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GSX-R1000
SERVICE MANUAL
9 9 5 0 0 - 3 9 3 8 0 - 0 1 E

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   Summary of Contents for Suzuki GSX-R1000

  • Page 1

    GSX-R1000 SERVICE MANUAL 9 9 5 0 0 - 3 9 3 8 0 - 0 1 E...

  • Page 2

    FOREWORD This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.

  • Page 3

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

  • Page 5

    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 6

    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 7

    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 8

    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 9

    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 10

    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 11

    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 12

    : 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 13: General Information

    Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Valve Clearance Inspection and Adjustment ..0B-5 Spark Plug Replacement ........0B-9 General Description ..........0A-1 Spark Plug Inspection and Cleaning ....0B-9 Symbols .............. 0A-1 Fuel Line Inspection ..........0B-10 Abbreviations ............

  • Page 14

    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 15

    ECM: Engine Control Module Engine Control Unit SAE: Society of Automotive Engineers (ECU) (FI Control Unit) SDS: Suzuki Diagnosis System ECT Sensor: Engine Coolant Temperature Sensor SRAD: Suzuki Ram Air Direct (ECTS) STC System: Secondary Throttle Control System Water Temp. Sensor (WTS) (STCS)

  • Page 16

    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 17

    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 18

    0A-5 General Information: Country and Area Codes B947H10101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX-R1000 K9 (E-02) U.K. JS1CY111100100001 – GSX-R1000 K9 (E-14) Thailand JS1CY121400100001 – GSX-R1000 K9 (E-19) E.U.

  • Page 19

    General Information: 0A-6 Warning, Caution and Information Labels Location B947H10101011 6, 7, 8, 9 6 (E-28) 1 (E-24), 2 1 (E-03, 33) 3, 21, 23 10, 11, 12 16, 17, 18, 19, 20 13, 14, 15 22, 24 I947H1010008-04 1. Noise label (For E-03, 24, 33) 16.

  • Page 20

    0A-7 General Information: Component Location Electrical Components Location B947H10103001 I947H1010006-06 1. Steering damper solenoid valve 9. Fuel level gauge 17. TO sensor 2. PAIR control solenoid valve 10. Fuel pump 18. CKP sensor 3. CMP sensor 11. Mode select switch/SDS coupler 19.

  • Page 21

    General Information: 0A-8 I947H1010007-02 23. Ignition switch/Immobilizer antenna (E-02, 19, 24, 51) 30. Turn signal/Side-stand relay 37. Horn 24. IAT sensor 31. Cooling fan relay 38. EXCV actuator 25. Secondary fuel injector 32. ECT sensor 39. Oil pressure switch 26. Primary fuel injector 33.

  • Page 22: Specifications

    0A-9 General Information: Specifications Specifications B947H10107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 045 mm (80.5 in) Overall width 720 mm (28.3 in) Overall height 1 130 mm (44.5 in) Wheelbase 1 405 mm (55.3 in) Ground clearance...

  • Page 23

    General Information: 0A-10 Chassis Item Specification Remark Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 125 mm (4.9 in) Rear wheel travel 130 mm (5.1 in) Caster 23° 50’ Trail 98 mm (3.86 in) Steering angle...

  • Page 24

    Small bore gauge (10 Small bore gauge (18 0.076 mm) 0.152 mm) – 18 mm) – 35 mm) 09900–25008 09900–25009 09904–41010 09913–50121 09913–70210 Multi circuit tester set Needle-point probe SUZUKI Diagnostic Oil seal remover Bearing installing set (10 – 75 Φ) system set...

  • Page 25

    General Information: 0A-12 09915–17410 09915–40610 09915–63311 09915–64512 09915–74521 Oil pressure gauge Oil filter wrench Compression gauge Compression gauge Adapter hose adapter attachment 09915–77331 09916–10911 09916–14510 09916–14522 09916–33210 Oil pressure gauge Valve lapper set Valve lifter Valve lifter attachment Valve guide reamer (1000 kPa) (4.5 mm) 09916–33320...

  • Page 26

    0A-13 General Information: 09925–18011 09930–10121 09930–11920 09930–11940 09930–11950 Bearing installer Spark plug wrench set Torx bit (JT40H) Torx bit holder Torx wrench (5 mm) 09930–11960 09930–30104 09930–30460 09930–34970 09930–40113 Torx wrench (4 mm) Rotor remover sliding Rotor remover bolt Rotor remover Flywheel rotor holder shaft 09930–44530...

  • Page 27

    General Information: 0A-14 09943–74111 09943–88211 09944–28321 99565–01010–020 Front fork oil level Pinion bearing installer Hexagon socket (19 CD-ROM Ver.20 gauge...

  • Page 28: Maintenance And Lubrication

    0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B947H10200001 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 29: Scheduled Maintenance

    Maintenance and Lubrication: 0B-2 Scheduled Maintenance Periodic Maintenance Schedule Chart B947H10205001 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace. T = Tighten. Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000...

  • Page 30

    0B-3 Maintenance and Lubrication: Lubrication Points B947H10205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. NOTE • Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. •...

  • Page 31

    Maintenance and Lubrication: 0B-4 3) Drain water from the air cleaner box by removing the Exhaust Control Valve Inspection B947H10206004 drain plug (1). Inspect exhaust control valve Initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter Inspect exhaust control valve as follows: 1) Remove the left side cowling.

  • Page 32

    0B-5 Maintenance and Lubrication: Valve Clearance Inspection and Adjustment B947H10206005 “A” “A” Inspect valve clearance “B” “B” Initially every 24 000 km (14 500 miles, 48 months) Inspection Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.

  • Page 33

    Maintenance and Lubrication: 0B-6 7) In this condition, read the valve clearance at the Adjustment valves “F” (IN and EX of No. 4 cylinder, EX of No. 3 The clearance is adjusted by replacing the existing and IN of No. 2). If the clearance is out of tappet shim with a thicker or thinner shim.

  • Page 34

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

  • Page 35

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

  • Page 36

    0B-9 Maintenance and Lubrication: 6) Install the camshafts and cam chain tension adjuster. 2) Measure the spark plug gap using a wire gauge. If it Refer to “Engine Top Side Assembly” in Section 1D is not within the specification, replace the spark plug. (Page 1D-28).

  • Page 37

    Maintenance and Lubrication: 0B-10 Fuel Line Inspection Engine Oil Replacement B947H10206008 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 38

    (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 39

    Maintenance and Lubrication: 0B-12 Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization B947H10206011 B947H10206013 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 40

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

  • Page 41

    Maintenance and Lubrication: 0B-14 Clutch Cable Play Inspection and Adjustment 7) From this position, turn out the clutch release B947H10206015 adjusting screw (6) 1 rotation, and tighten the lock- nut (5) while holding the screw (6). Inspect clutch cable play Every 6 000 km (4 000 miles, 12 months) Tightening torque Clutch release adjusting screw lock-nut: 6 N·m (...

  • Page 42

    0B-15 Maintenance and Lubrication: 2) Visually check the drive chain for the possible defects listed as follows. If any defects are found, the 1 2 3 19 20 21 drive chain must be replaced. Refer to “Drive Chain Replacement” in Section 3A (Page 3A-7). •...

  • Page 43

    “drive chain oil”. Such oil can damage the meets the following specification. O-rings. BF: Brake fluid (DOT 4) • The standard drive chain is a DID 50VAZ. SUZUKI recommends to use this standard drive chain as a replacement. “A” I947H1020023-01 I947H1020022-01...

  • Page 44

    0B-17 Maintenance and Lubrication: Brake Pads Check The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Front Brake Pad Replacement”...

  • Page 45

    Maintenance and Lubrication: 0B-18 Air Bleeding from Brake Fluid Circuit CAUTION Refer to “Air Bleeding from Brake Fluid Circuit” in The standard tire fitted on this motorcycle is Section 4A (Page 4A-4). 120/70 ZR17 M/C (58W) for front and 190/50 ZR17 M/C (73W) for rear.

  • Page 46

    0B-19 Maintenance and Lubrication: Front Fork Inspection Chassis Bolt and Nut Inspection B947H10206021 B947H10206023 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 47

    Maintenance and Lubrication: 0B-20 I947H1020043-02 I947H1020046-02 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Rear shock absorber bracket nut 115 N⋅m (11.5 kgf-m, 83.0 lbf-ft) Front axle bolt 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) Front axle pinch bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Front brake disc bolt 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) Front brake caliper mounting bolt 39 N⋅m (3.9 kgf-m, 28.0 lbf-ft) Brake caliper air bleeder valve 7.5 N⋅m (0.75 kgf-m, 5.5 lbf-ft)

  • Page 48

    0B-21 Maintenance and Lubrication: Compression Pressure Check B947H10206024 Refer to “Compression Pressure Check” in Section 1D (Page 1D-3). Oil Pressure Check B947H10206025 Refer to “Oil Pressure Check” in Section 1E (Page 1E- SDS Check B947H10206026 Refer to “SDS Check” in Section 1A (Page 1A-16). I947H1020049-04 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Brake caliper air bleeder valve 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft)

  • Page 49

    Maintenance and Lubrication: 0B-22 Special Tools and Equipment Recommended Service Material B947H10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-16) NOTE Required service material is also described in the following. “Lubrication Points” (Page 0B-3)

  • Page 50: Service Data

    0C-1 Service Data: Service Data General Information Specifications Service Data B947H10307001 Valve + Guide Unit: mm (in) Item Standard Limit 31.0 (1.22) — Valve diam. 25.0 (0.98) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...

  • Page 51

    Service Data: 0C-2 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 – 256 psi) (10 kgf/cm 142 psi) 200 kPa Compression pressure difference —...

  • Page 52

    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. 19.992 – 20.000 (0.7871 – 0.7874) — Oil Pump Item Standard Limit 100 – 400 kPa (1.0 – 4.0 kgf/cm , 14 –...

  • Page 53

    Service Data: 0C-4 Thermostat + Radiator + Cooling 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 54

    0C-5 Service Data: FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 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 55

    Service Data: 0C-6 Throttle Body Item Specification Bore size 44 mm (1.73 in) I.D. No. 47H1 (For E-33), 47H0 (For others) 1 150 ± 100 r/min Idle r/min Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) Electrical Unit: mm Item Specification...

  • Page 56

    0C-7 Service Data: Wattage Unit: W Specification Item E-02, 19, 24, 51 E-03, 14, 28, 33 ← Headlight ← ← Position light 5 x 2 ← Brake light/Taillight ← Turn signal light 21 x 4 ← License plate light ← Combination meter light ←...

  • Page 57

    75 (2.95) — outer tube fully compressed) 70 (2.76) 10 min. after adjustment Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 476 ml (16.1/16.8 US/lmp oz) — Front fork inner tube O.D.

  • Page 58

    0C-9 Service Data: Tightening Torque List B947H10307002 Engine Item N⋅m kgf-m lbf-ft Exhaust pipe bolt 16.5 Muffler chamber connecting bolt 21.5 Muffler chamber bracket bolt 18.0 Muffler chamber mounting bolt 16.5 Muffler connecting bolt 16.5 Muffler mounting bolt 18.0 Speed sensor rotor bolt 20.0 Speed sensor mounting bolt 0.65...

  • Page 59

    Service Data: 0C-10 Item N⋅m kgf-m lbf-ft 37 N⋅m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/6 Conrod cap bolt (60°) turn Breather cover bolt Oil pan bolt Oil cooler mounting bolt Driveshaft bearing case bolt (LH and RH) Driveshaft oil seal retainer screw Gearshift arm stopper 13.5 Gearshift cam stopper bolt...

  • Page 60

    0C-11 Service Data: Chassis Item N⋅m kgf-m lbf-ft Steering stem head nut 65.0 Steering stem lock-nut 58.0 Steering damper bolt 16.5 Steering damper nut 16.5 Front fork clamp bolt (Upper and Lower) 16.5 Front fork cap 25.5 Front fork piston rod nut 20.0 Rod guide case 65.0...

  • Page 61

    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 lbf-ft N⋅m kgf-m lbf-ft 0.15 0.23 0.45 0.55...

  • Page 62

    0C-13 Service Data:...

  • Page 63

    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-75 Precautions for Engine.......... 1-1 DTC “C28” (P1655): Secondary Throttle Engine General Information and Valve Actuator (STVA) Malfunction....1A-75 DTC “C29”...

  • Page 64

    1-ii Table of Contents Emission Control Devices ...... 1B-1 ECT Sensor Inspection ........1C-4 IAT Sensor Removal and Installation ....1C-5 Precautions............1B-1 IAT Sensor Inspection.........1C-5 Precautions for Emission Control Devices ..1B-1 AP Sensor Inspection..........1C-5 General Description ..........1B-1 AP Sensor Removal and Installation....1C-5 Fuel Injection System Description.......

  • Page 65

    Table of Contents 1-iii Camshaft Inspection .........1D-36 Oil Pressure Switch Inspection ......1E-10 Camshaft Sprocket ...........1D-38 Oil Jet Removal and Installation......1E-10 Cam Chain Tension Adjuster Inspection...1D-38 Oil Jet Inspection..........1E-12 Cam Chain Guide / Cam Chain Tensioner Oil Pump Removal and Installation ....1E-12 Removal and Installation.........1D-39 Oil Pump Inspection ..........1E-14 Cam Chain Guide Inspection ......1D-40...

  • Page 66

    1-iv Table of Contents Schematic and Routing Diagram....... 1G-3 Component Location ..........1I-1 Fuel Tank Drain Hose and Breather Hose Starting System Components Location ....1I-1 Routing Diagram ..........1G-3 Diagnostic Information and Procedures ..... 1I-1 Diagnostic Information and Procedures... 1G-4 Starting System Symptom Diagnosis ....

  • Page 67

    Table of Contents 1-v Exhaust System........1K-1 EXCVA Pulley Inspection........1K-9 EXCVA Adjustment ..........1K-9 Precautions............1K-1 Muffler / Muffler Chamber / Exhaust Pipe Precautions for Exhaust System ......1K-1 Removal and Installation.........1K-11 General Description ..........1K-1 Exhaust System Inspection.......1K-13 Exhaust Control System Description....1K-1 Specifications .............1K-14 Exhaust Control System Operation.....

  • Page 68

    1-1 Precautions: Precautions Engine Precautions Precautions for Engine B947H11000001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2).

  • Page 69: Engine General Information And Diagnosis

    Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine General Description Injection Timing Description B947H11101001 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 70

    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 71

    Engine General Information and Diagnosis: 1A-3 Self-Diagnosis Function B947H11101002 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 72

    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 73

    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/B Speed sensor 53*1 Lg/Bl O/Bl 65*1 Gr/W Gr/B Gr/Y Gr/R...

  • Page 74

    1A-6 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B947H11102002 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 75: Component Location, Fi System Parts Location

    Engine General Information and Diagnosis: 1A-7 Component Location FI System Parts Location B947H11103001 “I” “C” “J” “A” “D” “F” “B” “K” “H” “G” I947H1110005-01 “A”: ECM “E”: Intake air pressure sensor (IAPS) “I”: Fuel pump relay (FP relay) “B”: Throttle position sensor (TPS) “F”: EVAP system purge control solenoid valve (E-33 only) “J”: Fuel pump (FP) “C”: Secondary throttle position sensor (STPS)

  • Page 76

    1A-8 Engine General Information and Diagnosis: “Y” “M” “O” “S” “P” “A” “T” “Q” “R” “W” “U” “N” “L” “X” “V” I947H1110006-01 “A”: ECM “Q”: Camshaft position sensor (CMPS) “W”: Atmospheric pressure sensor (APS) “L”: Exhaust control valve actuator (EXCVA) “R”: Ignition coil (IG coil) “X”: Gear position switch (GP switch) “M”: Cooling fan relay...

  • Page 77

    Engine General Information and Diagnosis: 1A-9 Condition Possible cause Correction / Reference Item Engine will not start or is TP sensor out of adjustment. Adjust. hard to start (Incorrect Defective fuel pump. Replace. fuel/air mixture) Defective fuel pressure regulator. Replace. Defective TP sensor.

  • Page 78

    1A-10 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Noisy engine (Noise Worn down piston or cylinder. Replace. seems to come from Combustion chamber fouled with Clean. piston) carbon. Worn piston pin or piston pin bore. Replace.

  • Page 79

    Engine General Information and Diagnosis: 1A-11 Condition Possible cause Correction / Reference Item Engine runs poorly in Low fuel pressure. Repair or replace. high speed range Defective TP sensor. Replace. (Defective control circuit Defective IAT sensors. Replace. or sensor) Defective CMP sensor. Replace.

  • Page 80

    1A-12 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Dirty or heavy exhaust Too much engine oil. Check with inspection window, drain out smoke excess oil. Worn piston ring or cylinder. Replace. Worn valve guide. Replace. Scored or scuffed cylinder wall.

  • Page 81

    Removal and Installation” in Section 9D (Page 9D- 2) Set up the SDS tools. (Refer to the SDS operation manual for further details.) Special tool (A): 09904–41010 (SUZUKI Diagnostic I705H1110116-03 system set) 3) Click the DTC inspection button (1). (B): 99565–01010–020 (CD-ROM Ver.20)

  • Page 82

    1A-14 Engine General Information and Diagnosis: 4) Start the engine or crank the engine for more than 4 3) Check the DTC. seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part. still remains stored in the ECM.

  • Page 83

    Engine General Information and Diagnosis: 1A-15 Show Data When Trouble (Displaying Data at the Time of DTC) B947H11104004 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 84

    1) Remove the front seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6). 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) Special tool : 09904–41010 (SUZUKI Diagnostic system set) : 99565–01010–020 (CD-ROM Ver.20) NOTE •...

  • Page 85

    Engine General Information and Diagnosis: 1A-17 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 I947H1110146-01 Data at 3 000 r/min under no load Approx.

  • Page 86

    1A-18 Engine General Information and Diagnosis: 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 I947H1110148-01 Data of intake negative pressure during idling (100 °C)

  • Page 87

    Engine General Information and Diagnosis: 1A-19 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure. XXX kPa I947H1110150-01...

  • Page 88

    1A-20 Engine General Information and Diagnosis: 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 89

    Engine General Information and Diagnosis: 1A-21 Code Malfunction Part Remarks C25 (P0352) Ignition signal #2 (IG coil #2) For #2 cylinder (Page 1A-75) C26 (P0353) Ignition signal #3 (IG coil #3) For #3 cylinder (Page 1A-75) C27 (P0354) Ignition signal #4 (IG coil #4) For #4 cylinder (Page 1A-75) C28 (P1655)

  • Page 90

    1A-22 Engine General Information and Diagnosis: Fail-Safe Function Table B947H11104007 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 91

    Engine General Information and Diagnosis: 1A-23 Item Fail-Safe Mode Starting Ability Running Ability EVAP system purge control ECM stops controlling EVAP system purge “YES” “YES” solenoid valve (E-33 only) control solenoid valve. ECM stops controlling steering damper Vehicle speed sensor “YES”...

  • Page 92

    1A-24 Engine General Information and Diagnosis: 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 93

    Engine General Information and Diagnosis: 1A-25 Malfunction Code and Defective Condition Table B947H11104009 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 94

    1A-26 Engine General Information and Diagnosis: 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 95

    Engine General Information and Diagnosis: 1A-27 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 96

    1A-28 Engine General Information and Diagnosis: 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 97

    Engine General Information and Diagnosis: 1A-29 DTC “C11” (P0340): CMP Sensor Circuit Malfunction B947H11104010 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 98

    1A-30 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Y, R or B/Br wire • Inspect that metal open or shorted to particles or foreign 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 99

    Engine General Information and Diagnosis: 1A-31 Step Action 6) Under this condition, if a suitable screwdriver touching • B/Y, R or B/Br wire • Inspect that metal the pick-up surface of the CMP sensor is moved, the open or shorted to particles or foreign tester reading voltage changes (0.8 V and less ↔...

  • Page 100

    1A-32 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B947H11104011 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 101

    Engine General Information and Diagnosis: 1A-33 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 102

    1A-34 Engine General Information and Diagnosis: 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 103

    Engine General Information and Diagnosis: 1A-35 DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction B947H11104012 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 104

    1A-36 Engine General Information and Diagnosis: 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 105

    Engine General Information and Diagnosis: 1A-37 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”...

  • Page 106

    1A-38 Engine General Information and Diagnosis: Step Action 8) Check the continuity between the G/B wire and terminal Go to Step 3. G/B wire shorted to “19”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire and terminal “35”.

  • Page 107

    Engine General Information and Diagnosis: 1A-39 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 108

    1A-40 Engine General Information and Diagnosis: Step Action 8) Check the continuity between the R wire and terminal Go to Step 2. R and G/B wire open, G/ “7”. Also, check the continuity between the G/B wire and B wire shorted to terminal “19”.

  • Page 109

    Engine General Information and Diagnosis: 1A-41 Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum hose for crack or 2) Connect the ECM couplers and IAP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •...

  • Page 110

    1A-42 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”...

  • Page 111

    Engine General Information and Diagnosis: 1A-43 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B947H11104013 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 112

    1A-44 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 113

    Engine General Information and Diagnosis: 1A-45 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”...

  • Page 114

    1A-46 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 3. P/B wire shorted to “6”. Also, check the continuity between the B/Br wire and VCC, or B/Br wire open. terminal “35”.

  • Page 115

    Engine General Information and Diagnosis: 1A-47 P0120-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R or P/B wire open, or Y/W wire shorted to 2) Lift and support the fuel tank. Refer to “Fuel Tank ground.

  • Page 116

    1A-48 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the P/B wire and terminal Go to Step 2. R or P/B wire open, or “6”. Also, check the continuity between the R wire and Y/W wire shorted to terminal “7”.

  • Page 117

    Engine General Information and Diagnosis: 1A-49 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 ECM couplers and TP sensor couplers. ground, or poor “6”, sensor with a new one.

  • Page 118

    1A-50 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B947H11104014 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 119

    Engine General Information and Diagnosis: 1A-51 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) Remove the left side cowling. Refer to “Exterior Parts coupler.

  • Page 120

    1A-52 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) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6). 3) Check the ECT sensor coupler (1) for loose or poor contacts.

  • Page 121

    Engine General Information and Diagnosis: 1A-53 P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6). •...

  • Page 122

    1A-54 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-point probe set) Tester knob indication...

  • Page 123

    Engine General Information and Diagnosis: 1A-55 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B947H11104015 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 124

    1A-56 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 125

    Engine General Information and Diagnosis: 1A-57 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”...

  • Page 126

    1A-58 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 127

    Engine General Information and Diagnosis: 1A-59 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-point probe set) Tester knob indication...

  • Page 128

    1A-60 Engine General Information and Diagnosis: DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction B947H11104016 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 129

    Engine General Information and Diagnosis: 1A-61 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 couplers.

  • Page 130

    1A-62 Engine General Information and Diagnosis: P1450-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/Y wire shorted to VCC, or B/Br wire open. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation”...

  • Page 131

    Engine General Information and Diagnosis: 1A-63 Step Action 9) Check the continuity between the G/Y wire and terminal Go to Step 3. G/Y wire shorted to “20”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire and terminal “35”.

  • Page 132

    1A-64 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 133

    Engine General Information and Diagnosis: 1A-65 Step Action 9) Check the continuity between the R wire and terminal Go to Step 2. R and G/Y wire open, G/ “7”. Also, check the continuity between the G/Y wire and Y wire shorted to terminal “20”.

  • Page 134

    1A-66 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum port for crack or 2) Connect the ECM couplers and AP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •...

  • Page 135

    Engine General Information and Diagnosis: 1A-67 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”...

  • Page 136

    1A-68 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B947H11104017 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...

  • Page 137

    Engine General Information and Diagnosis: 1A-69 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”...

  • Page 138

    1A-70 Engine General Information and Diagnosis: 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”...

  • Page 139

    Engine General Information and Diagnosis: 1A-71 Step Action 8) Check the continuity between the B wire and terminal Go to Step 2. B wire shorted to VCC, “31”. Also, check the continuity between B/Br wire and or B/Br wire open. terminal “35”.

  • Page 140

    1A-72 Engine General Information and Diagnosis: 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”...

  • Page 141

    Engine General Information and Diagnosis: 1A-73 Step Action 8) Check the continuity between the R wire and terminal Go to Step 2. R or B wire open, or B “7”. Also, then check the continuity between B wire and wire shorted to ground. terminal “31”.

  • Page 142

    1A-74 Engine General Information and Diagnosis: 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 143

    Engine General Information and Diagnosis: 1A-75 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B947H11104018 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 B947H11104019 Detected Condition and Possible Cause Detected Condition...

  • Page 144

    1A-76 Engine General Information and Diagnosis: 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 cover.

  • Page 145

    Engine General Information and Diagnosis: 1A-77 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 146

    1A-78 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” (1). I947H1110128-01 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.

  • Page 147

    Engine General Information and Diagnosis: 1A-79 DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B947H11104020 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •...

  • Page 148

    1A-80 Engine General Information and Diagnosis: C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.

  • Page 149

    Engine General Information and Diagnosis: 1A-81 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”...

  • Page 150

    1A-82 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 3. Y/W wire shorted to “18”. Also, check the continuity between the B/Br wire VCC, or B/Br wire open. and terminal “35”.

  • Page 151

    Engine General Information and Diagnosis: 1A-83 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 152

    1A-84 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the Y/W wire and terminal Go to Step 2. R or Y/W wire open, or “18”. Also, check the continuity between the R wire and Y/W wire shorted to terminal “7”.

  • Page 153

    Engine General Information and Diagnosis: 1A-85 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 couplers and STP sensor couplers. ground, or poor “7”, STP sensor with a new 3) Remove the air cleaner box cover.

  • Page 154

    1A-86 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B947H11104021 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 155

    Engine General Information and Diagnosis: 1A-87 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 156

    1A-88 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction B947H11104022 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is •...

  • Page 157

    Engine General Information and Diagnosis: 1A-89 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”...

  • Page 158

    1A-90 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”...

  • Page 159

    Engine General Information and Diagnosis: 1A-91 DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction B947H11104023 Detected Condition and Possible Cause Detected Condition Possible Cause Some failure exists in the fuel injector signal in a high •...

  • Page 160

    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”...

  • Page 161

    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”...

  • Page 162

    1A-94 Engine General Information and Diagnosis: DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B947H11104024 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 163

    Engine General Information and Diagnosis: 1A-95 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 164

    1A-96 Engine General Information and Diagnosis: Step Action 1) Check the continuity between each ISC valve terminal If wire is OK, Replace the ISC valve and ground. intermittent trouble or with a new one. Refer to faulty ECM. “Throttle Body Removal Special tool and Installation”...

  • Page 165

    Engine General Information and Diagnosis: 1A-97 ACTIVE CONTROL INSPECTION (ISC RPM Check 2 CONTROL) 1) Click the button (4) and decrease the “Spec” (2) to 1 Check 1 050 rpm slowly. 1) Set up the SDS tool. (Refer to the SDS operation 2) Check that the “Desired idle speed”...

  • Page 166

    1A-98 Engine General Information and Diagnosis: 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 I947H1110158-01 rpm.

  • Page 167

    Engine General Information and Diagnosis: 1A-99 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 168

    1A-100 Engine General Information and Diagnosis: 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 frame covers. Refer to “Exterior Parts Removal and Installation”...

  • Page 169

    Engine General Information and Diagnosis: 1A-101 DTC “C41” (P2505): ECM Power Input Signal Malfunction B947H11104026 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 170

    1A-102 Engine General Information and Diagnosis: 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-6). Refer to “DTC “C41”...

  • Page 171

    Engine General Information and Diagnosis: 1A-103 DTC “C42” (P1650): IG Switch Circuit Malfunction B947H11104027 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 172

    1A-104 Engine General Information and Diagnosis: 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 173

    Engine General Information and Diagnosis: 1A-105 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 174

    1A-106 Engine General Information and Diagnosis: 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 175

    Engine General Information and Diagnosis: 1A-107 Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures” (Page 1A-14). Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.

  • Page 176

    1A-108 Engine General Information and Diagnosis: 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 177

    Engine General Information and Diagnosis: 1A-109 DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction B947H11104029 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 178

    1A-110 Engine General Information and Diagnosis: C46 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Go to Step 6. 2) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6). 3) Check the EXCVA coupler (1) for loose or poor contacts.

  • Page 179

    Engine General Information and Diagnosis: 1A-111 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) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation”...

  • Page 180

    1A-112 Engine General Information and Diagnosis: Step Action 8) Also, check the continuity between B/Br wire and Go to Step 4. Y wire shorted to VCC, terminal “35”. or B/Br wire open. Special tool (A): 09900–25008 (Multi circuit tester set) (B): 09900–25009 (Needle-point probe set) Tester knob indication Continuity (...

  • Page 181

    Engine General Information and Diagnosis: 1A-113 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) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation”...

  • Page 182

    1A-114 Engine General Information and Diagnosis: Step Action 9) Also, check the continuity between R wire and terminal Go to Step 2 and go to R or Y wire open, or Y “7”. Step 4. wire shorted to ground. Special tool (A): 09900–25008 (Multi circuit tester set) (B): 09900–25009 (Needle-point probe set) Tester knob indication...

  • Page 183

    Engine General Information and Diagnosis: 1A-115 Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Check the installation of EXCV cables. If it is necessary, coupler (terminal “7” adjust the EXCV cables.

  • Page 184

    1A-116 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 185

    Engine General Information and Diagnosis: 1A-117 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 coupler. inspect it again. 3) Set up the SDS tools. Refer to “Self-Diagnostic Procedures”...

  • Page 186

    1A-118 Engine General Information and Diagnosis: Step Action 9) Click “Full opened” (4). Replace the ECM with a Go to Step 5. known good one, and inspect it again. I947H1110098-02 10) Measure the EXCVA position sensor output voltage at EXCV fully opened position. Special tool (A): 09900–25008 (Multi circuit tester set) (B): 09900–25009 (Needle-point probe set)

  • Page 187

    Engine General Information and Diagnosis: 1A-119 Step Action 1) If the EXCVA position sensor output voltage is 0.45 V Replace the ECM with a Replace the EXCVA and less at EXCV fully closed position, adjust the output known good one, and with a new one.

  • Page 188

    1A-120 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 coupler (1). EXCVA or ECM • Inspect that the coupler (terminal “13”...

  • Page 189

    Engine General Information and Diagnosis: 1A-121 DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B947H11104030 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 190

    1A-122 Engine General Information and Diagnosis: 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”...

  • Page 191

    Engine General Information and Diagnosis: 1A-123 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 192

    1A-124 Engine General Information and Diagnosis: DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B947H11104031 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 193

    Engine General Information and Diagnosis: 1A-125 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 frame covers. Refer to “Exterior Parts ground, or poor “42”...

  • Page 194

    1A-126 Engine General Information and Diagnosis: 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 195

    Engine General Information and Diagnosis: 1A-127 DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only) B947H11104032 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 196

    1A-128 Engine General Information and Diagnosis: 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”...

  • Page 197

    Engine General Information and Diagnosis: 1A-129 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 198

    1A-130 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “EVAP purge valve operating control” (1). I947H1110139-01 4) Click each button (2). At this time, if an operating sound is heard from the EVAP system purge control valve, the function is normal.

  • Page 199

    Engine General Information and Diagnosis: 1A-131 DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction B947H11104033 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 200

    1A-132 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”...

  • Page 201

    Engine General Information and Diagnosis: 1A-133 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 202

    1A-134 Engine General Information and Diagnosis: DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction B947H11104034 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 203

    Engine General Information and Diagnosis: 1A-135 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 204

    1A-136 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch ON. • B/Bl (W) wire shorted • Low battery voltage to VCC, or poor “26” or fuse is blown. 2) Measure the voltage between B/Bl wire and ground. connection failure.

  • Page 205

    Engine General Information and Diagnosis: 1A-137 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). I947H1110141-01 5) Click each button (2) ON/OFF while turning the handlebars left and right.

  • Page 206

    1A-138 Engine General Information and Diagnosis: Specifications Service Data B947H11107001 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 0.5 V and more...

  • Page 207

    (Page 1A-102) / (Page 1A-54) / (Page 1A-104) / (Page 1A-56) / (Page 1A-105) / (Page 1A-57) / (Page 1A-106) (Page 1A-58) 09904–41010 09917–47011 SUZUKI Diagnostic system Vacuum pump gauge set (Page 1A-13) / (Page 1A-42) / (Page 1A-16) (Page 1A-67)

  • Page 208

    1A-140 Engine General Information and Diagnosis: 09930–82720 99565–01010–020 Mode selection switch CD-ROM Ver.20 (Page 1A-4) / (Page 1A- (Page 1A-13) / 12) / (Page 1A-12) (Page 1A-16)

  • Page 209

    Fuel Injection System Description B947H11201001 GSX-R1000 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 210

    1B-2 Emission Control Devices: Crankcase Emission Control System Description B947H11201002 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 211

    Emission Control Devices: 1B-3 Exhaust Emission Control System Description B947H11201003 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 ports through the PAIR control solenoid valve and PAIR reed valves.

  • Page 212

    1B-4 Emission Control Devices: PAIR System Diagram B947H11201006 “A” “B” I947H1120004-01 1. PAIR control solenoid valve 2. PAIR reed valve “A”: Fresh air “B”: Exhaust gas Noise Emission Control System Description B947H11201004 TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof: •...

  • Page 213

    Emission Control Devices: 1B-5 Among Those Acts Presumed to Constitute Tampering are the Acts Listed Below: • Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases. • Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air.

  • Page 214

    1B-6 Emission Control Devices: Schematic and Routing Diagram PAIR System Hose Routing Diagram B947H11202001 “F” “ b ” “C” “ a ” “B” “E” “D” “ b ” “A” “c ” “ b ” “B” I947H1120006-03 1. PAIR control solenoid valve “C”: Blue marking “a”: 90°...

  • Page 215

    Emission Control Devices: 1B-7 EVAP Canister Hose Routing Diagram (Only for E-33) B947H11202002 “A” “C” “D” “G” “F” “E” “B” “H” “J” “I” “L” “A” “K” I947H1120007-03 1. EVAP system purge control solenoid valve “A”: White marking “H”: Stick the clamp firmly in this area. 2.

  • Page 216

    1B-8 Emission Control Devices: Repair Instructions Heated Oxygen Sensor (HO2S) Removal and Installation Install the HO2 sensor in the reverse order of removal. Installation B947H11206001 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 217

    Emission Control Devices: 1B-9 4) Remove the PAIR reed valves (3). 3) Remove the PAIR control solenoid valve (1) along with the PAIR reed valve covers (2). I947H1120013-01 I947H1120015-02 Installation 4) Disconnect the PAIR control solenoid valve coupler Install the PAIR reed valve in the reverse order of (3).

  • Page 218

    1B-10 Emission Control Devices: 3) Inspect the PAIR hoses for wear or damage. If it is 2) Check that air flows through the air inlet port to the worn or damaged, replace the PAIR hose with a new air outlet ports. If air does not flow out, replace the one.

  • Page 219

    Installation is in the reverse order of removal. Pay attention to the following points: • Apply bond to the hatching part of crankcase breather (PCV) cover. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I947H1120022-01 4) Install the removed parts.

  • Page 220

    1B-12 Emission Control Devices: Crankcase Breather (PCV) Cover Inspection 3) Remove the EVAP canister (3) from the bracket. B947H11206008 Inspect the crankcase breather (PCV) cover in the following procedures: 1) Remove the crankcase breather (PCV) cover. Refer to “Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal and Installation”...

  • Page 221

    Emission Control Devices: 1B-13 Installation 6) Disconnect the license plate light coupler (2). Install the EVAP system purge control solenoid valve in the reverse order of removal. Pay attention to the following point: • Tighten the EVAP system purge control solenoid valve mounting nut to the specified torque.

  • Page 222

    1B-14 Emission Control Devices: 11) Disconnect the surge hose (9). EVAP Canister Inspect the EVAP canister for damage to the body. If any defect is found, replace the EVAP canister with a new one. I947H1120035-01 12) Move the rear fender (front) backward. 13) Disconnect the surge hose (10).

  • Page 223

    Emission Control Devices: 1B-15 3) Check the resistance between the terminals of the Fuel Shut-off Valve EVAP system purge control solenoid valve. If the WARNING resistance is not within the standard range, replace the EVAP system purge control solenoid valve with a Gasoline and gasoline vapor is toxic.

  • Page 224

    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 B947H11208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1B-11)

  • Page 225

    Engine Electrical Devices: 1C-1 Engine Electrical Devices 8Engine Precautions Precautions for Engine Electrical Device B947H11300001 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 B947H11303001 Refer to “Electrical Components Location”...

  • Page 226

    1C-2 Engine Electrical Devices: CMP Sensor Inspection CKP Sensor Removal and Installation B947H11306002 B947H11306005 Refer to “DTC “C11” (P0340): CMP Sensor Circuit Removal Malfunction” in Section 1A (Page 1A-29). 1) Remove the clutch cover. Refer to “Clutch Removal” in Section 5C (Page 5C-5). CMP Sensor Removal and Installation 2) Remove the CKP sensor (1).

  • Page 227

    Engine Electrical Devices: 1C-3 TP Sensor Removal and Installation 4) Check the position of the bar in the left of C code B947H11306009 displayed on the LCD panel. Refer to “Throttle Body Disassembly and Assembly” in Section 1D (Page 1D-11). Removal 1) Remove the throttle body.

  • Page 228

    1C-4 Engine Electrical Devices: ECT Sensor Removal and Installation ECT Sensor Inspection B947H11306011 B947H11306012 Removal Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction” in Section 1A (Page 1A-50). 1) Remove the left side cowling. Refer to “Exterior Inspect the ECT sensor in the following procedures: Parts Removal and Installation”...

  • Page 229

    Engine Electrical Devices: 1C-5 IAT Sensor Removal and Installation CAUTION B947H11306013 Removal • The IAT sensor operative temperature range is –30 – 120 °C (–22 – 248 °F). 1) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation” in Section 1D •...

  • Page 230

    1C-6 Engine Electrical Devices: TO Sensor Removal and Installation 2) Disconnect the STVA lead wire coupler (1). B947H11306018 Removal 1) Remove the AP sensor. Refer to “AP Sensor Removal and Installation” (Page 1C-5). 2) Disconnect the coupler (1) and remove the TO sensor (2).

  • Page 231

    Engine Electrical Devices: 1C-7 8) Tighten the STP sensor mounting screw to the STV Actuator Inspection B947H11306022 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- 75).

  • Page 232

    1C-8 Engine Electrical Devices: ISC Valve Preset and Opening Initialization NOTE B947H11306026 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 233

    Engine Electrical Devices: 1C-9 Specifications Service Data B947H11307001 FI Sensors Item Standard/Specification Note 142 – 194 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.

  • Page 234

    1C-10 Engine Electrical Devices: Special Tools and Equipment Special Tool B947H11308001 09900–25008 09900–25009 Multi circuit tester set Needle-point probe set (Page 1C-4) / (Page 1C- (Page 1C-6) 09930–11950 09930–82720 Torx wrench (5 mm) Mode selection switch (Page 1C-3) / (Page 1C- (Page 1C-3) 3) / (Page 1C-6) /...

  • Page 235: Engine Mechanical

    Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B947H11402001 I947H1140249-02...

  • Page 236

    1D-2 Engine Mechanical: Throttle Cable Routing Diagram B947H11402002 “A” “ a ” “ a ” “ a ” “B” “C” “D” I947H1140250-02 1. Throttle cable No. 1 “B”: Pass the clutch cable above the right air intake pipe. 2. Throttle cable No. 2 “C”: Clamp the clutch cable at the white taping point and make sure it does not slip out of the clamped position when steering.

  • Page 237

    Engine Mechanical: 1D-3 Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B947H11404001 Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-8). Compression Pressure Check B947H11404002 The compression pressure reading of a cylinder is a good indicator of its internal condition.

  • Page 238

    1D-4 Engine Mechanical: Repair Instructions Engine Components Removable with the Engine in Place B947H11406001 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 239

    Engine Mechanical: 1D-5 Engine Right Side Item Removal Inspection Installation Refer to “Cam Chain Tension Refer to “Engine Top Side Refer to “Engine Top Side Cam chain tension adjuster Adjuster Inspection” Disassembly” (Page 1D-26). Assembly” (Page 1D-28). (Page 1D-38). Refer to “Clutch Removal” in Refer to “Clutch Installation”...

  • Page 240

    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 241

    Engine Mechanical: 1D-7 Air Cleaner Box Removal and Installation 7) Remove the air cleaner box. B947H11406003 Removal 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G- 2) Remove the air cleaner box cover. Refer to “Air Cleaner Element Removal and Installation”...

  • Page 242

    1D-8 Engine Mechanical: Throttle Body Components B947H11406008 I947H1140252-03 1. Fuel delivery pipe 6. Secondary fuel injector 11. Vacuum hose : 6.5 Nm (0.65 kgf-m, 4.5 lbf-ft) 2. Fuel delivery pipe T-joint 7. Primary fuel injector 12. EVAP system purge control solenoid valve : 10 Nm (1.0 kgf-m, 7.0 lbf-ft) 3.

  • Page 243

    Engine Mechanical: 1D-9 Throttle Body Construction B947H11406009 “D” “A” “K” “G” “C” “B” “H” “7” “6” “2” “1” “5” “4” “3” “H” “3” “J” “5” “1” “6” “2” “4” “I” “F” “G” “E” I947H1140253-03 1. Intake pipe “C”: Face the end of clamps upward and keep clearance “K”: Face the clamp end right side.

  • Page 244

    1D-10 Engine Mechanical: Throttle Body Removal and Installation 10) Place a rag under the fuel feed hose (9) and B947H11406010 disconnect the fuel feed hose from the fuel pump. Removal 1) Remove the side cowlings. Refer to “Exterior Parts WARNING Removal and Installation”...

  • Page 245

    Engine Mechanical: 1D-11 14) Disconnect the throttle cables. • Connect the throttle cable No. 1 (3) and throttle cable No. 2 (4) to the throttle cable drum. CAUTION After disconnecting the throttle cables, do not snap the throttle valve from full open to “...

  • Page 246

    1D-12 Engine Mechanical: 2) Disconnect the purge hose (4). (E-33 only) 5) Remove the fuel pipe (9) from the primary fuel injectors (7). I947H1140299-01 3) Remove the fuel delivery pipe assembly (5). I947H1140010-01 6) Remove the T-joint (6) from the fuel delivery pipes. CAUTION Be careful not to twist the fuel delivery pipes and T-joint (6) when removing them, or joint...

  • Page 247

    “A” with the groove “B” of the STP sensor. • Apply grease to the secondary throttle valve shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool I947H1140014-01 : 09930–11950 (Torx wrench (5 mm))

  • Page 248

    “D” of the TP sensor. 1.5 lbf-ft) • Apply grease to the throttle valve shaft end “C” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool : 09930–11950 (Torx wrench (5 mm)) Tightening torque TP sensor mounting screw: 3.5 N·m (0.35 kgf-m,...

  • Page 249

    Engine Mechanical: 1D-15 • Apply thin coat of engine oil to the new O-rings (1) and • Install each fuel injector by pushing it straight to the cushion seals (2). delivery pipe. CAUTION CAUTION Replace the O-rings and cushion seals with Never turn the injector while pushing it.

  • Page 250

    1D-16 Engine Mechanical: Throttle Body Inspection and Cleaning ISC Valve Visual Inspection B947H11406012 B947H11406013 Refer to “Throttle Body Disassembly and Assembly” Visually inspect the ISC valve if necessary. (Page 1D-11). • Inspect the ISC valve for any carbon deposition defects. Clean or replace the ISC valve if necessary. Cleaning WARNING Some carburetor cleaning chemicals,...

  • Page 251

    Engine Mechanical: 1D-17 5) Disconnect the respective vacuum hoses (2) from 9) Start the engine. vacuum nipples on the throttle body. 10) Click “Data monitor”. 6) Disconnect the IAP sensor coupler (3). 11) Warm up the engine (Engine coolant temp. more than 80 °C (176 °F)).

  • Page 252

    1D-18 Engine Mechanical: 15) Check for the synchronization of vacuum from #1 to ISC Valve Reset B947H11406015 #4 cylinders. When removing or replacing the throttle body assembly, reset the ISC valve learned value in the following procedures: 1) Turn the ignition switch ON position. 2) Set up the SDS tools.

  • Page 253

    Engine Mechanical: 1D-19 NOTE 5) Click the “Reset” button (2) to clear the TP learned value. The learned value of the ISC valve is set at RESET position. I947H1140303-01 6) Close the SDS tool. 7) Turn the ignition switch OFF position. NOTE I947H1140305-01 The ISC valve opening initialization is...

  • Page 254

    1D-20 Engine Mechanical: Engine Assembly Removal 11) Remove the radiator assembly. Refer to “Radiator / B947H11406017 Cooling Fan Motor Removal and Installation” in Before taking the engine out of the frame, wash the Section 1F (Page 1F-6). engine using a steam cleaner. Engine removal is 12) Disconnect the water/air bleed hose (2) and radiator sequentially explained in the following steps: inlet hose (3).

  • Page 255

    Engine Mechanical: 1D-21 15) Remove the exhaust system components. Refer to 21) Remove the crankcase breather (PCV) hose (15). “Muffler / Muffler Chamber / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K-11). 16) Remove the clamp (7). 17) Disconnect the oil pressure switch lead wire coupler (8), generator lead wire coupler (9) and ECT sensor coupler (10).

  • Page 256

    1D-22 Engine Mechanical: 25) Remove the engine sprocket cover (19). Refer to 28) Support the engine using an engine jack. “Engine Sprocket Removal and Installation” in Section 3A (Page 3A-2). I947H1140274-01 29) Loosen the engine mounting pinch bolts (22) (RH). I947H1140271-02 30) Remove the engine mounting bolts (23) (RH).

  • Page 257

    Engine Mechanical: 1D-23 34) Loosen the engine mounting thrust adjuster (27) 37) Loosen the engine mounting thrust adjuster (30) fully. fully. Special tool Special tool (A): 09940–14990 (Engine mounting adjust (A): 09940–14990 (Engine mounting adjust wrench) wrench) NOTE NOTE Do not remove the engine mounting bolt at Do not remove the engine mounting bolt at this stage.

  • Page 258

    1D-24 Engine Mechanical: Engine Assembly Installation B947H11406018 Install the engine in the reverse order of engine removal. Pay attention to the following points: • Before installing the engine, install the collars (1). I947H1140285-02 I947H1140282-01 • Before installing the engine, install the engine mounting thrust adjusters (2).

  • Page 259

    Engine Mechanical: 1D-25 • Tighten all engine mounting bolts and nuts to the • Tighten the engine mounting pinch bolt to the specified torque, as shown in the following illustration. specified torque, as shown in the following illustration. NOTE The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.

  • Page 260

    1D-26 Engine Mechanical: • Install the engine sprocket. Refer to “Engine Sprocket Engine Top Side Disassembly B947H11406019 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 “Muffler / Muffler Chamber / Exhaust Pipe Removal camshafts.

  • Page 261

    Engine Mechanical: 1D-27 Camshafts 3) Remove the cam chain tension adjuster (2). 1) Remove the valve timing inspection cap (1). I947H1140034-02 4) Remove the gasket (3). I947H1140030-01 2) Turn the crankshaft to bring the line “A” on the CKP sensor rotor to the slit “B” of cap hole thread and also to bring the camshafts to the position as shown.

  • Page 262

    1D-28 Engine Mechanical: 8) Remove the intake camshaft (6) and exhaust 4) Remove the cylinder head. camshaft (7). I947H1140040-01 5) Remove the dowel pins and cylinder head gasket I947H1140037-01 (3). Cylinder Head NOTE The cylinder head can not be serviced with the engine installed in the frame.

  • Page 263

    Engine Mechanical: 1D-29 • Place the cylinder head on the gasket. • After firmly tightening the cylinder head bolts (M10), tighten the cylinder head bolts (M6) (2). NOTE Tightening torque • When installing the cylinder head, keep the Cylinder head bolt (M6) (a): 10 N·m (1.0 kgf-m, 7.0 cam chain taut.

  • Page 264

    1D-30 Engine Mechanical: • Turn the crankshaft clockwise and align the line “A” on • Bind the cam chain and the sprocket with a proper the CKP sensor rotor to the slit “B” of cap hole thread clamp (1) to prevent the cam chain disengagement while keeping the cam chain pulled upward.

  • Page 265

    Engine Mechanical: 1D-31 I947H1140051-01 • Install the dowel pins. “F” I947H1140053-02 • Tighten the camshaft journal holder bolts in ascending I947H1140052-01 • Install the camshaft journal holders and cam chain order of numbers to the specified torque. guide No. 2 (3). Tightening torque •...

  • Page 266

    1D-32 Engine Mechanical: (3) 11 (1) 7 (2) 8 (4) 12 (2) 6 (1) 5 I947H1140054-03 • Remove the clamps. “C” “A” “B” I823H1140365-01 I947H1140055-01 Cam Chain Tension Adjuster • Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body until the outer circlip “A”...

  • Page 267

    Engine Mechanical: 1D-33 • Hook the outer circlip “A” into the groove “B”, then turn • Rotate the crankshaft (some turns) and recheck the the plunger head clockwise more than 90° to make a valve timing. little play in the inner thread mechanism. CAUTION Make sure that the adjuster works properly by checking no slack at point “D”.

  • Page 268

    • Install new gaskets to the cylinder head cover. to the specified torque. • Apply bond to the cam end cap points of the gasket as shown. CAUTION : Sealant 99000–31140 (SUZUKI BOND Use a new gasket to prevent oil leakage. No.1207B or equivalent) Tightening torque CAUTION Cam chain tension adjuster service cap (b): 23 Use new gaskets to prevent oil leakage.

  • Page 269

    Engine Mechanical: 1D-35 • Tighten the cylinder head cover bolts to the specified 4) Remove the PAIR reed valves (5) and CMP sensor torque in two steps. (6). Tightening torque Cylinder head cover bolt (Initial): 10 N·m (1.0 kgf- m, 7.0 lbf-ft) Cylinder head cover bolt (Final): 14 N·m (1.4 kgf- m, 10.0 lbf-ft) I947H1140103-02...

  • Page 270

    1D-36 Engine Mechanical: • Apply thread lock to the PAIR reed valve cover bolts PAIR Reed Valve (2) and tighten them to the specified torque. Inspect the PAIR reed valves for carbon deposit. If the carbon deposit is found, replace the reed valve with a : Thread lock cement 99000–32110 new one.

  • Page 271

    Engine Mechanical: 1D-37 Camshaft Runout 3) Install each camshaft journal holder to its original Measure the runout using the dial gauge. Replace the position. Refer to “Engine Top Side Assembly” camshaft if the runout exceeds the limit. (Page 1D-28). 4) Tighten the camshaft journal holder bolts in Special tool ascending order of numbers to the specified torque.

  • Page 272

    1D-38 Engine Mechanical: 7) If the camshaft journal oil clearance exceeds the Camshaft Sprocket B947H11406022 limit, measure the inside diameter of the camshaft Inspect the camshaft sprocket in the following journal holder and the outside diameter of the procedures: camshaft journal. Replace the camshaft or the 1) Remove the intake and exhaust camshafts.

  • Page 273

    Engine Mechanical: 1D-39 3) Hook the outer circlip “A” into the groove “B”, then 4) Check that the plunger goes out automatically when turn the plunger head clockwise more than 90° to its head “D” is tapped. If it does not work smoothly, make a little play in the inner thread mechanism.

  • Page 274

    1D-40 Engine Mechanical: Installation Cylinder Head Disassembly and Assembly B947H11406027 Install the cam chain guides/cam chain tensioner in the Refer to “Engine Top Side Disassembly” (Page 1D-26). reverse order of removal. Refer to “Engine Top Side Assembly” (Page 1D-28). Cam Chain Guide Inspection CAUTION B947H11406025 Inspect the cam chain guide in the following procedures:...

  • Page 275

    Engine Mechanical: 1D-41 5) Pull out the valve (6) from the combustion chamber 11) Remove the bypass hose union (12). side. I947H1140076-01 12) Remove the oil jet (13). I947H1140073-01 6) Remove the oil seal (7) and spring seat (8). 7) Remove the other valves in the same manner as described previously.

  • Page 276

    Replace the O-rings with new ones. I947H1140083-01 • Apply bond to the thread part of bypass hose union (4) and tighten it to the specified torque. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Bypass hose union (d): 12 N·m (1.2 kgf-m, 8.5 lbf-...

  • Page 277

    Engine Mechanical: 1D-43 • Tighten the thermostat cover bolts (6) to the specified torque. Tightening torque Thermostat cover bolt (e): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) “B” I947H1140087-01 • Insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break.

  • Page 278

    1D-44 Engine Mechanical: • Put on the valve spring retainer (10), and using the • Install the tappet shims and the tappets to their special tools, press down the springs, fit the cotter original positions. halves to the stem end, and release the lifter to allow NOTE the cotter halves to wedge in between retainer and stem.

  • Page 279

    Engine Mechanical: 1D-45 Valve Stem Runout Valve Stem and Valve Face Wear Condition Support the valve using V-blocks, as shown in the figure, Visually inspect each valve stem and valve face for wear and check its runout using the dial gauge. If the runout and pitting.

  • Page 280

    1D-46 Engine Mechanical: Valve Stem Wear Measure the valve stem O.D. using the micrometer. If it is out of specification, replace the valve with a new one. If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, recheck the deflection.

  • Page 281

    Engine Mechanical: 1D-47 4) Check that the transferred red lead (blue) on the Valve Guide Replacement B947H11406029 valve face is uniform all around and in center of the 1) Remove the cylinder head. Refer to “Engine Top valve face. Side Disassembly” (Page 1D-26). If the seat width “a”...

  • Page 282

    1D-48 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 283

    Engine Mechanical: 1D-49 Valve Seat Repair Engine Bottom Side Disassembly B947H11406030 B947H11406031 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 284

    1D-50 Engine Mechanical: Gearshift System 2) Remove the cam chain tensioner (2) and cam chain Remove the gearshift shaft (1) and gearshift cam plate guide No. 1 (3). (2). Refer to “Gearshift Shaft / Gearshift Cam Plate 3) Remove the cam chain drive sprocket (4) and cam Removal and Installation”...

  • Page 285

    Engine Mechanical: 1D-51 2) Remove the water pump (2). I947H1140119-01 I947H1140116-01 Oil Pan Gear Position Switch 1) Remove the plate (1). Remove the gear position switch (1). 2) Remove the oil pan (2) and gasket. I947H1140117-01 I947H1140297-01 Oil Pressure Switch Oil Pressure Regulator / Oil Strainer Remove the oil pressure switch lead wire (1) and switch 1) Remove the oil pressure regulator (1).

  • Page 286

    1D-52 Engine Mechanical: Oil Pump Crankcase 1) Remove the spacer (1) and bearing (2). 1) Remove the clutch push rod oil seal retainer (1). I947H1140126-01 I947H1140123-01 2) Remove the oil pump drive sprocket (3) and chain 2) Remove the cap (2). (4).

  • Page 287

    Engine Mechanical: 1D-53 5) Remove the crankshaft journal bolts (M9). Transmission Remove the transmission component. Refer to “Transmission Removal” in Section 5B (Page 5B-3). I947H1140130-01 6) Make sure that all of the bolts are removed. Then, tap the sides of the lower crankcase using a plastic I947H1140133-01 hammer to separate the upper and lower crankcase halves and then lift the lower crankcase off the upper...

  • Page 288

    1D-54 Engine Mechanical: 3) Remove the crankshaft (1) and thrust bearings (2). I947H1140140-01 2) Remove the piston pin circlip (1). I947H1140137-01 Piston Cooling Oil Jet Remove the piston cooling oil jet (1) from the upper crankcase. I947H1140141-01 3) Draw out the piston pin (2) and remove the piston from the conrod.

  • Page 289

    Engine Mechanical: 1D-55 Crankshaft Journal Bearing Oil Jet Remove the crankshaft journal bearings, upper and Remove the oil jet (1) (for transmission) from the lower lower. crankcase. CAUTION • When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.

  • Page 290

    1D-56 Engine Mechanical: 2) Remove the oil gallery plug (4) from the upper Breather Oil Return Plate crankcase. Remove the breather oil return plate (1) from the upper crankcase. I947H1140149-01 I947H1140153-01 Water Jacket Plug Remove the water jacket plugs (1) from the upper Engine Bottom Side Assembly crankcase.

  • Page 291

    Engine Mechanical: 1D-57 • Tighten each plug to the specified torque. CAUTION Replace the O-rings with new ones. Tightening torque Water jacket plug (a): 9.5 N·m (0.95 kgf-m, 6.9 lbf- I947H1140157-01 • Tighten the oil gallery plugs to the specified torque. Tightening torque Oil gallery plug (M26) (c): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

  • Page 292

    1D-58 Engine Mechanical: Crankshaft Journal Bearing • Install the piston pin circlips (1). When fitting the crankshaft journal bearings to the upper CAUTION and lower crankcases, be sure to fix the stopper part “A” first and press the other end. Use new piston pin circlips (1) to prevent circlip failure which will occur when it is bent.

  • Page 293

    Engine Mechanical: 1D-59 • Install the pistons with conrods into the cylinders from topside using the special tool. NOTE When installing the pistons, the indent “D” of each piston head must be brought to the exhaust side. Special tool (A): 09916–77310 (Piston ring compressor) “D”...

  • Page 294

    1D-60 Engine Mechanical: 2) Position the No. 2 and No. 3 conrod big ends on the 6) Apply engine oil to the conrod cap bolts. same side, and the No. 1 and No. 4 conrod big ends on the opposite side of No. 2 and No. 3. “A”...

  • Page 295

    Engine Mechanical: 1D-61 10) Check the conrod movement for smooth turning. I947H1140179-01 I947H1140176-01 Balancer Shaft 11) Insert the right and left thrust bearings with the oil • Apply a molybdenum oil solution to each balancer grooves “B” facing towards the crankshaft web. shaft journal and bearing lightly.

  • Page 296

    • 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) I947H1140182-02 I947H1140183-02 : Apply bond.

  • Page 297

    Engine Mechanical: 1D-63 • Tighten the crankshaft journal bolts (M9). Tighten each bolt a little at a time to equalize the pressure in 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 lbf-ft) then turn in 50°...

  • Page 298

    The chamfer side “A” of thrust washer should face the crankcase side. “A” I947H1140191-01 • Apply grease to new O-ring (2). : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1140194-01 • Install the oil pump drive sprocket (5) to the CAUTION countershaft.

  • Page 299

    Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) • Apply grease to new O-ring (1). CAUTION Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) • Install the oil strainer (2). “A”...

  • Page 300

    Gear position switch mounting bolt (a): 6.5 N·m ( NOTE 0.65 kgf-m, 4.7 lbf-ft) Be careful not to apply bond to the hole of thread end. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lbf-ft) I947H1140203-01 Water Pump •...

  • Page 301

    Engine Mechanical: 1D-67 • Tighten the water pump mounting bolts (2) to the Cam Chain / Cam Chain Tensioner / Cam Chain specified torque. Guide No. 1 • Install the cam chain drive sprocket (1) to the Tightening torque crankshaft. Water pump mounting bolt (a): 10 N·m (1.0 kgf- m, 7.0 lbf-ft) NOTE...

  • Page 302

    • Apply bond to the hatching part of crankcase breather Install the gearshift cam plate (1) and gearshift shaft (2). (PCV) cover. Refer to “Gearshift Shaft / Gearshift Cam Plate Removal : Sealant 99000–31140 (SUZUKI BOND and Installation” in Section 5B (Page 5B-17). No.1207B or equivalent) I947H1140212-01 I947H1140293-01 •...

  • Page 303

    Engine Mechanical: 1D-69 • Tighten the crankcase breather (PCV) cover bolts. “A” I947H1140217-02 I947H1140215-03 Engine Top Side Assemble the engine top side. Refer to “Engine Top Side Disassembly” (Page 1D-26). Cylinder Inspection B947H11406033 Refer to “Engine Top Side Disassembly” (Page 1D-26). Refer to “Engine Top Side Assembly”...

  • Page 304

    1D-70 Engine Mechanical: 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 305

    Engine Mechanical: 1D-71 Piston and Piston Ring Inspection Piston Ring-to-groove Clearance B947H11406035 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-69). exceed the limit, replace both the piston and piston rings.

  • Page 306

    1D-72 Engine Mechanical: 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 307

    Engine Mechanical: 1D-73 Balancer Shaft Disassembly and Assembly • Set the dampers and install the balancer shaft to B947H11406036 balancer gear. Refer to “Engine Bottom Side Disassembly” (Page 1D- 49). NOTE Refer to “Engine Bottom Side Assembly” (Page 1D-56). • Fit the stopper of the balancer shaft between the dampers.

  • Page 308

    1D-74 Engine Mechanical: Balancer Shaft Journal Bearing Removal and Installation When installing the bearings to the crankcases, be sure Installation B947H11406038 to install the tab “A” first, and then press in the other Refer to “Engine Bottom Side Disassembly” (Page 1D- opposite side of the bearing.

  • Page 309

    Engine Mechanical: 1D-75 Balancer Shaft Journal Bearing Inspection and Selection B947H11406039 Refer to “Engine Bottom Side Disassembly” (Page 1D- 49). Refer to “Engine Bottom Side Assembly” (Page 1D-56). Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings.

  • Page 310

    1D-76 Engine Mechanical: 4) Check the corresponding crankcase journal I.D. Conrod Crank Pin Bearing Removal and code number “A”, [A], [B] or [C] which is stamped on Installation the rear of upper crankcase. B947H11406040 Refer to “Engine Bottom Side Disassembly” (Page 1D- 49).

  • Page 311

    Engine Mechanical: 1D-77 Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B947H11406041 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” 49).

  • Page 312

    1D-78 Engine Mechanical: Conrod Crank Pin Bearing Inspection and 4) Remove the conrod cap bolts and measure the width of the compressed plastigauge using the envelope Selection B947H11406042 scale. This measurement should be taken at the Refer to “Engine Bottom Side Disassembly” (Page 1D- widest part of the compressed plastigauge.

  • Page 313

    Engine Mechanical: 1D-79 2) Check the corresponding crank pin O.D. code Bearing thickness specification numbers ([1], [2] or [3]) “B”. Color “C” (Part No.) Thickness Yellow 1.488 – 1.492 mm (12164-47H00-0D0) (0.0586 – 0.0587 in) Brown 1.484 – 1.488 mm (12164-47H00-0C0) (0.0584 –...

  • Page 314

    1D-80 Engine Mechanical: 2) Set the crankshaft onto the upper crank case. 6) Remove the lower crankcase and measure the width of compressed plastigauge using the envelope 3) Install the plastigauge onto each crankshaft journal. scale. This measurement should be taken at the Special tool widest part of the compressed plastigauge.

  • Page 315

    Engine Mechanical: 1D-81 2) Check the corresponding crankshaft journal O.D. 4) Select the specified bearings from the bearing codes “B” ([A], [B] or [C]), which are stamped on the selection table. crankshaft. Bearing selection table Crankshaft O.D. “B” Code Green Black Brown Crankcase...

  • Page 316

    1D-82 Engine Mechanical: Crankshaft Thrust Clearance Inspection and Selection Selection 1) Remove the right-side thrust bearing and measure B947H11406044 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, 49).

  • Page 317

    Engine Mechanical: 1D-83 4) Select a left-side thrust bearing from the selection table. NOTE Right-side thrust bearing has the same specification as the GREEN (12228-48B00-0E0) of left-side thrust bearing. Thrust bearing selection table Clearance before inserting Color “A” (Part No.) Thrust bearing thickness Thrust clearance left-side thrust bearing...

  • Page 318

    1D-84 Engine Mechanical: Specifications Service Data B947H11407001 Valve + Guide Unit: mm (in) Item Standard Limit 31.0 (1.22) — Valve diam. 25.0 (0.98) — 0.08 – 0.18 (0.003 – 0.007) — Valve clearance (when cold) 0.18 – 0.28 (0.007 – 0.011) —...

  • Page 319

    Engine Mechanical: 1D-85 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 400 – 1 800 kPa (14 – 18 kgf/cm , 199 – 256 psi) (10 kgf/cm 142 psi) 200 kPa Compression pressure difference —...

  • Page 320

    1D-86 Engine Mechanical: Tightening Torque Specifications B947H11407002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Throttle cable lock-nut 0.45 (Page 1D-11) STP sensor mounting screw 0.35 (Page 1D-13) TP sensor mounting screw 0.35 (Page 1D-14) ISC valve mounting screw (Page 1D-14) Fuel delivery pipe mounting screw 0.35 (Page 1D-15)

  • Page 321

    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 B947H11408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1D-13) /...

  • Page 322

    1D-88 Engine Mechanical: Special Tool B947H11408002 09900–20102 09900–20202 Vernier calipers (200 mm) Micrometer (25 – 50 mm) (Page 1D-46) / (Page 1D-36) / (Page 1D-72) (Page 1D-79) / (Page 1D-81) 09900–20203 09900–20205 Micrometer (50 – 75 mm) Micrometer (0 – 25 mm) (Page 1D-71) (Page 1D-38) / (Page 1D-46) /...

  • Page 323

    Engine Mechanical: 1D-89 09900–22403 09915–40610 Small bore gauge (18 – 35 Oil filter wrench (Page 1D-38) (Page 1D-51) / (Page 1D-65) 09915–63311 09915–64512 Compression gauge Compression gauge attachment (Page 1D-3) (Page 1D-3) 09916–10911 09916–14510 Valve lapper set Valve lifter (Page 1D-46) (Page 1D-40) / (Page 1D-44) 09916–14522...

  • Page 324

    1D-90 Engine Mechanical: 09930–11960 09940–14990 Torx wrench (4 mm) Engine mounting adjust wrench (Page 1D-14) (Page 1D-23) / (Page 1D-23) / (Page 1D-24)

  • Page 325: Engine Lubrication System

    Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B947H11500001 Refer to “Fuel and Oil Recommendation” in Section 0A (Page 0A-3).

  • Page 326: Oil Pan

    1E-2 Engine Lubrication System: Schematic and Routing Diagram Engine Lubrication System Chart Diagram B947H11502001 OIL JET (#16) CAM CHAIN TENSION ADJUSTER INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER INTAKE CAMSHAFT JOURNALS, CAMFACES AND TAPPETS EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER #1 EXHAUST CAMSHAFT JOURNALS, CAMFACES AND TAPPETS SUB GALLERY...

  • Page 327

    Engine Lubrication System: 1E-3 Engine Lubrication Circuit Diagram B947H11502002 I947H1150002-03...

  • Page 328

    1E-4 Engine Lubrication System: I947H1150003-01...

  • Page 329

    Engine Lubrication System: 1E-5 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B947H11504001 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 330

    “Engine Assembly Removal” in Section 1D (Page 1D-20). Use a new O-ring to prevent oil leakage. 2) Remove the plate (1). : Grease 99000–25010 (SUZUKI SUPER 3) Remove the oil pan (2). GREASE “A” or equivalent) • Install the oil strainer (2).

  • Page 331

    Engine Lubrication System: 1E-7 • Push in the oil pressure regulator (4) to the oil pump Oil Pressure Regulator as shown. Inspect the operation of the oil pressure regulator by pushing the piston with a proper bar. If the piston does not operate smoothly, replace the oil pressure regulator with a new one.

  • Page 332

    1E-8 Engine Lubrication System: Oil Cooler Inspection CAUTION 1) Remove the oil cooler guard (1). • Make sure not to bend the fins when using compressed air. • If compressed air is applied from the front side, dirt will be forced into the pores of oil cooler.

  • Page 333

    Engine Lubrication System: 1E-9 5) Remove the oil cooler guard (4). I947H1150019-01 • Apply thread lock to the oil cooler hose bolts and I947H1150017-01 tighten them securely. Installation : Thread lock cement 99000–32110 Install the oil cooler and oil cooler hoses in the reverse (THREAD LOCK CEMENT SUPER “1322”...

  • Page 334

    3) Remove the piston cooling oil jets (1) from the upper NOTE crankcase. Be careful not to apply bond to the hole of thread end. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lbf- I947H1150022-01 Installation Installation is in the reverse order of removal.

  • Page 335

    Engine Lubrication System: 1E-11 • Apply a small quantity of thread lock to the bolts and 4) Remove the oil jet (2) (for cam chain tension tighten them to the specified torque. adjuster). : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER “1322” or equivalent) Tightening torque Piston cooling oil jet bolt (a): 10 N·m (1.0 kgf-m,...

  • Page 336

    1E-12 Engine Lubrication System: Oil Jet (For Transmission) Oil Pump Removal and Installation B947H11506011 Removal NOTE 1) Remove the engine assembly. Refer to “Engine Be careful not to drop any parts into the Assembly Removal” in Section 1D (Page 1D-20). crankcase.

  • Page 337

    Oil pump mounting bolt (a): 10 N·m (1.0 kgf-m, CAUTION 7.0 lbf-ft) Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1150033-01 5) Install the washer (1). 6) Install the oil pump driven sprocket (2) with the chain (3).

  • Page 338

    1E-14 Engine Lubrication System: Oil Pump Inspection B947H11506012 Inspect the oil pump in the following procedures: 1) Remove the oil pump. Refer to “Oil Pump Removal and Installation” (Page 1E-12). 2) Rotate the oil pump by hand and check that it moves smoothly.

  • Page 339

    Engine Lubrication System: 1E-15 Special Tools and Equipment Recommended Service Material B947H11508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1E-6) / (Page 1E- equivalent 6) / (Page 1E-13) Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140...

  • Page 340: Engine Cooling System

    1F-1 Engine Cooling System: Engine Cooling System Engine Precautions Precautions for Engine Cooling System B947H11600001 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 341

    Engine Cooling System: 1F-2 Schematic and Routing Diagram Cooling Circuit Diagram B947H11602001 RESERVOIR THERMOSTAT CYLINDER HEAD ECT SENSOR TANK CYLINDER RADIATOR WATER PUMP I947H1160001-02...

  • Page 342

    1F-3 Engine Cooling System: Water Hose Routing Diagram B947H11602002 “a” “ b ” “A” “C” “E” “D” “F” “B” “H” “G” “I” “A” “A” “B” “A” “J” “B” “K” I947H1160053-03 1. Thermostat air bleeder hole “D”: Clamp end should face right side. “K”: Screw head should face left side.

  • Page 343

    Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B947H11604001 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 344

    1F-5 Engine Cooling System: Radiator Cap Inspection Radiator Cleaning B947H11606002 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 345

    Engine Cooling System: 1F-6 4) Remove the radiator mounting bolts. 9) Apply thread lock to the oil cooler bolts and tighten them securely. : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER “1322” or equivalent) I947H1160007-01 I947H1160057-01 10) Reinstall the removed parts. Radiator / Cooling Fan Motor Removal and Installation B947H11606004...

  • Page 346

    1F-7 Engine Cooling System: 7) Remove the oil cooler (6) from the bracket. Installation Install the radiator in the reverse order of removal. Pay attention to the following points: • Install the radiator and oil cooler to their bracket. Refer to “Radiator Inspection and Cleaning”...

  • Page 347

    Engine Cooling System: 1F-8 3) Any leakage from the connecting section should be Installation corrected by proper tightening. Refer to “Water Hose 1) Install the water hose as shown in the water hose Routing Diagram” (Page 1F-3). routing diagram. Refer to “Water Hose Routing Diagram”...

  • Page 348

    1F-9 Engine Cooling System: 4) Disconnect the reservoir tank overflow hose (3). 2) Test the cooling fan motor for load current with an ammeter connected as shown in the figure. If the fan motor does not turn, replace the cooling fan assembly with a new one.

  • Page 349

    Engine Cooling System: 1F-10 3) First check the insulation between “A” and “B” 4) Remove the thermostat (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 350

    1F-11 Engine Cooling System: Thermostat Inspection 6) Read the thermometer just when opening the B947H11606014 thermostat. If this reading, which is the temperature Inspect the thermostat in the following procedures: level at which the thermostat valve begins to open, is 1) Remove the thermostat.

  • Page 351

    Engine Cooling System: 1F-12 Water Pump Components B947H11606015 I947H1160055-02 1. Impeller : 8 N⋅m (0.8 kgf-n, 6.0 Ib-ft) : Apply engine coolant. 2. Mechanical seal : 10 N⋅m (1.0 kgf-n, 7.0 Ib-ft) : Apply molybdenum oil solution. 3. Oil seal : 6 N⋅m (0.6 kgf-n, 4.5 Ib-ft) : Do not reuse.

  • Page 352

    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 water bypass hose (1). : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent)

  • Page 353

    Engine Cooling System: 1F-14 • Install the water pump assembly with the slot of the Water Pump Disassembly and Assembly B947H11606018 pump shaft end “A” securely engaged with the flat “B” Refer to “Water Pump Removal and Installation” of the oil pump shaft. (Page 1F-13).

  • Page 354

    1F-15 Engine Cooling System: 5) Remove the impeller (3). I947H1160034-01 9) Remove the oil seal (11). I947H1160031-01 6) Remove the mechanical seal ring (5) and rubber NOTE seal (6) from the impeller. If there is no abnormal condition, the oil seal removal is not necessary.

  • Page 355

    2) Apply a small quantity of the grease to the oil seal 5) Install the impeller shaft (1) and washer (2) to the lip. holder. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1160040-01 6) Install the rubber seal (3) into the impeller.

  • Page 356

    1F-17 Engine Cooling System: 10) Hold the impeller with water pump pliers and tighten the impeller securing bolt to the specified torque. Tightening torque Impeller securing bolt (a): 8 N·m (0.8 kgf-m, 6.0 lbf-ft) I947H1160045-01 Water Pump Related Parts Inspection B947H11606019 Refer to “Water Pump Disassembly and Assembly”...

  • Page 357

    Engine Cooling System: 1F-18 Seal Washer Impeller / Shaft Visually inspect the seal washer for damage, with Visually inspect the impeller and its shaft for damage. particular attention given to the sealing face. Replace the impeller or shaft if necessary. Replace the seal washer that shows indications of leakage.

  • Page 358

    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 B947H11608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1F-13) /...

  • Page 359: Fuel System

    Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B947H11700001 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 360

    1G-2 Fuel System: General Description Fuel Injection System Description B947H11701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipes (5) including fuel injectors (6) and (7), fuel pressure regulator (8). 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 361

    Fuel System: 1G-3 Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B947H11702001 “E” “D” “B” “I” “F” “G” “H” “C” “ c ” “A” “ b ” “ a ” I947H1170020-02 1. Fuel tank water drain hose “A”: White marking “G”: Stick the hose clamp along the line behind the cowling.

  • Page 362

    1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B947H11704001 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 363

    Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B947H11706001 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 364

    1G-6 Fuel System: Fuel Pump Inspection 3) Connect a proper fuel hose (2) to the fuel pump. B947H11706002 4) Place the measuring cylinder and insert the fuel Turn the ignition switch ON and check that the fuel pump hose end into the measuring cylinder. operates for a few seconds.

  • Page 365

    Fuel System: 1G-7 Fuel Pump Relay Inspection Fuel Hose Inspection B947H11706004 B947H11706005 Refer to “Electrical Components Location” in Section 0A Refer to “Fuel Line Inspection” in Section 0B (Page 0B- (Page 0A-7). 10). Inspect the fuel pump relay in the following procedures: Fuel Level Gauge Inspection 1) Remove the frame covers.

  • Page 366

    1G-8 Fuel System: Fuel Tank Construction B947H11706007 “A” “B” “B” “B” I947H1170025-02 1. Fuel tank heat shield 3. Fuel tank front bracket “A”: Insert to the bracket. : Aluminum film side should face the engine side. 2. Fuel tank front cover 4.

  • Page 367

    Fuel System: 1G-9 Fuel Tank Removal and Installation 5) Disconnect the fuel pump lead wire coupler (2). B947H11706008 6) Place a rag under the fuel feed hose (3) and disconnect the fuel feed hose from the fuel tank. Removal CAUTION WARNING When removing the fuel tank, do not leave •...

  • Page 368

    1G-10 Fuel System: Fuel Pump Components B947H11706009 I947H1170030-02 1. Fuel level gauge 4. Joint 7. Fuel mesh filter : Apply grease. 2. Fuel pressure regulator assembly 5. Fuel pump : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Do not reuse. 3.

  • Page 369

    Fuel System: 1G-11 Fuel Pump Disassembly and Assembly 5) Remove the fuel pressure regulator assembly (4). B947H11706010 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.

  • Page 370

    2. Fuel level gauge (+) lead wire (R/B) 3. Fuel pump (–) lead wire (B/W) 4. Fuel level gauge (–) lead wire (B/W) • Install a new O-ring and apply grease to it. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1170012-01 WARNING The O-ring must be replaced with a new one to prevent fuel leakage.

  • Page 371

    Fuel System: 1G-13 • When installing the fuel pump assembly, first tighten Fuel Injector / Fuel Delivery Pipe / T-joint all the fuel pump mounting bolts lightly and then to the Removal and Installation specified torque in the ascending of numbers. B947H11706012 Refer to “Throttle Body Disassembly and Assembly”...

  • Page 372

    1G-14 Fuel System: Specifications Service Data B947H11707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 222 ml (7.5/7.8 US/lmp oz) and more/10 sec. Fuel pressure regulator operating Approx.

  • Page 373

    Fuel System: 1G-15 Special Tools and Equipment Recommended Service Material B947H11708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1G-12) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components” (Page 1G-10)

  • Page 374: Ignition System

    1H-1 Ignition System: Ignition System Engine General Description Immobilizer Description (For E-02, 19, 24, 51) Operation B947H11801001 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 375

    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 376

    1H-3 Ignition System: Schematic and Routing Diagram Ignition System Diagram B947H11802001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery sensor sensor switch I947H1180004-01 Ignition System Components Location B947H11802002 Refer to “Electrical Components Location”...

  • Page 377

    Ignition System: 1H-4 Diagnostic Information and Procedures Ignition System Symptom Diagnosis B947H11804001 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.

  • Page 378

    1H-5 Ignition System: No Spark or Poor Spark B947H11804002 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 379

    Ignition System: 1H-6 Repair Instructions Ignition Coil and Spark Plug Removal and 5) Remove the spark plugs with the spark plug wrench. Installation Special tool B947H11806001 (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 380

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

  • Page 381

    Ignition System: 1H-8 5) Insert the needle pointed probe to the lead wire coupler. CAUTION “C” Use the special tool to prevent the rubber of “B” the water proof coupler from damage. “D” 6) Connect the multi-circuit tester with the peak voltage adaptor as follows.

  • Page 382

    1H-9 Ignition System: Ignition Coil Resistance 2) Disconnect the CKP sensor coupler (1). 1) Remove the ignition coil. Refer to “Ignition Coil and NOTE Spark Plug Removal and Installation” (Page 1H-6). Be sure that all of the couplers are connected 2) Measure the ignition coil for resistance in both properly and the battery is fully-charged.

  • Page 383

    Ignition System: 1H-10 6) If the peak voltage is within the specification, check CKP Sensor Removal and Installation B947H11806005 the continuity between the CKP sensor coupler and Refer to “Generator Removal and Installation” in Section ECM coupler. 1J (Page 1J-4). CAUTION Engine Stop Switch Inspection Normally, use the needle pointed probe to the...

  • Page 384

    1H-11 Ignition System: Ignition Switch Removal and Installation Installation B947H11806008 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”...

  • Page 385

    Ignition System: 1H-12 Drive Mode Selector Inspection B947H11806009 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 “Data monitor”. 4) Make sure each of “Driving mode selection”...

  • Page 386

    1H-13 Ignition System: Specifications Service Data B947H11807001 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 387

    Ignition System: 1H-14 Special Tools and Equipment Recommended Service Material B947H11808001 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 B947H11808002 09900–25008 09900–25009 Multi circuit tester set...

  • Page 388: Starting System

    1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B947H11902001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). Ignition Engine stop switch switch Fuse (30 A) ignition coil Gear position Starter Fuse Starter switch button motor Starter relay...

  • Page 389

    Starting System: 1I-2 Starter Motor Will Not Run B947H11904002 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 390

    1I-3 Starting System: Repair Instructions Starter Motor Components B947H11906001 I947H1190032-02 1. O-ring 5. Armature : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) 2. Housing end (Inside) 6. Housing end (Outside) : Apply grease to sliding surface. 3. O-ring : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Apply moly paste to sliding surface.

  • Page 391

    • Apply a small quantity of moly paste to the armature Installation shaft. Install the starter motor in the reverse order of removal. : Moly paste 99000–25140 (SUZUKI MOLY Pay attention to the following points: PASTE or equivalent) • Apply grease to the O-ring.

  • Page 392

    1I-5 Starting System: • Tighten the starter motor housing bolts (1) to the Commutator specified torque. Inspect the commutator for discoloration, abnormal wear or undercut “A”. Tightening torque If the commutator is abnormally worn, replace the Starter motor housing bolt (a): 5 N·m (0.5 kgf-m, armature assembly.

  • Page 393

    Starting System: 1I-6 Oil Seal Starter Relay Inspection B947H11906006 Check the seal lip for damage. Inspect the starter relay in the following procedures: If any damage is found, replace the housing end. 1) Remove the starter relay. Refer to “Starter Relay Removal and Installation”...

  • Page 394

    1I-7 Starting System: 3) Measure the relay coil resistance between the Side-stand / Ignition Interlock System Parts terminals using the multi-circuit tester. If the Inspection resistance is not within the specified value, replace B947H11906008 Check the interlock system for proper operation. If the the starter relay with a new one.

  • Page 395

    Starting System: 1I-8 5) Connect the side-stand switch coupler. Diode inspection 6) Install the removed parts. 1) Remove the turn signal/side-stand relay. Refer to “Turn Signal / Side-stand Relay Removal and Turn Signal / Side-stand Relay Installation” (Page 1I-7). The turn signal/side-stand relay is composed of the turn 2) Measure the voltage between the “A”, “B”...

  • Page 396

    1I-9 Starting System: 2) Disconnect the gear position switch coupler (1). CAUTION When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. I947H1190015-01 8) Turn the ignition switch OFF. 9) Install the removed parts.

  • Page 397

    Starting System: 1I-10 Starter Torque Limiter Inspection 3) Remove the starter idle gear No. 2 bearing (4), shaft B947H11906013 (5) and washer (6). Refer to “Starter Torque Limiter Removal and Installation” (Page 1I-9). CAUTION • Do not attempt to disassemble the starter torque limiter.

  • Page 398

    1I-11 Starting System: • When installing the starter clutch and CKP sensor Starter Clutch Inspection B947H11906010 rotor, align the wide spline tooth of them with that of Refer to “Starter Clutch Removal and Installation” crankshaft. (Page 1I-10). Starter Clutch 1) Install the starter driven gear onto the starter clutch. 2) Turn the starter driven gear by hand to inspect the starter clutch for a smooth movement.

  • Page 399

    Starting System: 1I-12 Starter Button Inspection 3) Inspect the starter button for continuity with the B947H11906011 tester. Inspect the starter button in the following procedures: If any abnormality is found, replace the right handle 1) Remove the air cleaner box. Refer to “Air Cleaner switch assembly with a new one.

  • Page 400

    Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-4) equivalent Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1I-4) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1I-9) / (Page 1I- NOTE Required service material is also described in the following.

  • Page 401: Charging System

    Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B947H11A02001 Regulator/Rectifier Ignition switch Generator I947H11A0021-01 Component Location Charging System Components Location B947H11A03001 Refer to “Electrical Components Location” in Section 0A (Page 0A-7). Diagnostic Information and Procedures Charging System Symptom Diagnosis B947H11A04001 Condition...

  • Page 402

    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 403

    Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection 3) Measure the DC voltage between the battery (+) and B947H11A06001 (–) 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 404

    1J-4 Charging System: 3) Measure the resistance between the three lead Special tool wires. : 09900–25008 (Multi circuit tester set) If the resistance is out of specified value, replace the Tester knob indication stator with a new one. Also, check that the generator Voltage (~) core is insulated properly.

  • Page 405

    (B): 09930–30460 (Rotor remover bolt) Generator lead wire set bolt (b): 5.5 N·m (0.55 kgf- (C): 09930–34970 (Rotor remover) m, 4.0 lbf-ft) • Apply bond lightly to the generator lead wire grommet (1). : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I947H11A0009-03 I947H11A0011-03...

  • Page 406

    • Route the generator lead wire. Refer to “Wiring I947H11A0012-02 Harness Routing Diagram” in Section 9A (Page 9A-7). • 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) I947H11A0013-01...

  • Page 407

    Charging System: 1J-7 Regulator / Rectifier Construction B947H11A06005 “A” I947H11A0020-03 1. Regulator/rectifier 4. Spacer : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Regulator/rectifier bracket 5. Wiring harness 3. Air intake pipe (RH) “A”: Connect the regulator/rectifier couplers under the wiring harness. Regulator / Rectifier Removal and Installation 4) Remove the EVAP system purge control solenoid B947H11A06006...

  • Page 408

    1J-8 Charging System: 5) Disconnect the regulator/rectifier couplers (1). 6) Remove the regulator/rectifier as shown in the regulator/rectifier construction. Refer to “Regulator / Rectifier Construction” (Page 1J-7). Installation 1) Install the regulator/rectifier as shown in the regulator/rectifier construction. Refer to “Regulator / Rectifier Construction”...

  • Page 409

    Charging System: 1J-9 Battery Components 2) Remove the caps (2) from the electrolyte container. B947H11A06008 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 410

    1J-10 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 411

    Charging System: 1J-11 Battery Recharging 4) Install the battery to the motorcycle. Refer to “Battery Removal and Installation” (Page 1J-11). 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 412

    1J-12 Charging System: Installation Battery Visual Inspection B947H11A06011 Install the battery in the reverse order of removal. Inspect the battery in the following procedures: Pay attention to following points: 1) Remove the front seat. Refer to “Exterior Parts CAUTION Removal and Installation” in Section 9D (Page 9D- Never use anything except the specified 2) Visually inspect the surface of the battery container.

  • Page 413

    Charging System: 1J-13 Special Tools and Equipment Recommended Service Material B947H11A08001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1J-5) / (Page 1J- equivalent Special Tool B947H11A08002 09900–25008 09930–30460 Multi circuit tester set...

  • Page 414: Exhaust System

    1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B947H11B00001 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 415

    Exhaust System: 1K-2 Exhaust Control System Operation B947H11B01002 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 416

    1K-3 Exhaust System: FULL OPEN I947H11B0003-01...

  • Page 417

    Exhaust System: 1K-4 Repair Instructions Exhaust Control System Construction B947H11B06001 “ a ” “ b ” “A” “ c ” I947H11B0004-02 1. EXCV cable No. 1 (CL) : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) “c”: 11 – 12 mm (0.43 – 0.47 in) 2.

  • Page 418

    1K-5 Exhaust System: Exhaust System Components B947H11B06002 “A” I947H11B0005-03 1. Exhaust pipe gasket 7. EXCV cable No. 1 : 5.5 N⋅m (0.55 kgf-m, 4.0 lbf-ft) 2. Exhaust pipe assembly 8. EXCV cable No. 2 : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) 3.

  • Page 419

    Exhaust System: 1K-6 EXCV Cable Removal and Installation 8) Loosen the lock-nut (1) on the No. 2 cable (2) and B947H11B06003 turn in the cable adjuster (3) fully. Removal 9) Loosen the lock-nut (4) on the No. 1 cable (5) and 1) Turn the ignition switch OFF.

  • Page 420

    1K-7 Exhaust System: Installation 6) Connect the other end of EXCV cable No. 1 (1) and No. 2 (2) to the EXCVA pulley (9). CAUTION The cable slots of EXCVA pulley must be located adjustment position. 1) Temporarily connect the EXCV cable No. 1 (47H0CL) (1) and No.

  • Page 421

    Exhaust System: 1K-8 4) After turning the mode select switch ON, turn the 9) Remove the EXCVA (3) with the bracket. ignition switch ON. Special tool (A): 09930–82720 (Mode selection switch) I947H11B0017-01 10) Remove the bracket from the EXCVA. I947H11B0014-01 5) Check that the cable slots of the EXCVA pulley comes to the middle (Adjustment position) “A”.

  • Page 422

    1K-9 Exhaust System: Installation EXCVA Pulley Inspection B947H11B06006 Install the EXCVA in the reverse order of removal. Pay Inspect the EXCVA pulley in the following procedures: attention to the following points: 1) Remove the EXCVA pulley. Refer to “EXCV Cable •...

  • Page 423

    Exhaust System: 1K-10 4) Turn the mode select switch ON. If DTC “C46” is not 7) Measure the EXCVA position sensor output voltage indicated on the LCD display, the adjustment is at EXCV fully closed position. correctly completed. If “C46” is indicated, repeat the Special tool procedures from Step 3 to Step 4.

  • Page 424

    1K-11 Exhaust System: Step 4 b) Turn out the No. 2 cable adjuster (2) in or out to set the output voltage within the specified value. 1) Click “Full opened” (1). I947H11B0023-02 2) Measure the EXCVA position sensor output voltage I947H11B0025-02 at EXCV fully opened position.

  • Page 425

    Exhaust System: 1K-12 3) Remove the side cowlings. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D- 4) Lift and support the fuel tank with the prop stay. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-9). 5) Disconnect the HO2 sensor coupler (4).

  • Page 426

    1K-13 Exhaust System: 12) Remove the exhaust pipe assembly by removing the exhaust pipe bolts. CAUTION Take care not to bend the radiator/oil cooler fins. NOTE Support the exhaust pipe assembly to prevent it from falling. I947H11B0036-01 • Install new gaskets and connectors and tighten each bolt to the specified torque.

  • Page 427

    Exhaust System: 1K-14 Specifications Service Data B947H11B07001 FI Sensors Item Standard/Specification Note 0.3 V and less at idle speed HO2 sensor output voltage 0.6 V and more at 5 000 r/min EXCVA position sensor input 4.5 – 5.5 V voltage EXCVA position sensor output Closed 0.45 –...

  • Page 428

    1K-15 Exhaust System: Special Tools and Equipment Recommended Service Material B947H11B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-13) (commercially available) or equivalent NOTE Required service material is also described in the following.

  • Page 429

    Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Swingarm Removal and Installation....2C-9 Swingarm Pivot Boss Removal and Precautions............. 2-1 Installation ............2C-12 Precautions for Suspension ........2-1 Swingarm Related Parts Inspection ....2C-12 Suspension General Diagnosis....2A-1 Swingarm Bearing Removal and Installation ..2C-13 Specifications .............2C-15 Diagnostic Information and Procedures....2A-1 Service Data............2C-15...

  • Page 430

    2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B947H12000001 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 431: Suspension General Diagnosis

    Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B947H12104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

  • Page 432: Front Suspension

    2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B947H12206001 I947H1220001-03 1. Front fork cap 8. Rod guide case 15. Outer tube 22. Front axle pinch bolt 2. O-ring 9. Spring 16. Guide bushing : 35 N⋅m (3.5 kgf-m, 25.5 lbf-ft) 3.

  • Page 433

    Front Suspension: 2B-2 Front Fork Removal and Installation 6) Loosen the handlebar clamp bolt (4). B947H12206002 NOTE NOTE The right and left front forks are installed Slightly loosen the front fork cap (5) to symmetrically and therefore the removal facilitate later disassembly. procedure for one side is the same as that for Special tool the other side.

  • Page 434

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

  • Page 435

    Front Suspension: 2B-4 Front Suspension Adjustment Compression damping force B947H12206003 Fully turn the compression damping force adjuster (1) After installing the front fork, adjust the spring pre-load clockwise. From that position (stiffest), turn it out to and two kinds of damping force as follows: standard setting position.

  • Page 436

    2B-5 Front Suspension: 2) Loosen the front fork cap using the special tool and 5) Remove the spring collar B (3) and spring (4). vise. CAUTION Do not clamp the outer tube too tight. Special tool (A): 09941–53670 (Front fork cap socket wrench (45 mm)) I947H1220017-01 6) Drain fork oil and remove the spring collar A (5).

  • Page 437

    Front Suspension: 2B-6 9) Pull out the inner tube from the outer tube. I947H1220023-01 I947H1220020-01 Assembly 10) Remove the slide bushing (8) from the inner tube. 11) Remove the following parts from the inner tube. CAUTION a) Guide bushing (9) •...

  • Page 438

    2B-7 Front Suspension: 3) Remove the plastic film and install the oil seal spacer 7) Install the stopper ring (2). (4), guide bushing (5) and slide bushing (6) keep CAUTION them free from dust. Make sure that the stopper ring is fitted CAUTION securely into the groove.

  • Page 439

    CAUTION side holes of inner tube. Insert the piston rod assembly into the inner : Fork Oil 99000–99001–SS5 (SUZUKI tube with the outer tube lifted up. Be sure not FORK OIL SS-05 or equivalent) to damage the piston ring (12) of the rod guide case.

  • Page 440

    17) Pour specified fork oil up to the top of the rod guide CAUTION case. Use new O-ring to prevent oil leakage. : Fork Oil 99000–99001–SS5 (SUZUKI FORK OIL SS-05 or equivalent) 21) Tighten the front fork cap to the specified torque. CAUTION Do not clamp the outer tube too tight.

  • Page 441

    Front Suspension: 2B-10 Front Fork Parts Inspection Piston Rod / Piston Ring B947H12206005 Inspect the piston rod and piston ring (1) for wear or Refer to “Front Fork Disassembly and Assembly” damage. If any defects are found, replace the piston rod (Page 2B-4).

  • Page 442

    75 (2.95) — outer tube fully compressed) 70 (2.76) 10 min. after adjustment Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (Each leg) 476 ml (16.1/16.8 US/lmp oz) — Front fork inner tube O.D 43 (1.7)

  • Page 443

    Front Suspension: 2B-12 Special Tools and Equipment Recommended Service Material B947H12208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL SS-05 or P/No.: 99000–99001– (Page 2B-8) / (Page 2B- equivalent NOTE Required service material is also described in the following.

  • Page 444: Rear Suspension

    2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B947H12306001 I947H1230001-02 1. Rear shock absorber 10. Swingarm : 115 N⋅m (11.5 kgf-m, 83.0 lbf-ft) 2. Rear shock absorber mounting nut 11. Chain case : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) 3.

  • Page 445

    Rear Suspension: 2C-2 Rear Suspension Assembly Construction B947H12306002 “ a ” “ a ” “ c ” “ c ” “ b ” “ b ” “ a ” “ a ” “ a ” “ a ” I947H1230002-04 1. Rear shock absorber mounting bolt (Upper) 8.

  • Page 446

    2C-3 Rear Suspension: Rear Shock Absorber Removal and Installation Installation B947H12306003 Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: Removal • Tighten the rear shock absorber upper/lower 1) Remove the right side cowling and side frame mounting bolts and nuts.

  • Page 447

    Rear Suspension: 2C-4 Rear Shock Absorber Inspection Rear Shock Absorber Bearing B947H12306005 1) Insert the spacer into bearing. Refer to “Rear Shock Absorber Removal and 2) Check the play by moving the spacer up and down. If Installation” (Page 2C-3). excessive play is noted, replace the bearing with a new one.

  • Page 448

    STD position NOTE 184.3 mm (7.26 in) Apply a small quantity of the grease to housing when installing the bearing. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool (A): 09924–84521 (Bearing installer set) I947H1230014-01 Damping Force Adjustment NOTE “...

  • Page 449

    Rear Suspension: 2C-6 Compression side (Low speed) Gas Pressure Release Fully turn the compression damping force (Low speed) Make sure to observe the following precautions: adjuster (1) clockwise. From that position (stiffest), turn it WARNING out to standard setting position. STD position •...

  • Page 450

    2C-7 Rear Suspension: Cushion Lever Removal and Installation • Install the rear shock absorber. Refer to “Rear Shock B947H12306008 Absorber Removal and Installation” (Page 2C-3). • Install the muffler chamber heat guard No. 2 and left Removal muffler. Refer to “Muffler / Muffler Chamber / Exhaust 1) Remove the right side cowling and side frame Pipe Removal and Installation”...

  • Page 451

    Rear Suspension: 2C-8 Installation Cushion Rod Inspection B947H12306012 Install the cushion rod in the reverse order of removal. Refer to “Cushion Rod Removal and Installation” Pay attention to the following points: (Page 2C-7). • Before installing the cushion rod to the frame, insert the collar into the bearing from the left side.

  • Page 452

    2C-9 Rear Suspension: Cushion Rod Bearing Removal and Installation 2) Apply grease to the bearings. B947H12306013 : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Removal 1) Remove the cushion rod. Refer to “Cushion Rod Removal and Installation” (Page 2C-7).

  • Page 453

    Rear Suspension: 2C-10 6) Remove the left muffler and muffler chamber heat 10) Remove the swingarm pivot shaft. guard No. 2. Refer to “Muffler / Muffler Chamber / 11) Remove the swingarm assembly. Exhaust Pipe Removal and Installation” in Section 12) Remove the mudguard (7), chain case (8) and chain 1K (Page 1K-11).

  • Page 454

    2C-11 Rear Suspension: • Adjust swingarm pivot thrust clearance in the following – Tighten the swingarm pivot lock-nut (4) to the procedures: specified torque with the special tool. – Insert the swingarm pivot shaft (2) and tighten it to Special tool the specified torque with the special tool.

  • Page 455

    Rear Suspension: 2C-12 Swingarm Pivot Boss Removal and Installation • Tighten the swingarm boss nut (2) to the specified B947H12306018 torque. Tightening torque Removal Swingarm pivot boss nut (a): 65 N·m (6.5 kgf-m, 1) Remove the swingarm. Refer to “Swingarm Removal 47.0 lbf-ft) and Installation”...

  • Page 456

    2C-13 Rear Suspension: Plate Swingarm Pivot Shaft Inspect the plate for damage and excessive bend. If any Measure the swingarm pivot shaft runout using the dial defect is found, replace the plate with a new one. gauge. If the runout exceeds the service limit, replace the pivot shaft.

  • Page 457

    Special tool (A): 09921–20240 (Bearing remover set) NOTE Apply a small quantity of the grease to housing when installing the bearing. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool (B): 09924–84521 (Bearing installer set) I947H1230053-01 Installation CAUTION “...

  • Page 458

    2C-15 Rear Suspension: Specifications Service Data B947H12307001 Suspension Unit: mm (in) Item Standard Limit Rear shock absorber spring pre-set 184.3 (7.26) — length Rebound 2-3/4 turns from stiffed position — Rear shock absorber damping force Lo: 2-1/4 turns from stiffest position adjuster Compression —...

  • Page 459

    Rear Suspension: 2C-16 Special Tools and Equipment Recommended Service Material B947H12308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 2C-5) / (Page 2C- equivalent 5) / (Page 2C-9) / (Page 2C-9) /...

  • Page 460: Wheels And Tires

    2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B947H12400001 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 461

    Wheels and Tires: 2D-2 Repair Instructions Front Wheel Components B947H12406001 I947H1240030-01 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 462

    2D-3 Wheels and Tires: Front Wheel Assembly Construction B947H12406002 “ a ” I947H1240031-02 1. Brake disc bolt “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake caliper mounting bolt : 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) : Apply grease. 3.

  • Page 463

    Wheels and Tires: 2D-4 Front Wheel Assembly Removal and Installation 7) Remove the collar (5) (RH only). B947H12406003 NOTE Removal After removing the front wheel, fit the 1) Remove the brake calipers, left and right. calipers temporarily to the original positions. CAUTION Do not operate the brake lever with the caliper removed.

  • Page 464

    2D-5 Wheels and Tires: 2) Insert the front axle from the left side and tighten the 5) Tighten two axle pinch bolts (4) on the right fork leg front axle bolt temporarily. to the specified torque. 3) Tighten the brake caliper mounting bolts (2) to the Tightening torque specified torque.

  • Page 465

    Wheels and Tires: 2D-6 Front Wheel Related Parts Inspection Wheel B947H12406004 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 466

    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) I947H1240009-01 3) Remove the wheel bearings using the special tool. Special tool (B): 09921–20240 (Bearing remover set)

  • Page 467

    CAUTION The sealed cover of the bearing must face outside. I947H1240012-01 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I837H1240014-01 I947H1240013-01 5) Install the front wheel assembly. Refer to“Front Wheel Assembly Removal and Installation”...

  • Page 468

    2D-9 Wheels and Tires: Rear Wheel Components B947H12406006 I947H1240033-01 1. Rear axel nut 9. Bearing 17. Rear brake disc 2. Collar 10. Spacer 18. Rear axle 3. Dust seal 11. Air valve : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) 4. Bearing 12.

  • Page 469

    Wheels and Tires: 2D-10 Rear Wheel Assembly Construction B947H12406007 “a” I947H1240034-02 1. Rear sprocket nut “a”: Clearance : 35 N⋅m (3.5 kgf-m, 25.5 lbf-ft) 2. Rear axle nut : 60 N⋅m (6.0 kgf-m, 43.0 lbf-ft) : Apply grease. 3. Brake disc bolt : 100 N⋅m (10 kgf-m, 72.5 lbf-ft) : Apply thread lock to the thread part.

  • Page 470

    2D-11 Wheels and Tires: Rear Wheel Assembly Removal and Installation 7) Remove the collars (5) and (6). B947H12406008 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 471

    Wheels and Tires: 2D-12 Rear Wheel Related Parts Inspection B947H12406009 Refer to “Rear Wheel Assembly Removal and Installation” (Page 2D-11). Tire Refer to “Tire Inspection” in Section 0B (Page 0B-18). Rear Brake Disc Refer to “Rear Brake Disc Inspection” in Section 4C (Page 4C-7).

  • Page 472

    The removed dust seal and bearings must be I947H1240020-02 replaced with new ones. 4) Remove the dust seal. 1) Apply grease to the wheel bearings. Special tool (A): 09913–50121 (Oil seal remover) : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1240021-01 I649G1240019-02...

  • Page 473

    I947H1240024-01 4) Install the rear sprocket mounting drum assembly (2). 5) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER I649G1240030-02 GREASE “A” or equivalent) I947H1240025-03 6) Install the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation”...

  • Page 474

    2D-15 Wheels and Tires: 4) Remove the tire using the tire changer. 2) Install the tire onto the wheel. CAUTION CAUTION For operating procedures, refer to the For installation procedure of tire onto the instructions supplied by the tire changer wheel, follow the instructions given by the manufacturer.

  • Page 475

    Wheels and Tires: 2D-16 7) When the bead has been fitted properly, adjust the pressure to specification. 8) As necessary, adjust the tire balance. Refer to “Wheel Balance Check and Adjustment” (Page 2D- 17). Cold inflation tire pressure Front Rear Solo 250 kPa 290 kPa...

  • Page 476

    2D-17 Wheels and Tires: 3) Remove the air valve (1) from the wheel. Wheel Balance Check and Adjustment B947H12406014 Check and adjust the wheel balance in the following procedures: 1) Removal the wheel assembly. Refer to “Front Wheel Assembly Removal and Installation” (Page 2D-4) and “Rear Wheel Assembly Removal and Installation”...

  • Page 477

    Wheels and Tires: 2D-18 Specifications Service Data B947H12407001 Wheel Unit: mm (in) Item Standard Limit Axial Wheel rim runout — 2.0 (0.08) Radial Front 17 M/C x MT 3.50 — Wheel rim size Rear 17 M/C x MT 6.00 — Front Wheel axle runout —...

  • Page 478

    2D-19 Wheels and Tires: Special Tools and Equipment Recommended Service Material B947H12408001 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 479

    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-5 Precautions for Driveline / Axle ......3-1 Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation........3A-5 Drive Chain / Drive Train / Drive Shaft...

  • Page 480

    • 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 DID 50VAZ. Suzuki recommends to use this standard drive chain as a replacement.

  • Page 481

    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 B947H13104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

  • Page 482

    3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 7) Remove the speed sensor rotor (7) by removing its B947H13106002 bolt while depressing the rear brake pedal. Removal 1) Remove the gearshift link arm (1) from the gearshift shaft.

  • Page 483

    • Before installing the engine sprocket cover, apply a B947H13106003 small quantity of grease to the clutch push rod. Removal : Grease 99000–25010 (SUZUKI SUPER 1) Remove the rear wheel assembly. Refer to “Rear GREASE “A” or equivalent) Wheel Assembly Removal and Installation” in Section 2D (Page 2D-11).

  • Page 484

    3A-4 Drive Chain / Drive Train / Drive Shaft: 5) Remove the retainer (3). • Apply grease to the retainer. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1310003-01 6) Remove the wheel dampers (4). I947H1310006-01 • Install the rear sprocket so that the letters “B” face outside.

  • Page 485

    Drive Chain / Drive Train / Drive Shaft: 3A-5 Drive Chain Related Parts Inspection Wheel Damper B947H13106004 Inspect the dampers for wear and damage. Replace the Refer to “Rear Sprocket / Rear Sprocket Mounting Drum dampers if there is anything unusual. Removal and Installation”...

  • Page 486

    5) Remove the sprocket mounting drum bearing with the special tool. Special tool (B): 09921–20240 (Bearing remover set) I947H1310016-01 3) Apply grease to the retainer. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1310015-01 Installation CAUTION The removed dust seal and bearing must be replaced with new ones.

  • Page 487

    Drive Chain / Drive Train / Drive Shaft: 3A-7 Drive Chain Replacement NOTE B947H13106006 The tip of pin remover (7) should be Use the special tool in the following procedures, to cut positioned inside “a” approximately 5 mm and rejoin the drive chain. (0.2 in) from the end face of pressure bolt [A] NOTE (3) as shown in the figure.

  • Page 488

    3A-8 Drive Chain / Drive Train / Drive Shaft: 6) Remove the joint pin (9) of the other side of joint 2) Apply grease to the joint pins (8), O-rings (9) and plate. plates (10). CAUTION CAUTION Never reuse joint pins, O-rings and plates. Replace the joint pins (8), O-rings (9) and plates (10) with new ones.

  • Page 489

    Drive Chain / Drive Train / Drive Shaft: 3A-9 7) Turn in the pressure bolt [A] (6) further using the bar 2) Stake the joint pin by turning (approximately 7/8 turn) (7) to press the joint plate over the joint pins. the pressure bolt [A] (3) with the bar until the pin end diameter becomes the specified dimension.

  • Page 490

    3A-10 Drive Chain / Drive Train / Drive Shaft: Specifications Service Data B947H13107001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Final reduction ratio 2.470 (42/17) — Type DID 50VAZ — Drive chain Links 114 links — 20-pitch length —...

  • Page 491

    Drive Chain / Drive Train / Drive Shaft: 3A-11 Special Tools and Equipment Recommended Service Material B947H13108001 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 492

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

  • Page 493

    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 494

    4-1 Precautions: Precautions Brake Precautions Precautions for Brake System B947H14000001 Refer to “General Precautions” in Section 00 (Page 00-1). Brake Fluid Information B947H14000002 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 495: Brake Control System And Diagnosis

    Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B947H14102001 “C” “B” “A” “B” I947H1410046-02 1. Hose clamp “A”: White marking : Clamp end should face downward. : White marking should be on right side and face upward. 2.

  • Page 496

    4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B947H14102002 “B” “A” “C” I947H1410047-04 1. Hose clamp “A”: White marking : 12 N⋅m (1.2 kgf-m, 8.5 lbf-ft) : Face the clamp end backward. 2. Stopper “B”: Yellow marking : 17 N⋅m (1.7 kgf-m, 12.5 lbf-ft) : After the brake hose union has contacted to the stopper, tighten the union bolt.

  • Page 497

    Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis B947H14104001 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 498

    4A-4 Brake Control System and Diagnosis: Rear Brake Light Switch Inspection Rear Brake Light Switch Inspection and B947H14106003 Adjustment Inspect the rear brake light switch in the following B947H14106004 procedures: Check the rear brake light switch so that the brake light will come on just before pressure is felt when the brake 1) Lift and support the fuel tank.

  • Page 499

    Brake Control System and Diagnosis: 4A-5 Front Brake 8) Close the air bleeder valve and disconnect the hose. Tightening torque NOTE Air bleeder valve (Front caliper): 7.5 N·m (0.75 If air is trapped in the master cylinder, bleed kgf-m, 5.5 lbf-ft) air from the master cylinder first in the same manner as follows.

  • Page 500

    4A-6 Brake Control System and Diagnosis: 4) Fill the reservoir with brake fluid to the upper line of 5) Fill the reservoir with brake fluid to the upper line of the reservoir. Place the reservoir cap to prevent dirt the reservoir. from entering.

  • Page 501

    Brake Control System and Diagnosis: 4A-7 6) Loosen the air bleeder valve and pump the brake Rear Brake lever until the old brake fluid flows out of the brake 1) Place the motorcycle on a level surface. system. 2) Remove the right side frame cover. Refer to “Exterior Parts Removal and Installation”...

  • Page 502

    4A-8 Brake Control System and Diagnosis: 8) Loosen the air bleeder valve and pump the brake Front Brake Hose Removal and Installation B947H14106009 pedal until the old brake fluid flows out of the brake Removal system. 1) Drain brake fluid. Refer to “Brake Fluid Replacement”...

  • Page 503

    Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Components B947H14106011 I947H1410051-02 1. Reservoir cap 8. Brake lever : 1 N⋅m (0.1 kgf-m, 0.5 lbf-ft) 2. PLATE 9. Brake lever pivot bolt : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) 3.

  • Page 504

    4A-10 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal Installation Install the front brake master cylinder in the reverse and Installation B947H14106012 order of removal. Pay attention to the following points: • When installing the master cylinder (1) onto the Removal handlebar, align the master cylinder holder’s mating 1) Drain brake fluid.

  • Page 505

    Brake Control System and Diagnosis: 4A-11 • After setting the brake hose union to the stopper, Front Brake Master Cylinder / Brake Lever tighten the union bolt (2) to the specified torque. Disassembly and Assembly B947H14106013 Refer to “Front Brake Master Cylinder Assembly CAUTION Removal and Installation”...

  • Page 506

    4A-12 Brake Control System and Diagnosis: 5) Remove the following parts from the master cylinder. Assembly Assemble the master cylinder in the reverse order of • Piston (10) disassembly. Pay attention to the following points: • Return spring (11) • Return spring guide (12) CAUTION •...

  • Page 507

    4A-13 • Apply grease to the push rod. • When installing the brake light switch, align the projection “C” on the switch with the hole “D” in the : Grease 99000–25100 (SUZUKI SILICONE master cylinder. GREASE or equivalent) “C” “D”...

  • Page 508

    4A-14 Brake Control System and Diagnosis: Rear Brake Master Cylinder Components B947H14106015 I947H1410052-02 1. Reservoir cap 6. Brake hose 11. Piston/Cup set : 17 N⋅m (1.7 kgf-m, 12.5 lbf-ft) 2. PLATE 7. Brake hose union bolt 12. Push rod : Apply silicone grease. 3.

  • Page 509

    Brake Control System and Diagnosis: 4A-15 Rear Brake Master Cylinder Assembly Removal Installation Install the rear brake master cylinder in the reverse order and Installation B947H14106016 of removal. Pay attention to the following points: Refer to “Rear Brake Hose Routing Diagram” (Page 4A- CAUTION The seal washers should be replaced with the Removal...

  • Page 510

    4A-16 Brake Control System and Diagnosis: Rear Brake Master Cylinder Disassembly and 4) Pull out the dust boot (5) and remove the snap ring (6). Assembly B947H14106017 Special tool Refer to “Rear Brake Master Cylinder Assembly : 09900–06108 (Snap ring remover (Close Removal and Installation”...

  • Page 511

    Inspect the master cylinder bore for any scratches or other damage. I947H1410038-01 • Apply grease to the push rod end. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) I947H1410040-02 Piston / Rubber Parts Inspect the piston surface for any scratches or other damage.

  • Page 512

    4A-18 Brake Control System and Diagnosis: Rear Brake Pedal Construction B947H14106019 I947H1410056-02 1. Footrest bracket No. 2 5. Footrest : Apply grease. 2. Footrest bracket No. 1 : 35 N⋅m (3.5 kgf-m, 25.5 lbf-ft) : Apply thread lock to the thread part. 3.

  • Page 513

    Brake Control System and Diagnosis: 4A-19 Specifications Service Data B947H14107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 65 – 75 (2.6 – 3.0) — Front 17.460 – 17.503 (0.6874 – 0.6891) — Master cylinder bore Rear 14.000 –...

  • Page 514

    4A-20 Brake Control System and Diagnosis: Special Tools and Equipment Recommended Service Material B947H14108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-6) / (Page 4A- 7) / (Page 4A-12) / (Page 4A-17) Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100...

  • Page 515: Front Brakes

    Front Brakes: 4B-1 Front Brakes Brake Repair Instructions Front Brake Components B947H14206001 I947H1420020-01 1. Seal set 5. Front brake disc : 18 N⋅m (1.8 kgf-m, 13.0 lbf-ft) 2. Piston and seal set : 7.5 N⋅m (0.75 kgf-m, 5.5 lbf-ft) : Apply thread lock to the thread part. 3.

  • Page 516

    4B-2 Front Brakes: Front Brake Pad Inspection 4) Clean up the caliper especially around the caliper B947H14206002 pistons. The extent of brake pads wear can be checked by 5) When installing the spring to caliper, bring its wider observing the grooved limit line “A” on the pads. When pawl “A”...

  • Page 517

    Front Brakes: 4B-3 Front Brake Caliper Removal and Installation Installation B947H14206004 Install the brake caliper in the reverse order of removal. Pay attention to the following points: NOTE • Tighten each bolt to the specified torque. The right and left calipers are installed symmetrically and therefore the removal Tightening torque procedure for one side is the same as that for...

  • Page 518

    4B-4 Front Brakes: Disassembly Assembly Assemble the caliper in the reverse order of 1) Remove the brake pads (1) and spring from the disassembly. Pay attention to the following points: caliper by removing the pad mounting pins. • Wash the caliper bores and pistons with specified brake fluid.

  • Page 519

    Front Brakes: 4B-5 • When installing the spring to the caliper, bring its Brake Caliper Piston wider pawl “A” facing top side. Inspect the surface of brake caliper pistons for any scratches or other damage. If any damage is found, replace the pistons with a new set.

  • Page 520

    4B-6 Front Brakes: Front Brake Disc Removal and Installation Front Brake Disc Inspection B947H14206007 B947H14206008 Brake Disc Thickness Removal Check the brake disc for damage or cracks and measure the thickness using the micrometer. 1) Remove the front wheel assembly. Refer to “Front Replace the brake disc if the thickness is less than the Wheel Assembly Removal and Installation”...

  • Page 521

    Front Brakes: 4B-7 Specifications Service Data B947H14207001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Front 5.3 – 5.7 (0.21 – 0.22) 5.0 (0.20) Brake disc runout — 0.30 (0.012) Leading 30.280 – 30.330 (1.1921 – 1.1941) — Brake caliper cylinder bore Front Trailing...

  • Page 522

    4B-8 Front Brakes: Special Tools and Equipment Recommended Service Material B947H14208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-4) / (Page 4B- Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32130 (Page 4B-6) “1360” or equivalent NOTE Required service material is also described in the following.

  • Page 523: Rear Brakes

    Rear Brakes: 4C-1 Rear Brakes .Brake Repair Instructions Rear Brake Components B947H14306001 I947H1430026-02 1. Rear brake caliper 8. Brake pad spring : Apply silicone grease to sliding surface. 2. Piston seal : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) : Apply thread lock to the thread part. 3.

  • Page 524

    4C-2 Rear Brakes: Rear Brake Pad Inspection 2) Remove the brake pads (3). B947H14306002 The extent of brake pads wear can be checked by CAUTION observing the grooved limit line “A” on the pads. When Do not operate the brake pedal while the the wear exceeds the grooved limit line, replace the pads are removed.

  • Page 525

    • Apply grease to the sliding pins. 1) Remove the rear wheel. Refer to “Rear Wheel Assembly Removal and Installation” in Section 2D : Grease 99000–25100 (SUZUKI SILICONE (Page 2D-11). GREASE or equivalent) 2) Drain brake fluid. Refer to “Brake Fluid Replacement”...

  • Page 526

    4C-4 Rear Brakes: • Tighten the caliper sliding pin A (1) to the specified • Bleed air from the brake system after installing the torque. caliper. Refer to “Air Bleeding from Brake Fluid Circuit” in Section 4A (Page 4A-4). Tightening torque •...

  • Page 527

    4) Remove the rubber boot (5), pad spring (6) and sliding pin B (7) from the bracket. • Apply grease to the piston seal (2). : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) • Install the piston seal (2) as shown in the figure.

  • Page 528

    4C-6 Rear Brakes: • Install the rear brake caliper. Refer to “Rear Brake Boot Caliper Removal and Installation” (Page 4C-3). Inspect the boots for damage and wear. If any defects are found, replace it with a new one. Rear Brake Caliper Parts Inspection B947H14306006 Refer to “Rear Brake Caliper Disassembly and Assembly”...

  • Page 529

    Rear Brakes: 4C-7 Installation Install the rear brake disc in the reverse order of removal. Pay attention to the following points: • Make sure that the brake disc is clean and free of any grease. • Apply thread lock to the brake disc bolts (1) and tighten them to the specified torque.

  • Page 530

    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 B947H14308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-5) /...

  • Page 531

    Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Specifications .............5B-21 Service Data............5B-21 Precautions............. 5-1 Tightening Torque Specifications......5B-22 Precautions for Transmission / Transaxle..... 5-1 Special Tools and Equipment ......5B-22 Manual Transmission......5B-1 Recommended Service Material .......5B-22 Special Tool ............5B-23 Diagnostic Information and Procedures....5B-1 Manual Transmission Symptom Diagnosis ..

  • Page 532

    5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B947H15000001 Refer to “General Precautions” in Section 00 (Page 00-1).

  • Page 533

    Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B947H15204001 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 534

    5B-2 Manual Transmission: Repair Instructions Transmission Components B947H15206001 I947H1520072-02 1. 2nd drive gear 11. 5th driven gear : 145 N⋅m (14.5 kgf-m, 105.0 lbf-ft) 2. 6th drive gear 12. 1st driven gear : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 3. 3rd/4th drive gear 13.

  • Page 535

    Manual Transmission: 5B-3 Transmission Removal Gearshift Fork and Gearshift Cam B947H15206002 1) Remove the gearshift cam bearing retainer screws. 1) Remove the engine assembly from the frame. Refer 2) Remove the gearshift fork shaft (1). to “Engine Assembly Removal” in Section 1D 3) Remove the gearshift cam (2) along with its bearing.

  • Page 536

    5B-4 Manual Transmission: 4) Using suitable size bolts (3), remove the driveshaft Bearing and Oil Seal left bearing case (4). NOTE 5) Remove the dowel pin. If there is no abnormal condition, the oil seal and bearing removal is not necessary. CAUTION The removed oil seal and bearing must be replaced with a new one.

  • Page 537

    Manual Transmission: 5B-5 3) Remove the gearshift shaft bearings (3) and (4) with Transmission Installation B947H15206003 the special tool. Install the transmission in the reverse order of removal. Special tool Pay attention to the following points: (C): 09921–20240 (Bearing remover set) Bearing and Oil Seal CAUTION Replace the removed bearings and oil seals...

  • Page 538

    – 75 Φ)) equivalent) • Apply grease to the oil seal lip. Tightening torque Driveshaft right bearing case bolt (a): 12 N·m (1.2 : Grease 99000–25010 (SUZUKI SUPER kgf-m, 8.7 lbf-ft) GREASE “A” or equivalent) I947H1520041-01 I947H1520039-01 • Install the dowel pin.

  • Page 539

    CAUTION (THREAD LOCK CEMENT SUPER “1322” or Replace the O-ring with a new one. equivalent) Tightening torque : Grease 99000–25010 (SUZUKI SUPER Driveshaft oil seal retainer screw (c): 12 N·m (1.2 GREASE “A” or equivalent) kgf-m, 8.7 lbf-ft) I947H1520042-01 I947H1520044-01 •...

  • Page 540

    5B-8 Manual Transmission: • Install the gearshift cam (2) with the bearing fitted. • Install the countershaft assembly to the upper crankcase. NOTE Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.

  • Page 541

    Manual Transmission: 5B-9 Transmission Construction B947H15206004 I947H1520060-02 1. Countershaft 2. Driveshaft...

  • Page 542

    5B-10 Manual Transmission: Countershaft Gear / Driveshaft Gear • Slide the 6th (3) and 2nd (4) drive gears toward the 3rd/4th drive gears (2), then remove the 2nd drive Disassembly and Assembly B947H15206005 gear circlip (5). Refer to “Transmission Removal” (Page 5B-3) and •...

  • Page 543

    • Before installing the oil seal, apply grease to the oil seal lip. Special tool (A): 09913–70210 (Bearing installing set (10 : Grease 99000–25010 (SUZUKI SUPER – 75 Φ)) GREASE “A” or equivalent) • When installing a new snap ring (1), pay attention to its direction.

  • Page 544

    5B-12 Manual Transmission: • When installing the gear bushing onto the Gearshift Fork Groove Width countershaft, align the shaft oil hole “A” with the Measure the gearshift fork groove width using the bushing oil hole “B”. vernier calipers. Special tool (A): 09900–20102 (Vernier calipers (200 mm)) Gearshift fork groove width Standard: 5.0 –...

  • Page 545

    Manual Transmission: 5B-13 Gearshift Cam Inspect the driveshaft right bearing for abnormal noise Inspect the gearshift cam groove for abnormal wear and and smooth rotation. damage. If any defects are found, replace the gearshift If there is anything unusual, replace the bearing cam with a new one.

  • Page 546

    3) Disconnect the gear position switch lead wire NOTE coupler (1). Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) “B” I947H1520068-01 “A” 4) Remove the engine sprocket cover. Refer to “Engine Sprocket Removal and Installation”...

  • Page 547

    Manual Transmission: 5B-15 Gearshift Lever Construction B947H15206009 “A” “ a ” I947H1520058-02 1. Gearshift lever bracket 4. Snap ring “a”: 65 – 75 mm (2.6 – 3.0 in) : Apply grease. 2. Gearshift lever shaft 5. Gearshift lever : 28 N⋅m (2.8 kgf-m, 20.0 lbf-ft) : Do not reuse.

  • Page 548

    5B-16 Manual Transmission: Gearshift Lever Height Inspection and 2) Loosen the lock-nuts (1). Adjustment 3) Turn the gearshift link rod (2) until the gearshift lever B947H15206011 is 65 – 75 mm (2.6 – 3.0 in) below the top of the Inspect and adjust the gearshift lever height in the footrest.

  • Page 549

    Manual Transmission: 5B-17 Gearshift Shaft Construction B947H15206013 I947H1520059-03 1. Gearshift shaft 6. Gearshift plate return spring : Apply thread lock to the thread part. 2. Washer : 8.5 N⋅m (0.85 kgf-m, 6.0 lbf-ft) : Apply thread lock to the thread part. 3.

  • Page 550

    5B-18 Manual Transmission: 5) Remove the following parts from the gearshift shaft. • Apply a small quantity of thread lock to the gearshift arm stopper and tighten it to the specified torque. Special tool : 09900–06107 (Snap ring remover (Open : Thread lock cement 99000–32030 type)) (THREAD LOCK CEMENT SUPER “1303”...

  • Page 551

    Manual Transmission: 5B-19 • Check the gearshift cam stopper moves smoothly. • Apply a small quantity of thread lock to the gearshift shaft end screw and tighten it to the specified torque. • Locate the gearshift cam in the neutral position. •...

  • Page 552

    5B-20 Manual Transmission: • Install a new snap ring (9). Gearshift Shaft Bearing Inspect the gearshift shaft bearings for abnormal noise Special tool and smooth rotation. Replace the bearing if there is : 09900–06107 (Snap ring remover (Open anything unusual. type)) I947H1520017-01 I947H1520014-01...

  • Page 553

    The stamped mark side of gearshift shaft bearing faces outside. Special tool (A): 09913–70210 (Bearing installing set (10 – 75 Φ)) I947H1520021-01 • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I947H1520020-01 I947H1520022-01 Specifications Service Data B947H15207001...

  • Page 554

    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 B947H15208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 5B-6) /...

  • Page 555

    Manual Transmission: 5B-23 Special Tool B947H15208002 09900–06104 09900–06107 Snap ring remover (Open Snap ring remover (Open type) type) (Page 5B-10) (Page 5B-17) / (Page 5B-18) / (Page 5B-20) 09900–20102 09900–20803 Vernier calipers (200 mm) Thickness gauge (Page 5B-12) / (Page 5B-12) (Page 5B-12) 09913–70210 09921–20210...

  • Page 556

    5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B947H15300001 Refer to “General Precautions” in Section 00 (Page 00-1). Schematic and Routing Diagram Clutch Cable Routing Diagram B947H15302001 Refer to “Throttle Cable Routing Diagram” in Section 1D (Page 1D-2). Diagnostic Information and Procedures Clutch System Symptom Diagnosis B947H15304001...

  • Page 557

    Clutch: 5C-2 Repair Instructions Clutch Lever Position Switch Inspection Clutch Cable Inspection B947H15306001 B947H15306002 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 558

    5C-3 Clutch: Clutch Control System Components B947H15306004 I947H1530043-02 1. Push rod 4. Clutch cable : 10 N⋅m (1.0 kgf-m, 0.7 lbf-ft) 2. Clutch release camshaft : 1 N⋅m (0.1 kgf-m, 0.7 lbf-ft) : Apply grease. 3. Clutch release arm : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) : Do not reuse.

  • Page 559

    Clutch: 5C-4 Clutch Components B947H15306005 I947H1530044-03 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. 1 drive plate (8 pcs.) 10. Clutch sleeve hub : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 4.

  • Page 560

    5C-5 Clutch: Clutch Removal 6) Remove the clutch springs and pressure plate (4). B947H15306006 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 561

    Clutch: 5C-6 9) Remove the thrust washer (9), bearing (10) and 13) Remove the clutch sleeve hub nut. clutch push piece (11). I947H1530010-01 14) Remove the spring washer (13), washer (14) and I947H1530007-01 10) Remove the clutch push rod (12). clutch sleeve hub (15).

  • Page 562

    5C-7 Clutch: 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. I947H1530014-01 I947H1530017-01 18) Remove the spacer (21) and bearing (22). 3) Install the thrust washer (4). 19) Remove the primary driven gear assembly (23).

  • Page 563

    Clutch: 5C-8 7) Install the clutch lifter drive cam (9). I947H1530022-01 11) Lock the clutch sleeve hub nut with a center punch. I947H1530020-02 8) Install the clutch sleeve hub, washer (10) and spring washer (11). NOTE The conical curve side of spring washer (11) faces outside.

  • Page 564

    5C-9 Clutch: 14) Install the spring washer seat (16) and spring washer NOTE (17) onto the clutch sleeve hub correctly. Two kinds of drive plate (No. 1 and No. 2) are equipped in the clutch system, they can be distinguished by inside diameter. Drive plate I.D.

  • Page 565

    Tightening torque Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lbf- : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) NOTE Tighten the clutch spring set bolt little by little and diagonally.

  • Page 566

    5C-11 Clutch: 26) 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 new gasket washer to the bolt “F” and (A): 09900–20102 (Vernier calipers (200 mm)) clamp to the bolt “G”.

  • Page 567

    Clutch: 5C-12 Clutch Release Bearing Wave Spring Washer Inspect the clutch release bearing for any abnormality, Measure the free height “A” of each wave spring washer especially cracks. When removing the bearing from the with a vernier calipers. clutch, decide whether it can be reused or if it should be If each wave spring washer height “A”...

  • Page 568

    5C-13 Clutch: Clutch Lifter Pin Inspection and Adjustment 3) Inspect the height “A” of clutch lifter pin at three B947H15306009 positions using the thickness gauge. If the Refer to “Clutch Removal” (Page 5C-5) and “Clutch measurement is out of the specification, adjust the Installation”...

  • Page 569

    Clutch: 5C-14 8) Tighten the lock-nut (1). Tightening torque Clutch lifter pin lock-nut (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) I947H1530041-02 I837H1530046-02 Specifications Service Data B947H15307001 Clutch Unit: mm (in) Item Standard Limit Clutch drive plate thickness No. 1 and 2 3.22 –...

  • Page 570

    5C-15 Clutch: Special Tools and Equipment Recommended Service Material B947H15308001 Material SUZUKI recommended product or Specification Note Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 5C-10) 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 571

    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 572

    6-1 Precautions: Precautions Steering Precautions Precautions for Steering B947H16000001 Refer to “General Precautions” in Section 00 (Page 00-1).

  • Page 573: Steering General Diagnosis

    Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B947H16104001 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 574

    6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Components B947H16206001 “A” I947H1620001-05 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 lbf-ft) 3. Right handlebar switch box 7.

  • Page 575

    Steering / Handlebar: 6B-2 Handlebar Removal and Installation 3) Loosen the handlebar clamp bolts (9) and front fork B947H16206002 upper clamp bolts (10). 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) Clutch cable (4) I947H1620004-01...

  • Page 576

    6B-3 Steering / Handlebar: 7) Remove the clutch lever assembly (15) from the left • Insert the protrusion “B” of the handlebar into the hole handlebar. “C” of the steering stem upper bracket. “C” “C” “B” “B” I947H1620007-01 I947H1620010-01 • Tighten the front fork upper clamp bolts (4) and Installation handlebar clamp bolts (5) to the specified torque.

  • Page 577

    – Clutch cable routing (Refer to “Throttle Cable Routing Diagram” in Section 1D (Page 1D-2)) : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) – Throttle cable play (Refer to “Throttle Cable Play Inspection and Adjustment” in Section 1D •...

  • Page 578

    6B-5 Steering / Handlebar: Steering Components B947H16206004 I947H1620017-04 1. Steering stem head nut 7. Dust seal : 90 N⋅m (9.0 kgf-m, 65.0 lbf-ft) 2. Steering stem upper bracket 8. Steering stem upper bearing : 80 N⋅m (8.0 kgf-m, 58.0 lbf-ft) 3.

  • Page 579

    Steering / Handlebar: 6B-6 Steering Damper Construction B947H16206005 I837H1620040-01 1. Steering damper 2. Dust seal 3. Bearing : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply grease. Steering / Steering Damper Removal and 5) Remove the steering damper mounting bolt (5). Installation 6) Remove the steering damper (6).

  • Page 580

    6B-7 Steering / Handlebar: 6) Remove the air cleaner box. Refer to “Air Cleaner 11) Remove the steering stem lock-nut (7), washer and Box Removal and Installation” in Section 1D steering stem nut (8) with the special tools. (Page 1D-7). NOTE 7) Disconnect the ignition switch lead wire coupler (1) When loosening the stem nuts, hold the...

  • Page 581

    NOTE • Apply grease to the bearings, bearing races and dust seals before remounting the steering stem. This adjustment will vary from motorcycle to motorcycle. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) “ a ” I947H1620028-01 I947H1620025-01 • When installing the washer (2), align the lug of the washer to the groove of the steering stem.

  • Page 582

    • 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) I947H1620034-01 I823H1620019-02...

  • Page 583

    Steering / Handlebar: 6B-10 Bearing Steering System Inspection B947H16206008 • Bearing wear or damage Refer to “Steering System Inspection” in Section 0B • Abnormal bearing noise (Page 0B-18). • Race wear or damage Steering Stem Bearing Removal and Installation • Bearing lower seal damage B947H16206009 Removal 1) Remove the steering stem upper bearing and...

  • Page 584

    6B-11 Steering / Handlebar: Outer race 4) With the front wheel in the straight ahead state, hitch the spring scale (special tool) on one handlebar grip • Press in the upper and lower outer races using the end as shown in the figure and read the graduation special tool.

  • Page 585

    Steering / Handlebar: 6B-12 Specifications Tightening Torque Specifications B947H16207001 Tightening torque Fastening part Note N⋅m kgf-m lbf-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 lbf-ft) then turn (Page 6B-8)

  • Page 586

    6B-13 Steering / Handlebar: Special Tools and Equipment Recommended Service Material B947H16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 6B-4) / (Page 6B- equivalent 8) / (Page 6B-9) Handle grip bond Handle Grip Bond (commercially —...

  • Page 587

    Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Specifications .............9B-13 Service Data............9B-13 Precautions............. 9-1 Tightening Torque Specifications......9B-13 Precautions for Electrical System ......9-1 Special Tools and Equipment ......9B-13 Component Location ..........9-1 Recommended Service Material .......9B-13 Electrical Components Location ......

  • Page 588

    9-ii Table of Contents Specifications.............9D-12 Pillion Footrest Construction .......9E-4 Tightening Torque Specifications......9D-12 Side-stand Removal and Installation....9E-4 Specifications ............9E-5 Body Structure .........9E-1 Tightening Torque Specifications......9E-5 Repair Instructions ..........9E-1 Special Tools and Equipment ......9E-5 Body Frame Construction ........9E-1 Recommended Service Material ......9E-5 Front Footrest Bracket Construction ....

  • Page 589

    Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B947H19000001 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 B947H19003001 Refer to “Electrical Components Location” in Section 0A (Page 0A-7).

  • Page 590: Wiring Diagram

    9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B947H19102001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). For E-02, 19, 24, 51 HANDLEBAR SWITCH (RH) STARTER BUTTON FREE FREE DOWN ENGINE PUSH STOP IGNITION IGNITION...

  • Page 591

    Wiring Systems: 9A-2 LICENSE PLTE LIGHT REAR TURN SIGNAL LIGHT (RH) B/Bl REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (LH) COOLING SENSOR FAN RELAY TO SENSOR COOLING HO2 SENSOR SENSOR SENSOR FAN MOTOR GEAR POSITION SWITCH EXCVA SENSOR SENSOR REGULATOR/ STVA RECTIFIER PRIMARY...

  • Page 592

    9A-3 Wiring Systems: For E-03, 28 HANDLEBAR SWITCH (RH) STARTER BUTTON FREE FREE DOWN PUSH ENGINE FRONT BRAKE STOP IGNITION IGNITION SWITCH SIDE-STAND SWITCH COIL #2 COIL #4 SWITCH PUSH FREE PAIR IGNITION SWITCH BRAKE LIGHT CONTROL SPEED SWITCH SOLENOID SENSOR IGNITION IGNITION...

  • Page 593

    Wiring Systems: 9A-4 LICENSE PLTE LIGHT REAR TURN SIGNAL LIGHT (RH) B/Bl REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (LH) COOLING SENSOR FAN RELAY TO SENSOR COOLING HO2 SENSOR SENSOR FAN MOTOR SENSOR GEAR POSITION SWITCH EXCVA SENSOR SENSOR REGULATOR/ STVA RECTIFIER PRIMARY...

  • Page 594

    9A-5 Wiring Systems: For E-14, 33 HANDLEBAR SWITCH (RH) STARTER BUTTON FREE FREE DOWN PUSH ENGINE FRONT BRAKE STOP IGNITION IGNITION SWITCH SIDE-STAND SWITCH COIL #4 COIL #2 SWITCH PUSH FREE PAIR IGNITION SWITCH CONTROL BRAKE LIGHT SPEED SWITCH SOLENOID SENSOR IGNITION IGNITION...

  • Page 595

    Wiring Systems: 9A-6 EVAP SYSTEM PURGE CONTROL SOLENOID VALVE LICENSE PLTE LIGHT REAR TURN SIGNAL LIGHT (RH) B/Bl REAR COMBINATION LIGHT REAR TURN SIGNAL LIGHT (LH) COOLING SENSOR FAN RELAY TO SENSOR COOLING HO2 SENSOR SENSOR FAN MOTOR SENSOR GEAR POSITION SWITCH EXCVA...

  • Page 596

    9A-7 Wiring Systems: Wiring Harness Routing Diagram B947H19102002 “A”, “B” “A” “C” “D” “E” “F” I947H1910907-03 1. Wiring harness No. 2 “B”: Pass the left position light lead wires under the wiring harness No. 2. 2. Tapping clamp “C”: Route the steering damper lead wire under the wiring harness No. 2. : Insert the clamp from the front side.

  • Page 597

    Wiring Systems: 9A-8 “C” “B” Upside “A” “D” “E” “ a ” I947H1910908-03 1. Clamp 13. Battery negative lead wire : Pass the side-stand switch lead wire left side of the water by- : Pass the battery negative lead wire in front of the PCV hose. (For E-33, pass pass hose and clamp them in this range.

  • Page 598

    9A-9 Wiring Systems: “B” Upside “A” “D” “C” “E” I947H1910909-03 1. Steel clamp 8. Clamp : Set the clamp facing downward and bend it to outside. : Put the coupler in the frame rib and face the clamp end inside. 2.

  • Page 599

    Wiring Systems: 9A-10 “a” “a” “ a ” “A” “ b ” “ d ” “ c” I947H1910910-02 1. Cylinder head cover “A”: Pass the oil pressure switch lead wire between cylinder and : 14 N⋅m (1.4 kgf-m, 10.0 lbf-ft) generator lead wires.

  • Page 600

    9A-11 Wiring Systems: Specifications Service Data B947H1910S001 Electrical Item Specification Note 10 A Headlight 10 A Ignition 15 A Fuse size Signal 10 A Fuel 10 A 15 A Main 30 A Tightening Torque Specifications B947H1910S002 NOTE The specified tightening torque is described in the following. “Wiring Harness Routing Diagram”...

  • Page 601

    Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B947H19206001 I947H1920001-02 1. Headlight Low beam bulb (12 V 55 W, H11) 2. Headlight High beam bulb (12 V 65 W, H9) 3. Position light bulb (12 V 5 W) x 2 Headlight Removal and Installation 3) Remove the wiring harness No.

  • Page 602

    9B-2 Lighting Systems: 4) Remove the intake pipe covers (3). Headlight Bulb and Position Light Bulb Replacement B947H19206003 CAUTION When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

  • Page 603

    Lighting Systems: 9B-3 Position Light Bulb Headlight Beam Adjustment B947H19206004 1) Disconnect the position light socket (1). Adjust the headlight beam, both horizontally and vertically. NOTE • To adjust the headlight beam, adjust the beam horizontally first, then vertically. • It is not necessary to remove the combination meter to turn the adjusters.

  • Page 604

    9B-4 Lighting Systems: Front Turn Signal Light Removal and Front Turn Signal Light Bulb Replacement B947H19206007 Installation B947H19206006 CAUTION Removal When you touch the bulb with your bare 1) Remove the screw. hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

  • Page 605

    Lighting Systems: 9B-5 Rear Lighting System Construction B947H19206008 I947H1920017-01 1. License plate light assembly 4. Rear combination light : 1.8 N⋅m (0.18 kgf-m, 1.5 lbf-ft) 2. Reflex reflector (E-03, 28, 33 only) 5. Rear turn signal light assembly (LH/RH) : 2.8 N⋅m (0.28 kgf-m, 2.0 lbf-ft) 3.

  • Page 606

    9B-6 Lighting Systems: Rear Combination Light Removal and Installation Install the rear combination light in the reverse order of Installation B947H19206009 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 607

    Lighting Systems: 9B-7 License Plate Light Components B947H19206011 I947H1920021-01 1. License plate light bulb (12 V 5 W) 3. Lens 2. Lens cover : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) License Plate Light Removal and Installation 3) Remove the nuts. B947H19206012 Removal 1) Remove the frame cover.

  • Page 608

    9B-8 Lighting Systems: Installation 2) Remove the lens cover (1) by removing the screws. Install the license plate light in the reverse order of removal. Pay attention to the following point: • Tighten the license plate light mounting nuts (1) to the specified torque.

  • Page 609

    Lighting Systems: 9B-9 Rear Turn Signal Light Components B947H19206014 I947H1920030-01 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 B947H19206015 frame cover (4).

  • Page 610

    9B-10 Lighting Systems: 6) Remove the rear turn signal light (5). 1) Remove the rear turn signal light lens (1). I947H1920033-02 I947H1920034-01 2) Replace the bulb (2). Installation Install the rear turn signal light in the reverse order of removal. Rear Turn Signal Light Bulb Replacement B947H19206016 CAUTION...

  • Page 611

    Lighting Systems: 9B-11 Turn Signal / Side-Stand Relay Inspection Hazard Switch Inspection B947H19206019 B947H19206021 Refer to “Electrical Components Location” in Section 0A Inspect the hazard switch in the following procedures: (Page 0A-7). 1) Remove the air cleaner box. Refer to “Air Cleaner Box Removal and Installation”...

  • Page 612

    9B-12 Lighting Systems: Turn Signal Switch Inspection Dimmer / Passing Light Switch Inspection B947H19206022 B947H19206023 Inspect the turn signal switch in the following Inspect the dimmer/passing light switch in the following procedures: procedures: 1) Remove the air cleaner box. Refer to “Air Cleaner 1) Remove the air cleaner box.

  • Page 613

    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 B947H19208001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9B-6) “1322”...

  • Page 614

    9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B947H19301001 This combination meter mainly consists of a stepping motor, LCD (Liquid Crystal Display) and LEDs (Light Emitting Diode).

  • Page 615

    Combination Meter / Fuel Meter / Horn: 9C-2 Repair Instructions Combination Meter Components B947H19306001 I947H1930002-01 1. Combination meter unit 2. Combination meter case 3. Combination meter cover Combination Meter Removal and Installation 2) Disconnect the coupler (2) and remove the B947H19306002 combination meter assembly (3).

  • Page 616

    9C-3 Combination Meter / Fuel Meter / Horn: Combination Meter Disassembly and Assembly NOTE B947H19306003 Refer to “Combination Meter Removal and Installation” • The pointers may not return to the proper (Page 9C-2). position even turning the ignition switch on under low temperature condition. In that case, you can reset the pointers to the Disassembly Disassemble the combination meter as shown in the...

  • Page 617

    Combination Meter / Fuel Meter / Horn: 9C-4 Engine Coolant Temperature Indicator Light Inspection B947H19306005 Inspect the engine coolant temperature meter and indicator light (LED) in the following procedures: 1) Remove the left side cowling. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-6). 2) Disconnect the ECT sensor coupler (1).

  • Page 618

    9C-5 Combination Meter / Fuel Meter / Horn: Fuel Level Indicator Inspection 3) Install the fuel pump. Refer to “Fuel Pump B947H19306007 Disassembly and Assembly” in Section 1G If the fuel level indicator light (1) does not function (Page 1G-11). properly, check the fuel level gauge and its lead wire/ coupler.

  • Page 619

    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 620

    9C-7 Combination Meter / Fuel Meter / Horn: 4) Check if the oil pressure indicator (LED) (2) will light Ignition Switch Inspection B947H19306015 up and LCD (3) will flicker when grounding the lead Inspect the ignition switch in the following procedures: wire (1).

  • Page 621

    Combination Meter / Fuel Meter / Horn: 9C-8 Horn Inspection Horn Inspection B947H19306017 1) Disconnect the horn coupler (1). NOTE If the horn sound condition is normal, it is not necessary to inspect the horn button continuity. Horn Button Inspection 1) Remove the air cleaner box.

  • Page 622

    9C-9 Combination Meter / Fuel Meter / Horn: Specifications Service Data B947H19307001 Wattage Unit: W Specification Item E-02, 19, 24, 51 E-03, 14, 28, 33 ← Combination meter light ← Turn signal indicator light ← High beam indicator light ← Neutral position indicator light Oil pressure indicator light/Engine ←...

  • Page 623: Exterior Parts

    Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B947H19406001 “B” “A” “C” “A” “A” “A” “D” I947H1940001-01 1. Upper cowling bracket “A”: To frame “C”: To sprocket cover : Set the punch mark to the front and upper side. 2.

  • Page 624

    9D-2 Exterior Parts: Rear Fender Construction B947H19406004 I947H1940002-02 1. Electric parts holder bracket 3. Rear fender (Rear) 5. Rear fender guard (E-24 only) 2. Rear fender (Front) 4. Rear fender (Lower)

  • Page 625

    Exterior Parts: 9D-3 Frame Cover Construction B947H19406005 I947H1940003-01 1. Frame cover (Center) 2. Frame cover (Rear), LH/RH 3. Frame cover (LH/RH)

  • Page 626

    9D-4 Exterior Parts: Rear View Mirror Construction B947H19406008 I947H1940004-01 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 lbf-ft) : Locate the turn signal lead wire coupler (5) between the mirror cover (6) and mirror body (7).

  • Page 627

    Exterior Parts: 9D-5 Fastener Removal and Installation Type B B947H19406010 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 628

    9D-6 Exterior Parts: Exterior Parts Removal and Installation Installation B947H19406011 1) Slide the seat hooks into the seat hook retainers on Side Frame Cover the frame and tighten the bolts. Removal NOTE The left and right side frame covers are installed symmetrically and therefore the removal/installation procedure for one side is the same as that for the other side.

  • Page 629

    Exterior Parts: 9D-7 Installation Installation Slide the hook into the hook retainer and push down Install the windscreen in the reverse order of removal. firmly until the rear seat/seat tail cover snaps into the Pay attention to the following point: locked position.

  • Page 630

    9D-8 Exterior Parts: • Tighten the rear view mirror mounting nuts to the Side Cowling specified torque. Removal 1) Remove the fasteners and cowling bracket (1). Tightening torque Rear view mirror mounting nut (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) I947H1940019-01 I947H1940017-01 Body Cowling Cover...

  • Page 631

    Exterior Parts: 9D-9 Installation 6) Remove the combination meter. Refer to Install side cowling in the reverse order of removal. “Combination Meter Removal and Installation” in Pay attention to the following points: Section 9C (Page 9C-2). • When installing the right side cowling, make sure that 7) Disconnect the turn signal lead wire couplers (1).

  • Page 632

    9D-10 Exterior Parts: 12) Remove the body cowling assembly (4) forward. Cowling Brace Removal 1) Remove the body cowling. 2) Remove the cowling brace (1). I947H1940026-01 13) Disassemble the body cowling assembly. Refer to “Headlight Removal and Installation” in Section 9B (Page 9B-1).

  • Page 633

    Exterior Parts: 9D-11 Frame Cover 4) Disconnect the rear combination light coupler (2). Removal 5) Remove the frame cover assembly from the frame. 1) Remove the front and rear seats. 2) Remove the bolts and fasteners. I947H1940033-02 6) Disassemble the frame cover assembly. Refer to “Rear Combination Light Removal and Installation”...

  • Page 634

    9D-12 Exterior Parts: Specifications Tightening Torque Specifications B947H19407001 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Rear view mirror mounting nut (Page 9D-8) Cowling brace mounting bolt 16.5 (Page 9D-10) NOTE The specified tightening torque is described in the following. “Rear View Mirror Construction”...

  • Page 635: Body Structure

    Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B947H19506001 I947H1950001-01 1. Frame 5. Engine mounting thrust adjuster : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Seat rail 6. Engine mounting thrust adjuster lock-nut : 45 N⋅m (4.5 kgf-m, 32.5 lbf-ft) 3.

  • Page 636

    9E-2 Body Structure: Front Footrest Bracket Construction B947H19506002 “A” “ a ” I947H1950002-02 1. Footrest bracket bolt 8. Rear brake pedal : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Rear brake master cylinder mounting bolt 9. Footrest bracket No. 2 (LH) : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 3.

  • Page 637

    Body Structure: 9E-3 Side-stand Construction B947H19506003 I947H1950003-03 1. Frame 3. Washer : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) : Apply grease to sliding surface. 2. Side-stand bracket 4. Side-stand : 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft)

  • Page 638

    9E-4 Body Structure: Pillion Footrest Construction B947H19506004 I947H1950004-02 1. Pillion footrest 3. Ball 5. Washer 7. Footrest pin : Do not reuse. 2. Spring 4. E-ring 6. O-ring : Apply grease. Side-stand Removal and Installation B947H19506005 Removal 1) Support the motorcycle with a jack or wooden block. CAUTION •...

  • Page 639

    Body Structure: 9E-5 Specifications Tightening Torque Specifications B947H19507001 NOTE The specified tightening torque is described in the following. “Body Frame Construction” (Page 9E-1) “Front Footrest Bracket Construction” (Page 9E-2) “Side-stand Construction” (Page 9E-3) Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-9).

  • Page 640

    Prepared by March, 2009 Part No. 99500-39380-01E Printed in Japan...

  • Page 641

    Printed in Japan...

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