tighten the camshaft journal holder bolts in 7) If the camshaft journal oil clearance exceeds the ascending order of numbers to the specified torque. limit, measure the inside diameter of the camshaft Refer to “Engine Top Side Assembly (Page 1D-27)”. journal holder and the outside diameter of the camshaft journal.

  • Page 280

    1D-36 Engine Mechanical: Camshaft Sprocket NOTE B838H21406022 If it is difficult to compress the plunger Inspect the camshaft sprocket in the following because of internal engine oil, disassemble procedures: the adjuster by releasing the inner circlip “C” 1) Remove the intake and exhaust camshafts. Refer to and spill out the oil.

  • Page 281

    Engine Mechanical: 1D-37 Cam Chain Guide / Cam Chain Tensioner Cam Chain Guide Inspection B838H21406025 Removal and Installation Inspect the cam chain guide in the following procedures: B838H21406024 Removal 1) Remove the cam chain guides. Refer to “Cam Chain Guide / Cam Chain Tensioner Removal and 1) Remove the cylinder head cover.

  • Page 282

    1D-38 Engine Mechanical: Cylinder Head Disassembly and Assembly 4) Remove the valve spring retainer (4) and valve B838H21406027 spring (5). Refer to “Engine Top Side Disassembly (Page 1D-25)”. 5) Pull out the valve (6) from the combustion chamber Refer to “Engine Top Side Assembly (Page 1D-27)”. side.

  • Page 283

    I837H1140045-01 13) Remove the intake pipes (14). CAUTION Replace the O-rings with new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1140046-01 14) Remove the oil gallery plug (15). 15) Remove the cam chain tension adjuster service cap (16).

  • Page 284

    1D-40 Engine Mechanical: • Apply thread lock to the intake pipe mounting bolts. • Install the thermostat (4). : Thread lock cement 99000–32110 NOTE (THREAD LOCK CEMENT SUPER 1322 or The air bleeder hole “A” of the thermostat equivalent) faces upside. “A”...

  • Page 285

    Engine Mechanical: 1D-41 • Apply engine oil to the oil seal (8), and press-fit it into • Put on the valve spring retainer (9), and using the the position. special tools, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow CAUTION the cotter halves to wedge in between retainer and stem.

  • Page 286

    1D-42 Engine Mechanical: • Install the tappet shims and the tappets to their Valve Stem Runout original positions. Support the valve using V-blocks, as shown in the figure, and check its runout using the dial gauge. If the runout NOTE exceeds the service limit, replace the valve.

  • Page 287

    Engine Mechanical: 1D-43 Valve Stem and Valve Face Wear Condition Valve Stem Wear Measure the valve stem O.D. using the micrometer. If it • Visually inspect each valve stem and valve face for is out of specification, replace the valve with a new one. wear and pitting.

  • Page 288

    1D-44 Engine Mechanical: Valve Spring Valve Seat Width The force of the coil spring keeps the valve seat tight. A 1) Visually check for valve seat width on each valve weakened spring results in reduced engine power output face. If the valve face has worn abnormally, replace and often accounts for the chattering noise coming from the valve.

  • Page 289

    Engine Mechanical: 1D-45 Valve Seat Sealing Condition Valve Guide Replacement B838H21406029 1) Clean and assemble the cylinder head and valve 1) Remove the cylinder head. Refer to “Engine Top components. Side Disassembly (Page 1D-25)”. 2) Fill the intake and exhaust ports with gasoline to 2) Remove the valves.

  • Page 290

    1D-46 Engine Mechanical: 5) Cool down the new valve guides in a freezer for 8) After installing the valve guides, refinish their guiding about one hour and heat the cylinder head to 100 – bores using the reamer. Be sure to clean and oil the 150 °C (212 –...

  • Page 291

    Engine Mechanical: 1D-47 Valve Seat Repair Engine Bottom Side Disassembly B838H21406030 B838H21406031 The valve seats (1) for both the intake and exhaust NOTE valves are machined to three different angles. The seat The crankcase must be separated to service contact surface is cut at 45°. the crankshaft and conrod.

  • Page 292

    1D-48 Engine Mechanical: Starter Motor 3) Remove the thrust washer (5). Remove the starter motor (1). I837H1140075-01 I838H1140018-01 Gearshift System Clutch 1) Remove the snap ring (1) and washer (2) from the Remove the clutch component parts (1). Refer to “Clutch gearshift shaft.

  • Page 293

    Engine Mechanical: 1D-49 Starter Idle Gear / Generator Cover Cam Chain / Cam Chain Tensioner / Cam Chain Guide 1) Remove the starter idle gear component parts (1). Refer to “Starter Clutch Removal and Installation in 1) While holding the generator rotor with the special Section 1I (Page 1I-10)”.

  • Page 294

    1D-50 Engine Mechanical: Water Pump Oil Filter Remove the oil filter (1) with the special tool. 1) Remove the oil cooler water hose (1), cylinder inlet hose (2) and water inlet connector (3). Special tool 2) Remove the water pump (4). (A): 09915–40610 (Oil filter wrench) I837H1140084-01 I837H1140088-01...

  • Page 295

    Engine Mechanical: 1D-51 Oil Pressure Regulator / Oil Strainer 1) Remove the oil pressure regulator (1). 2) Remove the oil strainer (2). I838H1140019-01 I837H1140091-01 Oil Pump 1) Remove the oil pump (1). 2) Remove the dowel pins (2) and O-ring (3). I837H1140095-01 5) Make sure that all of the bolts are removed.

  • Page 296

    1D-52 Engine Mechanical: Transmission Piston Cooling Oil Jet Remove the transmission component. Refer to Remove the piston cooling oil jets (1) from the upper “Transmission Removal in Section 5B (Page 5B-3)”. crankcase. I837H1140097-01 I838H1140024-01 Piston / Conrod 1) Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase.

  • Page 297

    Engine Mechanical: 1D-53 NOTE 2) Remove the piston pin circlip (1). • Do not remove the crankshaft journal bearings unless absolutely necessary. • Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions.

  • Page 298

    1D-54 Engine Mechanical: 2) Remove the oil jet (2) (for transmission) from the Water Jacket Plug lower crankcase. Remove the water jacket plugs (1) from the upper crankcase. I837H1140115-03 I837H1140119-01 Oil Gallery Plug Oil seal / Bearing 1) Remove the oil gallery plug (1) from the lower Remove the oil seal and bearings if necessary.

  • Page 299

    Engine Mechanical: 1D-55 Engine Bottom Side Assembly Oil Gallery Plug B838H21406032 • Tighten each plugs (for lower crankcase) to the Assemble the engine bottom side in the reverse order of specified torque. disassembly. Pay attention to the following points: CAUTION NOTE Replace the gaskets with new ones.

  • Page 300

    1D-56 Engine Mechanical: Oil Jet Crankshaft Journal Bearing • Apply thread lock to the oil gallery jet (1) (for • When fitting the crankshaft journal bearings to the generator) and tighten it to the specified torque. upper and lower crankcases, be sure to fix the stopper part “A”...

  • Page 301

    Engine Mechanical: 1D-57 Piston and Conrod • Apply a small quantity of molybdenum oil solution to the sliding surface of the pistons and cylinder walls. • Apply a small quantity of molybdenum oil solution onto each piston pin. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION)

  • Page 302

    1D-58 Engine Mechanical: • Check that I.D. code “E” on each conrod faces intake • Install each piston cooling oil jet. side. NOTE CAUTION Apply a small quantity of thread lock to the bolts and tighten them to the specified Be sure to clean the conrod big end.

  • Page 303

    Engine Mechanical: 1D-59 3) Set the crankshaft to the conrods and upper 7) Tighten the conrod cap bolt by using a 10 mm, 12 crankcase. point socket wrench in the following two steps. Tightening torque Conrod cap bolt: 15 N⋅m (1.5 kgf-m, 11.0 lb-ft) then turn in 1/4 (90°) turn I838H1140036-01 4) Apply engine oil to each crank pin and bearing...

  • Page 304

    1D-60 Engine Mechanical: 11) Insert the right and left-thrust bearings with the oil Balancer Shaft grooves “A” facing towards the crankshaft web. • Apply a molybdenum oil solution to each balancer shaft journal and bearing lightly. NOTE M/O: Molybdenum oil (MOLYBDENUM OIL •...

  • Page 305

    • Take extreme care not to apply sealant to any oil hole, oil groove and bearing. • Apply sealant to distorted surfaces as it forms a comparatively thick film. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I838H1140044-01 I837H1140281-02 : Apply bond.

  • Page 306

    1D-62 Engine Mechanical: • Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in “B” the following two steps. CAUTION Fit new gasket washers to the bolts “A” to prevent oil leakage. Tightening torque Crankshaft journal bolt (M9): 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) then turn in 50°...

  • Page 307

    : Thread lock cement 99000–32110 strainer (1) and oil pressure regulator (2) to the (THREAD LOCK CEMENT SUPER 1322 or crankcase. equivalent) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Use a new O-ring to prevent oil leakage. I837H1140146-01 Oil Pump •...

  • Page 308

    Be careful not to apply bond to the hole of Oil Cooler thread end. • Apply grease to the O-ring (1). : Sealant 99000–31140 (SUZUKI BOND CAUTION No.1207B or equivalent) Use a new O-ring to prevent oil leakage. Tightening torque Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft)

  • Page 309

    CAUTION Replace the O-ring with a new one. Use the new O-ring to prevent oil leakage. NOTE : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER...

  • Page 310

    1D-66 Engine Mechanical: • Tighten the water inlet connector mounting bolts (3) to • Tighten the cam chain tensioner bolt (2) and cam the specified torque. chain guide No. 1 bolt (3). Tightening torque Tightening torque Water inlet connector mounting bolt (b): 10 N·m ( Cam chain tensioner bolt (a): 23 N·m (2.3 kgf-m, 1.0 kgf-m, 7.0 lb-ft) 16.5 lb-ft)

  • Page 311

    Engine Mechanical: 1D-67 • While holding the generator rotor with the special tool, • Apply a small quantity of thread lock to the gearshift tighten the CKP sensor rotor/cam chain drive sprocket cam stopper bolt (2) and tighten it to the specified bolt (5) and tighten its bolt to the specified torque.

  • Page 312

    1D-68 Engine Mechanical: • Apply a small quantity of thread lock to the gearshift • Install the gearshift shaft assembly (8) and washers cam stopper plate bolt (6) and tighten it to the (9) as shown. specified torque. NOTE : Thread lock cement 99000–32110 Pinch the gearshift arm stopper (7) with (THREAD LOCK CEMENT SUPER 1322 or return spring ends “D”.

  • Page 313

    Engine Mechanical: 1D-69 • Install the oil pump drive sprocket (2) to the Starter Motor countershaft. • Install the starter motor (1). Refer to “Starter Motor Removal and Installation in Section 1I (Page 1I-4)”. NOTE Teeth “A” on the sprocket must face the clutch side.

  • Page 314

    1D-70 Engine Mechanical: Cylinder Inspection B838H21406033 Refer to “Engine Top Side Disassembly (Page 1D-25)”. Refer to “Engine Top Side Assembly (Page 1D-27)”. Cylinder Distortion Check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places.

  • Page 315

    Engine Mechanical: 1D-71 Installation b) Install the 2nd ring (3) and 1st ring (4) to piston. NOTE NOTE 1st ring (4) and 2nd ring (3) differ in shape. • When installing the piston ring, be careful not to damage the piston. •...

  • Page 316

    1D-72 Engine Mechanical: Piston and Piston Ring Inspection Piston Ring-to-groove Clearance B838H21406035 Measure the side clearances of the 1st and 2nd piston Refer to “Piston Ring Removal and Installation rings using the thickness gauge. If any of the clearances (Page 1D-70)”. exceed the limit, replace both the piston and piston rings.

  • Page 317

    Engine Mechanical: 1D-73 Piston Ring Free End Gap and Piston Ring End Gap Piston Pin and Pin Bore Measure the piston ring free end gap using vernier Measure the piston pin bore inside diameter using the calipers. Next, fit the piston ring squarely into the small bore gauge.

  • Page 318

    1D-74 Engine Mechanical: 2) Remove the washers, balancer gear and dampers from the shaft. I838H1140054-01 Balancer Shaft Journal Bearing Removal and I838H1140054-01 Installation Assembly B838H21406038 Refer to “Engine Bottom Side Disassembly (Page 1D- Assembly is in the reverse order of disassembly. Pay 47)”.

  • Page 319

    Engine Mechanical: 1D-75 Installation Inspection When installing the bearings to the crankcases, be sure Inspect the bearing surfaces for any signs of fusion, to install the tab “A” first, and then press in the other pitting, burn or flaws. If any, replace them with a opposite side of the bearing.

  • Page 320

    1D-76 Engine Mechanical: 2) Mate the lower crankcase with the upper crankcase, 4) Check the corresponding crankcase journal I.D. and tighten the crankcase bolts (M8) and crankshaft code number “A”, [A] or [B] which is stamped on the journal bolts (M9) to the specified torque. rear of upper crankcase.

  • Page 321

    Engine Mechanical: 1D-77 Special tool Conrod Crank Pin Bearing Removal and (B): 09900–20205 (Micrometer (0 – 25 mm)) Installation B838H21406040 Refer to “Engine Bottom Side Disassembly (Page 1D- 47)”. Refer to “Engine Bottom Side Assembly (Page 1D-55)”. Removal Remove the conrod crank pin bearings (1). NOTE •...

  • Page 322

    1D-78 Engine Mechanical: Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B838H21406041 and measure the conrod big end width and crank pin Refer to “Engine Bottom Side Disassembly (Page 1D- width. Refer to “Engine Bottom Side Assembly 47)”.

  • Page 323

    Engine Mechanical: 1D-79 Conrod Crank Pin Bearing Inspection and 4) Remove the conrod cap bolts and measure the width of the compressed plastigauge using the envelope Selection B838H21406042 scale. This measurement should be taken at the Refer to “Engine Bottom Side Disassembly (Page 1D- widest part of the compressed plastigauge.

  • Page 324

    1D-80 Engine Mechanical: 2) Check the corresponding crank pin O.D. code 4) Select the specified bearings from the bearing numbers ([1], [2] or [3]) “B”. selection table. CAUTION The bearings should be replaced as a set. Bearing selection table Crank pin O.D. “B ”...

  • Page 325

    Engine Mechanical: 1D-81 Crankshaft Journal Bearing Inspection and 5) Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in Selection B838H21406043 the following two steps. Refer to “Engine Bottom Side Disassembly (Page 1D- 47)”.

  • Page 326

    1D-82 Engine Mechanical: Selection Special tool (A): 09900–20202 (Micrometer (1/100 mm, 1) Check the corresponding crankcase journal I.D. 25 – 50 mm)) codes “A” ([A], [B] or [C]), which are stamped on the rear of the upper crankcase. “A” I837H1140195-01 4) Select the specified bearings from the bearing I838H1140073-02 selection table.

  • Page 327

    Engine Mechanical: 1D-83 Crankshaft Thrust Clearance Inspection and Selection Selection 1) Remove the right-side thrust bearing and measure B838H21406044 its thickness using the micrometer. If the thickness of Refer to “Engine Bottom Side Disassembly (Page 1D- the right-side thrust bearing is below standard, 47)”.

  • Page 328

    1D-84 Engine Mechanical: 4) Select a left-side thrust bearing from the selection table. NOTE Right-side thrust bearing has the same specification as the GREEN (12228-17E00-0D0) of left-side thrust bearing. Left-side thrust bearing selection table Clearance before inserting Color “A” (Part No.) Thrust bearing thickness Thrust clearance the left-side thrust bearing...

  • Page 329

    Engine Mechanical: 1D-85 Specifications Service Data B838H21407001 Valve + Guide Unit: mm (in) Item Standard Limit 29.0 (1.14) — Valve diam. 23.0 (0.91) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...

  • Page 330

    1D-86 Engine Mechanical: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 300 – 1 700 kPa (13 – 17 kgf/cm , 185 – 242 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —...

  • Page 331

    Engine Mechanical: 1D-87 Tightening Torque Specifications B838H21407002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft STP sensor mounting screw 0.35 (Page 1D-13) ISC valve mounting screw (Page 1D-14) TP sensor mounting screw 0.35 (Page 1D-14) Fuel delivery pipe mounting screw 0.35 (Page 1D-15) Engine mounting thrust adjuster...

  • Page 332

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B838H21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-13) /...

  • Page 333

    Engine Mechanical: 1D-89 09900–20203 09900–20205 Micrometer (1/100 mm, 50 – Micrometer (0 – 25 mm) 75 mm) (Page 1D-72) (Page 1D-35) / (Page 1D-43) / (Page 1D-72) / (Page 1D-73) / (Page 1D-77) / (Page 1D-78) / (Page 1D-83) 09900–20530 09900–20602 Cylinder gauge set Dial gauge (1/1000 mm, 1...

  • Page 334

    1D-90 Engine Mechanical: 09915–40610 09915–64512 Oil filter wrench Compression gauge (Page 1D-50) / (Page 1D-3) (Page 1D-64) 09916–10911 09916–14510 Valve lapper set Valve spring compressor (Page 1D-44) (Page 1D-38) / (Page 1D-41) 09916–14522 09916–33210 Valve spring compressor Valve guide reamer (4.5 attachment (Page 1D-38) / (Page 1D-46)

  • Page 335: Engine Lubrication System

    Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B838H21500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-4)”.

  • Page 336: Oil Pan

    1E-2 Engine Lubrication System: Schematic and Routing Diagram Engine Lubrication System Chart Diagram B838H21502001 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 SUB GALLERY #2 #1 PISTON COOLING #2 PISTON COOLING...

  • Page 337

    Engine Lubrication System: 1E-3 Engine Lubrication Circuit Diagram B838H21502002 I838H1150001-01...

  • Page 338

    1E-4 Engine Lubrication System: I838H1150002-01...

  • Page 339

    Engine Lubrication System: 1E-5 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B838H21504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler. Clean or replace.

  • Page 340

    “Engine Assembly Removal in Section 1D CAUTION (Page 1D-19)”. Use the new O-rings to prevent oil leakage. 2) Remove the plate (1). 3) Remove the oil pan (2) and gasket. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1150006-01...

  • Page 341

    Engine Lubrication System: 1E-7 • Install the oil pressure regulator (1) and oil strainer (2). : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or NOTE equivalent) When installing the oil strainer, fit the concave part “A” of the oil strainer onto the “D”...

  • Page 342

    Parts Removal and Installation in Section 9D (Page 9D-11)”. : Grease 99000–25010 (SUZUKI SUPER 2) Inspect the oil cooler for engine oil leakage. If any GREASE A or equivalent) defects are found, replace the oil cooler with a new one.

  • Page 343

    Engine Lubrication System: 1E-9 Oil Pressure Switch Removal and Installation 2) Connect the oil pressure switch lead wire securely. B838H21506007 Refer to “Wiring Harness Routing Diagram in Refer to “Electrical Components Location in Section 0A Section 9A (Page 9A-3)”. (Page 0A-8)”. Tightening torque Oil pressure switch lead wire bolt (b): 1.5 N·m ( Removal...

  • Page 344

    1E-10 Engine Lubrication System: Installation Oil Jet (For Cam Chain Tension Adjuster) Installation is in the reverse order of removal. Pay Removal attention to the following points: 1) Remove the throttle body. Refer to “Throttle Body • Fit the new O-ring (1) to each piston cooling oil jet and Removal and Installation in Section 1D (Page 1D- apply engine oil to them.

  • Page 345

    Engine Lubrication System: 1E-11 Oil Jet (For Transmission) Installation Installation is in the reverse order of removal. Pay Removal attention to the following point: 1) Remove the engine assembly. Refer to “Engine • Apply thread lock to the oil gallery jet and tighten it to Assembly Removal in Section 1D (Page 1D-19)”.

  • Page 346

    NOTE Use a new O-ring to prevent oil leakage. Be careful not to drop any parts into the crankcase. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Removal 1) Remove the oil pan, oil strainer and oil pressure regulator. Refer to “Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation (Page 1E-6)”.

  • Page 347

    Engine Lubrication System: 1E-13 3) Tighten the oil pump mounting bolts to the specified Oil Pump Inspection B838H21506012 torque. Inspect the oil pump in the following procedures: Tightening torque 1) Remove the oil pump. Refer to “Oil Pump Removal Oil pump mounting bolt (a): 10 N·m (1.0 kgf-m, and Installation (Page 1E-12)”.

  • Page 348

    1E-14 Engine Lubrication System: 3) Remove the oil pump drive sprocket (3) and chain • Install the oil pump drive sprocket (2) to the (4). countershaft. 4) Remove the thrust washer (5). NOTE Teeth “B” on the sprocket must face the clutch side.

  • Page 349

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B838H21508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-6) /...

  • Page 350: Engine Cooling System

    1F-1 Engine Cooling System: Engine Cooling System Engine Precautions Precautions for Engine Cooling System B838H21600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.

  • Page 351

    Engine Cooling System: 1F-2 Schematic and Routing Diagram Cooling Circuit Diagram B838H21602001 RESERVOIR THERMOSTAT CYLINDER HEAD ECT SENSOR TANK CYLINDER RADIATOR WATER PUMP Oil cooler I837H1160001-01...

  • Page 352

    1F-3 Engine Cooling System: Water Hose Routing Diagram B838H21602002 “b ” “a” “ a ” “A” “ a ” “B” “A” “C” “E” “D” “E” “I” “F” “G” “J” “H” “P” “K” “F” “I” “M” “O” “M” “F” “L” “L” “L”...

  • Page 353

    Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B838H21604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.

  • Page 354

    1F-5 Engine Cooling System: Radiator Cap Inspection Radiator Cleaning B838H21606002 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. 1) Remove the radiator cap. Refer to “Cooling Circuit CAUTION Inspection (Page 1F-4)”.

  • Page 355

    Engine Cooling System: 1F-6 4) Disconnect the radiator outlet hose (3) and water 8) Remove the cooling fan motor (8) from the radiator. bypass hose (4). I837H1160011-02 I837H1160007-01 Installation 5) Disconnect the radiator inlet hose (5) and oil cooler Install the radiator in the reverse order of removal. Pay water inlet hose (6).

  • Page 356

    1F-7 Engine Cooling System: 3) Any leakage from the connecting section should be Water Hose Removal and Installation B838H21606006 corrected by proper tightening. Refer to “Water Hose Removal Routing Diagram (Page 1F-3)”. 1) Remove the under cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

  • Page 357

    Engine Cooling System: 1F-8 Radiator Reservoir Tank Removal and 2) Test the cooling fan motor for load current with an ammeter connected as shown in the figure. Installation B838H21606008 If the fan motor does not turn, replace the cooling fan Removal assembly with a new one.

  • Page 358

    1F-9 Engine Cooling System: 3) First check the insulation between “A” and “B” 4) Remove the thermostat cover (2). terminals with tester. Then apply 12 volts to “C” and “D” terminals, (+) to “C” and (–) to “D”, and check the continuity between “A”...

  • Page 359

    Engine Cooling System: 1F-10 • Tighten the thermostat cover bolts to the specified 4) Immerse the thermostat (1) in the water contained in torque. a beaker and note that the immersed thermostat is in suspension. Tightening torque 5) Heat the water by placing the beaker on a stove and Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.0 observe the rising temperature on a thermometer lb-ft)

  • Page 360

    1F-11 Engine Cooling System: Water Pump Components B838H21606015 I837H1160026-02 1. Water pump case : 8 N⋅m (0.8 kgf-n, 6.0 Ib-ft) : Apply molybdenum oil solution. 2. O-ring : 5.5 N⋅m (0.55 kgf-n, 4.0 Ib-ft) : Apply thread lock. 3. Impeller : 10 N⋅m (1.0 kgf-n, 7.0 Ib-ft) : Do not reuse.

  • Page 361

    Filter Replacement in Section 0B (Page 0B-10)” CAUTION and “Cooling System Inspection in Section 0B (Page 0B-12)”. Replace the O-ring with the a new one. 3) Disconnect the cylinder inlet hose (1). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)

  • Page 362

    1F-13 Engine Cooling System: • Install the water pump assembly with the slot on the 2) Remove the water pump case (2). pump shaft end “A” securely engaged with the flat “B” on the oil pump shaft. “B” “A” I837H1160031-01 3) Remove the O-ring (3).

  • Page 363

    Special tool (A): 09921–20240 (Bearing remover set) I837H1160038-01 2) Apply a small quantity of the grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1160036-01 9) Remove the oil seal (10). NOTE If there is no abnormal condition, the oil seal removal is not necessary.

  • Page 364

    1F-15 Engine Cooling System: 3) Install a new mechanical seal using a suitable size 6) Install the rubber seal (3) into the impeller. socket wrench. 7) After wiping off the oily or greasy matter from the mechanical seal ring (4), install it into the impeller. CAUTION NOTE The removed mechanical seal must be...

  • Page 365

    Engine Cooling System: 1F-16 10) Apply a small quantity of thread lock to the impeller 13) Tighten the water pump air bleeder bolt (10) to the securing bolt and tighten it to the specified torque. specified torque. : Thread lock cement 99000–32110 CAUTION (THREAD LOCK CEMENT SUPER 1322 or Use a new gasket washer to prevent engine...

  • Page 366

    1F-17 Engine Cooling System: Oil Seal Impeller / Shaft Visually inspect the oil seal for damage, with particular Visually inspect the impeller and its shaft for damage. attention given to the lip. Replace the impeller or shaft if necessary. Replace the oil seal that shows indications of leakage. I837H1160050-01 I837H1160048-01 Impeller Shaft Journal...

  • Page 367

    Engine Cooling System: 1F-18 Specifications Service Data B838H21607001 Thermostat + Radiator + Fan + Coolant Item Specification Note Thermostat valve opening Approx. 82 °C (180 °F) — temperature Over 8 mm (0.31 in) and at 95 °C (203 °F) Thermostat valve lift —...

  • Page 368

    1F-19 Engine Cooling System: Special Tools and Equipment Recommended Service Material B838H21608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-12) / equivalent (Page 1F-14) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1F-15)

  • Page 369: Fuel System

    Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B838H21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. •...

  • Page 370

    1G-2 Fuel System: General Description Fuel Injection System Description B838H21701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filters (3) and (4), fuel feed hose (5), fuel delivery pipes (6) including fuel injectors (7) and (8), fuel pressure regulator (9). There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injectors installed in the fuel delivery pipe.

  • Page 371

    Fuel System: 1G-3 Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B838H21702001 “ a ” “ d ” “ b ” “c” “a” “A” “B” I837H1170001-03 1. Fuel tank water drain hose 6. Breather hose clamp (Except for E-33) “b”: 13 mm (0.5 in) 2.

  • Page 372

    1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B838H21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.

  • Page 373

    Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B838H21706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...

  • Page 374

    1G-6 Fuel System: Fuel Discharge Amount Inspection 6) Connect a proper lead wire into the fuel pump lead B838H21706003 wire coupler (fuel pump side) and apply 12 V to the WARNING fuel pump (between (+) Y/R wire and (–) B/W wire) for 10 seconds and measure the amount of fuel •...

  • Page 375

    Fuel System: 1G-7 Fuel Pump Relay Inspection Fuel Hose Inspection B838H21706004 B838H21706005 Refer to “Electrical Components Location in Section 0A Refer to “Fuel Line Inspection in Section 0B (Page 0B- (Page 0A-8)”. 10)”. Inspect the fuel pump relay in the following procedures: Fuel Level Gauge Inspection 1) Remove the front seat.

  • Page 376

    1G-8 Fuel System: Fuel Tank Construction B838H21706007 “A” “B” “B” “B” I837H1170032-02 1. Fuel tank heat shield 3. Fuel tank front bracket “A”: Insert to the fuel tank heat shield bracket. : Aluminum film side should face the engine side. 2.

  • Page 377

    Fuel System: 1G-9 Fuel Tank Removal and Installation 6) Place a rag under the fuel feed hose (4) and B838H21706008 disconnect the fuel feed hose from the fuel tank. Removal CAUTION When removing the fuel tank, do not leave WARNING the fuel feed hose on the fuel pump side.

  • Page 378

    1G-10 Fuel System: Fuel Pump Components B838H21706009 I837H1170033-02 1. Fuel level gauge 4. Fuel pump case : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Do not reuse. 2. Fuel filter cartridge 5. Fuel mesh filter : Apply engine oil. 3. Fuel pump 6.

  • Page 379

    Fuel System: 1G-11 Fuel Pump Disassembly and Assembly 5) Remove the fuel filter cartridge (4). B838H21706010 Disassembly CAUTION 1) Remove the fuel tank. Refer to “Fuel Tank Removal Never remove the fuel pressure regulator (5) and Installation (Page 1G-9)”. from the holder. 2) Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.

  • Page 380

    1G-12 Fuel System: 8) Remove the O-ring (10) and lead wires (11). I837H1170025-01 • Connect all lead wires securely so as not to cause I837H1170022-01 9) Remove the fuel mesh filter (12). contact failure. 10) Remove the fuel pump (13). I837H1170026-01 I837H1170023-01 Assembly...

  • Page 381

    • Install a new O-ring and apply grease to it. 2) If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of : Grease 99000–25010 (SUZUKI SUPER engine power. Such a filter should be cleaned by GREASE A or equivalent) blowing with compressed air.

  • Page 382

    1G-14 Fuel System: Specifications Service Data B838H21707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 167 ml (5.6/5.9 US/lmp oz) and more/10 sec. Fuel pressure regulator operating Approx.

  • Page 383

    Fuel System: 1G-15 Special Tools and Equipment Recommended Service Material B838H21708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-13) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-10)”...

  • Page 384: Ignition System

    1H-1 Ignition System: Ignition System Engine General Description Immobilizer Description (For E-02, 19, 24) Operation B838H21801001 When the ignition switch is turned ON with the engine The immobilizer, an anti-theft system, is installed as a stop switch in ON, the immobi-antenna and ECM are standard equipment.

  • Page 385

    Ignition System: 1H-2 NOTE Operation Drive mode is preset at A-mode when the ignition switch If the indicator light flashes fast, turn the and engine stop switch are turned on. Follow the ignition switch OFF then ON to make procedure below to operate drive mode selector. judgment again as there is possible 1) Turn on the ignition switch and engine stop switch.

  • Page 386

    1H-3 Ignition System: Schematic and Routing Diagram Ignition System Diagram B838H21802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery sensor sensor switch I837H1180001-02 Ignition System Components Location B838H21802002 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

  • Page 387

    Ignition System: 1H-4 Diagnostic Information and Procedures Ignition System Symptom Diagnosis B838H21804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defective ignition coil/plug caps.

  • Page 388

    1H-5 Ignition System: No Spark or Poor Spark B838H21804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.

  • Page 389

    Ignition System: 1H-6 Repair Instructions Ignition Coil / Plug Cap and Spark Plug Removal 5) Remove the spark plugs with a spark plug wrench. and Installation Special tool B838H21806001 (A): 09930–10121 (Spark plug wrench set) Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch.

  • Page 390

    1H-7 Ignition System: • Install the ignition coil/plug caps and connect their 2) Disconnect all ignition coil/plug caps. Refer to lead wire couplers. “Ignition Coil / Plug Cap and Spark Plug Removal and Installation (Page 1H-6)”. CAUTION Do not hit the ignition coil/plug cap with a plastic hammer when installing it.

  • Page 391

    Ignition System: 1H-8 5) Insert the needle pointed probe to the lead wire 7) Measure the ignition coil primary peak voltage in the coupler. following procedures: CAUTION WARNING Use the special tool to prevent the rubber of Do not touch the tester probes and spark the water proof coupler from damage.

  • Page 392

    1H-9 Ignition System: Ignition Coil / Plug Cap Resistance 2) Disconnect the CKP sensor coupler (1). 1) Remove the ignition coil/plug caps. Refer to “Ignition NOTE Coil / Plug Cap and Spark Plug Removal and Be sure that all of the couplers are connected Installation (Page 1H-6)”.

  • Page 393

    Ignition System: 1H-10 5) Repeat the b) procedure several times and measure 4) After measuring the CKP sensor resistance, connect the highest CKP sensor peak voltage. the CKP sensor coupler. 5) Reinstall the fuel tank. Refer to “Fuel Tank Removal CKP sensor peak voltage and Installation in Section 1G (Page 1G-9)”.

  • Page 394

    1H-11 Ignition System: Ignition Switch Removal and Installation Installation B838H21806008 Install the ignition switch in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the air cleaner box. Refer to “Air Cleaner • Tighten the ignition switch mounting bolts (1), right Box Removal and Installation in Section 1D and left with the special tools.

  • Page 395

    Ignition System: 1H-12 Drive Mode Selector Inspection B838H21806009 Inspect the drive mode selector in the following procedures: 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Date monitor”. 4) Make sure each of “Driving mode selection”...

  • Page 396

    1H-13 Ignition System: Specifications Service Data B838H21807001 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 ⋅ 4 ⋅ 3 Firing order NGK: CR9EIA-9 Type Spark plug DENSO: IU27D 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. 142 –...

  • Page 397

    Ignition System: 1H-14 Special Tools and Equipment Recommended Service Material B838H21808001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1H-11) 1322 or equivalent Special Tool B838H21808002 09900–25008 09900–25009 Multi-circuit tester set...

  • Page 398: Starting System

    1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B838H21902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Ignition Engine stop switch switch Fuse (30 A) ignition coil Gear position Starter Fuse Starter switch button motor Starter relay...

  • Page 399

    Starting System: 1I-2 Starter Motor Will Not Run B838H21904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to Step 2. Go to Step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”...

  • Page 400

    1I-3 Starting System: Repair Instructions Starter Motor Components B838H21906001 I837H1190035-03 1. O-ring 6. Starter motor case : 3.5 N⋅m (0.35 kgf-m, 2.5 lb-ft) 2. Housing end (Inside) 7. Housing end (Outside) : Apply grease to sliding surface. 3. O-ring 8. Starter motor lead wire nut : Apply moly paste to sliding surface.

  • Page 401

    Disassemble the starter motor as shown in the starter motor components diagram. Refer to “Starter Motor • Apply grease to the O-ring. Components (Page 1I-3)”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Assembly Reassemble the starter motor in the reverse order of CAUTION removal.

  • Page 402

    Starter motor housing bolt (a): 3.5 N·m (0.35 kgf- m, 2.5 lb-ft) I837H1190005-01 • Apply a small quantity of moly paste to the armature shaft. I837H1190007-03 : Moly paste 99000–25140 (SUZUKI MOLY Starter Motor Inspection PASTE or equivalent) B838H21906004 Refer to “Starter Motor Disassembly and Assembly (Page 1I-4)”.

  • Page 403

    Starting System: 1I-6 Commutator Oil Seal Inspect the commutator for discoloration, abnormal wear Check the seal lip for damage. or undercut “A”. If any damage is found, replace the housing end. If the commutator is abnormally worn, replace the armature assembly. If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth.

  • Page 404

    1I-7 Starting System: Starter Relay Inspection 3) Measure the relay coil resistance between the B838H21906006 terminals using the multi-circuit tester. If the Inspect the starter relay in the following procedures: resistance is not within the specified value, replace 1) Remove the starter relay. Refer to “Starter Relay the starter relay with a new one.

  • Page 405

    Starting System: 1I-8 Side-stand / Ignition Interlock System Parts 5) Connect the side-stand switch coupler. Inspection 6) Install the removed parts. B838H21906008 Check the interlock system for proper operation. If the Turn Signal / Side-stand Relay interlock system does not operate properly, check each The turn signal/side-stand relay is composed of the turn component for damage or abnormalities.

  • Page 406

    1I-9 Starting System: Diode inspection Gear Position Switch 1) Remove the turn signal/side-stand relay. Refer to 1) Lift and support the fuel tank. Refer to “Fuel Tank “Turn Signal / Side-stand Relay Removal and Removal and Installation in Section 1G (Page 1G- Installation (Page 1I-7)”.

  • Page 407

    Starting System: 1I-10 7) Measure the voltage between P and B/W lead wires 3) Remove the shaft (4), bearing (5), starter idle gear using the multi-circuit tester when shifting the (6) and thrust washer (7). gearshift lever from low to top. Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe...

  • Page 408

    1I-11 Starting System: 8) Remove the starter driven gear (12). Installation Install the starter clutch in the reverse order of removal. Pay attention to the following points: • When inserting the one way clutch (1) into the starter clutch guide (2), fit the flange “A” in the step of the starter clutch guide (2).

  • Page 409

    Replace to the O-ring with a new one. Tightening torque Starter clutch bolt (a): 13 N·m (1.3 kgf-m, 9.5 lb-ft) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1190028-02 • Apply engine oil to the bushing of the starter driven I837H1190031-01 gear.

  • Page 410

    1I-13 Starting System: Starter Clutch Starter Button Inspection B838H21906011 1) Install the starter driven gear onto the starter clutch. Inspect the starter button in the following procedures: 2) Turn the starter driven gear by hand to inspect the 1) Remove the air cleaner box. Refer to “Air Cleaner starter clutch for a smooth movement.

  • Page 411

    Starting System: 1I-14 Specifications Service Data B838H21907001 Electrical Unit: mm Item Specification Note Standard 10.0 (0.39) Starter motor brush length Limit 6.5 (0.26) 3 – 6 Ω Starter relay resistance Tightening Torque Specifications B838H21907002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Starter motor mounting bolt...

  • Page 412

    SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-4) equivalent (Page 1I-5) / (Page 1I- Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1I-5) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1I-12) / (Page 1I- NOTE Required service material is also described in the following.

  • Page 413: Charging System

    Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B838H21A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B838H21A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B838H21A04001 Condition...

  • Page 414

    1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.

  • Page 415

    Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection 3) Measure the DC voltage between the battery (+) and B838H21A06001 (–) terminals using the multi-circuit tester. If the Inspect the battery current leakage in the following voltage is not within the specified value, inspect the procedures: generator and regulator/rectifier.

  • Page 416

    1J-4 Charging System: 3) Measure the resistance between the three lead 4) Using the multi-circuit tester, measure the voltage wires. between three lead wires. If the resistance is out of specified value, replace the If the tester reads under the specified value, replace stator with a new one.

  • Page 417

    Charging System: 1J-5 4) Remove the starter idle gear No. 1 component parts 8) Hold the generator rotor with the special tool. (2). Refer to “Starter Clutch Removal and Installation Special tool in Section 1I (Page 1I-10)”. (A): 09930–44520 (Rotor holder) 9) Remove the generator rotor bolt.

  • Page 418

    I837H11A0016-02 • Apply a bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I837H11A0014-02 • Degrease the tapered portion “A” of generator rotor and also the crankshaft “B”.

  • Page 419

    • Route the generator lead wire. Refer to “Wiring Harness Routing Diagram in Section 9A (Page 9A-3)”. I837H11A0019-02 • Apply grease to the starter motor O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the O-ring with a new one.

  • Page 420

    1J-8 Charging System: Regulator / Rectifier Construction B838H21A06005 “A” “B” “C” I837H11A0027-02 1. Regulator/rectifier 4. Clamp “B”: Pass the regulator/rectifier harness between the bracket and frame. 2. Regulator/rectifier bracket mold 5. Frame “C”: After the clamp has contacted to the projection on the bracket, tighten the bolt.

  • Page 421

    Charging System: 1J-9 Regulator / Rectifier Removal and Installation B838H21A06006 Removal 1) Turn the ignition switch OFF. 2) Lift the air cleaner box upside. Refer to “Air Cleaner Box Removal and Installation in Section 1D (Page 1D-7)”. 3) Remove the left under cowling. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-11)”. 4) Disconnect the regulator/rectifier couplers (1).

  • Page 422

    1J-10 Charging System: Regulator / Rectifier Inspection B838H21A06007 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch OFF. 2) Disconnect the regulator/rectifier couplers. Refer to “Regulator / Rectifier Removal and Installation (Page 1J-9)”. 3) Measure the voltage between the terminals using the multi-circuit testers as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

  • Page 423

    Charging System: 1J-11 Battery Components 2) Remove the caps (2) from the electrolyte container. B838H21A06008 NOTE • Do not remove or pierce the sealed areas “B” of the electrolyte container. • After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes.

  • Page 424

    1J-12 Charging System: 5) Make sure that air bubbles (4) rise to the top of each electrolyte container, and leave in this position for about more than 20 minutes. I718H11A0027-01 Correct I649G11A0042-03 NOTE If no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times.

  • Page 425

    Charging System: 1J-13 Battery Recharging 4) Install the battery to the motorcycle. Refer to “Battery Removal and Installation (Page 1J-13)”. CAUTION Do not remove the caps on the battery top while recharging. NOTE When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.

  • Page 426

    1J-14 Charging System: Battery Visual Inspection • Tighten the battery lead wire mounting bolts securely. B838H21A06011 Inspect the battery in the following procedures: 1) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

  • Page 427

    Charging System: 1J-15 Special Tools and Equipment Recommended Service Material B838H21A08001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1J-7) equivalent Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1J-7) Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140...

  • Page 428: Exhaust System

    1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B838H21B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipes and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.

  • Page 429

    Exhaust System: 1K-2 Exhaust Control System Operation B838H21B01002 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 430

    1K-3 Exhaust System: FULL OPEN I837H11B0043-02...

  • Page 431

    Exhaust System: 1K-4 Repair Instructions Exhaust Control System Construction B838H21B06001 “ a ” “ b ” “A” “c” I837H11B0040-02 1. EXCV cable No. 1 “A”: When loosening or tightening the pulley bolt, : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) “b”: 60 – 61 mm (2.36 – 2.40 in) be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

  • Page 432

    1K-5 Exhaust System: Exhaust System Components B838H21B06002 “A” I837H11B0041-04 1. Exhaust pipe gasket “A”: When loosening or tightening the pulley bolt, be sure to fix the : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) pulley with an adjustable wrench, or EXCVA may get damaged. 2.

  • Page 433

    Exhaust System: 1K-6 EXCV Cable Removal and Installation 9) Loosen the lock-nut (5) on the No. 1 cable (6) and B838H21B06003 turn in the cable adjuster (4) fully. Removal 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G- 9)”.

  • Page 434

    1K-7 Exhaust System: Installation 6) Connect the other end of EXCV cable No. 1 (1) and No. 2 (2) to the EXCVA pulley. CAUTION The cable slots of EXCVA pulley must be located adjustment position. 1) Temporarily connect the EXCV cable No. 1 (37H0CL) (1) and No.

  • Page 435

    Exhaust System: 1K-8 5) After turning the mode select switch ON, turn the 11) Hold the pulley with an adjustable wrench, and ignition switch ON. loosen the pulley mounting bolt (5). Special tool CAUTION (A): 09930–82720 (Mode select switch) • When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.

  • Page 436

    1K-9 Exhaust System: • Hold the pulley with an adjustable wrench, and then EXCVA Adjustment B838H21B06007 tighten the pulley mounting bolt (1) to the specified Inspect the EXCVA operation and adjust it if necessary torque. in the following steps: Tightening torque EXCVA pulley mounting bolt (a): 5 N·m (0.5 kgf- Step 1 m, 3.5 lb-ft)

  • Page 437

    Exhaust System: 1K-10 Step 3 7) If the measured voltage is less than specification, adjust the No. 1 cable adjuster as follows: 1) Turn the ignition switch OFF. a) Set the EXCVA to the adjustment position. Refer 2) Disconnect the EXCVA motor coupler (1). to “EXCV Cable Removal and Installation 3) To set the EXCV to fully closed position, apply 12 V (Page 1K-6)”.

  • Page 438

    1K-11 Exhaust System: 2) Measure the position sensor output voltage at fully Exhaust Pipe / Muffler Removal and Installation B838H21B06008 opened position. Special tool Removal (A): 09900–25008 (Multi-circuit tester set) 1) Remove the right under cowling. Refer to “Exterior (B): 09900–25009 (Needle pointed probe Parts Removal and Installation in Section 9D set) (Page 9D-11)”.

  • Page 439

    Exhaust System: 1K-12 8) Disconnect the EXCV cables (5) from the EXCV pulley. 9) Remove the EXCV cables (5) with the bracket (6). I837H11B0007-01 I837H11B0004-01 10) Remove the radiator mounting bolts. I837H11B0008-01 13) Remove the exhaust pipe gaskets (7). I837H11B0005-01 I837H11B0009-03 14) Remove the HO2 sensor (8) from the exhaust pipe.

  • Page 440

    1K-13 Exhaust System: Installation • Tighten the exhaust pipe bolts and exhaust pipe Installation is in the reverse order of removal. Pay mounting bolts to the specified torque. attention to the following points: Tightening torque • Tighten the HO2 sensor to the specified torque. Exhaust pipe bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb- Tightening torque Exhaust pipe mounting bolt (c): 23 N·m (2.3 kgf-...

  • Page 441

    Exhaust System: 1K-14 • Install the connector (2). • Tighten the muffler mounting nut (3) and muffler connecting bolt (4) to the specified torque. CAUTION Tightening torque Replace the connectors with new one. Muffler mounting nut (e): 25 N·m (2.5 kgf-m, 18.0 lb-ft) NOTE Muffler connecting bolt (f): 23 N·m (2.3 kgf-m,...

  • Page 442

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B838H21B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-14)

  • Page 443: Suspension General Diagnosis

    Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Swingarm Removal and Installation....2C-10 Swingarm Related Parts Inspection ....2C-12 Precautions............. 2-1 Swingarm Bearing Removal and Installation ..2C-13 Precautions for Suspension ........2-1 Specifications .............2C-15 Suspension General Diagnosis....2A-1 Service Data............2C-15 Tightening Torque Specifications......2C-15 Diagnostic Information and Procedures....2A-1 Special Tools and Equipment ......2C-16...

  • Page 444

    2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B838H22000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.

  • Page 445

    Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B838H22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

  • Page 446: Front Suspension

    2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B838H22206001 I838H1220001-01 1. Front fork cap bolt 10. Outer tube 19. Compression damping force adjuster 2. O-ring 11. Oil seal retainer : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3. O-ring 12.

  • Page 447

    Front Suspension: 2B-2 Front Fork Removal and Installation 6) Loosen the handlebar clamp bolt (3). B838H22206002 NOTE NOTE The right and left front forks are installed • Slightly loosen the front fork cap bolt (4) to symmetrically and therefore the removal facilitate later disassembly.

  • Page 448

    2B-3 Front Suspension: 2) Tighten the front fork cap bolt (2) to the specified 7) Tighten the handlebar clamp bolt (4). torque. Tightening torque Tightening torque Handlebar clamp bolt (d): 23 N·m (2.3 kgf-m, Front fork cap bolt (a): 35 N·m (3.5 kgf-m, 25.5 16.5 lb-ft) lb-ft) 3) Loosen the lower clamp bolts.

  • Page 449

    Front Suspension: 2B-4 Front Suspension Adjustment Compression damping force (High speed) B838H22206003 Fully turn the compression damping force (High speed) After installing the front fork, adjust the spring pre-load adjuster (1) clockwise. From that position (stiffest), turn it and three kinds of damping force as follows: out to standard setting position.

  • Page 450

    2B-5 Front Suspension: Front Fork Disassembly and Assembly 5) Compress the fork spring with the special tool (A) B838H22206004 and remove the special tool (B). Refer to “Front Fork Removal and Installation (Page 2B- Special tool 2)”. (A): 09940–94930 (Front fork spacer holder) NOTE (B): 09940–94922 (Front fork spring stopper plate)

  • Page 451

    Front Suspension: 2B-6 9) Remove the outer tube from the inner tube. 14) Remove the compression damping force adjuster (12). I838H1220017-01 10) Remove the dust seal (7) and oil seal stopper ring I838H1220021-01 (8). 15) Remove the damper rod bolt with the special tool. Special tool (D): 09940–30221 (Front fork assembling tool)

  • Page 452

    2) Apply fork oil to the oil seal lip. I823H1220025-01 5) Install the oil seal stopper ring (2). : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) CAUTION Make sure that the oil seal stopper ring is fitted securely.

  • Page 453

    2) Compress it fully. 3) Pour specified front fork oil up to the top level of the outer tube. : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) Front fork oil capacity (each leg) 418 ml (14.1/14.7 lmp oz)

  • Page 454

    2B-9 Front Suspension: 4) Move the inner rod slowly with the special tool (A) 7) Hold the front fork vertically and adjust fork oil level more than ten times until bubbles do not come out with the special tool. from the oil. NOTE NOTE When adjusting the fork oil level, remove the...

  • Page 455

    3) Apply fork oil to the O-ring. CAUTION Use a new O-ring to prevent oil leakage. : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) 4) Insert the adjuster rod (1) in to the front fork cap bolt I838H1220032-01 (2).

  • Page 456

    Use a new O-ring to prevent oil leakage. Front fork spring free length Service limit: 259 mm (10.2 in) : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) I837H1220037-01 Damper Rod...

  • Page 457

    Front fork oil level (Without spring, 115 (4.5) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 418 ml (14.1/14.7 US/lmp oz) — Front fork inner tube O.D 41 (1.6)

  • Page 458

    2B-13 Front Suspension: Special Tools and Equipment Recommended Service Material B838H22208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL SS-05 or P/No.: 99000–99001– (Page 2B-7) / (Page 2B- equivalent 7) / (Page 2B-8) / (Page 2B-8) /...

  • Page 459: Rear Suspension

    Rear Suspension: 2C-1 Rear Suspension Suspension Repair Instructions Rear Suspension Components B838H22306001 I837H1230055-05 1. Rear shock absorber 9. Swingarm pivot nut : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft) 2. Rear shock absorber mounting nut 10. Swingarm : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 3.

  • Page 460

    2C-2 Rear Suspension: Rear Suspension Assembly Construction B838H22306002 “ a ” “a” “ b ” “ b ” “b” “ b ” “ a ” “ a ” I837H1230056-02 1. Rear shock absorber mounting bolt (Upper) 6. Swingarm pivot shaft : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft) 2.

  • Page 461

    Rear Suspension: 2C-3 Rear Shock Absorber Removal and Installation 7) Remove the rear shock absorber upward. B838H22306003 Removal 1) Remove the under cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”. 2) Support the motorcycle with a jack to relieve load on the rear shock absorber.

  • Page 462

    2C-4 Rear Suspension: • Tighten the cushion rod rear mounting bolt and nut. Tightening torque Cushion rod rear mounting nut (d): 78 N·m (7.8 kgf-m, 56.5 lb-ft) I837H1230009-01 3) Install the rear shock absorber. Refer to “Rear Shock Absorber Removal and Installation (Page 2C-3)”. Rear Suspension Adjustment I837H1230007-02 B838H22306006...

  • Page 463

    Rear Suspension: 2C-5 Rebound side Gas Pressure Release Turn the damping force adjuster (1) to the desired Make sure to observe the following precautions: position. WARNING STD position 1-3/4 turns out from stiffest position • Never apply heat or disassemble the damper unit since it can explode or oil can splash hazardously.

  • Page 464

    2C-6 Rear Suspension: Cushion Lever Removal and Installation Spacer B838H22306008 1) Remove the spacers from the cushion lever. 2) Inspect the spacers for any flaws or other damage. If Removal any defects are found, replace the spacers with new 1) Remove the under cowlings. Refer to “Exterior Parts ones.

  • Page 465

    Rear Suspension: 2C-7 Cushion Lever Bearing Removal and Installation Installation CAUTION B838H22306010 The removed bearings must be replaced with Removal new ones. 1) Remove the cushion lever. Refer to “Cushion Lever Removal and Installation (Page 2C-6)”. 1) Press the bearings into the cushion lever at 1 mm 2) Remove the cushion lever bearings with the special (0.04 in) depth “A”...

  • Page 466

    2) Apply grease to the bearings. Installation Install the cushion rod in the reverse order of removal. : Grease 99000–25010 (SUZUKI SUPER Pay attention to the following points: GREASE A or equivalent) • Tighten each bolts and nuts to the specified torque.

  • Page 467

    Inspect the cushion lever for damage. If any defect is found, replace the cushion rod with a new one. “A” I837H1230030-01 2) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1230028-01 Cushion Rod Bearing Removal and Installation B838H22306013 Removal 1) Remove the cushion rod.

  • Page 468

    2C-10 Rear Suspension: Swingarm Removal and Installation 7) Remove the swingarm pivot shaft lock-nut with the B838H22306014 special tool. Special tool Removal (A): 09940–14940 (Swingarm pivot thrust 1) Cut the drive chain. Refer to “Drive Chain adjuster socket wrench) Replacement in Section 3A (Page 3A-7)”. 2) Remove the rear wheel assembly.

  • Page 469

    Rear Suspension: 2C-11 12) Remove the plate (10). • Adjust swingarm pivot thrust clearance in the following procedures: – Insert the swingarm pivot shaft (2) and tighten it to the specified torque. Special tool (A): 09944–28321 (Hexagon socket (19 mm)) Tightening torque Swingarm pivot shaft (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)

  • Page 470

    2C-12 Rear Suspension: Swingarm Related Parts Inspection – Tighten the swingarm pivot lock-nut (4) to the B838H22306015 specified torque with the special tool. Refer to “Swingarm Removal and Installation (Page 2C- 10)”. Special tool (B): 09940–14940 (Swingarm pivot thrust Spacers adjuster socket wrench) 1) Remove the spacers from the swingarm.

  • Page 471

    Rear Suspension: 2C-13 Swingarm Bearing Swingarm Bearing Removal and Installation B838H22306016 1) Insert the spacers into bearings. 2) Check the play by moving the spacers up and down. Removal If excessive play is noted, replace the bearing with a 1) Remove the swingarm. Refer to “Swingarm Removal new ones.

  • Page 472

    2C-14 Rear Suspension: Installation 3) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) The removed bearings must be replaced with new ones. 1) Install the center spacer. 2) Press the bearings into the swingarm pivot with the special tool.

  • Page 473

    Rear Suspension: 2C-15 Specifications Service Data B838H22307001 Suspension Unit: mm (in) Item Standard Limit Rear shock absorber spring pre-set 182.3 (7.18) — length Rebound 1-3/4 turns from stiffed position — Rear shock absorber damping force Lo: 2 turns from stiffest position adjuster Compression —...

  • Page 474

    2C-16 Rear Suspension: Special Tools and Equipment Recommended Service Material B838H22308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-8) / (Page 2C- equivalent 9) / (Page 2C-14) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110...

  • Page 475: Wheels And Tires

    Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B838H22400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •...

  • Page 476

    2D-2 Wheels and Tires: Repair Instructions Front Wheel Components B838H22406001 I837H1240035-02 1. Front axle 6. Spacer 11. Collar : Apply thread lock to the thread part. 2. Brake disc bolt 7. Air valve 12. Front axle bolt : Do not reuse. 3.

  • Page 477

    Wheels and Tires: 2D-3 Front Wheel Assembly Construction B838H22406002 “ a ” I837H1240036-01 1. Brake disk bolt “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake caliper mounting bolt : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) : Apply grease. 3.

  • Page 478

    2D-4 Wheels and Tires: Front Wheel Assembly Removal and Installation 8) Remove the collar (4) (RH only). B838H22406003 NOTE Removal After removing the front wheel, fit the 1) Remove the under cowlings. Refer to “Exterior Parts calipers temporarily to the original positions. Removal and Installation in Section 9D (Page 9D- 11)”.

  • Page 479

    Wheels and Tires: 2D-5 3) Tighten the brake caliper mounting bolts (2) to the 6) Move the front fork up and down 4 or 5 times. specified torque. Tightening torque Front brake caliper mounting bolt (a): 39 N·m ( 3.9 kgf-m, 28.0 lb-ft) WARNING After remounting the brake calipers, pump the brake lever until the pistons push the...

  • Page 480

    2D-6 Wheels and Tires: Front Wheel Related Parts Inspection Wheel B838H22406004 1) Remove the brake pads. Refer to “Front Brake Pad Refer to “Front Wheel Assembly Removal and Replacement in Section 4B (Page 4B-2)”. Installation (Page 2D-4)”. 2) Make sure that the wheel runout checked as shown in the figure does not exceed the service limit.

  • Page 481

    CAUTION The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1240011-01 3) Remove the bearings (2) using the special tool. Special tool (B): 09921–20240 (Bearing remover set)

  • Page 482

    CAUTION The sealed cover of the bearing must face outside. I837H1240015-01 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1240014-01 I837H1240016-01 5) Install the front wheel assembly. Refer to“Front Wheel Assembly Removal and Installation (Page 2D-4)”.

  • Page 483

    Wheels and Tires: 2D-9 Rear Wheel Components B838H22406006 I837H1240038-01 1. Rear axel nut 9. Spacer : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Spacer 10. Air valve : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Dust seal 11. Rear wheel : 60 N⋅m (6.0 kgf-m, 43.0 lb-ft) 4.

  • Page 484

    2D-10 Wheels and Tires: Rear Wheel Assembly Construction B838H22406007 “ a” I837H1240039-03 1. Rear sprocket nut “a”: Clearance : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) 2. Rear axle nut : 60 N⋅m (6.0 kgf-m, 43.0 lb-ft) : Apply grease. 3. Brake disc bolt : 100 N⋅m (10 kgf-m, 72.5 lb-ft) : Apply thread lock to the thread part.

  • Page 485

    Wheels and Tires: 2D-11 Rear Wheel Assembly Removal and Installation Installation B838H22406008 1) Install the spacer (1) and collar (2). Removal 1) Loosen the axle nut (1). 2) Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block. CAUTION Make sure that the motorcycle is supported securely.

  • Page 486

    2D-12 Wheels and Tires: Sprocket Wheel Refer to “Drive Chain Related Components in Section 1) Remove the rear brake pads. Refer to “Rear Brake 3A (Page 3A-1)”. Pad Replacement in Section 4C (Page 4C-2)”. 2) Make sure that the wheel runout checked as shown Dust Seal in the figure does not exceed the service limit.

  • Page 487

    I837H1240027-02 Installation CAUTION The removed dust seal and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. I837H1240024-02 4) Remove the wheel dampers (3). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1240025-02 I649G1240019-02...

  • Page 488

    The sealed cover of the bearing must face outside. I837H1240028-01 4) Install the rear sprocket mounting drum assembly (2). 5) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240030-02 I838H1240004-01 “ a” I837H1240030-01 6) Install the rear wheel assembly.

  • Page 489

    Wheels and Tires: 2D-15 Tire Removal and Installation Installation B838H22406011 Removal CAUTION The most critical factor of a tubeless tire is the seal Do not reuse the valve which has been once between the wheel rim and the tire bead. For this removed.

  • Page 490

    2D-16 Wheels and Tires: 4) Install the valve core and inflate the tire. Wheel / Tire / Air Valve Inspection and Cleaning B838H22406012 Refer to “Tire Removal and Installation (Page 2D-15)”. WARNING Wheel • Do not inflate the tire to more than 400 kPa Wipe the wheel clean and check for the following points: (4.0 kgf/cm , 57 psi).

  • Page 491

    Wheels and Tires: 2D-17 Air Valve Installation Inspect the air valve for peeling and damage. If any Install the air valve in the reverse order of removal. Pay defect is found, replace the air valve with a new one. attention to the following points: Refer to “Air Valve Removal and Installation (Page 2D- •...

  • Page 492

    2D-18 Wheels and Tires: Wheel Balance Check and Adjustment 5) Recheck the wheel balance. B838H22406014 6) Install the mounting drum to the rear wheel. (For rear Check and adjust the wheel balance in the following wheel) procedures: Refer to “Rear Wheel Assembly Removal and 1) Removal the wheel assembly.

  • Page 493

    Wheels and Tires: 2D-19 Specifications Service Data B838H22407001 Wheel Unit: mm (in) Item Standard Limit Axial Wheel rim runout — 2.0 (0.08) Radial Front Wheel axle runout — 0.25 (0.010) Rear Front 17 M/C x MT3.50 — Wheel rim size Rear 17 M/C x MT5.50 —...

  • Page 494

    2D-20 Wheels and Tires: Special Tools and Equipment Recommended Service Material B838H22408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-7) / (Page 2D- equivalent 8) / (Page 2D-13) / (Page 2D-14) NOTE Required service material is also described in the following.

  • Page 495: Drive Chain / Drive Train / Drive Shaft

    Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation ......3A-3 Precautions............. 3-1 Drive Chain Related Parts Inspection ....3A-4 Precautions for Driveline / Axle ......3-1 Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation........3A-5 Drive Chain / Drive Train / Drive Shaft...

  • Page 496

    • Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is RK 525SMOZ7Y. Suzuki recommends to use this standard drive chain as a replacement.

  • Page 497

    Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B838H23104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

  • Page 498

    3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 7) Remove the speed sensor rotor (6) by removing its B838H23106002 bolt while depressing the rear brake pedal. Removal 1) Remove the gearshift link arm (1) by removing the bolt.

  • Page 499

    • Before installing the engine sprocket cover, apply a small quantity of grease to the clutch push rod. Removal : Grease 99000–25010 (SUZUKI SUPER 1) Remove the rear wheel assembly by disengaging GREASE A or equivalent) the drive chain. Refer to “Rear Wheel Assembly Removal and Installation in Section 2D (Page 2D- 11)”.

  • Page 500

    • Apply grease to the contacting surface between the rear wheel hub and rear sprocket mounting drum. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Apply a special tire lubricant or neutral soapy liquid to the wheel damper surface.

  • Page 501

    Drive Chain / Drive Train / Drive Shaft: 3A-5 Engine Sprocket and Rear Sprocket Sprocket Mounting Drum Dust Seal / Bearing Inspect the sprocket teeth for wear. If they are worn as Removal and Installation shown, replace the engine sprocket, rear sprocket and B838H23106005 drive chain as a set.

  • Page 502

    Special tool (B): 09921–20240 (Bearing remover set) I837H1310022-01 3) Apply grease to the retainer before installing the rear sprocket mounting drum. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1310021-02 Installation CAUTION The removed dust seal and bearing must be replaced with new ones.

  • Page 503

    Drive Chain / Drive Train / Drive Shaft: 3A-7 6) Install the spacer. Drive Chain Cutting 1) Set up the special tool as shown in the figure. I837H1310024-01 I649G1310024-02 7) Install the rear wheel assembly. Refer to “Rear 1. Tool body Wheel Assembly Removal and Installation in Section 2.

  • Page 504

    3A-8 Drive Chain / Drive Train / Drive Shaft: 4) Tighten the pressure bolt [A] (3) with the bar. Drive Chain Connecting WARNING Do not use joint clip type of drive chain. The joint clip may have a chance to drop which may cause severe damage to motorcycle and severe injury.

  • Page 505

    Drive Chain / Drive Train / Drive Shaft: 3A-9 4) Apply grease on the recessed portion of the joint 8) Continue pressing the joint plate until the distance plate holder (3) and set the joint plate (10). between the two joint plates comes to the specification.

  • Page 506

    3A-10 Drive Chain / Drive Train / Drive Shaft: 2) 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. CAUTION • After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.

  • Page 507

    Drive Chain / Drive Train / Drive Shaft: 3A-11 Special Tools and Equipment Recommended Service Material B838H23108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-3) / (Page 3A- equivalent 4) /...

  • Page 508

    3A-12 Drive Chain / Drive Train / Drive Shaft:...

  • Page 509: Brake Control System And Diagnosis

    Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Tightening Torque Specifications......4A-19 Special Tools and Equipment ......4A-20 Precautions............. 4-1 Recommended Service Material .......4A-20 Precautions for Brake System ......4-1 Special Tool ............4A-20 Brake Fluid Information ......... 4-1 Front Brakes ..........4B-1 Brake Control System and Diagnosis ...

  • Page 510

    4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B838H24000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B838H24000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.

  • Page 511

    Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B838H24102001 “a” “C” “B” “B” “ b ” “ c” “A” “ d ” I837H1410054-03 1. Hose clamp “B”: Clamp the brake hose firmly. “b”: 15°...

  • Page 512

    4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B838H24102002 “a” “ c” “b” “A” “ d” “B” I837H1410055-01 1. Stopper : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) “a”: 28° : After the brake hose union has contacted to the stopper, tighten the union bolt.

  • Page 513

    Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B838H24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.

  • Page 514

    4A-4 Brake Control System and Diagnosis: Repair Instructions Brake Pedal Height Inspection and Adjustment 2) Disconnect the rear brake light switch lead wire B838H24106001 coupler (1). Refer to “Brake System Inspection in Section 0B (Page 0B-17)”. Front Brake Light Switch Inspection B838H24106002 Inspect the front brake light switch in the following procedures:...

  • Page 515

    Brake Control System and Diagnosis: 4A-5 Brake Fluid Level Check 3) Squeeze and release the brake lever several times B838H24106005 in rapid succession and squeeze the lever fully Refer to “Brake System Inspection in Section 0B without releasing it. (Page 0B-17)”. Brake Hose Inspection B838H24106006 Refer to “Brake System Inspection in Section 0B...

  • Page 516

    4A-6 Brake Control System and Diagnosis: 8) Fill the reservoir with brake fluid to the upper mark of • Fill the reservoir with brake fluid to the upper mark of the reservoir. the reservoir. Place the reservoir cap to prevent dirt from entering.

  • Page 517

    Brake Control System and Diagnosis: 4A-7 • Fill the reservoir with brake fluid to the upper mark of 6) Loosen the air bleeder valve and pump the brake the reservoir. lever until the old brake fluid flows out of the brake system.

  • Page 518

    4A-8 Brake Control System and Diagnosis: 8) Fill the reservoir with brake fluid to the upper mark of 7) Loosen the air bleeder valve and pump the brake the reservoir. pedal until the old brake fluid flows out of the brake system.

  • Page 519

    Brake Control System and Diagnosis: 4A-9 9) Fill the reservoir with brake fluid to the upper mark of Rear Brake Hose Removal and Installation B838H24106010 the reservoir. Removal 1) Remove the brake fluid reservoir tank mounting bolt. 2) Drain brake fluid. Refer to “Brake Fluid Replacement (Page 4A-7)”.

  • Page 520

    4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Components B838H24106011 I837H1410056-02 1. Reservoir cap 8. Brake lever : 1 N⋅m (0.1 kgf-m, 0.7 lb-ft) 2. Insulator 9. Brake lever pivot bolt : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 3.

  • Page 521

    Brake Control System and Diagnosis: 4A-11 Front Brake Master Cylinder Assembly Removal Installation Install the front brake master cylinder in the reverse and Installation B838H24106012 order of removal. Pay attention to the following points: • When installing the master cylinder (1) onto the Removal handlebars (2), align the master cylinder holder’s 1) Drain brake fluid.

  • Page 522

    4A-12 Brake Control System and Diagnosis: • Bleed air from the master cylinder in the same manner 2) Remove the brake light switch (5) and brake lever as caliper side. (6). NOTE If air is trapped in the master cylinder, bleed air from the master cylinder first.

  • Page 523

    I837H1410032-01 7) Remove the connector (17), O-ring (18) and air bleeder valve (19). I837H1410035-01 • Apply grease to the push rod. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) I837H1410033-01 Assembly Assemble the master cylinder in the reverse order of disassembly.

  • Page 524

    4A-14 Brake Control System and Diagnosis: • Tighten the pivot bolt (1) and lock-nut (2) to the Front Brake Master Cylinder Parts Inspection B838H24106014 specified torque. Refer to “Front Brake Master Cylinder / Brake Lever Tightening torque Disassembly and Assembly (Page 4A-12)”. Brake lever pivot bolt (a): 1 N·m (0.1 kgf-m, 0.7 lb-ft) Master Cylinder...

  • Page 525

    Brake Control System and Diagnosis: 4A-15 Rear Brake Master Cylinder Components B838H24106015 I837H1410057-02 1. Reservoir cap 6. Brake hose 11. Push rod : Apply silicone grease. 2. Insulator 7. Brake hose union bolt 12. Dust boot : Apply thread lock to the thread part. 3.

  • Page 526

    4A-16 Brake Control System and Diagnosis: Rear Brake Master Cylinder Assembly Removal • Apply thread lock to the master cylinder mounting and Installation bolts (1) and tighten them to the specified torque. B838H24106016 Refer to “Rear Brake Hose Routing Diagram (Page 4A- : Thread lock cement 99000–32110 2)”.

  • Page 527

    BF: Brake fluid (DOT 4) Special tool : 09900–06108 (Snap ring pliers) I649G1410036-02 • Apply grease to the push rod end. : Grease 99000–25100 (SUZUKI Silicone I837H1410047-01 Grease or equivalent) 5) Remove the push rod (8), piston/cup set (9) and spring (10).

  • Page 528

    4A-18 Brake Control System and Diagnosis: Rear Brake Master Cylinder Parts Inspection Piston / Rubber Parts B838H24106018 Inspect the piston surface for any scratches or other Refer to “Rear Brake Master Cylinder Disassembly and damage. Assembly (Page 4A-16)”. Inspect the primary cup, secondary cup and dust boot for wear or damage.

  • Page 529

    Brake Control System and Diagnosis: 4A-19 Rear Brake Pedal Removal and Installation Installation B838H24106020 Removal CAUTION 1) Remove the master cylinder assembly. Refer to Replace the snap ring with a new one. “Rear Brake Master Cylinder Assembly Removal and Installation (Page 4A-16)”. Install the rear brake pedal as shown in the rear brake 2) Disconnect the rear brake light switch lead wire pedal construction.

  • Page 530

    4A-20 Brake Control System and Diagnosis: Special Tools and Equipment Recommended Service Material B838H24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-7) / (Page 4A- 8) / (Page 4A-13) / (Page 4A-17) Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100...

  • Page 531: Front Brakes

    Front Brakes: 4B-1 Front Brakes Brake Repair Instructions Front Brake Components B838H24206001 I837H1420022-02 1. O-ring 7. Front brake disc : Apply thread lock to the thread part. 2. Piston seal : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) : Apply brake fluid. 3.

  • Page 532

    4B-2 Front Brakes: Front Brake Pad Inspection 4) Clean up the caliper especially around the caliper B838H24206002 piston. The extent of brake pads wear can be checked by 5) Install the spring to caliper, bring its wider side of observing the grooved limit line “A” on the pads. When pawl “A”...

  • Page 533

    Front Brakes: 4B-3 8) Tighten the front brake caliper mounting bolts (4) and 2) Remove the brake hose from the caliper by front brake pad mounting pins (5) to the specified removing the union bolt (1) and catch the brake fluid torque.

  • Page 534

    4B-4 Front Brakes: Installation Front Brake Caliper Disassembly and Assembly B838H24206005 Install the brake caliper in the reverse order of removal. Refer to “Front Brake Caliper Removal and Installation Pay attention to the following points: (Page 4B-3)”. • Tighten each bolt to the specified torque. NOTE Tightening torque The right and left calipers are installed...

  • Page 535

    Front Brakes: 4B-5 4) Place a rag over the pistons to prevent it from Assembly popping out and then force out the pistons using Assemble the caliper in the reverse order of compressed air. disassembly. Pay attention to the following points: •...

  • Page 536

    4B-6 Front Brakes: • Install a new O-ring and reassemble caliper halves. Front Brake Caliper Parts Inspection B838H24206006 Refer to “Front Brake Caliper Disassembly and CAUTION Assembly (Page 4B-4)”. Replace the O-ring with a new one. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage.

  • Page 537

    Front Brakes: 4B-7 Brake Pad Spring Installation Inspect the brake pad spring for damage and excessive Install the front brake disc in the reverse order of bend. If any damage is found, replace it with a new one. removal. Pay attention to the following points: •...

  • Page 538

    4B-8 Front Brakes: Brake Disc Runout 1) Dismount the front brake caliper. Refer to “Front Brake Caliper Removal and Installation (Page 4B- 3)”. 2) Measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit.

  • Page 539

    Front Brakes: 4B-9 Special Tools and Equipment Recommended Service Material B838H24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) / (Page 4B- Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130 (Page 4B-7)

  • Page 540: Rear Brakes

    4C-1 Rear Brakes: Rear Brakes Brake Repair Instructions Rear Brake Components B838H24306001 I837H1430022-02 1. Rear caliper 7. Rear brake disc : 35 N⋅m (3.5 kgf-m, 2.5 lb-ft) 2. Piston seal 8. Brake pad spring : Apply silicone grease to sliding surface. 3.

  • Page 541

    Rear Brakes: 4C-2 Rear Brake Pad Inspection 3) Remove the brake pads (3) with the rear caliper B838H24306002 pivoted up. The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When NOTE the wear exceeds the grooved limit line, replace the When removing the pads, push the piston all...

  • Page 542

    4C-3 Rear Brakes: 6) Tighten the caliper mounting bolt (4) and pad 4) Pivot the caliper up and remove the caliper from the mounting pin (5) to the specified torque. caliper bracket. Tightening torque Rear brake caliper mounting bolt (a): 18 N·m ( 1.8 kgf-m, 13.0 lb-ft) Rear brake pad mounting pin (b): 16 N·m (1.6 kgf-m, 11.5 lb-ft)

  • Page 543

    Rear Brakes: 4C-4 Rear Brake Caliper Disassembly and Assembly 5) Remove the dust seal (7) and piston seal (8). B838H24306005 Refer to “Rear Brake Caliper Removal and Installation (Page 4C-3)”. Disassembly 1) Remove the pad spring (1), rubber boot (2) and sliding pin (3).

  • Page 544

    • Install the brake caliper to its bracket. I649G1420013-02 I837H1430020-01 • Apply grease to the inside of the rubber boot. Rear Brake Caliper Parts Inspection : Grease 99000–25100 (SUZUKI Silicone B838H24306006 Grease or equivalent) Refer to “Rear Brake Caliper Disassembly and Assembly (Page 4C-4)”.

  • Page 545

    Rear Brakes: 4C-6 Brake Caliper Sliding Pin Rear Brake Disc Removal and Installation B838H24306007 Inspect the brake caliper sliding pin for wear and other damage. If any damage is found, replace the sliding pin Removal with a new one. 1) Remove the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation in Section 2D (Page 2D-11)”.

  • Page 546

    4C-7 Rear Brakes: Rear Brake Disc Inspection 2) Measure the runout using the dial gauge. B838H24306008 Replace the disc if the runout exceeds the service Brake Disc Thickness limit. Check the brake disc for damage or cracks and measure Special tool the thickness using the micrometer.

  • Page 547

    Rear Brakes: 4C-8 Special Tools and Equipment Recommended Service Material B838H24308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-4) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-5) / (Page 4C-...

  • Page 548

    4C-9 Rear Brakes:...

  • Page 549

    Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Specifications .............5B-20 Service Data............5B-20 Precautions............. 5-1 Tightening Torque Specifications......5B-20 Precautions for Transmission / Transaxle..... 5-1 Special Tools and Equipment ......5B-21 Manual Transmission......5B-1 Recommended Service Material .......5B-21 Special Tool ............5B-21 Diagnostic Information and Procedures....5B-1 Manual Transmission Symptom Diagnosis ..

  • Page 550

    5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B838H25000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 551

    Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B838H25204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.

  • Page 552

    5B-2 Manual Transmission: Repair Instructions Transmission Components B838H25206001 I837H1520070-03 1. 2nd drive gear 11. 5th driven gear : 115 N⋅m (11.5 kgf-m, 83.0 lb-ft) 2. 6th drive gear 12. 1st driven gear : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 3. 3rd/4th drive gears 13.

  • Page 553

    Manual Transmission: 5B-3 Transmission Removal Gearshift Fork and Gearshift Cam B838H25206002 1) Remove the screws (1). 1) Remove the engine assembly from the frame. Refer 2) Remove the gearshift fork shaft (2). to “Engine Assembly Removal in Section 1D 3) Remove the gearshift cam (3) along with its bearing (Page 1D-19)”.

  • Page 554

    5B-4 Manual Transmission: 5) Remove the dowel pin (5). Bearing and Oil Seal 1) Remove the gearshift cam bearing (1) with the special tools. CAUTION Be careful not to lean the bearing remover. Special tool (A): 09923–74511 (Bearing remover) (B): 09930–30104 (Rotor remover slide shaft) I837H1520006-01 6) Remove the driveshaft right bearing case bolts.

  • Page 555

    Manual Transmission: 5B-5 4) Remove the driveshaft left bearing (4) with the Transmission Installation B838H25206003 special tool. Install the transmission in the reverse order of removal. Special tool Pay attention to the following points: (D): 09913–70210 (Bearing installer set) Bearing and Oil Seal CAUTION Replace the removed bearings and oil seals with new ones.

  • Page 556

    I837H1520019-03 • Install the dowel pin (3). • Apply grease to the oil seal lip. • Apply grease to the O-ring (4). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the O-ring (4) with a new one.

  • Page 557

    : Thread lock cement 99000–32110 Replace the O-ring (6) with a new one. (THREAD LOCK CEMENT SUPER 1322 or equivalent) : Grease 99000–25010 (SUZUKI SUPER Tightening torque GREASE A or equivalent) Driveshaft left bearing case bolt (b): 12 N·m (1.2 •...

  • Page 558

    5B-8 Manual Transmission: • With engaging each fork end to the cam groove, insert • Install the countershaft assembly to the upper the fork shaft (3). crankcase. • Apply thread lock to the screws and tighten them to NOTE the specified torque. Align the C-ring with the groove of bearing : Thread lock cement 99000–32110 and the bearing pin with the indent on the...

  • Page 559

    Manual Transmission: 5B-9 Transmission Construction B838H25206004 I837H1520068-01 1. Countershaft 2. Driveshaft Countershaft Gear / Driveshaft Gear • Remove the 6th drive gear snap ring (1) from its Disassembly and Assembly groove and slide it towards the 3rd/4th drive gears (2). B838H25206005 Refer to “Transmission Removal (Page 5B-3)”...

  • Page 560

    Refer to “Transmission Construction (Page 5B-9)”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • When installing a new snap ring (1), pay attention to its direction. Fit it to the side where the thrust is as shown in the figure.

  • Page 561

    Manual Transmission: 5B-11 Driveshaft • When installing the gear bushing onto the countershaft, align the shaft oil hole “A” with the • When installing the gear bushings onto the driveshaft, bushing oil hole “B”. align the shaft oil holes “A” with the bushing oil hole “B”.

  • Page 562

    5B-12 Manual Transmission: Gearshift Fork Groove Width Driveshaft Bearing Measure the gearshift fork groove width using the • Inspect the driveshaft left bearing for abnormal noise vernier calipers. and smooth rotation while it is in the case. Replace the bearing if there is anything unusual. Special tool Refer to “Transmission Removal (Page 5B-3)”...

  • Page 563

    Align the gear position switch pin “A” with Removal and Installation in Section 1G (Page 1G- the gearshift cam hole “B”. 9)”. : Grease 99000–25010 (SUZUKI SUPER 3) Remove the engine sprocket cover. Refer to “Engine GREASE A or equivalent) Sprocket Removal and Installation in Section 3A (Page 3A-2)”.

  • Page 564

    5B-14 Manual Transmission: Gearshift Lever Construction B838H25206009 “a” “b” “A” “c ” I837H1520073-02 “A”: Footrest top surface “b”: 30 mm (1.2 in) : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) : Apply grease. “a”: Approx. 4° 50’ “c”: 65 – 75 mm (2.6 – 3.0 in) : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) Gearshift Lever Removal and Installation B838H25206010...

  • Page 565

    Manual Transmission: 5B-15 Gearshift Shaft / Gearshift Cam Plate Components B838H25206012 I837H1520072-06 1. Gearshift shaft : 19 N⋅m (1.9 kgf-m, 13.5 lb-ft) : Apply thread lock to the thread part. 2. Gearshift cam drive plate : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft) : Apply thread lock to the thread part.

  • Page 566

    5B-16 Manual Transmission: Gearshift Shaft / Gearshift Cam Plate Removal 6) Remove the gearshift cam plate bolt (11) and gearshift cam plate (12). and Installation B838H25206014 7) Remove the gearshift cam stopper (13). 8) Remove the gearshift arm stopper (14). Removal 1) Remove the engine sprocket cover.

  • Page 567

    Manual Transmission: 5B-17 • Install the gearshift cam stopper (1), bolt (2), collar (3) • Apply a small quantity of thread lock to the gearshift and return spring (4). cam stopper plate bolt and tighten it to the specified torque. •...

  • Page 568

    5B-18 Manual Transmission: • Install the washer (6) and gearshift shaft assembly (7) Gearshift Linkage Inspection B838H25206015 as shown in the figure. Refer to “Gearshift Shaft / Gearshift Cam Plate Removal and Installation (Page 5B-16)”. NOTE Pinch the gearshift arm stopper (8) with Gearshift Shaft return spring ends “F”.

  • Page 569

    (A): 09921–20210 (Bearing remover) (B): 09930–30104 (Rotor remover slide shaft) I837H1520069-01 • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER I837H1520065-01 GREASE A or equivalent) Installation Install the oil seal and bearing in the reverse order of removal.

  • Page 570

    5B-20 Manual Transmission: Specifications Service Data B838H25207001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.761 (74/42) — Final reduction ratio 2.647 (45/17) — 2.785 (39/14) — 2.052 (39/19) — 1.714 (36/21) — Gear ratios 1.500 (36/24) —...

  • Page 571

    Manual Transmission: 5B-21 Special Tools and Equipment Recommended Service Material B838H25208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-6) / (Page 5B- equivalent 6) / (Page 5B-7) / (Page 5B-7) /...

  • Page 572

    5B-22 Manual Transmission: 09930–30104 Rotor remover slide shaft (Page 5B-4) / (Page 5B-...

  • Page 573

    Clutch: 5C-1 Clutch Transmission / Transaxle Precautions Precautions for Clutch System B838H25300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Schematic and Routing Diagram Clutch Cable Routing Diagram B838H25302001 Refer to “Throttle Cable Routing Diagram in Section 1D (Page 1D-2)”. Diagnostic Information and Procedures Clutch System Symptom Diagnosis B838H25304001...

  • Page 574

    5C-2 Clutch: Repair Instructions Clutch Lever Position Switch Inspection Clutch Cable Inspection B838H25306001 B838H25306002 Inspect the clutch lever position switch in the following Refer to “Clutch Cable Play Inspection and Adjustment procedures: in Section 0B (Page 0B-14)”. 1) Disconnect the clutch lever position switch lead Clutch Cable Removal and Installation wires (1).

  • Page 575

    Clutch: 5C-3 Clutch Control System Components B838H25306004 I837H1530049-04 1. Push rod 4. Clutch cable : 10 N⋅m (1.0 kgf-m, 0.7 lb-ft) 2. Clutch release camshaft : 1 N⋅m (0.1 kgf-m, 0.7 lb-ft) : Apply grease. 3. Clutch release arm : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Do not reuse.

  • Page 576

    5C-4 Clutch: Clutch Components B838H25306005 I837H1530047-02 1. Clutch pressure plate 8. Spring washer 15. Primary driven gear assembly 2. Clutch push piece 9. Spring washer seat 16. Push rod 3. No. 2 drive plate 10. Clutch sleeve hub : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 4.

  • Page 577

    Clutch: 5C-5 Clutch Removal 6) Remove the clutch springs and pressure plate (4). B838H25306006 NOTE 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”. Loosen the clutch spring set bolts little by 2) Lift and support the fuel tank with the prop stay. little and diagonally.

  • Page 578

    5C-6 Clutch: 9) Remove the thrust washer (9), bearing (10) and 13) Remove the clutch sleeve hub nut. clutch push piece (11). I837H1530010-02 14) Remove the conical spring washer (13), washer (14) I837H1530007-01 10) Remove the clutch push rod (12). and clutch sleeve hub (15).

  • Page 579

    Clutch: 5C-7 17) Remove the clutch lifter drive cam (19) and thrust 2) Install the spacer (2) and bearing (3), and apply washer (20). engine oil to them. I837H1530014-01 I837H1530018-02 18) Remove the spacer (21) and bearing (22). 3) Install the thrust washer (4). 19) Remove the primary driven gear assembly (23).

  • Page 580

    5C-8 Clutch: 7) Install the clutch lifter drive cam (8). 10) Tighten the clutch sleeve hub nut to the specified torque. Tightening torque Clutch sleeve hub nut (a): 95 N·m (9.5 kgf-m, 68.7 lb-ft) I837H1530020-02 8) Install the clutch sleeve hub (9), washer (10) and spring washer (11).

  • Page 581

    Clutch: 5C-9 13) Install the clutch push piece (13), bearing (14) and thrust washer (15) to the countershaft. NOTE Thrust washer (15) is located between the pressure plate and bearing (14). “C” 21 22 I837H1530029-01 18. No. 2 drive plate 19.

  • Page 582

    NOTE as shown in the figure. When install the pressure plate, fit the : Sealant 99000–31140 (SUZUKI BOND convex part “E” of the pressure plate onto No.1207B or equivalent) the concave part “F” of the clutch sleeve hub.

  • Page 583

    Clutch: 5C-11 24) Install the clutch cover and tighten the clutch cover Measure the claw width of drive plates with a vernier bolts. calipers. Replace the drive plates found to have worn down to the limit. NOTE Special tool Fit the new gasket washer to the bolt “G”. (A): 09900–20102 (Vernier calipers (1/20 mm, 200 mm)) Clutch drive plate claw width...

  • Page 584

    5C-12 Clutch: Clutch Spring Clutch Sleeve Hub and Primary Driven Gear Measure the free length of each coil spring with a vernier Assembly calipers, and compare the length with the specified limit. Inspect the slot of the clutch sleeve hub and primary Replace all the springs if any spring is not within the driven gear assembly for damage or wear caused by the limit.

  • Page 585

    Clutch: 5C-13 Clutch Lifter Pin Inspection and Adjustment 3) Inspect the height “A” of clutch lifter adjusting pin B838H25306009 screws at three positions using the thickness gauge. Refer to “Clutch Removal (Page 5C-5)” and “Clutch If the measurement is out of the specification, adjust Installation (Page 5C-7)”.

  • Page 586

    5C-14 Clutch: 7) Slowly turn in the adjusting pin screw (1) until resistance is felt. Tighten the lock-nut (2). Tightening torque Clutch lifter lock-nut: 23 N·m (2.3 kgf-m, 16.5 lb- I837H1530042-01 I837H1530046-02 Specifications Service Data B838H25307001 Clutch Unit: mm (in) Item Standard Limit...

  • Page 587

    Clutch: 5C-15 Special Tools and Equipment Recommended Service Material B838H25308001 Material SUZUKI recommended product or Specification Note Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 5C-7) Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 5C-10) / equivalent (Page 5C-10) NOTE Required service material is also described in the following.

  • Page 588

    5C-16 Clutch:...

  • Page 589: Steering General Diagnosis

    Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Steering Damper Construction......6B-6 Steering / Steering Damper Removal and Precautions............. 6-1 Installation ............6B-6 Precautions for Steering ........6-1 Steering / Steering Damper Related Parts Steering General Diagnosis....6A-1 Inspection............6B-9 Steering System Inspection ......6B-10 Diagnostic Information and Procedures....6A-1 Steering Stem Bearing Removal and...

  • Page 590

    6-1 Precautions: Precautions Steering Precautions Precautions for Steering B838H26000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 591

    Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B838H26104001 Condition Possible cause Correction / Reference Item Heavy steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.

  • Page 592

    6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Components B838H26206001 “A” I837H1620038-01 1. Throttle grip 5. Right handlebar “A”: Apply handle grip bond. 2. Grip rubber 6. Left handlebar : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Right handlebar switch box 7.

  • Page 593

    Steering / Handlebar: 6B-2 Handlebar Removal and Installation 3) Loosen the handlebar clamp bolts (10) and front fork B838H26206002 upper clamp bolts (11). Removal 1) Remove the following parts from the left handlebar. a) Left handlebar switch box (1) b) Handlebar balancer (2) c) Grip rubber (3) d) Disconnect the clutch cable (4) e) Clutch lever (5)

  • Page 594

    • Install the front brake master cylinder. Refer to “Front Brake Master Cylinder Assembly Removal and Installation in Section 4A (Page 4A-11)”. • Apply grease to the end of the throttle cables and cable pulley. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)

  • Page 595

    Steering / Handlebar: 6B-4 • Insert the projection “C” of the right handlebar switch • After installing the steering, the following adjustments box into the hole of the handlebars. are required before driving. – Throttle cable routing (Refer to “Throttle Cable Routing Diagram in Section 1D (Page 1D-2)”) –...

  • Page 596

    6B-5 Steering / Handlebar: Steering Components B838H26206004 I837H1620039-02 1. Steering stem head nut 7. Dust seal cover : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 2. Steering stem upper bracket 8. Dust seal : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft) 3. Handlebars 9.

  • Page 597

    Steering / Handlebar: 6B-6 Steering Damper Construction B838H26206005 I837H1620040-01 1. Steering damper 2. Dust seal 3. Bearing : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply grease. Steering / Steering Damper Removal and 6) Remove the steering damper (6). Installation B838H26206006 Removal Steering damper...

  • Page 598

    6B-7 Steering / Handlebar: 6) Lift and support the fuel tank. Refer to “Fuel Tank 12) It is not necessary to remove the ignition switch from Removal and Installation in Section 1G (Page 1G- the upper bracket when servicing the steering 9)”.

  • Page 599

    • Apply grease to the bearings, bearing races and dust bearings seat properly. seals before remounting the steering stem. • Loosen the steering stem nut 1/4 – 1/2 turn “a”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE This adjustment will vary from motorcycle to motorcycle.

  • Page 600

    4) Tighten the front fork upper and lower clamp bolts. Refer to “Front Fork Removal and Installation in Section 2B (Page 2B-2)”. Steering damper • Apply grease to the bearings and dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I837H1620028-01 I823H1620019-02...

  • Page 601

    Steering / Handlebar: 6B-10 Bearing Steering System Inspection B838H26206008 • Bearing wear or damage Refer to “Steering System Inspection in Section 0B • Abnormal bearing noise (Page 0B-19)”. • Race wear or damage Steering Stem Bearing Removal and Installation • Bearing lower seal damage B838H26206009 Removal 1) Remove the steering stem lower bracket.

  • Page 602

    6B-11 Steering / Handlebar: Installation Steering Tension Adjustment B838H26206010 Install the steering stem bearings in the reverse order of Check the steering movement in the following removal. Pay attention to the following points: procedures: CAUTION 1) By supporting the motorcycle with a jack, lift the front wheel unit is off the floor 20 –...

  • Page 603

    Steering / Handlebar: 6B-12 Specifications Tightening Torque Specifications B838H26207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Front fork upper clamp bolt 16.5 (Page 6B-3) Handlebar clamp bolt 16.5 (Page 6B-3) Steering stem head nut (Page 6B-3) / 65.0 (Page 6B-9) Steering stem nut 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) then turn back (Page 6B-8)

  • Page 604

    6B-13 Steering / Handlebar: Special Tools and Equipment Recommended Service Material B838H26208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-3) / (Page 6B- equivalent 8) / (Page 6B-9) Handle grip bond Handle Grip Bond (commercially —...

  • Page 605: Wiring Systems

    Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Passing Light Switch Inspection......9B-13 Dimmer Switch Inspection.........9B-14 Precautions............. 9-1 Specifications .............9B-14 Precautions for Electrical System ......9-1 Service Data............9B-14 Component Location ..........9-1 Tightening Torque Specifications......9B-14 Electrical Components Location ......9-1 Special Tools and Equipment ......9B-15 Wiring Systems........

  • Page 606: Body Structure

    9-ii Table of Contents Body Structure......... 9E-1 Rear Fender Construction........9D-4 Frame Cover Construction ........9D-5 Repair Instructions ..........9E-1 Frame Side Cover Cushion Attachment....9D-6 Body Frame Construction ........9E-1 Fuel Tank Cover Cushion Attachment ....9D-7 Front Footrest Bracket Construction ....9E-2 Rear View Mirror Construction ......9D-8 Side-stand Construction........9E-3 Rear View Mirror Cushion Attachment....9D-9 Pillion Footrest Construction .......9E-3...

  • Page 607

    Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B838H29000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B838H29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

  • Page 608

    9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B838H29102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”.

  • Page 609

    Wiring Systems: 9A-2 For E-03, 28, 33 I837H2910901-02...

  • Page 610

    9A-3 Wiring Systems: Wiring Harness Routing Diagram B838H29102002 “B” “A” “C” “D” “E” “G” “F” I837H1910901-03 1. Horn 10. Clamp 19. IAP sensor : Bind the wiring harness, CKP sensor lead wire, rear brake light switch lead wire, HO2 sensor lead wire and side-stand switch lead wire with the clamp.

  • Page 611

    Wiring Systems: 9A-4 “ a ” “ a ” “A” “C” “B” “D” I837H1910902-02 1. ECM cushion 7. Clamp “B”: Do not slacken the lead wires. : Bind the wiring harness and battery (–) lead wire with the clamp. Set the lock part of the clamp to inside. 2.

  • Page 612

    9A-5 Wiring Systems: “C” “B” “A” I837H1910903-04 1. CMP sensor 7. Clamp : 14 N⋅m (1.4 kgf-m, 10 lb-ft) : Fix the clamp in parallel with the cover surface. 2. CKP sensor “A”: White tape : 6.5 N⋅m (0.65 kgf-m, 4.7 lb-ft) 3.

  • Page 613

    Wiring Systems: 9A-6 “C” “B” “A” I837H1910904-04 1. HO2 sensor “B”: Pass the HO2 sensor lead wire between the frame and engine. 2. Clutch cable “C”: Pass the HO2 sensor lead wire rear of the clutch cable. 3. Oil pan : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) “A”: Pass the HO2 sensor lead wire inside the right side cowling.

  • Page 614

    9A-7 Wiring Systems: Specifications Service Data B838H29107001 Electrical Item Specification Note 15 A Headlight 10 A Ignition 15 A Fuse size Signal 10 A Fuel 10 A 15 A Main 30 A Tightening Torque Specifications B838H29107002 NOTE The specified tightening torque is also described in the following. “Wiring Harness Routing Diagram (Page 9A-3)”...

  • Page 615

    Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B838H29206001 I837H1920001-02 1. Headlight Low beam bulb (12 V 55 W, H11) 2. Headlight High beam bulb (12 V 60 W, HB3 x 2) 3. Position light bulb (12 V 5 W)

  • Page 616

    9B-2 Lighting Systems: Headlight Removal and Installation 6) Remove the headlight assembly (7) from body B838H29206002 cowling (8). Removal 1) Remove the body cowlings. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”. “A” 2) Remove the air intake pipes. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 11)”.

  • Page 617

    Lighting Systems: 9B-3 3) Remove the headlight bulb/socket (Low beam) (2) 8) Disconnect the position light coupler (5). by turning it counterclockwise. I837H1920011-02 9) Remove the back cover assembly (6) by turning it I837H1920007-01 4) Replace the headlight bulb (Low beam) with a new coupler clockwise.

  • Page 618

    9B-4 Lighting Systems: Headlight Beam Adjustment B838H29206004 Adjust the headlight beam, both horizontally and vertically. NOTE To adjust the headlight beam, adjust the beam horizontally first, then vertically. “B” I837H1920015-01 “B”: Horizontal adjuster “A” I837H1920014-02 “A”: Vertical adjuster Front Turn Signal Light Components B838H29206005 I837H1920016-02 1.

  • Page 619

    Lighting Systems: 9B-5 Front Turn Signal Light Removal and Front Turn Signal Light Bulb Replacement B838H29206007 Installation B838H29206006 CAUTION Removal When you touch the bulb with your bare 1) Remove the turn signal light assembly (1). hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

  • Page 620

    9B-6 Lighting Systems: Rear Lighting System Construction B838H29206008 I837H1920021-03 1. License plate light assembly : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Reflex reflector (E-03, 28, 33 only) : 1.8 N⋅m (0.18 kgf-m, 1.5 lb-ft) 3. Rear combination light screw : 2.8 N⋅m (0.28 kgf-m, 2.0 lb-ft) 4.

  • Page 621

    Lighting Systems: 9B-7 Rear Combination Light Removal and Installation Install the rear combination light in the reverse order of Installation B838H29206009 removal. Pay attention to the following point: Removal • Tighten the combination light mounting bolts (1) to the 1) Remove the frame cover assembly. Refer to specified torque.

  • Page 622

    9B-8 Lighting Systems: Rear Combination Light Replacement B838H29206010 CAUTION If LED operation is abnormal, replace the rear combination light with a new one. License Plate Light Components B838H29206011 I837H1920025-01 1. License plate light bulb (12 V 5 W) 3. Lens 2.

  • Page 623

    Lighting Systems: 9B-9 Installation License Plate Light Bulb Replacement B838H29206013 Install the license plate light in the reverse order of CAUTION removal. Pay attention to the following point: • Tighten the license plate light mounting nuts (1) to the When you touch the bulb with your bare specified torque.

  • Page 624

    9B-10 Lighting Systems: Rear Turn Signal Light Components B838H29206014 I837H1920034-02 1. Rear turn signal light lens 2. Rear turn signal light bulb (12 V 21 W) 3. Socket Rear Turn Signal Light Removal and Installation 5) Remove the side frame cover (3) from the center B838H29206015 frame cover (4).

  • Page 625

    Lighting Systems: 9B-11 Installation 1) Remove the rear turn signal light lens (1). Install the rear turn signal light in the reverse order of removal. Pay attention to the following point: • Insert the convex part “A” of the side frame cover to the hole “B”...

  • Page 626

    9B-12 Lighting Systems: Headlight Relay Inspection Turn Signal / Side-Stand Relay Removal and B838H29206018 Installation Refer to “Electrical Components Location in Section 0A B838H29206020 (Page 0A-8)”. Removal Inspect the headlight relay in the following procedure: 1) Remove the frame cover. Refer to “Exterior Parts 1) Remove the frame cover.

  • Page 627

    Lighting Systems: 9B-13 3) Inspect the hazard switch for continuity with a tester. Passing Light Switch Inspection B838H29206023 If any abnormality is found, replace the left Inspect the passing light switch in the following handlebar switch assembly with a new one. Refer to procedures: “Handlebar Removal and Installation in Section 6B 1) Remove the air cleaner box.

  • Page 628

    9B-14 Lighting Systems: Dimmer Switch Inspection 3) Inspect the dimmer switch for continuity with a tester. B838H29206024 If any abnormality is found, replace the left Inspect the dimmer switch in the following procedures: handlebar switch assembly with a new one. 1) Remove the air cleaner box.

  • Page 629

    Lighting Systems: 9B-15 Special Tools and Equipment Recommended Service Material B838H29208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9B-7) / (Page 9B- 1322 or equivalent Special Tool B838H29208002 09900–25008 Multi-circuit tester set...

  • Page 630

    9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B838H29301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).

  • Page 631

    Combination Meter / Fuel Meter / Horn: 9C-2 Repair Instructions Combination Meter Components B838H29306001 I838H1930001-01 1. Combination meter unit 2. Combination meter case 3. Combination meter cover Combination Meter Removal and Installation Installation B838H29306002 Install the combination meter in the reverse order of Removal removal.

  • Page 632

    9C-3 Combination Meter / Fuel Meter / Horn: Combination Meter Inspection 2) With the ADJ button (1) pressed, turn the ignition B838H29306004 switch ON. LED Inspection 3) Keep pushing the ADJ button for more than 3 to 5 Check that the LEDs (FI, fuel, engine RPM, indicator sec.

  • Page 633

    Combination Meter / Fuel Meter / Horn: 9C-4 3) Connect a variable resistor (2) between the terminals. I718H1930009-05 4) Turn the ignition switch ON. 5) Check the engine coolant temperature meter (3) and indicator light (LED) (4) operations when the resistance is adjusted to the specified values.

  • Page 634

    9C-5 Combination Meter / Fuel Meter / Horn: Fuel Level Indicator Inspection 3) Install the fuel pump. Refer to “Fuel Pump B838H29306007 Disassembly and Assembly in Section 1G (Page 1G- If the fuel level indicator light does not function properly, 11)”.

  • Page 635

    Combination Meter / Fuel Meter / Horn: 9C-6 Installation 3) Move a screwdriver back and forth across the pick- Install the speed sensor in the reverse order of removal. up surface of the speed sensor. The voltage readings should cycle as follows (0 V → 12 V or 12 V Pay attention to the following points: →...

  • Page 636

    9C-7 Combination Meter / Fuel Meter / Horn: 4) Check if the oil pressure indicator (LED) (2) will light Ignition Switch Inspection B838H29306015 up and LCD (3) will flicker when grounding the lead Inspect the ignition switch in the following procedures: wire (1).

  • Page 637

    Combination Meter / Fuel Meter / Horn: 9C-8 Ignition Switch Removal and Installation Horn Inspection B838H29306016 1) Disconnect the horn coupler (1). Refer to “Ignition Switch Removal and Installation in Section 1H (Page 1H-11)”. Horn Inspection B838H29306017 NOTE If the horn sound condition is normal, it is not necessary to inspect the horn button continuity.

  • Page 638

    9C-9 Combination Meter / Fuel Meter / Horn: Specifications Service Data B838H29307001 Wattage Unit: W Specification Item E-02, 19, 24 The other countries ← Combination meter light ← Turn signal indicator light ← High beam indicator light ← Neutral position indicator light FI indicator light/Oil pressure ←...

  • Page 639

    Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B838H29406001 “A” “B” “B” “A” “A” “A” “A” I837H1940026-02 “A”: To frame “B”: To headlight assembly : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)

  • Page 640

    9D-2 Exterior Parts: Body Cowling Cushion Attachment B838H29406002 I837H1940027-01 1. Cushion 2. Velcro fastening 3. Body cowling...

  • Page 641

    Exterior Parts: 9D-3 Under Cowling Heat Shield / Cushion Attachment B838H29406003 “ a ” I837H1940028-01 1. Cushion 2. Heat shield 3. Heat shield 4. Cushion “a”: 15 mm (0.59 in)

  • Page 642

    9D-4 Exterior Parts: Rear Fender Construction B838H29406004 I837H1940029-02 1. Rear fender (Front) 3. Plate 5. Rear fender (Lower) 7. Rivet 2. Rear fender (Rear) 4. Bracket 6. Bracket (For E-24) 8. Hooking...

  • Page 643

    Exterior Parts: 9D-5 Frame Cover Construction B838H29406005 “ a ” “ b ” Outside I837H1940030-02 1. Frame cover (Rear) 3. Frame cover (Center) 5. Frame cover (LH/RH) 7. Rear fender front cover “a”: 3 mm (0.12 in) 2. Cushion 4. Cushion 6.

  • Page 644

    9D-6 Exterior Parts: Frame Side Cover Cushion Attachment B838H29406006 “ a ” I837H1940031-02 1. Frame side cover 3. Cushion “a”: 15 mm (0.59 in) 2. Cushion 4. Double-faced adhesive tape : Adhere the cushion along the rib of the cover.

  • Page 645

    Exterior Parts: 9D-7 Fuel Tank Cover Cushion Attachment B838H29406007 I837H1940032-01 1. Fuel tank cover No. 2 2. Cushion 3. Velcro fastenings...

  • Page 646

    9D-8 Exterior Parts: Rear View Mirror Construction B838H29406008 I837H1940033-01 1. Body cowling 4. Turn signal lead wire 7. Mirror body 2. Cowling brace 5. Turn signal lead wire coupler : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Locate the turn signal lead wire coupler (5) between the mirror cover (6) and mirror body (7).

  • Page 647

    Exterior Parts: 9D-9 Rear View Mirror Cushion Attachment B838H29406009 “ a ” I837H1940034-03 1. Tape affix mark rib 4. Cushion : Align the cushion corner to the indicated point. 2. Tape “a”: 1.5 mm (0.06 in) : Tape should not run over the indicated line. 3.

  • Page 648

    9D-10 Exterior Parts: Fastener Removal and Installation Type B B838H29406010 Removal Type A 1) Pry up the head of fastener center piece (1) with a Removal screw driver. 1) Depress the head of fastener center piece (1). 2) Pull out the fastener “A”. 2) Pull out the fastener (2).

  • Page 649

    Exterior Parts: 9D-11 Exterior Parts Removal and Installation B838H29406011 Seat Tail Cover Front Seat Removal Remove the front seat by removing the bolts. I838H1940002-01 Installation Slide the seat hooks into the seat hook retainers and I837H1940001-03 push down firmly until the seat snaps into the locked Installation position.

  • Page 650

    9D-12 Exterior Parts: Installation Inner Under Cowling Install the windscreen in the reverse order of removal. Removal Pay attention to the following point: 1) Remove the body cowling cover. 2) Remove the inner under cowlings (1). NOTE The screws “A” are 3 mm shorter than the others.

  • Page 651

    Exterior Parts: 9D-13 3) Pull out the hooked points “A” from each lug hole 6) Disconnect the lead wire coupler (2) and remove the and remove the side cowling (2). wire clamp (3). “A” I837H1940011-04 I837H1940016-01 7) Disconnect the steering damper lead wire coupler “A”: Hooked point (4).

  • Page 652

    9D-14 Exterior Parts: Installation Cowling Brace Install the body cowling in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the body cowling. • Fit the lead wire clamp to the screw “A”. 2) Remove the cowling brace (1). “A”...

  • Page 653

    Exterior Parts: 9D-15 4) Remove the following fasteners. Installation Install the frame cover assembly in the reverse order of removal. Front Fender Removal Refer to “Front Fork Removal and Installation in Section 2B (Page 2B-2)”. Installation Refer to “Front Fork Removal and Installation in Section 2B (Page 2B-2)”.

  • Page 654

    9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction B838H29506001 I837H1950001-03 1. Frame 5. Adjuster : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Seat rail 6. Adjuster lock-nut : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) 3. Seat rail bolt 7.

  • Page 655

    Body Structure: 9E-2 Front Footrest Bracket Construction B838H29506002 “A” I837H1950002-03 1. Footrest bracket bolt 8. Rear brake pedal : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Rear master cylinder bolt 9. Footrest bracket No. 2 (Left) : 4.5 N⋅m (0.45 kgf-m, 3.0 lb-ft) 3.

  • Page 656

    9E-3 Body Structure: Side-stand Construction B838H29506003 I837H1950003-02 : 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) : Apply grease to sliding surface. Pillion Footrest Construction B838H29506004 I837H1950004-03 1. Footrest 2.

  • Page 657

    Body Structure: 9E-4 Side-stand Removal and Installation B838H29506005 Removal 1) Support the motorcycle with a jack or wooden block. CAUTION • Do not support the motorcycle with the exhaust pipes. • Make sure that the motorcycle is supported securely. 2) Remove the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction (Page 9E-3)”. Installation Install the side-stand as shown in the side-stand construction.

  • Page 658

    Prepared by February, 2008 Part No. 99500-37140-03E Printed in U.S.A.

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