Suzuki GSX1400K4 2004 Manuals

Manuals and User Guides for Suzuki GSX1400K4 2004. We have 1 Suzuki GSX1400K4 2004 manual available for free PDF download: Service Manual

Suzuki GSX1400K4 2004 Service Manual

Suzuki GSX1400K4 2004 Service Manual (396 pages)

Brand: Suzuki | Category: Motorcycle | Size: 31.27 MB

Table of Contents

Foreword Group Index

2
- Table of Contents
  2
- General Precautions
  4
- Warning/Caution/Note
  4
- Serial Number Location
  6
- Suzuki Gsx1400K2 (2002-Model)
  6
- Fuel and Oil Recommendation
  7
  - Fuel
    7
  - Engine Oil
    7
  - Brake Fluid
    7
  - Front Fork Oil
    7
- Break-In Procedures
  8
- Cylinder Identification
  8
- Information Labels
  9
- Specifications
  10
Table of Contents

11
- Country and Area Codes
  12
- Periodic Maintenance Schedule
  14
  - Periodic Maintenance Chart
    14
  - Lubrication Points
    15
- Maintenance and Tune-Up Procedures
  16
  - Air Cleaner
    16
  - Engine
    16
  - Spark Plug
    17
  - Valve Clearance
    18
  - Engine Oil and Oil Filter
    25
  - Fuel Hose
    26
  - Engine Idle Speed
    26
  - Throttle Valve Synchronization
    27
  - Throttle Cable Play
    27
  - Clutch
    28
  - Drive Chain
    29
  - Brake
    31
  - Tire
    34
  - Steering
    35
  - Front Fork
    36
  - Rear Suspension
    36
  - Exhaust Pipe Bolt and Nut
    36
  - Chassis Bolt and Nut
    37
- Compression Pressure Check
  39
- Oil Pressure Check
  40
Engine

41
- Engine Removal and Installation
  43
  - Engine Removal
    43
  - Engine Installation
    48
- Engine Disassembly
  51
- Engine Components Inspection and Service
  62
  - Pair Valve
    62
  - Cylinder Head Cover
    63
  - Camshaft
    63
  - Cam Chain Tension Adjuster
    65
  - Cam Chain Tensioner/Cam Chain Guide
    65
  - Cylinder Head and Valve
    66
  - Cylinder
    74
  - Piston and Piston Ring
    75
  - Clutch
    77
  - Gearshift System
    78
  - Generator
    80
  - Oil Pump
    80
  - Starter Clutch
    80
  - Oil Pressure Regulator/Oil Strainer
    81
  - Crank Balancer
    81
  - Transmission
    82
  - Crankshaft and Conrod
    85
    
    Crankshaft Journal Bearing
    89
    
    Crankshaft Thrust Bearing
    91
  - Crankcase/Oil Pan
    93
- Engine Reassembly
  96
Fi System

119
- Precautions in Servicing
  121
  - Electrical Circuit Inspection Procedure
    123
  - Using Testers
    126
- Fi System Technical Features
  127
  - Injection Time
    127
  - Compensation of Injection Time
    128
  - Injection Stop Control
    128
  - Fuel Delivery System
    129
  - Fuel Pump
    130
  - Fuel Pressure Regulator
    131
  - Fuel Injector
    131
  - Fuel Pump Control System
    132
  - Ecm (Fi Control Unit)
    133
  - Injection Timing
    133
  - Sensors
    134
- Fi System Parts Location
  138
- Fi System Diagram
  140
- Fi System Wiring Diagram
  141
- Self-Diagnosis Function
  142
  - User Mode
    142
  - Dealer Mode
    143
- Fail-Safe Function
  145
- Fi System Troubleshooting
  146
- Fuel System
  167
  - Fuel Tank Removal
    167
  - Fuel Tank Installation
    167
  - Fuel Pressure Inspection
    168
  - Fuel Pump Inspection
    169
  - Fuel Pump Relay Inspection
    170
  - Fuel Pump and Fuel Filter Removal
    170
  - Fuel Mesh Filter Inspection and Cleaning
    171
  - Fuel Pump and Fuel Mesh Filter Installation
    172
- Throttle Body and Stv Actuator
  173
  - Construction
    173
  - Throttle Body Removal
    174
  - Throttle Body Disassembly
    175
  - Throttle Body Cleaning
    178
  - Inspection
    178
  - Throttle Body Reassembly
    178
  - Stp Sensor Adjustment
    181
  - Tp Sensor Adjustment
    183
  - Throttle Body Installation
    183
  - Fuel Injector Inspection
    183
  - Fuel Injector Removal
    183
  - Fuel Injector Installation
    183
  - Fast Idle Inspection
    184
  - Fast Idle Adjustment
    184
  - Throttle Valve Synchronization
    185
  - Throttle Cable Adjustment
    185
- Sensors
  186
  - Iap Sensor Inspection
    186
  - Iap Sensor Removal/Installation
    186
  - Tp Sensor Inspection
    186
  - Tp Sensor Removal/Installation
    186
  - Stp Sensor Inspection
    186
  - Stp Sensor Removal/Installation
    186
  - Ckp Sensor Inspection
    186
  - Ckp Sensor Removal/Installation
    186
  - Cmp Sensor Inspection
    187
  - Cmp Sensor Removal/Installation
    187
  - Iat Sensor Inspection
    187
  - Iat Sensor Removal/Installation
    187
  - Eot Sensor Inspection
    187
  - Eot Sensor Removal/Installation
    187
  - Ap Sensor Inspection
    187
  - Ap Sensor Removal/Installation
    187
  - To Sensor Inspection
    187
  - To Sensor Removal/Installation
    187
Oil Cooling and Lubrication System

188
- Oil Cooling and
  188
- Oil Cooling System/Lubrication System
  189
  - Cylinder Head Oil Cooling Circuit
    189
  - Cylinder Head Cooling System Chart
    190
  - Oil Pan
    190
  - Engine Lubrication Circuit
    191
  - Engine Lubrication System Chart
    193
- Oil Cooler and Oil Hose
  194
  - Oil Cooler Removal
    194
  - Oil Cooler Inspection and Cleaning
    194
  - Oil Hose/Oil Pipe Inspection
    195
  - Oil Cooler Installation
    195
- Cooling Fan
  195
  - Removal
    195
  - Inspection
    196
  - Installation
    196
- Cooling Fan Thermo-Switch
  196
  - Removal
    196
  - Inspection
    197
  - Installation
    197
- Oil Temperature Sensor
  198
  - Removal
    198
  - Inspection
    198
  - Installation
    198
- Oil Filter
  199
- Oil Jet
  199
- Oil Pressure
  199
- Oil Pressure Switch
  199
- Oil Pump
  199
- Oil Strainer
  199
Chassis

200
- Exterior Parts
  202
  - Construction
    202
  - Removal
    203
  - Remounting
    204
  - Fastener Removal and Reinstallation
    205
- Front Wheel
  206
  - Construction
    206
  - Removal
    207
  - Inspection and Disassembly
    207
  - Reassembly and Remounting
    209
- Front Fork
  212
  - Construction
    212
  - Removal and Disassembly
    213
  - Inspection
    216
  - Reassembly and Remounting
    217
  - Suspension Setting
    222
- Steering and Handlebars
  223
  - Construction
    223
  - Removal and Disassembly
    224
  - Inspection and Disassembly
    227
  - Reassembly and Remounting
    228
  - Steering Tension Adjustment
    231
- Rear Wheel
  232
  - Construction
    232
  - Removal
    233
  - Inspection and Disassembly
    234
  - Reassembly and Remounting
    236
- Rear Shock Absorber
  240
  - Construction
    240
  - Removal
    241
  - Inspection
    242
  - Rear Shock Absorber Scrapping Procedure
    242
  - Remounting
    242
  - Suspension Setting
    243
- Rear Swingarm
  244
  - Construction
    244
  - Removal
    245
  - Inspection and Disassembly
    246
  - Reassembly
    247
  - Remounting
    248
  - Final Inspection and Adjustment
    248
- Front Brake
  249
  - Construction
    249
    
    Brake Pad Replacement
    250
    
    Brake Fluid Replacement
    250
    
    Caliper Removal and Disassembly
    251
    
    Caliper Inspection
    252
    
    Caliper Reassembly and Remounting
    252
    
    Brake Disc Inspection
    253
    
    Master Cylinder Removal and Disassembly
    254
    
    Master Cylinder Inspection
    255
    
    Master Cylinder Reassembly and Remounting
    255
- Rear Brake
  257
  - Construction
    257
    
    Brake Pad Replacement
    258
    
    Brake Fluid Replacement
    258
    
    Caliper Removal and Disassembly
    259
    
    Caliper Inspection
    260
    
    Caliper Reassembly and Remounting
    260
    
    Master Cylinder Removal and Disassembly
    261
    
    Master Cylinder Inspection
    262
    
    Master Cylinder Reassembly and Remounting
    262
  - Clutch Release Cylinder and Master Cylinder
    264
    
    Construction
    264
    
    Clutch Fluid Replacement
    265
    
    Clutch Release Cylinder Removal and Disassembly
    265
    
    Clutch Release Cylinder Inspection
    266
    
    Clutch Release Cylinder Reassembly and Remounting
    266
    
    Clutch Master Cylinder Removal and Disassembly
    267
    
    Clutch Master Cylinder Inspection
    268
    
    Clutch Master Cylinder Reassembly and Remounting
    269
  - Tire and Wheel
    270
    
    Tire Removal
    270
    
    Inspection
    270
    
    Valve Installation
    271
    
    Tire Installation
    271
Electrical System

273
- Cautions in Servicing
  274
- Battery
  275
  - Connecting the Battery
    275
  - Using the Multi Circuit Tester
    275
  - Location of Electrical Components
    276
- Generator
  277
  - Charging System
    278
    
    Troubleshooting
    278
    
    Inspection
    279
  - Starter System and Side-Stand/Ignition Interlock System
    283
    
    Troubleshooting
    283
    
    Starter Motor Removal and Disassembly
    284
    
    Starter Motor Inspection
    285
    
    Starter Motor Reassembly
    285
    
    Starter Relay Inspection
    286
    
    Side-Stand/Ignition Interlock System Parts Inspection
    287
  - Ignition System
    290
    
    Troubleshooting
    290
    
    Inspection
    292
  - Combination Meter
    295
    
    Removal and Disassembly
    295
    
    Inspection
    296
- Brake Light/Taillight
  300
  - Lamps
    300
  - Relays
    301
  - Switches
    301
    
    Starter Relay
    301
    
    Fuel Pump Relay
    301
  - Battery
    303
    
    Specifications
    303
    
    Initial Charging
    303
    
    Servicing
    304
    
    Recharging Operation
    305
- Turn Signal Light
  300
Servicing Information

306
- Troubleshooting
  307
  - Fi System Malfunction Code and Defective Condition
    307
  - Engine
    309
  - Cooling System
    314
  - Chassis
    315
  - Brakes
    316
  - Electrical
    317
  - Battery
    318
  - Wiring Harness Routing
    321
  - High-Tension Cord Routing
    322
  - Engine Electrical Parts Set-Up
    323
  - Clutch Hose Routing
    324
  - Throttle Cable Routing
    325
  - Fuel Pump/Fuel Level Gauge Set-Up
    326
  - Front Brake Hose Routing
    327
  - Rear Brake Hose Routing
    328
  - Side-Stand Set-Up
    329
  - Center Stand Set-Up
    329
  - Seat Lock Cable Routing and Luggage Hook Set-Up
    330
  - Brake Pedal Set-Up
    330
  - Fuel Hose Routing
    331
  - Fuel Tank Set-Up
    332
  - Throttle Body Set-Up
    333
  - Pair (Air Supply) System Hose Routing
    334
- Special Tools
  335
- Tightening Torque
  338
- Service Data
  342
- High Beam Indicator Light
  348
- Neutral Indicator Light
  348
- Oil Pressure Indicator Light
  348
- Speedometer Light
  348
- Tachometer Light
  348
- Turn Signal Indicator Light
  348
Gsx1400K3 ('03-Model)

351
- Specifications
  352
- Chassis
  353
  - Steering
    353
- Engine
  353
  - Gearshift Cam
    353
- Wire Harness Routing
  355
- Service Data
  356
- Gsx1400K4 ('04-Model)
  365
Specifications

366
- Type
  372
- Brake Light/Taillight
  373
- High Beam Indicator Light
  373
- Neutral Indicator Light
  373
- Oil Pressure Indicator Light
  373
  - Gsx1400K5/Udk5 ('05-Model)
    378
- Position Light
  373
- Rear Brake
  373
- Speedometer Light
  373
- Tachometer Light
  373
- Turn Signal Indicator Light
  373
- Turn Signal Light
  373
- Engine Oil, Oil Change
  379
- Fuel Tank, Including Reserve
  379
- With Filter Change
  379
  - Center Stand Installation
    392
  - Wiring Diagram
    394

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