Suzuki GSXR 1000 K5 K6
TOP GSX-R1000 GSX-R1000 Printed in Japan K5 99500-39270-01E K5 No.7892 GSX-R1000_01E 99500-39270-01E 2005.1.19 Cover_14 for PS printing (20mm) 1/1 BOTTOM TDP7
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION 1 nents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to PERIODIC MAINTENANCE 2 familiarize yourself with the motorcycle and its main- tenance. Use this section as well as other sections to use as a guide for proper inspection and service. ENGINE 3 This manual will help you know the motorcycle bet- ter so that you can assure your customers of fast and reliable service. FI SYSTEM DIAGNOSIS 4 * This manual has been prepared on the basis of the latest specifications at the time of publi- cation. If modifications have been made since FUEL SYSTEM AND THROTTLE 5 then, differences may exist between the con- BODY tent of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work EXHAUST SYSTEM 6 procedures. They may not represent the E actual motorcycle exactly in detail. L * This manual is written for persons who have COOLING AND LUBRICATION 7 enough knowledge, skills and tools, including P SYSTEM special tools, for servicing SUZUKI motorcy- M cles. If you do not have the proper knowledge CHASSIS 8 and tools, ask your authorized SUZUKI motorcycle dealer to help you. A S ELECTRICAL SYSTEM 9 Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the SERVICING INFORMATION 10 services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle EMISSION CONTROL 11 unsafe for the rider and passenger. INFORMATION WIRING DIAGRAM 12 © COPYRIGHT SUZUKI MOTOR CORPORATION 2005
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel 1 Brake disc 2 Collar 3 Dust seal 4 Bearing E 5 Spacer L 6 Front axle 7 Front wheel P A Front axle bolt B Brake disc bolt M A ITEM N·m kgf-m lb-ft S A 100 10.0 72.5 B 23 2.3 16.5
SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Apply THREAD LOCK SUPER “1360”. Data beside it indicates specified 99000-32130 torque. Apply oil. Use engine oil unless other- Use engine coolant. wise specified. 99000-99032-11X (Except USA) Apply molybdenum oil solution. Use fork oil. (Mixture of engine oil and SUZUKI 99000-99044-L01 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. 99000-25010 (Others) Apply or use brake fluid. 99000-25030 (USA) Apply SUZUKI MOLY PASTE. Measure in voltage range. 99000-25140 E L Apply SUZUKI BOND “1215”. PMeasure in current range. 99000-31110 (Except USA) M Apply SUZUKI BOND “1207B”. 99104-31140 (USA) A Measure in resistance range. S Apply SUZUKI BOND “1207B”. Measure in diode test range. 99000-31140 (Except USA) Apply THREAD LOCK SUPER “1303”. Measure in continuity test range. 99000-32030 Apply THREAD LOCK SUPER “1322”. Use special tool. 99000-32110 (Except USA) Apply THREAD LOCK “1342”. Indication of service data. 99000-32050 (USA)
ABBREVIATIONS USED IN THIS MANUAL A E ABDC : After Bottom Dead Center ECM : Engine Control Module AC : Alternating Current Engine Control Unit (ECU) ACL : Air Cleaner, Air Cleaner Box (FI Control Unit) API : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp. ATM Pressure : Atmospheric Pressure Sensor (WTS) : Atmospheric Pressure sensor EVAP : Evaporative Emission (APS, AP Sensor) EVAP Canister: Evaporative Emission A/F : Air Fuel Mixture Canister (Canister) EXC System : Exhaust Control System (EXCS) B EXC Valve : Exhaust Control Valve (EXCV) BBDC : Before Bottom Dead Center EXCV Actuator : Exhaust Control Valve Actuator BTDC : Before Top Dead Center (EXCVA) B+ : Battery Positive Voltage F C FI : Fuel Injection, Fuel Injector E CKP Sensor : Crankshaft Position Sensor FP : Fuel Pump (CKPS) FPR : Fuel Pressure Regulator L CKT : Circuit FP Relay : Fuel Pump Relay CLP Switch : Clutch Lever Position Switch P (Clutch Switch) G M CMP Sensor : Camshaft Position Sensor GEN : Generator (CMPS) A GND : Ground CO : Carbon Monoxide GP Switch : Gear Position Switch CPU : Central Processing Unit S H D HC : Hydrocarbons DC : Direct Current DMC : Dealer Mode Coupler I DOHC : Double Over Head Camshaft IAP Sensor : Intake Air Pressure Sensor (IAPS) DRL : Daytime Running Light (MAP Sensor) DTC : Diagnostic Trouble Code IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition L LCD : Liquid Crystal Display LED : Light Emitting Diode (Malfunction Indicator Lamp) LH : Left Hand
M MAL-Code : Malfunction Code (Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp (LED) Min : Minimum N NOX : Nitrogen Oxides O OHC : Over Head Camshaft OPS : Oil Pressure Switch P PCV : Positive Crankcase Ventilation (Crankcase Breather) R E RH : Right Hand ROM : Read Only Memory L S P SAE : Society of Automotive Engineers SDS : Suzuki Diagnosis SystemM STC System : Secondary Throttle Control System (STCS) A STP Sensor : Secondary Throttle Position Sensor (STPS) S ST Valve : Secondary Throttle Valve (STV) STV Actuator : Secondary Throttle Valve Actuator (STVA) T TO Sensor : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS)
WIRE COLOR B : Black G : Green P :Pink Bl : Blue Gr : Gray R : Red Br : Brown Lbl : Light blue W : White Dg : Dark green Lg : Light green Y : Yellow Dgr : Dark gray O : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer B/G : Black with Green tracer B/Lg : Black with Light green tracer B/R : Black with Red tracer B/W : Black with White tracer B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer Bl/G : Blue with Green tracer Bl/R : Blue with Red tracer Bl/W : Blue with White tracer Bl/Y : Blue with Yellow tracer Br/Y : Brown with Yellow tracer G/B : Green with Black tracer G/Bl : Green with Blue tracer G/R : Green with Red tracer G/W : Green with White tracer G/Y : Green with Yellow tracer Gr/B : Gray with Black tracer Gr/R : Gray with Red tracer Gr/W : Gray with White tracer Gr/Y : Gray with Yellow tracer Lg/BI : Light green with Blue tracer Lg/G : Light green with Green tracer Lg/W : Light green with White tracer O/B : Orange with Black tracer E O/BI : Orange with Blue tracer O/G : Orange with Green tracer L O/R : Orange with Red tracer O/W : Orange with White tracer O/Y : Orange with Yellow tracer P/B : Pink with Black tracer P P/W : Pink with White tracer R/B : Red with Black tracer R/Bl : Red with Blue tracer R/Y : Red with Yellow tracer M R/W : Red with White tracer W/B : White with Black tracer W/Bl : White with Blue tracer A W/G : White with Green tracer W/R : White with Red tracer S W/Y : White with Yellow tracer Y/B : Yellow with Black tracer Y/Bl : Yellow with Blue tracer Y/G : Yellow with Green tracer Y/R : Yellow with Red tracer Y/W : Yellow with White tracer
GENERAL INFORMATION 1-1 GENERAL INFORMATION 1 CONTENTS WARNING/CAUTION/NOTE......................................................................... 1- 2 GENERAL PRECAUTIONS.......................................................................... 1- 2 SUZUKI GSX-R1000K5 (’05-MODEL).......................................................... 1- 4 SERIAL NUMBER LOCATION..................................................................... 1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION.......................1- 5 FUEL (FOR USA AND CANADA).......................................................... 1- 5 FUEL (FOR OTHER COUNTRIES)........................................................ 1- 5 ENGINE OIL (FOR USA)........................................................................ 1- 5 ENGINE OIL (FOR OTHER COUNTRIES)............................................. 1- 5 BRAKE FLUID........................................................................................ 1- 5 FRONT FORK OIL.................................................................................. 1- 6 ENGINE COOLANT................................................................................ 1- 6 WATER FOR MIXING............................................................................. 1- 6 ANTI-FREEZE/ENGINE COOLANT....................................................... 1- 6 LIQUID AMOUNT OF WATER/ENGINE COOLANT.............................1- 6 E BREAK-IN PROCEDURES........................................................................... 1- 7 L CYLINDER IDENTIFICATION....................................................................... 1- 7 P INFORMATION LABELS.............................................................................. 1- 8 SPECIFICATIONS......................................................................................... 1- 9 M DIMENSIONS AND DRY MASS............................................................. 1- 9 ENGINE.................................................................................................. 1- 9 A DRIVE TRAIN......................................................................................... 1- 9 CHASSIS................................................................................................ 1-10 S ELECTRICAL......................................................................................... 1-10 CAPACITIES.......................................................................................... 1-10 COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA EFFECTIVE FRAME NO. E-02 U.K. JS1B6111200100001 – E-03 U.S.A. (Except for California) JS1GT76A 52100001 – E-19 (GSX-R1000) E.U. JS1B6111100100001 – E-19 (GSX-R1000UF) E.U. JS1B6211100100001 – E-24 Australia JS1B6121300100001 – E-28 Canada JS1GT76A 52100001 – E-33 California (U.S.A.) JS1GT76A 52100001 –
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN- INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. E GENERAL PRECAUTIONS L P * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.M * When 2 or more persons work together, pay attention to the safety of each other. A * When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors. S * When working with toxic or flammable materials, make sure that the area you work in is well- ventilated and that you follow all of the material manufacturer’s instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled. After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks.
GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative cable from the battery. * When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci- fied tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger E than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. L * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. P * After reassembling, check parts for tightness and proper operation. M A * To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries and tires. S * To protect Earth’s natural resources, properly dispose of used motorcycle and parts.
1-4 GENERAL INFORMATION SUZUKI GSX-R1000K5 (’05-MODEL) RIGHT SIDE PLE AM S LEFT SIDE • Difference between photograph and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the rear side of the crankcase. These num- bers are required especially for registering the machine and ordering spare parts.
GENERAL INFORMATION 1-5 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (FOR USA AND CANADA) Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. FUEL (FOR OTHER COUNTRIES) Gasoline used should be graded 95 octane (Research Method) or higher. Unleaded gasoline is recom- mended. ENGINE OIL (FOR USA) Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of API SF/SG or SH/SJ with JASO MA. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart. ENGINE OIL (FOR OTHER COUNTRIES) Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of API E SF/SG or SH/SJ with JASO MA. L Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative accord- ing to the right chart. P M BRAKE FLUID A Specification and classification: DOT 4 S Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu- facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
1-6 GENERAL INFORMATION FRONT FORK OIL Use fork oil L01 or an equivalent fork oil. ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): Approx. 2 400 ml (2.5/2.1 US/Imp qt) For engine coolant mixture information, refer to cooling system section in page 7-2. E Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce L its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting perfor- mance is greatly reduced. Be sure to mix it above 50% even though the atmospheric tempera- ture does not go down to the freezing point. P M A S
GENERAL INFORMATION 1-7 BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. • Keep to these break-in engine speed limits: Initial 800 km ( 500 miles): Below 6 500 r/min Up to 1 600 km (1000 miles): Below 10 000 r/min Over to 1 600 km (1000 miles): Below 13 500 r/min • Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throt- tle operation. However, do not exceed 13 500 r/min at any time. CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No. 1, No. 2, No. 3 and No. 4 cylinder, as counted from left to right (as viewed by the rider on the seat.) E PL #1 #2 M A#3 S #4
1-8 GENERAL INFORMATION INFORMATION LABELS GSX-R1000 GSX-R1000UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Fuel information label A A 6 Manual notice label A (For E-03, 33) 7 Frame caution plate A A 8 Screen label A A 9 Warning steering label A A 0 Tire information label A A A General warning label A A B ICES Canada label A (For E-28) C I.D. plate A (Except E-03, 28, 33) A D E-19 I.D. label A E Safety plate A (For E-03, 28, 33) A: Attached *1: This label is attached on the left side of rear fender. E *2: This label is attached on the right side of rear fender. L *3: This label is attached on the right side of seat rail. P M E-28 (English) SA Others Air intake cover *3 *2 *1 Frame (Right side) Frame (Left side) Chain cover
GENERAL INFORMATION 1-9 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length.......................................................................... 2 030 mm (79.9 in) Overall width ........................................................................... 710 mm (28.0 in) Overall height.......................................................................... 1 130 mm (44.5 in) Wheelbase.............................................................................. 1 405 mm (55.3 in) Ground clearance.................................................................... 130 mm (5.1 in) Seat height.............................................................................. 810 mm (31.9 in) Dry mass................................................................................. 167 kg (368 lbs) ...........E-33 166 kg (365 lbs) ...........Others ENGINE Type........................................................................................ Four stroke, liquid-cooled, DOHC Number of cylinders................................................................ 4 Bore......................................................................................... 73.4 mm (2.900 in) Stroke...................................................................................... 59.0 mm (2.323 in) Displacement .......................................................................... 999 cm³ (61.0 cu. in) Compression ratio................................................................... 12.5 : 1 Fuel system............................................................................. Fuel injection Air cleaner............................................................................... Paper element Starter system......................................................................... Electric E Lubrication system.................................................................. Wet sump L Idle speed................................................................................ 1 150 ± 100 r/min DRIVE TRAIN P M Clutch...................................................................................... Wet multi-plate type Transmission........................................................................... 6-speed constant mesh A Gearshift pattern ..................................................................... 1-down, 5-up Primary reduction ratio............................................................ 1.553 (73/47) S Gear ratios, Low.................................................................... 2.562 (41/16) 2nd..................................................................... 2.052 (39/19) 3rd...................................................................... 1.714 (36/21) 4th...................................................................... 1.500 (36/24) 5th...................................................................... 1.360 (34/25) Top..................................................................... 1.269 (33/26) Final reduction ratio................................................................. 2.470 (42/17) Drive chain.............................................................................. DID530 V9, 110 links
1-10 GENERAL INFORMATION CHASSIS Front suspension.................................................................... Inverted telescopic, coil spring, oil damped Rear suspension..................................................................... Link type, coil spring, oil damped Front fork stroke...................................................................... 120 mm (4.7 in) Rear wheel travel.................................................................... 130 mm (5.1 in) Steering angle......................................................................... 27° Caster..................................................................................... 23° 45’ Trail......................................................................................... 96 mm (3.78 in) Turning radius......................................................................... 3.4 m (11.2 ft) Front brake.............................................................................. Disc brake, twin Rear brake.............................................................................. Disc brake Front tire size.......................................................................... 120/70 ZR 17 M/C (58 W), tubeless Rear tire size........................................................................... 190/50 ZR 17 M/C (73 W), tubeless ELECTRICAL Ignition type............................................................................. Electronic ignition (Transistorized) Ignition timing.......................................................................... 10° B.T.D.C.at 1 150 r/min Spark plug............................................................................... NGK CR9E or DENSO U27ESR-N Battery..................................................................................... 12 V 36.0 kC (10 Ah)/10 HR Generator................................................................................ Three-phase A.C. generator Main fuse................................................................................ 30 A E Fuse........................................................................................ 15/10/10/10/10/10 A L Headlight................................................................................. 12 V 55 W (H7) + 12 V 60 W (HB3) Turn signal light....................................................................... 12 V 21 W P License plate light................................................................... 12 V 5 W Brake light/Taillight.................................................................. LED M Speedometer light................................................................... LED Tachometer light..................................................................... LED A Neutral indicator light.............................................................. LED S High beam indicator light ........................................................ LED Turn signal indicator light........................................................ LED Position/Parking light .............................................................. 12 V 5 W × 2 Oil pressure/Coolant temperature/Fuel injection warning light .... LED Fuel level indicator light .......................................................... LED Engine RPM indicator light...................................................... LED Immobilizer indicator light ....................................................... LED.........E-03, 19, 24 CAPACITIES Fuel tank, including reserve.................................................... 17.5 L (4.6/3.8 US/lmp gal)......E-33 18.0 L (4.8/4.0 US/lmp gal)......Others Engine oil, oil change............................................................. 3 000 ml (3.2/2.6 US/Imp qt) with filter change .................................................. 3 300 ml (3.5/2.9 US/lmp qt) overhaul................................................................ 3 600 m (3.8/3.2 US/lmp qt) Coolant.................................................................................... 2.4 L (2.5/2.1 US/lmp qt) These specifications are subject to change without notice.
PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE..................................................... 2- 2 2 PERIODIC MAINTENANCE CHART...................................................... 2- 2 LUBRICATION POINTS......................................................................... 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES........................................2- 4 AIR CLEANER........................................................................................ 2- 4 SPARK PLUG......................................................................................... 2- 5 VALVE CLEARANCE............................................................................. 2- 7 ENGINE OIL AND OIL FILTER.............................................................. 2-12 EXHAUST CONTROL VALVE............................................................... 2-13 FUEL LINE.............................................................................................. 2-14 ENGINE IDLE SPEED............................................................................ 2-14 THROTTLE VALVE SYNCHRONIZATION............................................ 2-15 EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY)...........2-15 PAIR (AIR SUPPLY) SYSTEM............................................................... 2-15 THROTTLE CABLE PLAY..................................................................... 2-15 E CLUTCH................................................................................................. 2-16 L COOLING SYSTEM................................................................................ 2-17 P DRIVE CHAIN......................................................................................... 2-20 BRAKE................................................................................................... 2-23 M TIRES...................................................................................................... 2-27 STEERING.............................................................................................. 2-27 A FRONT FORK......................................................................................... 2-28 REAR SUSPENSION............................................................................. 2-28 S EXHAUST PIPE BOLT AND NUT.......................................................... 2-29 CHASSIS BOLTS AND NUTS............................................................... 2-30 COMPRESSION PRESSURE CHECK......................................................... 2-32 COMPRESSION TEST PROCEDURE................................................... 2-32 OIL PRESSURE CHECK.............................................................................. 2-33 SDS CHECK.................................................................................................. 2-34
2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval miles 600 4 000 7 500 11 000 14 500 km 1 000 6 000 12 000 18 000 24 000 Item months 212243648 Air cleaner element ---- I I R I Spark plugs ---- I R I R Valve clearance ---- ---- ---- ---- I Exhaust valve I ---- I ---- I Engine oil R R R R R Engine oil filter R ---- ---- R ---- Fuel line ---- I I I I Idle speed IIIII I E Throttle valve synchronization (E-33 only) ---- I ---- I Evaporative emission control system L ---- ---- I ---- I (E-33 only) P PAIR (air supply) system ---- ---- I ---- I M Throttle cable play IIIII Clutch cable play ---- I I I I A Radiator hoses ---- I I I I Engine coolant Replace every 2 years. S Drive chain I I I I I Clean and lubricate every 1 000 km (600 miles). Brakes IIIII Brake hoses ---- I I I I Replace every 4 years. Brake fluid ---- I I I I Replace every 2 years. Tires ----IIII Steering I ---- I ---- I Front forks ---- ---- I ---- I Rear suspension ---- ---- I ---- I Exhaust pipe bolts and muffler bolt and nut T ---- T ---- T Chassis bolts and nuts T TTTT NOTE: I = Inspect and clean, adjust, replace or lubricate as necessary R = Replace T = Tighten
PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder E Brake pedal pivot and footrest pivot PL Clutch lever holder SAM Side-stand pivot Footrest pivot and and spring hook gearshift lever pivot Drive chain NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. * Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions.
2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months). Replace every 18 000 km (11 000 miles, 36 months). • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) • Remove the air cleaner element by removing the screws. • Remove the air cleaner element. • Inspect the air cleaner element for clogging. If the air cleaner element is clogged with dust, replace the air cleaner element with a new one. E L Do not blow the air cleaner element with compressed air. P NOTE: M If driving under dusty conditions, replace the air cleaner element more frequently. Make sure that the air cleaner is in good condi- A tion at all times. The life of the engine depends largely on this component. S • Install a new air cleaner element in the reverse order of removal. • Remove the drain plug from the air cleaner box to allow any water to drain out.
PERIODIC MAINTENANCE 2-5 SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). replace every 12 000 km (7 500 miles, 24 months). SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-13) • Disconnect all lead wire couplers from ignition coil/plug caps. Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler dam- age. • Remove the ignition coils/plug caps. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage. E * Be careful not to drop the ignition coil/plug cap to L prevent short/open circuit. P • Remove the spark plugs with a spark plug wrench. HEAT RANGE M • Check spark plug heat range by observing electrode color. If A the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or S glazed appearing, replace the spark plug with colder type one. Hot type Standard Cold type NGK CR8E CR9E CR10E ND U24ESR-N U27ESR-N U31ESR-N NOTE: “R” type spark plug has a resistor built into at the center elec- trode to prevent radio noise. CARBON DEPOSITS • Check carbon deposits on the spark plug. • If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.
2-6 PERIODIC MAINTENANCE SPARK PLUG GAP • Measure the spark plug gap with a thickness gauge. • Adjust the spark plug gap if necessary. Spark plug gap: Standard: 0.7 – 0.8 mm (0.028 – 0.031 in) 09900-20803: Thickness gauge ELECTRODE’S CONDITION • Check the condition of the electrode. • If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine dam- age may result. SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION E • Screw the spark plugs into the cylinder head with fingers, and L then tighten them to the specified torque. Spark plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft) P M Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head. SA • Install the ignition coils/plug caps and connect their lead wire couplers. * Do not hit the ignition coil/plug cap with a plastic hammer when installing it. * Place the ignition coil/spark plug cap so that the cou- pler does not touch the cylinder head cover. CONTACT INCORRECT INCORRECT
PERIODIC MAINTENANCE 2-7 VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the right under cowling. (8-5) • Lift and support the fuel tank. (5-3) • Remove the air cleaner box. (5-13) • Disconnect the CMP sensor coupler 1. • Remove the PAIR control solenoid valve 2. • Remove the spark plugs. (2-5) • Loosen the throttle body clamp screws at the intake pipe side. • Move the throttle body assembly. • Remove the cylinder head cover. (3-15) The valve clearance specification is different for intake and E exhaust valves. Valve clearance must be checked and adjusted, L 1) at the time of periodic inspection, 2) when the valve mecha- nism is serviced, and 3) when the camshafts are removed for servicing. P Valve clearance (when cold): M Standard: IN. : 0.10 – 0.20 mm (0.004 – 0.008 in) EX.: 0.20 – 0.30 mm (0.008 – 0.012 in) SA NOTE: * The cam must be at positions, A or B, when checking or adjusting the valve clearance. Clearance readings should not EX. IN. be taken with the cam in any other position than these two positions. * The clearance specification is for COLD state. * To turn the crankshaft for clearance checking, be sure to use a wrench, and rotate in the normal running direction. All spark plugs should be removed. • Remove the valve timing inspection cap 1.
2-8 PERIODIC MAINTENANCE • Turn the crankshaft to bring the “Top” line on the starter clutch to the index mark and also to bring the notches A on the left ends of both camshafts (Ex. and In.) to the positions as shown. • In this condition, read the valve clearance at the valves B (In. Front and Ex. of No. 4 cylinder, Ex. of No. 3 and In. of No. 2). E • If the clearance is out of specification, adjust the clearance. L (2-9) P 09900-20803: Thickness gauge AM S • Turn the crankshaft 360 degrees (one rotation) to bring the “TOP” line on the starter clutch to the index mark of valve tim- ing inspection hole and also to bring the notches A to the position as shown. • Read the clearance at the rest of the valves C and adjust the clearance if necessary. (2-9) Cam position Notch A position Exhaust Camshaft Intake Camshaft B ← Front ← Front C ← Front ← Front Front
PERIODIC MAINTENANCE 2-9 VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (3-15) • Remove the tappet and shim by fingers or magnetic hand. • Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated. • Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 25 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure its size. Refer to the tappet shim selection table (2-10 and -11) for details. 170 1.70 mm NOTE: E * Be sure to apply engine oil to tappet shim top and bottom faces. L * When seating the tappet shim, be sure the figure printed sur- face faces the tappet. P NOTE: M Reinstall the camshafts in the specified manner. (3-100) A • After replacing the tappet shim and camshafts, rotate the engine so that the tappet is depressed fully. This will squeeze S out oil trapped between the shim and the tappet that could cause an incorrect measurement. Then check the clearance again to confirm that it is within the specified range. • After finishing the valve clearance adjustment, reinstall the fol- lowing items. * Cylinder head cover (3-105) * Spark plug and plug cap (2-6) * Throttle body assembly (5-21) * Valve timing inspection plug (3-105) * PAIR control solenoid valve (11-7)
2-10 PERIODIC MAINTENANCE (INTAKE SIDE) ontal iz 220 2.20 2.102.15 e in hor 215 2.15 2.052.102.20 210 2.10 2.002.052.20 205 2.05 1.952.002.152.20 200 2.00 1.901.952.102.152.20 APPET SHIM SET (12800-05830)1951.951.851.902.052.102.152.20 0.23 mm1.70 mm1.80 mm T “ENGINE IS COLD”. e 190 : . 1.90 1.801.852.002.052.102.152.20 T tical column with present shim siz AKE] UIRED anceer 185 1.85 1.751.801.952.002.052.102.152.20 CHAR e 180 e clear 1.80 1.701.751.901.952.002.052.102.152.20 alv ance in vance is EXAMPLEe to be used ABLE [INT 175 1.75 1.651.701.851.901.952.002.052.102.152.20E T USE THIS e clear O alv 170 1.70 1.601.651.801.851.901.952.002.052.102.152.20L W T Measure vMeasure present shim sizMatch clearcolumn.VPresent shim sizShim siz 165 P HOI. II. III. (12892-05C00-XXX) 1.65 1.551.601.751.801.851.901.952.002.052.102.152.20 . 160 1.60 1.501.551.701.751.801.851.901.952.002.052.102.152.20 M 155 1.55 1.451.501.651.701.751.801.851.901.952.002.052.102.152.20 A SPECIFIED CLEARANCE/NO ADJUSTMENT REQ 150 1.50 1.401.451.601.651.701.751.801.851.901.952.002.052.102.152.20 S APPET SHIM SELECTION APPET SHIM NO1451.451.351.401.551.601.651.701.751.801.851.901.952.002.052.102.152.20 T T 140 1.40 1.301.351.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 135 1.35 1.251.301.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 130 1.30 1.201.251.401.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 125 1.25 1.201.351.401.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 120 1.20 1.301.351.401.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 . NO (mm) SUFFIXPRESENTSHIM SIZE 0.00 – 0.040.05 – 0.090.10 – 0.200.21 – 0.250.26 – 0.300.31 – 0.350.36 – 0.400.41 – 0.450.46 – 0.500.51 – 0.550.56 – 0.600.61 – 0.650.66 – 0.700.71 – 0.750.76 – 0.800.81 – 0.850.86 – 0.900.91 – 0.950.96 – 1.001.01 – 1.051.06 – 1.101.11 – 1.15 VE AL MEASURED VCLEARANCE (mm)
PERIODIC MAINTENANCE 2-11 (EXHAUST SIDE) ontal iz 220 2.202.052.102.15 e in hor 215 2.152.002.052.102.20 210 2.101.952.002.052.20 205 2.051.901.952.002.152.20 200 2.001.851.901.952.102.152.20 APPET SHIM SET (12800-05830)1951.951.801.851.902.052.102.152.20 0.33 mm1.70 mm1.80 mm T “ENGINE IS COLD”. e 190 : . UST] 1.901.751.801.852.002.052.102.152.20 T tical column with present shim siz UIRED anceer 185 1.851.701.751.801.952.002.052.102.152.20 CHAR e 180 e clear 1.801.651.701.751.901.952.002.052.102.152.20alvance in vance is EXAMPLEe to be used ABLE [EXHA 175 1.751.601.651.701.851.901.952.002.052.102.152.20E USE THIS T O e clear 170 1.551.60 L alv 1.70 1.651.801.851.901.952.002.052.102.152.20W TMeasure vMeasure present shim sizMatch clearcolumn.VPresent shim sizShim siz 165 1.501.55 P HOI.II.III. (12892-05C00-XXX) 1.65 1.601.751.801.851.901.952.002.052.102.152.20 . 160 1.601.451.501.551.701.751.801.851.901.952.002.052.102.152.20 M 155 1.551.401.451.501.651.701.751.801.851.901.952.002.052.102.152.20 A SPECIFIED CLEARANCE/NO ADJUSTMENT REQ 150 1.501.351.401.451.601.651.701.751.801.851.901.952.002.052.102.152.20 S APPET SHIM SELECTION APPET SHIM NO1451.451.301.351.401.551.601.651.701.751.801.851.901.952.002.052.102.152.20 T T 140 1.401.251.301.351.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 135 1.351.201.251.301.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 130 1.30 1.201.251.401.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 125 1.25 1.201.351.401.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 120 1.20 1.301.351.401.451.501.551.601.651.701.751.801.851.901.952.002.052.102.152.20 . NO (mm) SUFFIXPRESENTSHIM SIZE 0.05 – 0.090.10 – 0.140.15 – 0.190.20 – 0.300.31 – 0.350.36 – 0.400.41 – 0.450.46 – 0.500.51 – 0.550.56 – 0.600.61 – 0.650.66 – 0.700.71 – 0.750.76 – 0.800.81 – 0.850.86 – 0.900.91 – 0.950.96 – 1.001.01 – 1.051.06 – 1.101.11 – 1.151.16 – 1.201.21 – 1.25 E V L MEASURED VACLEARANCE (mm)
2-12 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter. ENGINE OIL REPLACEMENT • Remove the under cowlings. (8-5) • Keep the motorcycle upright. • Place an oil pan below the engine, and drain oil by removing the oil drain plug 1 and filler cap 2. • Tighten the drain plug 1 to the specified torque, and pour fresh oil through the oil filler. The engine will hold about 3.0 L (3.2/2.6 US/Imp qt) of oil. Use of API SF/SG or SH/SJ with JASO MA. Oil drain plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft) E L P • Start up the engine and allow it to run for several minutes at idling speed. M • Turn off the engine and wait about three minutes, then check A the oil level through the inspection window. If the level is S below mark “L”, add oil to “F” level. If the level is above mark “F”, drain oil to “F” level.
PERIODIC MAINTENANCE 2-13 OIL FILTER REPLACEMENT • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter 1 with the special tool. 09915-40610: Oil filter wrench • Apply engine oil lightly to the gasket of the new oil filter before installation. • Install the new oil filter. Turn it by hand until you feel that the oil filter gasket contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) with the special tool. NOTE: To properly tighten the oil filter, use the special tool. Never tighten the oil filter by hand. After contacting the gasket, tighten 2 turns. Oil filter: 20 N·m (2.0 kgf-m, 14.5 lb-ft) (20 N·m, 2.0 kgf-m, 14.5 lb-ft) • Add new engine oil and check the oil level is as described in E the engine oil replacement procedure. NECESSARY AMOUNT OF ENGINE OIL: L Oil change : 3.0 L (3.2/2.6 US/Imp qt) P Oil and filter change : 3.3 L (3.5/2.9 US/Imp qt) Engine overhaul : 3.6 L (3.8/3.2 US/Imp qt) M A ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in S thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle. EXHAUST CONTROL VALVE Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. Check the exhaust control valve actuator 1 for its movement when the ignition switch is turned on. If the exhaust valve actua- tor does not move, check exhaust valve actuator electrical circuit and exhaust valve carbon sticking. Check the exhaust control cable play. (6-16)
2-14 PERIODIC MAINTENANCE • Remove the two bolts and cover. • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. FUEL LINE E Inspect initially 6 000 km (4 000 miles, 12 months). L P • Inspect the fuel feed hose 1 for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced. M A S ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. NOTE: Warm up the engine before adjusting the engine idle speed. • Start the engine, turn the throttle stop screw and set the engine idle speed as follows. Engine idle speed: 1 150 ± 100 r/min
PERIODIC MAINTENANCE 2-15 THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths). Inspect the throttle valve synchronization periodically. (5-26) EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) Inspect every 12 000 km (7 500 miles, 24 months). Replace vapor hose every 4 years. Inspect the evaporative emission control system periodically. PAIR (AIR SUPPLY) SYSTEM Inspect every 12 000 km (7 500 miles, 24 months). Inspect the PAIR (air supply) system periodically. (11-6) E L THROTTLE CABLE PLAY P Inspect initially at 1 000 km (600 miles, 2 months) and M every 6 000 km (4 000 miles, 12 months) thereafter. A Adjust the throttle cable play A as follows. S • Loosen the lock-nut 2 of the throttle pulling cable 1. • Turn the adjuster 3 in or out until the throttle cable play (at the throttle grip) A is between 2.0 – 4.0 mm (0.08 – 0.16 in). • Tighten the lock-nut 2 while holding the adjuster 3. Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in) After the adjustment is completed, check that handle- bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto- matically.
2-16 PERIODIC MAINTENANCE CLUTCH Inspect every 6 000 km (4 000 miles, 12 months). • Lift and support the fuel tank with its prop stay. (5-3) • Turn in the adjuster 1 all the way into the clutch lever assem- bly. • Loosen the lock-nut 2 and turn the clutch cable adjuster 3 to obtain proper cable play. • Remove the clutch release adjuster cap. E • Loosen the lock-nut 4 and turn out the adjusting screw 5 two or three rotations. L • From that position, slowly turn in the adjusting screw 5 until resistance is felt. P • From this position, turn out the adjusting screw 5 1/2 rotation, M and tighten the lock-nut 4 while holding the screw 5. A S • Turn the cable adjuster 3 to obtain 10 – 15 mm (0.4 – 0.6 in) of free play A at the clutch lever end. • Tighten the lock-nut 2. Clutch lever play A: 10 – 15 mm (0.4 – 0.6 in) Clutch release screw: 1/2 turn out Clutch release adjuster cap: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
PERIODIC MAINTENANCE 2-17 COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. A Full line B Lower line • If the level is below the lower line, remove the right under cowling (8-5), and add engine coolant to the full line from the engine coolant reservoir filler. ENGINE COOLANT CHANGE E • Remove the under cowlings. (8-5) L • Remove the radiator cap 1. • Drain engine coolant by disconnecting the radiator hose 2 from the pump. P M * Do not open the radiator cap when the engine is hot, A as you may be injured by escaping hot liquid or vapor. S * Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes. If engine coolant gets into the eyes or in contact with the skin, flush thoroughly with plenty of water. If swallowed, induce vomiting and call physician immediately! • Flush the radiator with fresh water if necessary. • Connect the radiator hose 2 securely. • Pour the specified engine coolant up to the radiator inlet. Engine coolant capacity (excluding reservoir): 2 150 ml (2.3/1.9 US/lmp qt) • Bleed the air from the engine coolant circuit in the following procedure. (2-18) ENGINE COOLANT INFORMATION (7-2)
2-18 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. • Start up the engine and bleed air from the radiator inlet com- pletely. • Add engine coolant up to the radiator inlet. • Repeat the above procedure until no air bleeds from the radi- ator inlet. • Loosen the air bleeding bolt 1 and check that the engine coolant flows out. Air bleeder bolt: 6.0 N·m (0.6 kgf-m, 4.5 lb-ft) • Close the radiator cap securely. • After warming up and cooling down the engine several times, E add the engine coolant up to the full level of the reservoir. L Repeat the above procedure several times and makeP sure that the radiator is filled with engine coolant up to the reservoir full level. M Engine coolant capacity: A Engine side : 2 150 ml (2.3/1.9 US/Imp qt) S Reservoir tank side : 250 ml (0.3/0.2 US/lmp qt)
PERIODIC MAINTENANCE 2-19 RADIATOR HOSES • Remove the under cowlings. (8-5) • Lift and support the fuel tank. (5-3) • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one. E L P M A S
2-20 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.) * Loose pins * Excessive wear * Damaged rollers * Improper chain adjustment * Dry or rusted links * Missing O-ring seals * Kinked or binding links If any defect is found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the drive chain and Grease sprockets as a set. O-ring E PL CHECKING • Remove the axle cotter pin. (For E-03, 28, 33) M • Loosen the axle nut 1. A • Loosen the chain adjuster lock-nuts 2. • Give tension to the drive chain fully by turning both chain adjuster bolts 3. S
PERIODIC MAINTENANCE 2-21 • Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the 1 2 3 192021 service limit, the chain must be replaced. Drive chain 20-pitch length: Service limit: 319.4 mm (12.57 in) ADJUSTING • Loosen or tighten both chain adjuster bolts 1 until there is 20 – 30 mm (0.8 – 1.2 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The chain adjuster position relative to the reference marks A on both sides of the swingarm must be equal to ensure that the front and rear wheels are correctly aligned. 20 – 30 mm Drive chain slack: (0.8 – 1.2 in) Standard: 20 – 30 mm (0.8 – 1.2 in) • Place the motorcycle on its side-stand for accurate adjust- E ment. L • After adjusting the drive chain, tighten the axle nut 2 to the specified torque. P • Tighten both chain adjuster lock-nuts 3 securely. Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) M • Install a new cotter pin. (For E-03, 28, 33) A • Recheck the drive chain slack after tightening the axle nut. S
2-22 PERIODIC MAINTENANCE CLEANING AND LUBRICATING • Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings. Use only kerosine to clean the drive chain. • After washing and drying the chain, oil it with a heavyweight motor oil. * Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is DID530 V9. Suzuki rec- ommends to use this standard drive chain as a replacement. E L P M A S
PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years. Replace fluid every 2 years. BRAKE FLUID LEVEL CHECK • Keep the motorcycle upright and place the handlebars straight. • Check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs. • When the level is below the lower limit line, replenish with brake fluid that meets the following specification. Specification and classification: DOT 4 E * The brake system of this motorcycle is filled with a L glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petro- P leum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use M brake fluid left over from the last servicing or stored for a long period of time. A * Brake fluid, if it leaks, will interfere with safe running S and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and fluid leakage before riding.
2-24 PERIODIC MAINTENANCE BRAKE PADS Front brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. (8-63) Replace the brake pads as a set, otherwise braking performance will be adversely affected. Rear brake E The extent of brake pad wear can be checked by observing the L grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. P (8-74) M Replace the brake pads as a set, otherwise braking A performance will be adversely affected. S
PERIODIC MAINTENANCE 2-25 BRAKE PEDAL HEIGHT • Loosen the lock-nut 1. • Turn the push rod 2 until the brake pedal height becomes 55 – 65 mm (2.2 – 2.6 in) A below the top of the footrest. • Tighten the lock-nut 1 securely. Rear brake master cylinder rod lock-nut: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) Brake pedal height A: Standard: 55 – 65 mm (2.2 – 2.6 in) BRAKE LIGHT SWITCH • Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. AIR BLEEDING FROM BRAKE FLUID CIRCUIT E Air trapped in the brake fluid circuit acts like a cushion to absorb L a large proportion of the pressure developed by the master cyl- P inder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” M of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and A rider, it is essential that after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit S be purged of air in the following manner:
2-26 PERIODIC MAINTENANCE FRONT BRAKE (Caliper side) • Fill the master cylinder reservoir to the top of the inspection window. Replace the reservoir cap to prevent dirt from enter- ing. • Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle. • Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle. This will remove the tension of the brake lever causing it to touch the handle- bar grip. Then, close the air bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process until fluid flowing into the receptacle no longer contains air bubbles. NOTE: While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir. • Close the air bleeder valve and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window. E Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 Ib-ft) L P Handle brake fluid with care: the fluid reacts chemi- cally with paint, plastics, rubber materials, etc. M FRONT BRAKE (Master cylinder side) A • Bleed air from the master cylinder in the same manner as front brake (caliper side). S Air bleeder valve: 6.0 N·m (0.6 kgf-m, 4.5 Ib-ft) NOTE: If air is trapped in the master cylinder, bleed air from the master cylinder first. REAR BRAKE • Bleed air from the rear brake system in the same manner as front brake. Air bleeder valve: 6.0 N·m (0.6 kgf-m, 4.5 Ib-ft) NOTE: The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal.
PERIODIC MAINTENANCE 2-27 TIRES Inspect every 6 000 km (4 000 miles, 12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification. 09900-20805: Tire depth gauge Tire tread depth: Service Limit: FRONT : 1.6 mm (0.06 in) REAR : 2.0 mm (0.08 in) TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Cold inflation tire pressure E 2 Solo riding: Front: 250 kPa (2.50 kgf/cm , 36 psi) 2 Rear: 290 kPa (2.90 kgf/cm , 42 psi) L 2 Dual riding: Front: 250 kPa (2.50 kgf/cm , 36 psi) 2 P Rear: 290 kPa (2.90 kgf/cm , 42 psi) M The standard tire fitted on this motorcycle is 120/70 A ZR17 M/C (58 W) for the front and 190/50 ZR17 M/C (73 W) for the rear. The use of tires other than those spec- S ified may cause instability. It is highly recommended to use the specified tires. TIRE TYPE BRIDGESTONE (Front: BT014F SJ, Rear: BT014R J).........E-02, 19 (Front: BT014F J, Rear: BT014R E)...........Others STEERING Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtighten steering pre- vents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, read- just the steering. (8-33)
2-28 PERIODIC MAINTENANCE FRONT FORK Inspect every 12 000 km (7 500 miles, 24 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (8-18) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months). Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm. Replace any defective parts if necessary. (8-49) E L P M A S
PERIODIC MAINTENANCE 2-29 EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque. E L P M A S 1 Gasket 2 Exhaust pipe connector ITEM N·m kgf-m lb-ft AB 23 2.3 16.5 CD Replace the gaskets and exhaust pipe connector with the new ones.
2-30 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m kgf-m Ib-ft 1 Steering stem head nut 90 9.0 6.5 2 Steering stem lock-nut 90 9.0 65.0 3 Front fork upper clamp bolt 23 2.3 16.5 4 Front fork lower clamp bolt 23 2.3 16.5 5 Front fork cap bolt 23 2.3 16.5 6 Front axle bolt 100 10.0 72.5 7 Front axle pinch bolt 23 2.3 16.5 8 Handlebar clamp bolt 23 2.3 16.5 9 Front brake master cylinder mounting bolt 10 1.0 7.0 0 Front brake caliper mounting bolt 39 3.9 28.0 A Front brake caliper housing bolt 22 2.2 16.0 B Brake hose union bolt (Front & Rear) 23 2.3 16.5 E C Air bleeder valve (Front brake caliper) 7.5 0.75 5.5 D Air bleeder valve (Master cylinder & Rear brake caliper) 6.0L 0.6 4.5 E Brake disc bolt (Front) 23 2.3 16.5 P F Brake disc bolt (Rear) 35 3.5 25.5 G Rear brake caliper mounting bolt M 25 2.5 18.1 H Rear brake caliper housing bolt 37 3.7 27.0 I Rear brake master cylinder mounting bolt 10 1.0 7.0 A J Rear brake master cylinder rod lock-nut 18 1.8 13.0 S K Front footrest bracket mounting bolt 23 2.3 16.5 L Swingarm pivot nut 100 10.0 72.5 M Swingarm pivot lock-nut 90 9.0 65.0 N Rear suspension bracket nut 115 11.5 83.0 O Rear shock absorber mounting bolt/nut (Upper & Lower) 50 5.0 36.0 P Cushion rod nut 78 7.8 56.5 Q Cushion lever mounting nut 78 7.8 56.5 R Rear axle nut 100 10.0 72.5 S Rear sprocket nut 93 9.3 67.5 T Steering damper bolt/nut 23 2.3 16.5
PERIODIC MAINTENANCE 2-31 E L P M A S
2-32 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit Difference 1 300 – 1 700 kPa 1 000 kPa 200 kPa 2 2 2 (13 – 17 kgf/cm , 185 – 242 psi) (10 kgf/cm , 148 psi) (2 kgf/cm , 28 psi) Low compression pressure can indicate any of the following conditions: * Excessively worn cylinder walls * Worn piston or piston rings * Piston rings stuck in grooves * Poor valve seating * Ruptured or otherwise defective cylinder head gasket Overhaul the engine in the following cases: * Compression pressure in one of the cylinders is 1 000 kPa (10 kgf/cm2, 148 psi) and less. 2 * The difference in compression pressure between any two cylinders is 200 kPa (2 kgf/cm , 28 psi) and more. * All compression pressure readings are below 1 300 kPa (13 kgf/cm2, 185 psi) even when they measure 2 E 1000 kPa (10 kgf/cm , 148 psi) and more. L COMPRESSION TEST PROCEDURE P NOTE: M * Before testing the engine for compression pressure, make sure that the cylinder head nuts are tightened to the specified A torque values and the valves are properly adjusted. S * Have the engine warmed up before testing. * Make sure that the battery is fully-charged. Remove the related parts and test the compression pressure in the following manner. • Lift and support the fuel tank. (5-3) • Remove all the spark plugs. (2-5) • Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight. • Keep the throttle grip in the fully opened position. • Press the starter button and crank the engine for a few sec- onds. Record the maximum gauge reading as the cylinder compression. • Repeat this procedure with the other cylinders. 09915-64512: Compression gauge set 09913-10750: Adaptor
PERIODIC MAINTENANCE 2-33 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 100 – 400 kPa (1.0 – 4.0 kgf/cm2, 14 – 57 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) If the oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE * Clogged oil filter * Oil leakage from the oil passage * Damaged O-ring * Defective oil pump * Combination of the above items HIGH OIL PRESSURE * Engine oil viscosity is too high * Clogged oil passage * Combination of the above items OIL PRESSURE TEST PROCEDURE E Start the engine and check if the oil pressure indicator light is L turned on. If the light stays on, check the oil pressure indicator light circuit. If the circuit is OK, check the oil pressure in the fol- lowing manner. P • Remove the main oil gallery plug 1. M • Install the oil pressure gauge and adaptor into the main oil gallery. A • Warm up the engine as follows: S Summer: 10 min at 2 000 r/min Winter : 20 min at 2 000 r/min • After warming up, increase the engine speed to 3 000 r/min (observe the tachometer), and read the oil pressure gauge. 09915-74521: Oil pressure gauge hose 09915-74540: Oil pressure gauge attachment 09915-77331: Meter (for high pressure) Oil gallery plug (M16): 35 N·m (3.5 kgf-m, 25.5 lb-ft)
2-34 PERIODIC MAINTENANCE SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle. For example, when a motorcycle is brought in for service but the troubleshooting is difficult, comparison with the normal data that have been saved or filed can allow the specific engine failure to be determined. • Remove the front seat. (8-7) • Set up the SDS tool. (4-26) 09904-41010: SDS set tool 99565-01010-006: CD-ROM Ver. 6 A number of different data under a fixed condition as shown below should be saved or filed as sample. SAMPLE: Data sampled from cold starting through warm-up E L Fast idle section Check the engine r/min. XXXX r/min P M Check the fast idle time. Check the engine r/min. A XXXX r/min Approx. XX sec. S Check the manifold absolute pressure. XXXX r/min Check the secondary throttle valve operation in according with the engine r/min.
PERIODIC MAINTENANCE 2-35 Data at 3 000 r/min under no load 3 000 r/min Check the manifold absolute pressure. XXX mmHg Secondary valve moves approx. XX degree. Data at the time of racing E PL SAM Throttle: Throttle: Slowly open Quick wide open Secondary throttle valve opens closes in according with the engine r/min.
2-36 PERIODIC MAINTENANCE Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. Approx. XXX mmHg Data of secondary throttle valve operation at the time of starting E PL AM Closes fully in approx. XX sec. S
ENGINE 3-1 ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE...........3- 2 ENGINE REMOVAL AND INSTALLATION.................................................. 3- 3 ENGINE REMOVAL............................................................................... 3- 3 ENGINE INSTALLATION....................................................................... 3-10 3 ENGINE DISASSEMBLY.............................................................................. 3-15 ENGINE COMPONENTS INSPECTION AND SERVICE.............................................................................................. 3-27 CYLINDER HEAD COVER..................................................................... 3-27 CMP SENSOR........................................................................................ 3-27 PAIR REED VALVE................................................................................ 3-27 CAMSHAFT............................................................................................ 3-28 CAM CHAIN TENSION ADJUSTER...................................................... 3-30 CAM CHAIN TENSIONER...................................................................... 3-31 CAM CHAIN GUIDE............................................................................... 3-31 CYLINDER HEAD AND VALVE............................................................. 3-31 E CLUTCH................................................................................................. 3-43 L CLUTCH LIFTER.................................................................................... 3-45 P OIL PUMP............................................................................................... 3-46 STARTER CLUTCH............................................................................... 3-47 M GENERATOR......................................................................................... 3-47 WATER PUMP........................................................................................ 3-48 A GEARSHIFT SYSTEM............................................................................ 3-48 OIL PRESSURE REGULATOR.............................................................. 3-49 S OIL STRAINER....................................................................................... 3-49 TRANSMISSION..................................................................................... 3-50 CYLINDER.............................................................................................. 3-53 PISTON AND PISTON RING.................................................................. 3-54 CRANKCASE......................................................................................... 3-56 BALANCER SHAFT............................................................................... 3-63 BALANCER SHAFT JOURNAL BEARING...........................................3-63 CRANKSHAFT AND CONROD............................................................. 3-65 CRANKSHAFT JOURNAL BEARING................................................... 3-69 CRANKSHAFT THRUST BEARING...................................................... 3-72 ENGINE REASSEMBLY............................................................................... 3-74
3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION PAIR control solenoid valve 11-6 11-6 11-7 Starter motor 3-15 9-14 3-106 Breather cover 3-23 — 3-85 Thermostat 7-9 7-9 7-10 Cylinder head cover 3-15 — 3-105 Camshaft 3-15 3-28 3-100 Intake pipe 3-42 — 3-42 Oil filter 3-24 — 3-85 Oil cooler 3-4 7-18 7-18 Oil pan 3-24 — 3-84 ENGINE RIGHT SIDE ITEM REMOVAL INSPECTION INSTALLATION Exhaust pipe and muffler 3-5, 6-13 — E3-14, 6-14 Cam chain tension adjuster 3-16 3-30 3-103 Clutch cover 3-17 — 3-97 L Clutch (plates) 3-17 3-43 3-95 P Clutch lifter 3-19 3-45 3-93 Primary driven gear 3-19 M 3-44 3-93 Oil pump 3-20 3-46 3-92 Gearshift shaft 3-20 3-48 3-91 A Starter idle gear cover 3-21 — 3-90 S Starter idle gear 3-21 — 3-89 Starter clutch cover 3-21 — 3-89 Starter clutch 3-22 3-47 3-88 CKP sensor 3-22 4-35 3-87 Oil pump driven gear 3-20 — 3-92 Cam chain tensioner 3-22 3-21 3-88 Cam chain guide 3-22 3-21 3-88 ENGINE LEFT SIDE ITEM REMOVAL INSPECTION INSTALLATION Engine sprocket 3-8 — 3-13 Gear position switch 3-23 4-73 3-85 Generator (cover) 3-22 3-47 3-87 Generator rotor 3-22 — 3-86 Water pump 3-23 7-13 3-86
ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Remove the under cowlings. (8-5) • Remove the front seat. (8-7) • Lift and support the fuel tank with the prop stay. (5-3) • Disconnect the battery - lead wire. • Drain engine oil. (2-12) E L P M A S • Drain engine coolant by disconnecting the radiator hose. (2-17) • Remove the air cleaner box 1. (5-13)
3-4 ENGINE • Remove the throttle body assembly 2. (5-14) OIL COOLER • Remove the oil cooler pipes. • Remove the oil cooler 1. E L Be careful not to bent the oil cooler fin. P M A RADIATOR S • Disconnect the reservoir inlet hose 1 and radiator inlet hose 2. • Disconnect the cooling fan coupler 3.
ENGINE 3-5 • Remove the radiator mounting bolts. • Remove the radiator 4. Be careful not to bent the radiator fin. • Remove the front engine cover 5. E L P M A EXHAUST PIPE S • Remove the exhaust pipe bolts. • With the muffler connecting bolt loosened, remove the exhaust pipe 1.
3-6 ENGINE • Remove the radiator mounting bracket 2. ELECTRIC PARTS AND PAIR HOSE • Disconnect the oil pressure switch lead wire 1. • Disconnect the starter motor lead wire 2. E • Disconnect the ground lead wire 3. PL SAM • Disconnect the CKP sensor coupler 4. • Disconnect the GP switch coupler 5. • Disconnect the ECT sensor coupler 6. • Disconnect the generator coupler 7.
ENGINE 3-7 • Disconnect the ignition coil/plug cap lead wire couplers and CMP sensor lead wire coupler. Do not remove the ignition coil/plug cap before dis- connecting its coupler. • Remove the ignition coils/plug caps. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage. * Be careful not to drop the ignition coil/plug cap to prevent its short or open circuit. • Disconnect the PAIR hoses 8. E L P M A S ENGINE SPROCKET AND GEAR SHIFT LEVER • Remove the gearshift lever 1. • Remove the engine sprocket cover 2. • Remove the clutch push rod 3.
3-8 ENGINE • Remove the speed sensor rotor 4. • Remove the engine sprocket nut 5 and the washer 6. • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut 7. • Loosen the chain adjuster lock-nuts. • Loosen the chain adjusters 8. • Push the rear wheel forward and make sure that the drive E chain has enough slack. • Disengage the drive chain 9 from the rear sprocket. PL SAM • Remove the engine sprocket 0.
ENGINE 3-9 ENGINE MOUNTING • Support the engine using an engine jack. • Remove the engine mounting bolts A and C. • Loosen the engine mounting pinch bolts 1 and 2. E • Remove the engine mounting bolts B and D. L P M A S • Remove the engine mounting nut 3. • Remove the engine mounting thrust adjuster lock-nut 4 with the special tool. • Loosen the engine mounting thrust adjuster 5 fully. 09940-14990: Engine mounting thrust adjuster socket wrench
3-10 ENGINE • Remove the engine mounting nut 6. • Loosen the engine mounting thrust adjuster lock-nut 7 with the special tool. • Loosen the engine mounting thrust adjuster 8. 09940-14990: Engine mounting thrust adjuster socket wrench NOTE: Do not remove the engine mounting bolts at this stage. • Remove the engine mounting bolts and gradually lower the front side of the engine. Then, take off the drive chain from the E driveshaft. L • Remove the engine assembly. P ENGINE INSTALLATION M Install the engine in the reverse order of engine removal. Pay attention to the following points: A NOTE: S Be careful not to damage the frame and engine when installing the engine. • Before installing the engine, install the spacers 1. • Before installing the engine, install the engine mounting thrust adjusters 2 and 3.
ENGINE 3-11 • Gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft. • Install all engine mounting bolts, spacers and tighten them temporarily. (3-12) Be careful not to catch the wiring harness between the frame and the engine. • Tighten the engine mounting thrust adjusters to the specified torque. Engine mounting thrust adjuster: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Tighten the engine mounting thrust adjuster lock-nuts to the E specified torque with the special tool. Engine mounting thrust adjuster lock-nut: L 45 N·m (4.5 kgf-m, 32.5 lb-ft) P M A S • Tighten all engine mounting bolts and nuts to the specified torque. (3-12) NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. • Tighten the engine mounting pinch bolts to the specified torque. (3-12)
3-12 ENGINE E L P M A S LENGTH ITEM N·m kgf-m lb-ft ITEM mm in ABCD 55 5.5 40.0 AC 45 1.77 58 75 7.5 54.0 Bolt BD 55 2.17 12 23 2.3 16.5 EF 215 8.46 69 23 2.3 16.5 Spacer 34 30.5 1.20 70 45 4.5 32.5 Adjuster 69 40 1.57 a Left b Right
ENGINE 3-13 • Install the engine sprocket and the washer. • Apply a small quantity of THREAD LOCK to the driveshaft thread portion. 99000-32050: THREAD LOCK “1342” • Tighten the engine sprocket nut 1 to the specified torque. Engine sprocket nut: 115 N·m (11.5 kgf-m, 83.0 lb-ft) • Install the speed sensor rotor 2. • Tighten the speed sensor rotor bolt 3 to the specified torque. Speed sensor rotor bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the clutch push rod E end. L 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) P • Install the engine sprocket cover. M NOTE: When installing the engine sprocket cover, align the clutch A release cylinder hole with the end of clutch push rod. S • Tighten the speed sensor bolt 4 to the specified torque. Speed sensor bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft) • Install the gearshift lever as shown. A Footrest B 50 – 60 mm (1.97 – 2.36 in)
3-14 ENGINE • Install the radiator mounting bracket 1. • Install the exhaust pipe 2. Replace the gaskets with new ones. Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) E L P M A S • Fit the new O-rings to the union of the oil cooler pipes. • Apply THREAD LOCK to the bolts, install the oil cooler pipe union. 99000-32050: THREAD LOCK “1342” Oil cooler union bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Perform service and adjustment in the following items. * Engine oil (2-13) * Engine coolant (2-18) * Throttle cable play (2-15) *Clutch (2-16) * Idling adjustment (2-14) * Throttle valve synchronization (5-26) * Drive chain slack (2-20) * Wiring harness, cables and hoses (10-18)
ENGINE 3-15 ENGINE DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the spark plugs. (2-5) STARTER MOTOR • Remove the starter motor 1. CYLINDER HEAD COVER E • Remove the cylinder head cover 1 and its gaskets. L P M A S • Remove the dowel pins and O-rings. CAMSHAFT • Remove the valve timing inspection cap 1.
3-16 ENGINE • Turn the crankshaft to bring the line A on the starter clutch to the index mark B of the valve timing inspection hole and also to bring the cams to the position as shown. 11 1 14113 33 22 1 44 3 3 3 2 1 2 3 1 • Remove the cam chain tension adjuster cap bolt 2 and E spring. • Remove the cam chain tension adjuster 3. L P M A S • Remove the cam chain guide 4. • Remove the intake camshaft journal holder 5. • Remove the exhaust camshaft journal holder 6. • Remove the dowel pins. Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers. • Remove the intake camshaft 7. • Remove the exhaust camshaft 8.
ENGINE 3-17 CYLINDER HEAD • Remove the water hose 1. • Remove the thermostat cover 2 and thermostat. THERMOSTAT INSPECTION (7-9) • Remove the ECT sensor 3. ECT SENSOR INSPECTION (7-7) • Remove the cylinder head bolts (M6) 4. • Remove the cylinder head bolts and washers. E NOTE: L When loosening the cylinder head bolts, loosen each bolt little by little diagonally. P • Remove the cylinder head 5. • Remove the cylinder head gasket and dowel pins. M A CLUTCH S • Remove the clutch cover. • Hold the clutch housing with the special tool. Do not damage the clutch plates by the special tool. 09920-53740: Clutch sleeve hub holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally.
3-18 ENGINE • Remove the pressure plate. • Remove the clutch drive plates 1 and driven plates 2. • Remove the clutch push piece 3, bearing 4 and the thrust washer 5. • Remove the spring washer 6 and its seat 7. E L P M A S • Remove the clutch push rod 8. NOTE: If it is difficult to pull out the push rod 8, use a magnetic hand or a wire. • Unlock the clutch sleeve hub nut.
ENGINE 3-19 • Hold the clutch sleeve hub with the special tool. 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the conical spring washer 9, washer 0 and clutch sleeve hub A. • Remove the wave spring washers B and clutch lifter driven E cam C. L P M A S • Remove the clutch lifter drive cam D and washer E. • Remove the spacer F and bearing G. • Remove the primary driven gear assembly H. NOTE: If it is difficult to remove the primary driven gear, rotate the crankshaft.
3-20 ENGINE • Remove the thrust washer I. • Remove the oil pump drive gear J from the primary driven gear assembly K. OIL PUMP • Remove the snap ring 1. • Remove the oil pump driven gear 2. NOTE: Do not drop the snap ring 1 into the crankcase. • Remove the pin 3 and washer 4. E • Remove the oil pump 5. L NOTE: Do not drop the pin 3 and washer 4 into the crankcase. P SAM GEARSHIFT SYSTEM • With the snap ring 1 and washer removed, remove the gear- shift shaft assembly 2. • Remove the gearshift cam plate bolt 3 and gearshift cam plate 4. • Remove the gearshift cam stopper 5.
ENGINE 3-21 STARTER IDLE GEAR • Remove the starter idle gear cover. • Remove the dowel pins and gasket. • Remove the spring washer 1, washer 2 and starter idle gear No. 1 3. • Remove the shaft 4, bearing 5 and thrust washer 6. E PL SAM • Remove the starter clutch cover. • Remove the dowel pins and gasket. • Remove the spring washer 7, starter idle gear No. 2 8 and shaft 9.
3-22 ENGINE STARTER CLUTCH • Hold the starter clutch with the special tool. 09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. • Remove the starter clutch assembly and washer. CAM CHAIN/CAM CHAIN TENSIONER/CAM CHAIN GUIDE • Remove the cam chain tensioner 1 and cam chain guide 2. • Remove the cam chain 3 and cam chain drive sprocket 4. CKP SENSOR E • Remove the CKP sensor 1. L CKP SENSOR INSPECTION (4-35) P M A GENERATOR COVER S • Remove the generator cover. • Remove the dowel pins and gasket. GENERATOR ROTOR • Hold the generator rotor with the special tool. 09930-44520: Rotor holder • Remove the generator rotor bolt.
ENGINE 3-23 • Install a bolt A of suitable size to the left end of crankshaft. SUITABLE BOLT A [M12, length: 28 – 38 mm (1.1 – 1.5 in)] • Remove the generator rotor with the special tool. 09930-34980: Rotor remover 28 – 38 mm (1.1 – 1.5 in) WATER PUMP E • Remove the water hose 1 and water inlet cover 2. • Remove the water pump 3. L WATER PUMP SERVICING (7-11) P SAM GEAR POSITION SWITCH • Remove the gear position switch 1. CRANKCASE BREATHER (PCV) COVER • Remove the crankcase breather cover 1.
3-24 ENGINE OIL FILTER • Remove the oil filter with the special tool. (2-13) 09915-40610: Oil filter wrench OIL PAN • Remove the oil pan 1. OIL PRESSURE REGULATOR E • Remove the oil pressure regulator 1. L OIL PRESSURE SWITCH P • Remove the oil pressure switch 2. M OIL STRAINER • Remove the oil strainer 3 and O-ring. A LOWER CRANKCASE S • Remove the lower crankcase bolts (M6). • Remove the lower crankcase bolts (M8). • Remove the lower crankcase assembly.
ENGINE 3-25 TRANSMISSION • Remove the transmission 1 and O-rings. • Remove the dowel pins 2. MIDDLE CRANKCASE • Remove the crankcase bolts. • Remove the crankcase bolts (M6). E • Remove the crankcase bolts (M8). • Remove the crankshaft journal bolts (M9). L NOTE: P Loosen the crankcase bolts diagonally with the smaller sizes first. M • Remove the middle crankcase and dowel pins. SA BALANCER SHAFT • Remove the balancer shaft 1. CRANKSHAFT • Loosen the bearing cap bolts by using 12 mm, 12 point socket wrench, and tap the bearing cap bolt lightly with plastic ham- mer to remove the bearing cap. • Remove the O-ring 1. • Remove the crankshaft and thrust washers 2.
3-26 ENGINE PISTON AND CONROD • Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase. Be careful not to damage the cylinder wall by the con- rod. • Remove the piston pin circlip 1. E L P M A S • Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the piston head.
ENGINE 3-27 ENGINE COMPONENTS INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER • Clean and check the gasket grooves A and PAIR reed valve gasket mating surfaces B of cylinder head cover. • If it is damaged, replace the cylinder head cover with a new one. CMP SENSOR E REMOVAL L • Remove the CMP sensor 1 from the cylinder head cover. INSPECTION P • Inspect the CMP sensor. (4-33) M A S INSTALLATION • Install the oil seal 2 and CMP sensor 3. NOTE: When installing, clean the CMP sensor’s face. CMP sensor mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) PAIR REED VALVE REMOVAL • Remove the PAIR reed valve covers 1.
3-28 ENGINE INSPECTION • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. INSTALLATION • Install the PAIR reed valves and PAIR reed valve covers. • Apply THREAD LOCK to the bolts and tighten to the specified torque. 99000-32050: THREAD LOCK “1342” PAIR reed valve cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) CAMSHAFT E CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the L intake by the embossed letters “EX” (for exhaust) as against let- ters “IN” (for intake). P M A CAM WEAR S • Check the camshaft for wear or damage. • Measure the cam height H with a micrometer. Cam height H: Service Limit: (IN.) : 37.28 mm (1.468 in) (EX.): 35.98 mm (1.417 in) 09900-20202: Micrometer (25 – 50 mm)
ENGINE 3-29 CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge 1 to read the clearance at the widest portion, which is specified as follows: Camshaft journal oil clearance: Service Limit: (IN. & EX.): 0.150 mm (0.0059 in) 09900-22301: Plastigauge 09900-22302: Plastigauge NOTE: Install camshaft journal holders to their original positions. (3-102) • Tighten the camshaft journal holder bolts evenly and diago- nally to the specified torque. Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: E Do not rotate the camshaft with the plastigauge in place. L • Remove the camshaft holders, and read the width of the com- pressed plastigauge with envelope scale. P • This measurement should be taken at the widest part. M A S
3-30 ENGINE • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. Camshaft journal holder I.D.: Standard: (IN. & EX.): 24.012 – 24.025 mm (0.9454 – 0.9459 in) 09900-20602: Dial gauge (1/1000, 1 mm) 09900-22403: Small bore gauge (18 – 35 mm) Camshaft journal O.D.: Standard (IN. & EX.): 23.959 – 23.980 mm (0.9433 – 0.9441 in) 09900-20205: Micrometer (0 – 25 mm) CAMSHAFT RUNOUT E • Measure the runout using the dial gauge. • Replace the camshaft if the runout exceeds the limit. L Camshaft runout: P Service Limit (IN. & EX.): 0.10 mm (0.004 in) 09900-20607: Dial gauge (1/100 mm) M 09900-20701: Magnetic stand A 09900-21304: V-block set (100 mm) CAM SPROCKET S • Inspect the sprocket teeth for wear. • If they are worn, replace the sprocket/camshaft assembly and cam chain as a set. CAM CHAIN TENSION ADJUSTER INSPECTION • Remove the cam chain tension adjuster cap bolt and spring. • Check that the push rod slides smoothly when releasing stop- per 1. • If it does not slide smoothly, replace the cam chain tension adjuster with a new one.
ENGINE 3-31 CAM CHAIN TENSIONER INSPECTION • Check the contacting surface of the cam chain tensioner. • If it is worn or damaged, replace it with a new one. CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guides. • If they are worn or damaged, replace them with the new ones. E CYLINDER HEAD AND VALVE L VALVE AND VALVE SPRING DISASSEMBLY P • Remove the tappet 1 and shim 2 by fingers or magnetic hand. M A Identify the position of each removed part. S
3-32 ENGINE • When compressing the valve spring, use a protector that is handcrafted from a 35-mm film cartridge as shown in the right illustration. For intake side For exhaust side A 7 mm (0.28 in) A 7 mm (0.28 in) B 46 mm (1.81 in) B 46 mm (1.81 in) C 24 mm (0.95 in) C 22 mm (0.87 in) To prevent damage of the tappet sliding surface with the special tool, use a protector. • Install the protector 3 between the valve spring and cylinder head. • Using the special tools, compress the valve spring and remove the two cotter halves 4 from the valve stem. 09916-14510: Valve lifter 09916-14530: Valve lifter attachment 09916-84511: Tweezers E L P M A S • Remove the valve spring retainer 5 and valve spring 6. • Pull out the valve 7 from the combustion chamber side.
ENGINE 3-33 • Remove the oil seal 8 and spring seat 9. Do not reuse the removed oil seal. • Remove the other valves in the same manner as described previously. CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head. Cylinder head distortion: Service Limit: 0.20 mm (0.008 in) 09900-20803: Thickness gauge E VALVE STEM RUNOUT L • Support the valve using V-blocks and check its runout using the dial gauge as shown. P • If the runout exceeds the service limit, replace the valve. Valve stem runout: M Service Limit: 0.05 mm (0.002 in) A 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand S 09900-21304: V-block set (100 mm) Be careful not to damage the valve and valve stem when handling it. VALVE HEAD RADIAL RUNOUT • Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. • If it measures more than the service limit, replace the valve. Valve head radial runout: Service Limit: 0.03 mm (0.001 in) 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) Be careful not to damage the valve and valve stem when handling it.
3-34 ENGINE VALVE STEM AND VALVE FACE WEAR CONDITION • Visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one. VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one. Valve stem deflection (IN. & EX.): Service Limit: 0.25 mm (0.010 in) 09900-20607: Dial gauge (1/100 mm) E 09900-20701: Magnetic stand L VALVE STEM WEAR • If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. P • If the stem is within the limit, then replace the guide. M • After replacing valve or guide, be sure to recheck the deflec- tion. A Valve stem O.D.: S Standard (IN.) : 4.475 – 4.490 mm (0.1762 – 0.1768 in) (EX.): 4.455 – 4.470 mm (0.1754 – 0.1760 in) 09900-20205: Micrometer (0 – 25 mm) NOTE: If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing. (3-35)
ENGINE 3-35 VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. 09916-53310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No. 11115-29G70) • Re-finish the valve guide holes in cylinder head with the reamer and handle. 09916-33320: Valve guide reamer 09916-34542: Reamer handle When refinishing or removing the reamer from the valve guide hole, always turn it clockwise. • Cool down the new valve guides in a freezer for about one E hour and heat the cylinder head to 100 – 150 °C (212 – 302 °F) with a hot plate. L P Do not use a burner to heat the valve guide hole to prevent cylinder head distortion. M • Apply engine oil to the valve guide hole. A • Drive the valve guide into the hole using the valve guide S installer 1 and attachment 2. 09916-43211: Valve guide installer/remover 1 09916-53330: Attachment 2 NOTE: Install the valve guide until the attachment contacts the cylinder head 3. Failure to oil the valve guide hole before driving the 13.6 mm new guide into place may result in a damaged guide or head.
3-36 ENGINE • After installing the valve guides, re-finish their guiding bores using the reamer. • Clean and oil the guides after reaming. 09916-33210: Valve guide reamer 09916-34542: Reamer handle NOTE: * Be sure to cool down the cylinder head to ambient air temper- ature. * Insert the reamer from the combustion chamber and always turn the reamer handle clockwise. VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure. • Check that the transferred blue on the valve face is uniform all around and in center of the valve face. 09916-10911: Valve lapper set E • If the seat width W measured exceeds the standard value or L seat width is not uniform, reface the seat using the seat cutter. Valve seat width W: P Standard: 0.9 – 1.1 mm (0.035 – 0.043 in) M If the valve seat is out of specification, re-cut the seat. A S
ENGINE 3-37 VALVE SEAT SERVICING • The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to four different angles. The seat con- tact surface is cut at 45°. 60˚ 60˚ 30˚ 15˚ INTAKE EXHAUST 45˚ 45˚ 15° N-121 30° N-126 45° N-122 N-122 60° N-111 N-111 09916-21111: Valve seat cutter set 09916-20630: Valve seat cutter (N-126) 09916-20640: Solid pilot (N-100-4.5) 45˚ NOTE: 15˚ The valve seat cutters (N-121), (N-122) and (N-111) are included in the valve seat cutter set (09916-21111). 30˚ 60˚ The valve seat contact area must be inspected after each cut. E • When installing the solid pilot 1, rotate it slightly. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. L P SAM INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. 45˚
3-38 ENGINE • If the valve seat is pitted or burned, use the 45° cutter to con- dition the seat some more. NOTE: Cut only the minimum amount necessary from the seat to pre- vent the possibility of the valve stem becoming too close to the camshaft. TOP NARROWING CUT • If the contact area W is too high on the valve, or if it is too wide, use the 15° (for the exhaust side) and the 30° (for the intake side) to lower and narrow the contact area. E PL M 15˚ SA 30˚ BOTTOM NARROWING CUT • If the contact area W is too wide or too low, use the 60° cutter to narrow and raise the contact area. 60˚
ENGINE 3-39 FINAL SEAT CUT • If the contact area W is too low or too narrow, use the 45° cut- ter to raise and widen the contact area. NOTE: After cutting the 15°, 30° and 60° angles, it is possible that the valve seat (45°) is too narrow. If so, re-cut the valve seat to the correct width. 45˚ • After the desired seat position and width is achieved, use the E 45° cutter very lightly to clean up any burrs caused by the pre- vious cutting operations. L P Do not use lapping compound after the final cut is M made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny fin- A ish. This will provide a soft surface for the final seat- ing of the valve which will occur during the first few S seconds of engine operation. The titanium valves are coated with an oxidized mem- brane treatment to resist wear but the membrane tend to be removed if lapped after valve seat servicing. NOTE: After servicing the valve seats, be sure to check the valve clear- ance after the cylinder head has been reinstalled. (2-7)
3-40 ENGINE • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Always use extreme caution when handling gasoline. VALVE SPRING The force of the coil spring keeps the valve seat tight. Weak- ened spring results in reduced engine power output, and often accounts for the chattering noise coming from the valve mecha- nism. • Check the valve spring for proper strength by measuring its free length and also by the force required to compress it. • If the spring length is less than the service limit, or if the force required to compress the spring does not fall within the range specified, replace the spring. Valve spring free length: E Service limit: (IN. & EX.) : 37.5 mm (1.48 in) L 147 N 09900-20102: Vernier calipers Valve spring tension (IN. & EX.): P 33.55 mm Standard: M Approx. 147 N, 15.0 kgf/33.55 mm (33.1 lbs/1.32 in) SA
ENGINE 3-41 VALVE AND VALVE SPRING REASSEMBLY • Install the valve spring seat. • Apply MOLYBDENUM OIL SOLUTION to the oil seal 1, and press-fit it into position. MOLYBDENUM OIL SOLUTION Do not reuse the removed oil seal. • Insert the valve, with its stem coated with MOLYBDENUM OIL SOLUTION all around and along the full stem length with- out any break. When inserting the valve, take care not to damage the lip of the oil seal. MOLYBDENUM OIL SOLUTION • Install the valve spring with the small-pitch portion A facing E cylinder head. L P B Large-pitch portion M C UPWARD A S D Paint • Put on the valve spring retainer 2, and using the valve lifter and protector 3, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter 4 to wedge in between retainer and stem. 09916-14510: Valve lifter 09916-14530: Valve lifter attachment 09916-84511: Tweezers
3-42 ENGINE • Be sure that the rounded lip E of the cotter fits snugly into the groove F in the stem end. • Install the other valves and springs in the same manner as described previously. 5 Valve spring retainer 6 Cotter Be sure to restore each spring and valve to their origi- nal positions. Be careful not to damage the valve and valve stem when handling it. • Install the tappet shims and the tappets to their original posi- tions. NOTE: * Apply engine oil to the stem end, shim and tappet before fitting E them. * When seating the tappet shim, be sure the figure printed sur- L face faces the tappet. P INTAKE PIPE M • Remove the intake pipes. A S • Apply SUZUKI SUPER GREASE to the O-rings. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the intake pipes.
ENGINE 3-43 WATER BYPASS UNION • Remove the water bypass union 1. • Apply SUZUKI BOND to the thread part of water bypass union and tighten it to the specified torque. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31140: SUZUKI BOND “1207B” (Others) Water bypass union: 12 N·m (1.2 kgf-m, 8.5 lb-ft) CLUTCH E CLUTCH DRIVE PLATE INSPECTION L NOTE: P * Wipe off engine oil from the clutch drive plates with a clean rag. M * Clutch drive plate No.1: I.D. 111 mm (4.4 in)/Purple paint * Clutch drive plate No.2: I.D. 111 mm (4.4 in)/Black paint A * Clutch drive plate No.3: I.D. 118 mm (4.6 in)/NIL S A Paint • Measure the thickness of drive plates with a vernier calipers. • If the drive plate thickness is found to have reached the limit, replace it with a new one. Drive plate thickness: Service Limit: 2.42 mm (0.095 in) 09900-20102: Vernier calipers • Measure the claw width of drive plates with a vernier calipers. • Replace the drive plates found to have worn down to the limit. Drive plate claw width: Service Limit: 13.05 mm (0.5138 in) 09900-20102: Vernier calipers
3-44 ENGINE CLUTCH DRIVEN PLATE INSPECTION NOTE: Wipe off engine oil from the clutch driven plates with a clean rag. • Measure each driven plate for distortion with a thickness gauge and surface plate. • Replace driven plates which exceed the limit. Driven plate distortion (No. 1, No. 2 and No. 3): Service Limit: 0.10 mm (0.004 in) 09900-20803: Thickness gauge CLUTCH SPRING INSPECTION • Measure the free length of each coil spring with a vernier cali- pers, and compare the length with the specified limit. • Replace all the springs if any spring is not within the limit. Clutch spring free length: Service Limit: 54.2 mm (2.134 in) 09900-20102: Vernier calipers E CLUTCH BEARING INSPECTION L • Inspect the clutch release bearing for any abnormality, partic- ularly cracks, to decide whether it can be reused or should be replaced. P • Smooth engagement and disengagement of the clutch depends on the condition of this bearing. M A S CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY • Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one.
ENGINE 3-45 CLUTCH LIFTER CLUTCH LIFTER DRIVE CAM AND DRIVEN CAM INSPEC- TION • Inspect the clutch lifter drive cam and driven cam for wear or damage. If any defects are found, replace the clutch lifter drive cam and driven cam as a set. CLUTCH LIFTER PIN ADJUSTMENT NOTE: When adjusting the clutch lifter, it is not necessary to install the clutch onto the countershaft. • Assemble the following parts into the primary driven gear assembly. (3-94 to -97) * Clutch sleeve hub * Spring washer seat, Spring washer * Clutch drive plates, Clutch driven plates * Pressure plate E * Clutch springs, Clutch springs set bolts Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) L • Remove the clutch assembly from the primary driven gear assembly. P M A S
3-46 ENGINE • Check the height H of clutch lifter adjusting pin screws at three positions using the thickness gauge. • If the measurement is out of the specification, adjust the height H as shown in the following specification. Clutch lifter adjusting pin screw height H Standard: 0.2 – 0.4 mm (0.008 – 0.016 in) 09900-20803: Thickness gauge NOTE: Each clutch lifter adjusting pin screw height should be as closely as possible. • Loosen the lock-nut and turn out the adjusting pin screw. • Set the thickness gauge to 0.3 mm (0.012 in). • Place a proper flat plate on the thickness gauges and hold them by hand. • Slowly turn in the adjusting pin screw until resistance is felt. • Tighten the lock-nut. Clutch lifter pin lock-nut: 23 N·m (2.3 kgf-m, 16.5 lb-ft) E WAVE SPRING WASHER INSPECTION L Measure the free height H of each wave spring washer with a vernier calipers. If each wave spring washer height H is not within the specified limit, replace it with a new one. P 09900-20102: Vernier calipers M Wave spring washer height H A Service Limit: 4.30 mm (0.169 in) S OIL PUMP INSPECTION • Rotate the oil pump by hand and check that it moves smoothly. • If it does not move smoothly, replace the oil pump assembly. * Do not attempt to disassemble the oil pump assembly. * The oil pump is available only as an assembly.
ENGINE 3-47 STARTER CLUTCH INSPECTION • Install the starter driven gear 1 onto the starter clutch 2. • Turn the starter driven gear by hand. • Inspect the starter clutch for a smooth movement. • Check that the gear turns only in one direction. • If a large resistance is felt for rotation, inspect the starter E clutch bearing or the starter clutch contacting surface on the starter driven gear for wear and damage. L • If they are found to be damaged, replace them with the new ones. P M A S GENERATOR INSPECTION (9-10) REASSEMBLY • When installing the generator stator set bolts, tighten them to the specified torque. Generator stator set bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: Be sure to install the grommet 1 to the generator cover.
3-48 ENGINE WATER PUMP 7-13 GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. 1 Washer 4 Gearshift cam drive plate 2 Snap ring 5 Plate return spring 3 Gearshift shaft return spring GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION • Inspect the gearshift shaft/gearshift arm for wear or bend. • Inspect the return springs for damage or fatigue. • Replace the arm or spring if there is anything unusual. GEARSHIFT SHAFT/GEARSHIFT ARM REASSEMBLY • Install the following parts to the gearshift shaft/gearshift arm as shown in the illustration. 1 Washer 4 Gearshift cam drive plate 2 Snap ring 5 Plate return spring E 3 Gearshift shaft return spring PL SAM NOTE: When installing the gearshift shaft return spring, position the stopper A of gearshift arm between the shaft return spring ends B.
ENGINE 3-49 OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regula- tor with a new one. OIL STRAINER • Inspect the oil strainer body for damage. • Clean the oil strainer if necessary. E L P M A S
3-50 ENGINE TRANSMISSION DISASSEMBLY Disassemble the countershaft and driveshaft. Pay attention to the following points: • Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2. • Slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, then remove the 2nd drive gear circlip 5. E L P M A S 1 Countershaft/1st drive gear 8 6th driven gear 2 5th drive gear 9 3rd driven gear 3 3rd/4th drive gears 0 4th driven gear 4 6th drive gear A 5th driven gear 5 2nd drive gear B 1st driven gear 6 Driveshaft A Engine sprocket nut ITEM N·m kgf-m lb-ft 7 2nd driven gear A 115 11.5 83.0
ENGINE 3-51 REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE: * Rotate the bearings by hand to inspect for smooth rotation. Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE “A” to it. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) * Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed. * When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft. * After installing a snap ring, make sure that it is com- E pletely seated in its groove and securely fitted. L NOTE: P When reassembling the transmission, attention must be given to the locations and positions of washers and snap rings. The M cross sectional view shows the correct position of the gears, bushings, washers and snap rings. (3-52) A • When installing a new snap ring, pay attention to its direction. S Fit it to the side where the thrust is as shown in the illustration. A Thrust B Sharp edge When installing the gear bushing onto the counter- shaft 1 and driveshaft 2, align the shaft oil hole 3 with the bushing oil hole 4.
3-52 ENGINE TRANSMISSION PARTS LOCATION E L P M A S \ 1 Countershaft 2 Driveshaft
ENGINE 3-53 CYLINDER CRANKCASE SERVICING (3-56) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase set. Cylinder distortion: Service Limit: 0.02 mm (0.008 in) 09900-20803: Thickness gauge CYLINDER BORE • Inspect the cylinder wall for any scratches, nicks or other damage. • Measure the cylinder bore diameter at six places. Cylinder bore: Standard: 73.400 – 73.415 mm (2.8900 – 2.8903 in) 09900-20508: Cylinder gauge set E L P M A S
3-54 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. Piston diameter: Service Limit: 73.280 mm (2.8850 in) at 15 mm (0.6 in) from the skirt end 09900-20203: Micrometer (50 – 75 mm) PISTON-TO-CYLINDER CLEARANCE E • Subtract the piston diameter from the cylinder bore diameter. (3-53) L • If the piston-to-cylinder clearance exceeds the service limit, replace the crankcase set or the piston, or both. P Piston-to-cylinder clearance: M Service Limit: 0.120 mm (0.0047 in) A PISTON PIN AND PIN BORE S • Measure the piston pin bore diameter using the small bore gauge. • If the measurement is out of specification, replace the piston. Piston pin bore I.D.: Service Limit: 15.030 mm (0.5917 in) 09900-20602: Dial gauge (1/1000 mm) 09900-22401: Small bore gauge (10 – 18 mm) • Measure the piston pin outside diameter at three positions using the micrometer. • If any of the measurements is out of specification, replace the piston pin. Piston pin O.D.: Service Limit: 14.980 mm (0.5898 in) 09900-20205: Micrometer (0 – 25 mm)
ENGINE 3-55 PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0 – 25 mm) Piston ring-to-groove clearance: Service Limit (1st) : 0.180 mm (0.0071 in) (2nd): 0.150 mm (0.0059 in) Piston ring groove width: Standard (1st) : 1.30 – 1.32 mm (0.0512 – 0.0520 in) (2nd): 0.81 – 0.83 mm (0.0319 – 0.0327 in) (Oil) : 1.51 – 1.53 mm (0.0594 – 0.0602 in) Piston ring thickness: Standard (1st) : 1.08 – 1.10 mm (0.0425 – 0.0433 in) (2nd): 0.77 – 0.79 mm (0.0303 – 0.0311 in) E PISTON RING FREE END GAP AND PISTON RING END GAP L • Measure the piston ring free end gap using the vernier cali- pers. P • Next, fit the piston ring squarely into the cylinder and measure M the piston ring end gap using the thickness gauge. • If any of the measurements exceeds the service limit, replace the piston ring with a new one. A Piston ring free end gap: S Service Limit (1st) : 5.2 mm (0.20 in) (2nd): 6.4 mm (0.25 in) 09900-20102: Vernier calipers Piston ring end gap: Service Limit (1st) : 0.50 mm (0.020 in) (2nd): 0.50 mm (0.020 in) 09900-20803: Thickness gauge
3-56 ENGINE CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer screws 1 and gearshift fork shaft retainer 2 from the lower crankcase. • Remove the gearshift fork shafts 3 and gearshift forks 4 from the lower crankcase. • Remove the gearshift cam 5 and its bearing 6. GEARSHIFT FORK-TO-GROOVE CLEARANCE E • Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. L • The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. P Shift fork-to-groove clearance: M Service Limit: 0.5 mm (0.020 in)A 09900-20803: Thickness gauge • If the clearance checked is noted to exceed the limit specified, S replace the fork or its gear, or both. GEARSHIFT FORK GROOVE WIDTH • Measure the gearshift fork groove width using the vernier cali- pers. Shift fork groove width: Standard: 5.0 – 5.1 mm (0.197 – 0.201 in) 09900-20102: Vernier calipers
ENGINE 3-57 GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers. Shift fork thickness: Standard: 4.8 – 4.9 mm (0.189 – 0.193 in) 09900-20102: Vernier calipers GEARSHIFT CAM BEARING AND GEARSHIFT SHAFT BEARING Bearing inspection • Inspect the gearshift cam bearing for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • Inspect the gearshift cam bearing 1, gearshift shaft bearings E 2 and 3 for abnormal noise and smooth rotation while they are in the crankcase. L • Replace a bearing if there is anything unusual. P M A Bearing removal S • Remove the gearshift shaft bearing with the special tools. 09921-20210: Bearing remover 09930-30104: Sliding shaft • Remove the gearshift cam bearing with the special tools. 09923-74511: Bearing remover 09930-30104: Sliding shaft Be careful not to lean the bearing remover.
3-58 ENGINE • Remove the oil seal 1. • Remove the gearshift shaft bearing with the special tool. 09921-20240: Bearing remover set (15 mm) Installation • Install the bearings with the special tool. 09913-70210: Bearing installer set (1, 2 20) (3 32) NOTE: The stamped mark side of the gearshift shaft bearing faces out- side. E L P M A S • Install the oil seal with the special tool. 09913-70210: Bearing installer set (22) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the gearshift cam 4 with the bearing 5. NOTE: The stamped mark side of the gearshift cam bearing faces out- side.
ENGINE 3-59 • Install the gearshift forks and their shafts as shown. 6 For 3rd/4th drive gears 7 For 6th driven gear 8 For 5th driven gear • Apply a small quantity of THREAD LOCK to the bearing E retainer screws 9. • Tighten the bearing retainer screws 9 and gearshift fork shaft L retainer bolt 0 to the specified torque. P 99000-32050: THREAD LOCK “1342” Bearing retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft) M Gearshift fork shaft retainer bolt: A S10 N·m (1.0 kgf-m, 7.0 lb-ft)
3-60 ENGINE OIL JET Removal • Remove the piston cooling oil jets 1 from the upper crank- case. • Remove the oil jet 2 (for transmission) from the lower crank- E case. L P M A S • Remove the oil jet 3 (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • Check the oil jets for clogging. • If they are clogged, clean their oil passage with a proper wire and compressed air. 1 Piston cooling oil jet 2 Oil jet (#14) (For transmission) 3 Oil jet (#8) (For cam chain tension adjuster)
ENGINE 3-61 Installation • Fit the new O-ring 1 to each piston cooling oil jet as shown and apply engine oil to them. Use the new O-rings to prevent oil pressure leak. • Install each piston cooling oil jet with the bolt. NOTE: Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque. 99000-32050: THREAD LOCK “1342” Piston cooling oil jet bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the oil jet (for transmission). E L P M A S • Apply engine oil to the O-ring. • Install the oil jet (for cam chain tension adjuster). PLUG Removal • Remove the oil gallery plugs 1 and 2. 1 (for cylinder head side) 2 (for upper crankcase side)
3-62 ENGINE • Remove the water jacket plugs 3. • Remove the oil gallery plugs 4 (for lower crankcase side). Installation E • Apply engine coolant to the O-ring of the water jacket plug 1. L 99000-99032-11X: SUZUKI COOLANT (Except USA) • Apply THREAD LOCK to the oil gallery plug 2. P 99000-32050: THREAD LOCK “1342” M NOTE: It is not require to apply THREAD LOCK when installing the other removed oil gallery plugs. A S • Tighten each plug to the specified torque. 1 Water jacket plug: 9.5 N·m (0.95 kgf-m, 6.9 lb-ft) 2 Oil gallery plug (upper crankcase): 18 N·m (1.8 kgf-m, 13.0 lb-ft) 3 Oil gallery plug (lower crankcase): 35 N·m (3.5 kgf-m, 25.5 lb-ft) 4 Oil gallery plug (cylinder head): 10 N·m (1.0 kgf-m, 7.0 lb-ft) Use each new gasket or O-ring.
ENGINE 3-63 BALANCER SHAFT DISASSEMBLY • Remove the balancer gear along with the dampers from the balancer shaft. INSPECTION • Inspect the damper for wear and damage, replace it if any defects are found. REASSEMBLY • Apply MOLYBDENUM OIL SOLUTION to each part. MOLYBDENUM OIL SOLUTION • Set the dampers and install the balancer shaft to balancer gear. NOTE: * Fit the stopper of the balancer shaft between the dampers. * Align the line A on the balancer shaft with the punch B on the balancer gear. E BALANCER SHAFT JOURNAL BEARING L INSPECTION P • Inspect each bearing of upper and middle crankcases for any damage. M SELECTION • Place the plastigauge axially along the balancer shaft journal A as shown. S 09900-22301: Plastigauge Never rotate the balancer shaft when a piece of plasti- gauge is installed. • Mate the middle crankcase with the upper crankcase, and tighten the crankcase bolts (M8) and crankshaft bolts(M8) to the specified torque. Crankshaft journal bolt (M9): Initial : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Final : 50° Crankcase bolt (M8): Initial : 15 N·m (1.5 kgf-m, 11.0 lb-ft) Final : 26 N·m (2.6 kgf-m, 19.0 lb-ft)
3-64 ENGINE • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. Balancer shaft journal oil clearance: Standard: 0.028 – 0.052 mm (0.0011 – 0.0020 in) Service Limit: 0.080 mm (0.031 in) • If the oil clearance exceeds the service limit, select the speci- fied bearings from the bearing selection table. • Check the corresponding crankcase journal I.D. code number A, “A” or “B” which is stamped on the rear of upper crank- case. • Check the corresponding balancer shaft journal O.D. code number B, “A” or “B” which is stamped on the balancer shaft. Bearing selection table Balancer shaft journal O.D. B Code AB Crankcase A Green Black I.D. A B Black Brown E Crankcase I.D. specification L Code I.D. specification P A 26.000 – 26.008 mm (1.0236 – 1.0239 in) M B 26.009 – 26.016 mm (1.0240 – 1.0243 in) A S Balancer shaft journal O.D. specification Code O.D. specification A 22.984 – 22.992 mm (0.9049 – 0.9052 in) B 22.976 – 22.984 mm (0.9046 – 0.9049 in) 09900-20205: Micrometer (0 – 25 mm) Bearing thickness specification Color (Part No.) Thickness Green 1.486 – 1.490 mm (12229-40F50-0A0) (0.0585 – 0.0587 in) Black 1.490 – 1.494 mm (12229-40F50-0B0) (0.0587 – 0.0588 in) Brown 1.494 – 1.498 mm (12229-40F50-0C0) (0.0588 – 0.0590 in) NOTE: The balancer shaft journal bearings on upper and middle crank- cases are the same.
ENGINE 3-65 INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part A first and press the other end. Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell. CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with V-blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. • Replace the crankshaft if the runout is greater than the limit. Crankshaft runout: Service Limit: 0.05 mm (0.002 in) 09900-20607: Dial gauge (1/100 mm, 10 mm) E 09900-20701: Magnetic stand L 09900-21304: V-block set (100 mm) P CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the M conrod small end. A Conrod small end I.D.: Service Limit: 15.040 mm (0.5921 in) S 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22401: Small bore gauge (10 – 18 mm) • If the inside diameter of the conrod small end exceeds the limit, replace the conrod.
3-66 ENGINE CONROD BIG END SIDE CLEARANCE • Inspect the conrod side clearance by using a thickness gauge. • If the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width. • If the width exceed the limit, replace conrod or crankshaft. Conrod big end side clearance: Service Limit: 0.30 mm (0.012 in) 09900-20803: Thickness gauge Conrod big end width: Standard: 19.95 – 20.00 mm (0.7854 – 0.7874 in) 09900-20205: Micrometer (0 – 25 mm) Crank pin width: Standard: 20.10 – 20.15 mm (0.7913 – 0.7933 in) 09900-20605: Dial calipers (1/100 mm, 10 – 34 mm) CONROD-BIG END BEARING INSPECTION E • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of L bearings. P M A S CONROD-BIG END BEARING SELECTION • Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown. 09900-22301: Plastigauge • Tighten the conrod cap bolts to the specified torque, in two stages. (3-77) * Apply engine oil to the bearing cap bolt. * Never rotate the crankshaft or conrod when a piece of plastigauge is installed.
ENGINE 3-67 *1: The number faces the intake side. • Remove the bearing caps and measure the width of the com- pressed plastigauge using the envelope scale. This measure- ment should be taken at the widest part of the compressed plastigauge. Conrod big end oil clearance: Standard: 0.032 – 0.056 mm (0.0013 – 0.0022 in) Service Limit: 0.080 mm (0.0031 in) • If the oil clearance exceeds the service limit, select the speci- fied bearings from the bearing selection table. E • Check the corresponding conrod I.D. code number (“1” or “2”) A. L P M A S • Check the corresponding crank pin O.D. code number (“1”, “2” or “3”) B. Bearing selection table Crank pin O.D. B Code 123 Conrod 1 Green Black Brown I.D A 2 Black Brown Yellow Conrod I.D. Code I.D. specification 1 38.000 – 38.008 mm (1.4961 – 1.4964 in) 2 38.008 – 38.016 mm (1.4964 – 1.4967 in)
3-68 ENGINE Crank pin O.D. Code O.D. specification 1 34.992 – 35.000 mm (1.3776 – 1.3780 in) 2 34.984 – 34.992 mm (1.3773 – 1.3776 in) 3 34.976 – 34.984 mm (1.3770 – 1.3773 in) 09900-20202: Micrometer (25 – 50 mm) Bearing thickness Color (Part No.) Thickness Green 1.480 – 1.484 mm (12164-41G00-0A0) (0.0583 – 0.0584 in) Black 1.484 – 1.488 mm (12164-41G00-0B0) (0.0584 – 0.0586 in) Brown 1.488 – 1.492 mm (12164-41G00-0C0) (0.0586 – 0.0587 in) Yellow 1.492 – 1.496 mm (12164-41G00-0D0) (0.0587 – 0.0589 in) E L The bearings must be replaced as a set. P M A S
ENGINE 3-69 CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and middle crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown. 09900-22301: Plastigauge Never rotate the crankshaft when a piece of plasti- gauge is installed. • Tighten the crankshaft journal bolts (M9) in ascending order E of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure in the following two steps. L 10 6 2 4 8 Crankshaft journal bolt: (M9) P Initial : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Final : 50° M SA 9 5 1 3 7 • Remove the middle crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. Crankshaft journal oil clearance: Standard: 0.010 – 0.028 mm (0.0004 – 0.0011 in) Service Limit: 0.080 mm (0.0031 in) • If the oil clearance exceeds the service limit, select the speci- fied bearings from the bearing selection table.
3-70 ENGINE • Check the corresponding crankcase journal I.D. code number A, “A”, “B” or “C” which is stamped on the rear of upper crankcase. • Check the corresponding crankshaft journal O.D. code num- ber B, “A”, “B” or “C” which is stamped on the crankshaft. Bearing selection table Crankshaft journal O.D. B Code ABC Crankcase A Green Black Brown I.D. A B Black Brown Yellow C Brown Yellow Blue Crankcase I.D. specification Code I.D. specification A 38.000 – 38.006 mm (1.4961 – 1.4963 in) B 38.007 – 38.012 mm (1.4963 – 1.4965 in) C 38.013 – 38.018 mm (1.4966 – 1.4968 in) E L P M A S
ENGINE 3-71 Crankshaft journal O.D. specification Code O.D. specification A 34.994 – 35.000 mm (1.3777 – 1.3780 in) B 34.988 – 34.994 mm (1.3775 – 1.3777 in) C 34.982 – 34.988 mm (1.3772 – 1.3775 in) 09900-20202: Micrometer (25 – 50 mm) Bearing thickness specification Color (Part No.) Thickness Green 1.492 – 1.495 mm (12229-41G00-0A0) (0.0587 – 0.0589 in) Black 1.495 – 1.498 mm (12229-41G00-0B0) (0.0589 – 0.0590 in) Brown 1.498 – 1.501 mm (12229-41G00-0C0) (0.0590 – 0.0591 in) Yellow 1.501 – 1.504 mm (12229-41G00-0D0) (0.0591 – 0.0592 in) E Blue 1.504 – 1.507 mm L (12229-41G00-0E0) (0.0592 – 0.0593 in) NOTE: P Upper and middle crankshaft journal bearings are the same. M INSTALLATION A • When fitting the crankshaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part A first and press the other end. S Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.
3-72 ENGINE CRANKSHAFT THRUST BEARING • With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. L: Left-side thrust bearing R: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing. Thrust clearance: Standard: 0.060 – 0.110 mm (0.0024 – 0.0043 in) 09900-20803: Thickness gauge • If the thrust clearance exceeds the standard range, adjust the thrust clearance by the following procedures. CRANKSHAFT THRUST CLEARANCE ADJUSTMENT E • Remove the right-side thrust bearing and measure its thick- ness with a micrometer. L • If the thickness of the right-side thrust bearing is below stan- P dard, replace it with a new one and once again perform the thrust clearance measurement listed above, checking to make sure it is within standard. M Right-side thrust bearing thickness: A Standard: 2.420 – 2.440 mm (0.0953 – 0.0961 in) S 09900-20205: Micrometer (0 – 25 mm) • If the right-side thrust bearing is within the standard range, reinsert the right-side thrust bearing and remove the left-side thrust bearing. • As shown in the illustration, measure the clearance by using a thickness gauge before inserting the left-side thrust bearing. 09900-20803: Thickness gauge • Select a left-side thrust bearing from the selection table. (3-73)
ENGINE 3-73 Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side (Part No.) thickness Thrust clearance thrust bearing 2.570 – 2.590 mm Brown 2.480 – 2.500 mm 0.070 – 0.110 mm (0.1012 – 0.1020 in) (12228-48B00-0B0) (0.0976 – 0.0984 in) (0.0028 – 0.0043 in) 2.550 – 2.570 mm Red 2.460 – 2.480 mm 0.070 – 0.110 mm (0.1004 – 0.1012 in) (12228-48B00-0C0) (0.0969 – 0.0976 in) (0.0028 – 0.0043 in) 2.530 – 2.550 mm Yellow 2.440 – 2.460 mm 0.070 – 0.110 mm (0.0996 – 0.1004 in) (12228-48B00-0D0) (0.0961 – 0.0969 in) (0.0028 – 0.0043 in) 2.510 – 2.530 mm Green 2.420 – 2.440 mm 0.070 – 0.110 mm (0.0988 – 0.0996 in) (12228-48B00-0E0) (0.0953 – 0.0961 in) (0.0028 – 0.0043 in) 2.490 – 2.510 mm Blue 2.400 – 2.420 mm 0.070 – 0.110 mm (0.0980 – 0.0988 in) (12228-48B00-0F0) (0.0945 – 0.0953 in) (0.0028 – 0.0043 in) 2.470 – 2.490 mm Orange 2.380 – 2.400 mm 0.070 – 0.110 mm (0.0972 – 0.0980 in) (12228-48B00-0G0) (0.0937 – 0.0945 in) (0.0028 – 0.0043 in) 2.440 – 2.470 mm Black 2.360 – 2.380 mm 0.060 – 0.110 mm (0.0961 – 0.0972 in) (12228-48B00-0H0) (0.0929 – 0.0937 in) (0.0024 – 0.0043 in) • After selecting a left-side thrust bearing, insert it and again E perform the thrust clearance measurement to make sure it falls within the standard range. L A Color code NOTE: P Right-side thrust bearing has the same specification as the M GREEN (12228-48B00-0E0) of left-side thrust bearing. A S
3-74 ENGINE ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. • Be sure to install the following items to the crankcase. * Crankshaft journal bearing (3-69) * Gearshift fork (3-59) * Gearshift fork shaft (3-59) * Gearshift shaft bearing (3-58) * Gearshift cam bearing (3-58) * Gearshift cam (3-58) * Bearing retainer (3-59) * Oil jets (3-60) PISTON RING • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. E After placing the spacer, fit the two side rails 2. L NOTE: P Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way. M A S When installing the spacer, be careful not to allow its two ends to overlap in the groove. A INCORRECT B CORRECT • Install the 2nd ring 3 and the 1st ring 4 to the piston. NOTE: 1st ring and 2nd ring differ in shape.
ENGINE 3-75 • Be sure to bring the concave side of 1st ring to the top when fitting it to the piston. • 2nd ring has letters “T” marked on the side. Be sure to bring the marked side ring to the top when fitting it to the piston. • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located. C 2nd ring and lower side rail D Upper side rail E 1st ring and spacer PISTON AND CONROD E • Apply a small quantity of MOLYBDENUM OIL SOLUTION onto each piston pin. L MOLYBDENUM OIL SOLUTION P • Assemble the piston and conrod. M NOTE: When installing the pistons, the indent A on the piston head A must be brought to the other side of ID code B on the conrod big end. S • Install the piston pin circlips 1. Use new piston pin circlips to prevent circlip failure which will occur with a bend one. NOTE: End gap of the circlip should not be aligned with the cutaway in the piston pin bore. • Apply a small quantity of MOLYBDENUM OIL SOLUTION to the sliding surface of the pistons and cylinder walls. MOLYBDENUM OIL SOLUTION NOTE: Be sure to install the pistons in the cylinders from which they were removed in disassembly, referring to the cylinder numbers, “1” through “4”, scribed on the piston.
3-76 ENGINE • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent C of each piston head must be brought to the exhaust side. Be careful not to damage the cylinder wall and piston jet by the conrod. • Check that I.D. code D on each conrod faces intake side. E L Be sure to clean the conrod big end. P M A S • Apply a MOLYBDENUM OIL SOLUTION to each crank pin bearing surface and crankshaft journal bearing surface. MOLYBDENUM OIL SOLUTION CRANKSHAFT • Position the No. 2 and No. 3 conrod big ends on the same side, and the No. 1 and No. 4 conrod big ends on the opposite side of No. 2 and No. 3.
ENGINE 3-77 • Set the crankshaft to the conrods and upper crankcase. • Apply a MOLYBDENUM OIL SOLUTION to the crank pin and bearing surface. MOLYBDENUM OIL SOLUTION Be sure to clean the conrod big end. • When fitting the conrod cap, make sure that I.D. code A on each conrod faces intake side. • Apply engine oil to the bearing cap bolts. E • Tighten the bearing cap bolt by using a 12 mm, 12 point socket wrench in the following two steps. L Conrod bearing cap bolt: P Initial: 37 N·m (3.7 kgf-m, 27.0 lb-ft) Final : 60° (1/6 turn) M • Apply engine oil to the conrod big end side surfaces. A • Check the conrod movement for smooth turning. S 60˚ • Apply a MOLYBDENUM OIL SOLUTION to each crankshaft journal and bearing lightly. MOLYBDENUM OIL SOLUTION
3-78 ENGINE • Insert the right and left-thrust bearings with oil groove B fac- ing the crank web. NOTE: Right-thrust bearing has green painting. BALANCER SHAFT • Install the thrust washers 1, 2 and oil seal 3. • Apply a MOLYBDENUM OIL SOLUTION to each balancer shaft journal and bearing lightly. MOLYBDENUM OIL SOLUTION • Set the balancer shaft so that its punch mark A is aligned with the index B on the crankshaft. E L P M A CRANKCASE S • Clean the mating surfaces of the crankcases. • Install the dowel pins 1 and O-ring 2 to the upper crank- case.
ENGINE 3-79 • Apply SUZUKI BOND to the mating surface of the middle crankcase. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31110: SUZUKI BOND “1215” (Others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes. * Take extreme care not to apply any BOND to the oil hole, oil groove and bearing. * Apply to distorted surfaces as it forms a comparatively thick film. E PL SAM • Tighten the crankshaft journal bolts (M9) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure in the following two steps. 10 6 2 4 8 Crankshaft journal bolt: (M9) Initial : 18 N·m (1.8 kgf-m, 13.0 lb-ft) Final : 50° 9 5 1 3 7
3-80 ENGINE • Tighten the other crankcase bolts a little at a time to equalize the pressure. Crankcase bolt: (M6) Initial: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Final : 11 N·m (1.1 kgf-m, 8.0 lb-ft) (M8) Initial: 15 N·m (1.5 kgf-m, 11.0 lb-ft) Final : 26 N·m (2.6 kgf-m, 19.0 lb-ft) NOTE: Fit a new gasket washer to the crankcase bolt A. Use a new gasket washer to prevent oil leakage. NOTE: E After the crankshaft journal bolts and crankcase bolts have been tightened, check if the crankshaft rotates smoothly. L P M A S
ENGINE 3-81 TRANSMISSION • Install the bearing pins 1 and the C-rings 2 on the middle crankcase. • Install the countershaft assembly on the middle crankcase. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. • Install the driveshaft assembly on the middle crankcase. E NOTE: L Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. P SAM • Install the oil seal 3. • Turn the bearings to install the bearing dowel pins A in the respective positions. • Install the O-rings. • Install the dowel pins 4.
3-82 ENGINE • Apply SUZUKI BOND to the mating surface of the lower crankcase. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31110: SUZUKI BOND “1215” (Others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within few minutes. * Take extreme care not to apply any BOND to the oil hole, oil groove and bearing. * Apply to distorted surfaces as it forms a comparatively thick film. E PL SAM • Match the middle and lower crankcases. NOTE: Align the gearshift forks 5 with their grooves 6.
ENGINE 3-83 • Tighten the crankcase bolts a little at a time to equalize the pressure. NOTE: * Fit the new copper washers to the crankcase bolts B. * Fit the new gasket washers to the crankcase bolts C. Crankcase bolt: (M6) Initial: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Final : 11 N·m (1.1 kgf-m, 8.0 lb-ft) (M8) Initial: 15 N·m (1.5 kgf-m, 11.0 lb-ft) Final : 26 N·m (2.6 kgf-m, 19.0 lb-ft) Use the new copper washers and new gasket washers to prevent oil leakage. • Check that the driveshaft and countershaft rotate smoothly. E L P M A OIL STRAINER S • Install the O-ring. • Apply SUZUKI SUPER GREASE “A” to the O-ring. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) Use a new O-ring to prevent oil leakage. • Install the oil strainer 1 as shown and tighten the oil strainer bolts to the specified torque. Oil strainer bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
3-84 ENGINE OIL PRESSURE REGULATOR • Apply SUZUKI SUPER GREASE “A” to the O-ring and press in the oil pressure regulator to the crankcase. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) Use a new O-ring to prevent oil leakage. OIL PAN • Apply SUZUKI BOND to the mating surface of the oil pan. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31110: SUZUKI BOND “1215” (Others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Apply to distorted surfaces as it forms a comparatively thick film. E • Install the oil pan. L NOTE: Fit the new gasket washers to the oil pan bolts A. P M Use a new gasket washer to prevent oil leakage. A • Tighten the oil pan bolts diagonally to the specified torque. S Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) OIL PRESSURE SWITCH • Apply SUZUKI BOND to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31140: SUZUKI BOND “1207B” (Others) Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft) NOTE: Be careful not to apply SUZUKI BOND to the hole of thread end.
ENGINE 3-85 OIL FILTER • Install the oil filter with the special tool. (2-13) 09915-40610: Oil filter wrench Oil filter: 20 N·m (2.0 kgf-m, 14.5 lb-ft) CRANKCASE BREATHER COVER • Install a new gasket 1. • Install the breather cover 2. E Breather cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) L P M A S GEAR POSITION SWITCH • Apply SUZUKI SUPER GREASE “A” to the O-ring. NOTE: Align the gear position switch pin A with the gearshift cam hole B. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the gear position switch 3 as shown. • Apply THREAD LOCK to the gear position switch bolts. 99000-32050: THREAD LOCK “1342” (USA) 99000-32110: THREAD LOCK SUPER “1322” (Others)
3-86 ENGINE WATER PUMP • Apply SUZUKI SUPER GREASE “A” to the O-ring. Use a new O-ring to prevent oil leakage. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Tighten the water pump mounting bolts 1 to the specified torque. Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: Pass the gear position switch lead wire 2 under the water pump rib and clamp the gear position switch lead wire. • Apply engine coolant to the O-ring. E L Use a new O-ring to prevent engine coolant leakage. P M A • Install the water inlet cover 3.S Water inlet cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) GENERATOR ROTOR • Degrease the tapered portion A of generator rotor and also the crankshaft B. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry.
ENGINE 3-87 • Install the generator rotor onto the crankshaft. • Install the rotor bolt with the washer. • Hold the generator rotor with the special tool and tighten its bolt to the specified torque. 09930-44520: Rotor holder Generator rotor bolt: 120 N·m (12.0 kgf-m, 87.0 lb-ft) GENERATOR COVER • Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper and middle crankcases as shown. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31140: SUZUKI BOND “1207B” (Others) • Install the dowel pins 1 and new gasket 2. E L Use a new gasket to prevent oil leakage. P M A S • Install the generator cover and tighten the generator cover bolts to the specified torque. Generator cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) Be careful not to pinch the finger between the genera- tor cover and the crankcase. Use a new gasket washers to prevent oil leakage. NOTE: Fit the gasket washers to the bolts A. • Install the CKP sensor 3.
3-88 ENGINE • Apply SUZUKI BOND lightly to the groove of signal generator lead wire grommet. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31140: SUZUKI BOND “1207B” (Others) CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft. NOTE: When installing the cam chain drive sprocket, align the wide spline teeth A and B. CAM CHAIN TENSIONER/CAM CHAIN GUIDE E • Install the cam chain. • Apply a small quantity of THREAD LOCK to the cam chain L tensioner bolt and cam chain guide bolt. P • Install the cam chain tensioner 1 along with the washer 2. • Install the cam chain guide 3. M 99000-32050: THREAD LOCK “1342” A Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) Cam chain guide bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) S STARTER CLUTCH • Install the washer 1. • Install the starter clutch assembly onto the crankshaft. NOTE: When installing the starter clutch assembly, align the wide spline teeth A and B.
ENGINE 3-89 • Install the starter clutch bolt with the washer. • Hold the starter clutch with the special tool and tighten its bolt to the specified torque. 09920-34830: Starter clutch holder Starter clutch bolt: 55 N·m (5.5 kgf-m, 40.0 lb-ft) STARTER IDLE GEAR • Install the starter idle gear No. 2 1, shaft 2 and spring washer 3. • Apply SUZUKI BOND lightly to the mating surfaces A at the E parting line between the upper and middle crankcases and surface B as shown. L 99104-31140: SUZUKI BOND “1207B” (USA) P 99000-31140: SUZUKI BOND “1207B” (Others) M A S • Install the new gasket 4 and dowel pins 5. Use a new gasket to prevent oil leakage. • Install the starter clutch cover and tighten its bolt as shown. NOTE: * Fit a new gasket washer to the starter clutch cover bolt C as shown. Use a new gasket washer to prevent oil leakage. Starter clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
3-90 ENGINE • Install the starter idle gear No. 1 shaft 6, thrust washer 7, bearing 8, starter idle gear No. 1 9, washer 0, and spring washer A. • Install the dowel pins B and new gasket C. Use a new gasket to prevent oil leakage. • Install the starter idle gear cover and tighten its bolts to the E specified torque. L Starter idle gear cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: P Fit a new gasket washer to the bolt D. M Use a new gasket washer to prevent oil leakage. A S GEARSHIFT SYSTEM • Install the gearshift cam stopper 1, its bolt 2, washer 3 and return spring 4. NOTE: Apply a small quantity of THREAD LOCK to the gearshift cam stopper bolt 2 and tighten it to the specified torque. 99000-32050: THREAD LOCK “1342” Gearshift cam stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: Hook the return spring end A to the stopper 5. • Check the gearshift cam stopper moves smoothly. • Locate the gearshift cam in the neutral position.
ENGINE 3-91 • Install the gearshift cam stopper plate 6. NOTE: Align the gearshift cam pin B with the gearshift cam stopper plate hole C. • Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque. 99000-32050: THREAD LOCK “1342” Gearshift cam stopper plate bolt: 13 N·m (1.3 kgf-m, 9.5 lb-ft) • Install the gearshift shaft assembly 7 and washer 8 as E shown. L NOTE: Pinch the gearshift arm stopper 9 with return spring ends D. P SAM • Install the washer 0 and snap ring A.
3-92 ENGINE OIL PUMP • Install the O-ring to the oil pump and apply SUZUKI SUPER GREASE “A” to it. Use a new O-ring to prevent oil leakage. NOTE: Set the oil pump shaft end A to the water pump shaft. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the oil pump with the oil pump mounting bolts and then tighten them to the specified torque. Oil pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the washer 1 and pin 2. NOTE: Be careful not to drop the washer 1 and pin 2 into the crank- case. E • Install the oil pump driven gear 3. L • Install the snap ring 4. P M A S CLUTCH NOTE: Before assembling the clutch, adjust the clutch lifter. (3-45) • Install the thrust washer onto the countershaft. NOTE: The chamfer side A of thrust washer faces inside.
ENGINE 3-93 • Install the oil pump drive gear 1 to the primary driven gear assembly 2. • Install the primary driven gear assembly 2. NOTE: * If it is difficult to install the primary driven gear, rotate the crankshaft. * Be sure to engage the oil pump driven gear with the drive gear and the primary driven gear with the drive gear. • Install the bearing 3 and spacer 4, and apply engine oil to them. • Install the thrust washer 5. • Install the wave spring washers 6, clutch lifter driven cam 7 E and clutch lifter drive cam 8 to the clutch sleeve hub 9. L NOTE: * Apply a small quantity of MOLYBDENUM OIL SOLUTION to P the contact surfaces of the clutch lifter drive cam 8 and driven cam 7. M * Be sure to align the punch marks A on the clutch lifter drive cam 8 and driven cam 7. A MOLYBDENUM OIL SOLUTION S
3-94 ENGINE • Install the clutch sleeve hub assembly 9 onto the counter- shaft. • Install the washer 0 and spring washer A. NOTE: * Before installing the washer 0, visually inspect the washer surface for wear and damage. If necessary, replace it with a new one. * The conical curve side of spring washer A faces outside. • Hold the clutch sleeve hub with the special tool. E 09920-53740: Clutch sleeve hub holder L • Tighten the clutch sleeve hub nut to the specified torque. P Clutch sleeve hub nut: 95 N·m (9.5 kgf-m, 68.5 lb-ft) M A S • Lock the clutch sleeve hub nut with a center punch. • Install the spring washer seat B and spring washer C onto the clutch sleeve hub correctly.
ENGINE 3-95 • Install the clutch push rod D into the countershaft. • Install the clutch push piece E, bearing F and thrust washer G to the countershaft. NOTE: Thrust washer G is located between the pressure plate and bearing F. • Insert the clutch drive plates and driven plates one by one into E the clutch sleeve hub in the prescribed order. L NOTE: Insert the outermost No. 2 drive plate claws B to the other slits C of clutch housing as shown. P M A S
3-96 ENGINE *1 *2 or or *1: Direction of outside *2: Paint DRIVE PLATE: a No. 2 Drive plate.......1 pc. [Black paint/I.D. 111 mm (4.4 in)] b No. 1 Drive plate.......8 pcs. [Purple paint/I.D. 111 mm (4.4 in)] c No. 3 Drive plate.......1 pc. [NIL/I.D. 118 mm (4.6 in)] NOTE: No.3 drive plate can be distinguished by the inside diameter E (I.D.). DRIVEN PLATE: (d + e + f = Total 9 pcs) L d No. 1 Driven plate (Thickness): 2.3 mm (0.091 in).....8 – 9 pcs. P e No. 2 Driven plate (Thickness): 2.0 mm (0.079 in).....0 – 1 pc. f No. 3 Driven plate (Thickness): 2.6 mm (0.102 in).....0 – 1 pc. M • Install the pressure plate H. A NOTE: When install the pressure plate, fit the convex part D of the S pressure plate onto the concave part E of the clutch sleeve hub. • Install the clutch springs.
ENGINE 3-97 • Hold the clutch housing with the special tool. Be careful not to damage the clutch housing or clutch plates. 09920-53740: Clutch sleeve hub holder • Tighten the clutch spring set bolts to the specified torque. Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: * Tighten the clutch spring set bolts diagonally. * After mounting the engine, adjust the push rod. (2-16) CLUTCH COVER • Apply SUZUKI BOND lightly to the mating surfaces at the parting line between the upper, middle and lower crankcases as shown. 99104-31140: SUZUKI BOND “1207B” (USA) 99000-31140: SUZUKI BOND “1207B” (Others) E L • Install the gasket 1 and dowel pins 2. P M Use a new gasket to prevent oil leakage. A S • Install the clutch cover and tighten its bolts to the specified torque. Clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: * Fit the clamp to the bolt A as shown. * Fit the new gasket washers to the bolts B as shown. Use a new gasket washer to prevent oil leakage.
3-98 ENGINE CYLINDER HEAD • Fit the dowel pins 1 and new cylinder head gasket 2 to the cylinder. Use a new gasket to prevent gas leakage. • Place the cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Tighten the cylinder head bolts (M10) in the following four-step. Step 1: • Tighten the cylinder head bolts to the specified torque with a torque wrench sequentially and diagonally. Step 2: • Loosen all the cylinder head bolts diagonally. E Step 3: • Retighten the cylinder head bolts to the specified torque with L a torque wrench sequentially and diagonally. P Step 4: • Additionally tighten the cylinder head bolts with the specified M angles diagonally using an angular torque gauge. Cylinder head bolt (M10): A Step 1/Step 3 : 31 N·m (3.1 kgf-m, 22.5 lb-ft) Final step : 60° (1/6 turn) S NOTE: Apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts. • Tighten the cylinder head bolts to the specified torque. Cylinder head bolt (M6): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
ENGINE 3-99 • Fit the gasket 3 and tighten the ECT sensor. ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Install the thermostat 4. NOTE: The jiggle valve A of thermostat faces upside. • Install the thermostat cover 5. E Thermostat cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) L P M A S • Install the water hose 6. (10-24)
3-100 ENGINE CAMSHAFT • Turn the crankshaft clockwise with the box wrench and align the line A on the starter clutch with the index mark B of valve timing inspection hole while keeping the cam chain pulled upward. Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. To adjust the camshaft timing correctly, be sure to align the line A with the index mark B and hold this position when installing the camshafts. • The camshafts are identified by the embossed letters. E • Before replacing the camshafts on cylinder head, apply MOLYBDENUM OIL SOLUTION to their journals and cam L faces. P • Apply a MOLYBDENUM OIL SOLUTION to the camshaft jour- nal holders. M MOLYBDENUM OIL SOLUTION NOTE: A Before installing the camshaft, check that the tappets are installed correctly. S
ENGINE 3-101 • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked “1” C. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. • Bind the cam chain and sprocket with a proper wire clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders. • The other arrow marked “2” D should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked “2” D, count out 14 roller pins (from the exhaust cam- shaft side going towards the intake camshaft side). • Engage the 14th roller pin E on the cam chain with the arrow marked “3” on the intake sprocket. • Bind the cam chain and sprocket with a proper wire clamp 2 to prevent the cam chain disengagement while installing the camshaft journal holders. NOTE: The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft journal holders E and cam chain tension adjuster are secured. L P M 1114 131313 33 22 1 44 A S3 2 1 2 3 1
3-102 ENGINE • Install the dowel pins 3. • Install the camshaft journal holders, intake and exhaust, and cam chain guide. • Have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers. NOTE: * Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly. * Each camshaft journal holder is identified with a cast-on letter F. * The ascending order of numbers are indicated on the cam- shaft journal holders. • Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque. Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) The camshaft journal holder bolts are made of a spe- E cial material and much superior in strength, compared with other types of high strength bolts. L Take special care not to use other types of bolts. P SAM 9 EX (1) 5 7 3 11 10 (2) 6 8 4 12 10 (2) 6 8 4 12 9 IN (1) 5 7 3 11
ENGINE 3-103 CAM CHAIN TENSION ADJUSTER • Retract the push rod by pushing the stopper 1. • Install a new gasket 2. Use a new gasket to prevent oil leakage. • Install the cam chain tension adjuster 3 and tighten its mounting bolts. Cam chain tension adjuster mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the spring 4. E • Install the gasket 5 and cam chain tension adjuster cap bolt 6. L NOTE: P Click sound is heard when the cam chain tension adjuster cap bolt is installed. M • Tighten the cam chain tension adjuster cap bolt to the speci- fied torque. A Cam chain tension adjuster cap bolt: S 23 N·m (2.3 kgf-m, 16.5 lb-ft) After installing the cam chain tension adjuster, check to be sure that the adjuster works properly by check- ing the slack of cam chain. • Cut the wire clamps 7. • After installing the cam chain tension adjuster, rotate the crankshaft (some turns), and recheck the positions of the camshafts. (3-104)
3-104 ENGINE 23 N·m E (2.3 kgf-m, 16.5 lb-ft) L 10 N·m (1.0 kgf-m, 7.0 lb-ft) P SAM
ENGINE 3-105 • Tighten the valve timing inspection plug 8 to the specified torque. Valve timing inspection plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft) CYLINDER HEAD COVER • Pour engine oil in each oil pocket in the cylinder head. NOTE: Be sure to check the valve clearance. (2-7) • Install the dowel pins. • Install the O-rings. • Install the new gaskets to the cylinder head cover. E • Apply SUZUKI BOND to the cam end caps of the gaskets as shown. L 99104-31140: SUZUKI BOND “1207B” (USA) P 99000-31140: SUZUKI BOND “1207B” (Others) M Use the new gaskets to prevent oil leakage. A S • Place the cylinder head cover on the cylinder head. • Fit a new gasket 1 to each head cover bolt. Use a new gasket to prevent oil leakage. • Tighten the head cover bolts to the specified torque. Head cover bolt: Initial: 10 N·m (1.0 kgf-m, 7.0 lb-ft) Final: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
3-106 ENGINE STARTER MOTOR • Apply SUZUKI SUPER GREASE to the O-ring. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the starter motor 1. Starter motor mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Install the spark plugs. (2-6) E L P M A S
FI SYSTEM DIAGNOSIS 4-1 FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING................................................................... 4- 3 ELECTRICAL PARTS............................................................................ 4- 3 FUSE....................................................................................................... 4- 4 ECM/VARIOUS SENSORS.................................................................... 4- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE...........................4- 6 USING THE MULTI-CIRCUIT TESTER.................................................. 4- 9 FI SYSTEM TECHNICAL FEATURES.......................................................... 4-10 INJECTION TIME (INJECTION VOLUME)............................................ 4-10 4 COMPENSATION OF INJECTION TIME (VOLUME)............................4-11 INJECTION STOP CONTROL............................................................... 4-11 FI SYSTEM PARTS LOCATION............................................................ 4-12 FI SYSTEM WIRING DIAGRAM............................................................. 4-14 ECM TERMINAL........................................................................................... 4-15 SELF-DIAGNOSIS FUNCTION..................................................................... 4-17 USER MODE.......................................................................................... 4-17 E DEALER MODE...................................................................................... 4-18 L TPS ADJUSTMENT................................................................................ 4-20 P FAIL-SAFE FUNCTION................................................................................ 4-21 FI SYSTEM TROUBLESHOOTING.............................................................. 4-23 M CUSTOMER COMPLAINT ANALYSIS.................................................. 4-23 VISUAL INSPECTION............................................................................ 4-24 A SELF-DIAGNOSTIC PROCEDURES..................................................... 4-25 SELF-DIAGNOSIS RESET PROCEDURE............................................. 4-25 S USE OF SDS DIAGNOSTIC PROCEDURES........................................4-26 USE OF SDS DIAGNOSIS RESET PROCEDURE................................4-27 SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC)......................................... 4-28 MALFUNCTION CODE AND DEFECTIVE CONDITION.......................4-29 “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION....................4-33 “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION....................4-35 “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION...............4-37 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION................4-43 “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION..............4-48 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION...............4-52 “C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION................4-56 “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION................4-61 “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354) IGNITION SYSTEM MALFUNCTION..................................................... 4-64 “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION................4-65 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION..............4-68
4-2 FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION........................4-73 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION.......................4-75 “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION.................4-77 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION...................4-79 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION.......................4-81 “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION...................................................................................... 4-82 “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION...................................................................................... 4-91 “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION......4-93 SENSORS..................................................................................................... 4-95 CMP SENSOR INSPECTION................................................................. 4-95 CMP SENSOR REMOVAL AND INSTALLATION.................................4-95 E CKP SENSOR INSPECTION................................................................. 4-95 L CKP SENSOR REMOVAL AND INSTALLATION.................................4-95 P IAP SENSOR INSPECTION................................................................... 4-95 IAP SENSOR REMOVAL AND INSTALLATION...................................4-95 M TP SENSOR INSPECTION.................................................................... 4-95 TP SENSOR REMOVAL AND INSTALLATION....................................4-95 A TPS ADJUSTMENT................................................................................ 4-95 ECT SENSOR INSPECTION.................................................................. 4-96 S ECT SENSOR REMOVAL AND INSTALLATION..................................4-96 IAT SENSOR INSPECTION................................................................... 4-96 IAT SENSOR REMOVAL AND INSTALLATION...................................4-96 AP SENSOR INSPECTION.................................................................... 4-96 AP SENSOR REMOVAL AND INSTALLATION....................................4-96 TO SENSOR INSPECTION.................................................................... 4-96 TO SENSOR REMOVAL AND INSTALLATION....................................4-96 STP SENSOR INSPECTION.................................................................. 4-97 STP SENSOR REMOVAL AND INSTALLATION..................................4-97 STP SENSOR ADJUSTMENT............................................................... 4-97
FI SYSTEM DIAGNOSIS 4-3 PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt. Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- Click necting. • When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires. • Inspect each terminal on the connector/coupler for looseness or bending. E • Inspect each terminal for corrosion and contamination. L The terminals must be clean and free of any foreign material which could impede proper terminal contact. P • Inspect each lead wire circuit for poor connection by shaking it M by hand lightly. If any abnormal condition is found, repair or replace. SA • When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler. 1 Coupler 2 Probe
4-4 FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal. Never push in the probe where male terminal is supposed to fit. • Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (loose- ness), corrosion, dust, etc. 1 Coupler 2 Probe 3 Where male terminal fits FUSE • When a fuse blows, always investigate the cause to correct it and then replace the fuse. • Do not use a fuse of a different capacity. • Do not use wire or any other substitute for the fuse. E PL M ECM/VARIOUS SENSORS A • Since each component is a high-precision part, great care INCORRECT should be taken not to apply any sharp impacts during S removal and installation. • Be careful not to touch the electrical terminals of the ECM. The static electricity from your body may damage this part.
FI SYSTEM DIAGNOSIS 4-5 • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. • Battery connection in reverse polarity is strictly prohibited. INCORRECT Such a wrong connection will damage the components of the FI system instantly when reverse power is applied. • Removing any battery terminal of a running engine is strictly E prohibited. The moment such removal is made, damaging counter elec- L tromotive force will be applied to the ECM which may result in serious damage. P SAM • Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagno- sis. • Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECM when its coupler is disconnected. Otherwise, damage to ECM may result. • Never connect an ohmmeter to the ECM with its coupler con- nected. If attempted, damage to ECM or sensors may result. • Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.
4-6 FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully. • Loose connection of connector/coupler. • Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.). • Wire harness being open. • Poor terminal-to-wire connection. • Disconnect the negative cable from the battery. • Check each connector/coupler at both ends of the circuit *1 being checked for loose connection. Also check for condition of the coupler lock if equipped. E 1 Sensor L 2 ECM *1 Check for loose connection. P • Using a test male terminal, check the female terminals of the M circuit being checked for contact tension. A Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At *1 S the same time, check to make sure that each terminal is fully inserted in the coupler and locked. *2 If contact tension is not enough, rectify the contact to increase tension or replace. The terminals must be clean and free of any foreign material which could impede proper terminal contact. *1 Check contact tension by insert- ing and removing. *2 Check each terminal for bend and proper alignment. • Using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection. Locate abnormality, if any. A Looseness of crimping B Open C Thin wire (a few strands left)
FI SYSTEM DIAGNOSIS 4-7 Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B. If no continuity is indicated, the circuit is open between cou- plers A and B. If continuity is indicated, there is an open cir- cuit between couplers B’ and C or an abnormality in coupler B’ or coupler C. 1 ECM VOLTAGE CHECK E If voltage is supplied to the circuit being checked, voltage check can be used as circuit check. L • With all connectors/couplers connected and voltage applied P to the circuit being checked, measure voltage between each terminal and body ground. AM If measurements were taken as shown in the figure at the right S and results are as listed below, it means that the circuit is open between terminals A and B. Voltage Between: C and body ground: Approx. 5 V B and body ground: Approx. 5 V A and body ground: 0 V Also, if measured values are as listed below, a resistance 5 V (abnormality) exists which causes the voltage drop in the circuit 5 V between terminals A and B. Voltage Between: 0 V 5 V C and body ground: Approx. 5 V B and body ground: Approx. 5 V 2 V voltage drop A and body ground: 3 V
4-8 FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit *1 to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts. Otherwise, diagnosis will be misled. • Measure resistance between terminal at one end of circuit (A terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals A and C. 5 V 1 Other parts *1 To other parts • Disconnect the connector/coupler included in circuit (coupler E B) and measure resistance between terminal A and body L *1 ground. If continuity is indicated, the circuit is shorted to the ground between terminals A and B. P M 1 ECM A S *1 To other parts
FI SYSTEM DIAGNOSIS 4-9 USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout. • If the voltage and current are not known, make measure- ments using the highest range. • When measuring the resistance with the multi-circuit tester 1, ∞ will be shown as 10.00 MΩ and “1” flashes in the display. • Check that no voltage is applied before making the measure- ment. If voltage is applied the tester may be damaged. • After using the tester, turn the power off. 09900-25008: Multi-circuit tester set E NOTE: L * When connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and P connect the probes of tester to them. * Use the needle pointed probe to prevent the rubber of the M water proof coupler from damage. A 09900-25009: Needle pointed probe set S
4-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions. ECM Intake Air Pressure Intake air pressure Sensor (IAP Sensor) signal Basic Crankshaft Position Engine speed fuel Sensor (CKP Sensor) signal injection time Throttle Position Throttle opening Sensor (TP Sensor) signal Various Various signals Compensation Sensors E LUltimate Injectors Injection signal P fuel injection AM time S
FI SYSTEM DIAGNOSIS 4-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (volume). ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased. INTAKE AIR TEMPERATURE SENSOR When intake air temperature is low, injection time (volume) SIGNAL is increased. BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time, it monitors the voltage signal for compensation of the fuel injection time (volume). A longer injection time is needed to adjust injection volume in the case of low voltage. ENGINE RPM SIGNAL At high speed, the injection time (volume) is increased. This is the compensation of the SRAD. STARTING SIGNAL When starting engine, additional fuel is injected during cranking engine. ACCELERATION SIGNAL/ During acceleration, the fuel injection time (volume) is DECELERATION SIGNAL increased in accordance with the throttle opening speed and E engine rpm. During deceleration, the fuel injection time (vol- L ume) is decreased. P INJECTION STOP CONTROL M SIGNAL A DESCRIPTION TIP-OVER SENSOR SIGNAL When the motorcycle tips over, the tip-over sensor sends a (FUEL SHUT-OFF) S signal to the ECM. Then, this signal cuts OFF current sup- plied to the fuel pump, fuel injectors and ignition coils. OVER-REV. LIMITER SIGNAL The fuel injectors stop operation when engine rpm reaches rev. limit rpm.
4-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION ECM PLE SAM A Intake air temperature sensor (IATS) B Throttle position sensor (TPS) C Secondary throttle position sensor (STPS) D Secondary throttle valve actuator (STVA) E Exhaust control valve actuator (EXCVA) F Fuel pump relay (FP RELAY) G Fuel pump (FP) H Crankshaft position sensor (CKPS)
FI SYSTEM DIAGNOSIS 4-13 M C E E PL SAM I Tip-over sensor (TOS) J Atmospheric pressure sensor (APS) K Intake air pressure sensor (IAPS) L Engine coolant temperature sensor (ECTS) M Speed sensor N Camshaft position sensor (CMPS) O Ignition coil (IG COIL) P PAIR control solenoid valve Q Secondary fuel injector R Primary fuel injector S Speedometer T Cooling fan relay U Cooling fan
4-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM witch Ignition s 30 A ets are equipped k witch 15 A al indicator witch 10 A 15 A 10 A er system. Neutr light y *1 ter motor Engine stop s y Side-stand s Star or E-02, 19, 24 mar ter rela *1 F immobiliz Side-standrela Star y y witch A) an rela er position F Fuel pump rela 3 ter s v Fuel pump N 61 42 Star y throttle #4 5 E witch #3 Clutch les Ignition coil (IG COIL) Lwitch e actuator (STV y #2 alv Secondarv an motor imar #1 y #1 #2 #3 #4 Pr fuel injector #4 P Cooling f #3 M Gear position s #2 Secondarfuel injector #1 A G/R R/BI Gr/B Gr/Y Gr/R Lg SY/R Y/B O/Y O/G (E-02, 19, 24) O/W (E-03, 28, 33) W/BI B Y G W/G P Y/G B/Y B/W B/W B/W B/W P/W B/Lg W/B G Gr/W Lg/W Lg/G Lg/BI B/G ECM Speedometer B/Y Br G/W G/BI P/B R Y/W G/B G/Y B/BI Dg B B/Br Y B/R R/B ature OS) A EXCV ic pressure ature sensor er sensor (T y throttle position v e air pressure sensor Atmosphersensor (APS) Throttle position sensor(TPS) e air temper Tip-o Camshaft position sensor (CMPS) ankshaft position sensor (CKPS) Intak (IAPS) Engine coolant tempersensor (ECTS)TS) Cr Secondarsensor (STPS) Intak (IA
FI SYSTEM DIAGNOSIS 4-15 ECM TERMINAL TERMINAL CIRCUIT TERMINAL CIRCUIT NO. NO. 1 STVA signal (STVA. 2A) H STVA signal (STVA. 2B) 2 STVA signal (STVA. 1A) I STVA signal (STVA. 1B) 3 EXCVA power (MO–) J STP sensor signal (STP) 4 EXCVA power (MO+) K Ignition switch signal [For E-03, 28, 33] 5 EXCVA position sensor (MPS) L TO sensor signal (TOS) E 6 Serial data for speedometer M GP switch signal (GP) 7 — N L — 8 TP sensor signal (TP) O Blank P 9 IAP sensor signal (IAP) P AP sensor signal (AP) 0 ECT sensor signal (ECT) MQ IAT sensor signal (IAT) A Power source for sensors (VCC) R Blank B Blank A S Sensors ground (E2) C CMP sensor signal (CMP+) T CMP sensor signal (CMP–) S D CKP sensor signal (CKP+) U CKP sensor signal (CKP–) E Blank V Serial data for self-diagnosis F Power source for back-up W Power source for fuel injector (VM) G Power source X ECM ground (E1)
4-16 FI SYSTEM DIAGNOSIS TERMINAL CIRCUIT TERMINAL CIRCUIT NO. NO. Y — l — Z — m — [ Tachometer n — \ Immobilizer communication o Immobilizer communication [For E-02, 19, 24] [For E-02, 19, 24] ] Fuel pump relay (FP Relay) p — ^ Starter relay q Mode select switch E a Blank r Neutral switch b — s Clutch position switch L c Cooling fan relay (FAR) t PAIR control solenoid valve (PAIR) P d Immobilizer indicator light u Secondary fuel injector #4 (#42) [For E-02, 19, 24] M e Primary fuel injector #4 (#41) v Secondary fuel injector #3 (#32) f Primary fuel injector #3 (#31) w Secondary fuel injector #2 (#22) A g Primary fuel injector #2 (#21) x Secondary fuel injector #1 (#12) S h Primary fuel injector #1 (#11) y Ground i Ignition coil #3 z Ground j Ignition coil #2 { Ground for ignition system k Ignition coil #1 | Ignition coil #4
FI SYSTEM DIAGNOSIS 4-17 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is provided. In this check, the special tool is necessary to read the code of the malfunction items. USER MODE MALFUNCTION LCD (DISPLAY) FI LIGHT INDICATION MODE INDICATION INDICATION “NO” Coolant temperature ---- ---- “YES” Coolant temperature FI light turns ON. Each 2 sec. Coolant and “FI” letters temperature or “FI” is Engine can start *1 indicated. Engine can not start “FI” letter FI light turns ON “FI” is indicated *2 and blinks. continuously. *1 When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case, “FI” and coolant temperature are indicated in the LCD panel and motorcycle can run. *2 E L The injection signal is stopped, when the camshaft position sensor signal, crankshaft position sensor signal, tip-over sensor signal, #1, #2, #3 and #4 ignition signals, #1, #2, #3 and #4 injector signals, fuel pump relay P signal or ignition switch signal is not sent to ECM. In this case, “FI” is indicated in the LCD panel. Motorcycle does not run. M “CHEC”: The LCD panel indicates “CHEC” when no communication signal from the ECM is received for 5 seconds. A For Example: S The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speed- ometer does not receive any signal from ECM, and the panel indicates “CHEC”. If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the wir- ing harness between ECM and speedometer couplers. The possible cause of this indication is as follows; Engine stop switch is in OFF position. Side-stand/ignition inter-lock system is not working. Ignition fuse is burnt. NOTE: Until starting the engine, the FI light turns ON. The FI light is also turned ON when engine temperature is high or oil pressure is low.
4-18 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form. 09930-82720: Mode select switch E L P M A Before checking the malfunction code, do not disconnect the ECM lead wire couplers. S If the couplers from the ECM are disconnected, the malfunction code memory is erased and the malfunction code can not be checked. MALFUNCTION LCD (DISPLAY) FI LIGHT INDICATION INDICATION MODE INDICATION “NO” C00 ---- C**code is indicated from FI light turns OFF. For each 2 sec., code is “YES” small numeral to large indicated. one.
FI SYSTEM DIAGNOSIS 4-19 CODE MALFUNCTION PART REMARKS C00 None No defective part C11 Camshaft position sensor (CMPS) C12 Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator C13 Intake air pressure sensor (IAPS) C14 Throttle position sensor (TPS) *1 C15 Engine coolant temperature sensor (ECTS) C21 Intake air temperature sensor (IATS) C22 Atmospheric pressure sensor (APS) C23 Tip-over sensor (TOS) C24 Ignition signal #1 (IG coil #1) For #1 cylinder C25 Ignition signal #2 (IG coil #2) For #2 cylinder C26 Ignition signal #3 (IG coil #3) For #3 cylinder C27 Ignition signal #4 (IG coil #4) For #4 cylinder C28 Secondary throttle valve actuator (STVA) *2 C29 Secondary throttle position sensor (STPS) C31 Gear position signal (GP switch) C32 Primary injector signal #1 (FI #1) For #1 cylinder C33 Primary injector signal #2 (FI #2) For #2 cylinder C34 Primary injector signal #3 (FI #3) For #3 cylinder E C35 Primary injector signal #4 (FI #4) For #4 cylinder C36 Secondary injector signal #1 For #1 cylinder L C37 Secondary injector signal #2 For #2 cylinder C38 Secondary injector signal #3 For #3 cylinder P C39 Secondary injector signal #4 For #4 cylinder C41 Fuel pump control system (FP control system) Fuel pump, Fuel pump relay M C42 Ignition switch signal (IG switch signal) Anti-theft A C46 Exhaust control valve actuator (EXCVA) C49 PAIR control solenoid valve S Cooling fan relay C60 Cooling fan control system In the LCD (DISPLAY) panel, the malfunction code is indicated from small code to large code. *1 To get the proper signal from the throttle position sensor, the sensor basic position is indicated in the LCD (DISPLAY) panel. The malfunction code is indicated in three digits. In front of the three digits, a line appears in any of the three positions, upper, middle or lower line. If the indication is upper or lower line when engine rpm is 1 150 r/min, slightly turn the throttle position sensor and bring the line to the middle. In the normal condition, the throttle valve stop screw pushes throttle valves slightly, and the middle line will be indicated. *2 When the secondary throttle valve actuator and secondary throttle position sensor signals are not sent to ECM. In this case, C28 and C29 are indicated alternately.
4-20 FI SYSTEM DIAGNOSIS TPS ADJUSTMENT 1. Adjust the engine rpm to 1 150 r/min. (2-14) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3. If the throttle position sensor adjustment is necessary, loosen the screw and turn the throttle position sensor 1 and bring the line to the middle. 4. Then, tighten the screw to fix the throttle position sensor. 09930-11950: Torx wrench 09930-82720: Mode select switch The LCD displays the line for 0.4 sec. at a time, and when such a display repeats two times, it indicates the current position where the sensor is fixed. E L P M A Incorrect A SB Correct position
FI SYSTEM DIAGNOSIS 4-21 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. ITEM FAIL-SAFE MODE STARTING RUNNING ABILITY ABILITY CMP sensor When camshaft position signal has “NO” “YES” failed during running, the ECM Motorcycle can run, but once engine determines the cylinder positions as stops, engine can not start. # to be the same as before occur- rence of such a failure. IAP sensor Intake air pressure is fixed to 760 “YES” “YES” mmHg. TP sensor The throttle opening is fixed to full open position. “YES” “YES” Ignition timing is also fixed. ECT sensor Engine coolant temperature value is fixed to 80 °C (176 °F). “YES” “YES” Cooling fan is fixed on position. IAT sensor Intake air temperature value is fixed “YES” “YES” to 40 °C (104 °F). E AP sensor Atmospheric pressure is fixed to 760 “YES” “YES” mmHg. L Ignition signal #1 Ignition-off P “YES” “YES” #2, #3 & #4 cylinders can run. #2 Ignition-off “YES” “YES” M A #1, #3 & #4 cylinders can run. #3 Ignition-off “YES” “YES” S #1, #2 & #4 cylinders can run. #4 Ignition-off “YES” “YES” #1, #2 & #3 cylinders can run. Primary injection signal #1 Fuel-cut (primary side) “YES” “YES” #2, #3 & #4 cylinders can run. #2 Fuel-cut (primary side) “YES” “YES” #1, #3 & #4 cylinders can run. #3 Fuel-cut (primary side) “YES” “YES” #1, #2 & #4 cylinders can run. #4 Fuel-cut (primary side) “YES” “YES” #1, #2 & #3 cylinders can run.
4-22 FI SYSTEM DIAGNOSIS ITEM FAIL-SAFE MODE STARTING RUNNING ABILITY ABILITY Secondary injection signal #1 Fuel-cut (secondary side) — “YES” #2, #3 & #4 cylinders can run. #2 Fuel-cut (secondary side) — “YES” #1, #3 & #4 cylinders can run. #3 Fuel-cut (secondary side) — “YES” #1, #2 & #4 cylinders can run. #4 Fuel-cut (secondary side) — “YES” #1, #2 & #3 cylinders can run. Secondary throttle valve Secondary throttle valve is fixed to actuator full close position. When motor dis- “YES” “YES” connection or lock occurs, power from ECM is shut off. STP sensor Secondary throttle valve is fixed to “YES” “YES” full close position. Gear position signal Gear position signal is fixed to 6th “YES” “YES” gear. PAIR control solenoid valve ECM stops controlling PAIR control “YES” “YES” solenoid valve. E EXCV actuator EXCV actuator is fixed to full open L position. When motor disconnection “YES” “YES” or lock occurs, power from ECM is shut off. P M The engine can start and can run even if the above signal is not received from each sensor. But, the engine running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is nec- A essary to bring the motorcycle to the workshop for complete repair. When two ignition signals or two injector signals are not received by ECM, the fail-safe circuit can not work S and ignition or injection is stopped.
FI SYSTEM DIAGNOSIS 4-23 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: Malfunction indicator Always ON Sometimes ON Always OFF Good condition lamp condition (LED) Malfunction display/code User mode: No display Malfunction display ( ) (LCD) Dealer mode: No code Malfunction code ( ) PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire/ After fire E No combustion Lack of power Poor starting at Surging L ( cold warm always) Abnormal knocking P Other Engine rpm jumps briefly Other M Poor Idling Engine Stall when Poor fast Idle A Immediately after start Abnormal idling speedS Throttle valve is opened ( High Low) ( r/min) Throttle valve is closed Unstable Load is applied Hunting ( r/min to r/min) Other Other OTHERS:
4-24 FI SYSTEM DIAGNOSIS MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Hot Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill Downhill) Tarmacadam Gravel Other Motorcycle condition Engine condition Cold Warming up phase Warmed up Always Other at starting Immediately after start Racing without load Engine speed ( r/min) Motorcycle con- During driving: Constant speed Accelerating Decelerating dition Right hand corner Left hand corner At stop Motorcycle speed when problem occurs ( km/h, mile/h) Other NOTE: The above form is a standard sample. The form should be modified according to conditions and characteris- tics of each market. E VISUAL INSPECTION L • Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The rea- P son for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS. * Engine oil level and leakage (2-12) M * Engine coolant level and leakage (2-17) * Fuel level and leakage ( A 2-14 and 9-33) * Clogged air cleaner element (2-18) S * Battery condition (9-40) * Throttle cable play (2-15) * Vacuum hoses looseness, bend and disconnection * Broken fuse * FI light operation (4-17 and 9-31) * Each warning light operation (9-31) * Speedometer operation (9-34) * Exhaust gas leakage and noise (2-29) * Each coupler disconnection * Clogged radiator fins (7-4)
FI SYSTEM DIAGNOSIS 4-25 SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory. * Malfunction code stored in ECM memory can be checked by the special tool. * Before checking malfunction code, read SELF-DIAGNOSIS FUNCTION “USER MODE and DEALER MODE” (4-17 and 4-18) carefully to have good understanding as to what functions are available and how to use it. * Be sure to read “PRECAUTIONS IN SERVICING” (4-3) before inspection and observe what is written there. • Remove the front seat. (8-7) • Connect the special tool to the dealer mode coupler at the wir- ing harness, and start the engine or crank the engine for more than 4 seconds. • Turn the special tool’s switch ON and check the malfunction E code to determine the malfunction part. 09930-82720: Mode select switch L P M A S SELF-DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • If the malfunction code indicates (C00), the malfunction is cleared. • Disconnect the special tool from the dealer mode coupler. NOTE: * Even though the malfunction code (C00) is indicated, the previ- ous malfunction history code still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS. * The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.
4-26 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSTIC PROCEDURES * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory. * Malfunction code stored in ECM memory can be checked by the SDS. * Be sure to read “PRECAUTIONS IN SERVICING” (4-3) before inspection and observe what is written there. • Remove the front seat. (8-7) • Set up the SDS tool. (Refer to the SDS operation manual for further details.) • Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaying data at the time of DTC) according to instructions displayed on SDS. • Not only is SDS used for detecting Diagnostic Trouble Codes but also for reproducing and checking on screen the failure condition as described by customers using the trigger. • How to use trigger. (Refer to the SDS operation manual for further details.) E 09904-41010: SDS set tool L 99565-01010-006: CD-ROM Ver. 6 P M A S
FI SYSTEM DIAGNOSIS 4-27 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS tool. NOTE: The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS. • Click “Clear” 2 to delete history code (Past DTC). E L P • Follow the displayed instructions. M A S • Check that both “Current DTC” 3 and “Past DTC” 4 are deleted (NIL).
4-28 FI SYSTEM DIAGNOSIS SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble. This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM. Also, ECM has a function to store each show data when trouble for two different malfunctions in the order as the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been detected. Its use is helpful when rechecking or diagnosing a trouble. E L P M A • Click “Show data when trouble” 1 to display the data. By clicking the drop down button 2, either “Failure #1” or “Failure #2” can be selected. S
FI SYSTEM DIAGNOSIS 4-29 MALFUNCTION CODE AND DEFECTIVE CONDITION DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM C00 NO FAULT ––––––––––– ––––––––––– C11 CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts P0340 signal. CMP sensor, intake cam pin, wiring/coupler connection C12 CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts P0335 signal. CKP sensor, lead wire/coupler connection IAP sensor The sensor should produce following IAP sensor, lead wire/coupler voltage. connection C13 0.5 V sensor voltage < 4.85 V In other than the above range, C13 (P0105) is indicated. H Sensor voltage is higher than specified IAP sensor circuit shorted to value. VCC or ground circuit open P0105 Sensor voltage is lower than specified IAP sensor circuit open or E L value. shorted to ground or VCC circuit Lopen TP sensor The sensor should produce following TP sensor, lead wire/coupler voltage. P connection C14 0.2 V sensor voltage < 4.80 V M In other than the above range, C14 (P0120) is indicated. A H Sensor voltage is higher than specified TP sensor circuit shorted to value. VCC or ground circuit open S P0120 Sensor voltage is lower than specified TP sensor circuit open or L value. shorted to ground or VCC circuit open ECT sensor The sensor voltage should be the fol- ECT sensor, lead wire/coupler lowing. connection C15 0.15 V sensor voltage < 4.85 V In other than the above range, C15 (P0115) is indicated. H Sensor voltage is higher than specified ECT sensor circuit open or P0115 value. ground circuit open L Sensor voltage is lower than specified ECT sensor circuit shorted to value. ground
4-30 FI SYSTEM DIAGNOSIS DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection C21 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated. H Sensor voltage is higher than specified IAT sensor circuit open or P0110 value. ground circuit open L Sensor voltage is lower than specified IAT sensor circuit shorted to value. ground AP sensor The sensor voltage should be the fol- AP sensor, wiring/coupler con- lowing. nection C22 0.5 V sensor voltage < 4.85 V In other than the above range, C22 (P1450) is indicated. H Sensor voltage is higher than specified AP sensor circuit shorted to value. VCC or ground circuit open P1450 Sensor voltage is lower than specified AP sensor circuit open or L value. shorted to ground or VCC circuit E open TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler L lowing for 2 sec. and more, after igni- connection C23 tion switch is turned ON. P 0.2 V sensor voltage < 4.8 V M In other than the above value, C23 (P1651) is indicated. A H Sensor voltage is higher than specified TO sensor circuit shorted to value. VCC or ground circuit open S P1651 Sensor voltage is lower than specified TO sensor circuit open or L value. shorted to ground or VCC circuit open Ignition sig- CKP sensor (pick-up coil) signal is pro- Ignition coil, wiring/coupler con- C24/C25 nal duced, but signal from ignition coil is nection, power supply from the C26/C27 interrupted 8 times or more continu- battery ously. In this case, the code C24 P0351/P0352 (P0351), C25 (P0352), C26 (P0353) or P0353/P0354 C27 (P0354) is indicated. Secondary When no actuator control signal is STVA motor, STVA lead C28 throttle valve supplied from the ECM, communica- wire/coupler actuator tion signal does not reach ECM or operation voltage does not reach P1655 STVA motor, C28 (P1655) is indicated. STVA can not operate.
FI SYSTEM DIAGNOSIS 4-31 DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection C29 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated. H Sensor voltage is higher than specified STP sensor circuit shorted to value. VCC or ground circuit open P1654 Sensor voltage is lower than specified STP sensor circuit open or L value. shorted to ground or VCC circuit open Gear posi- Gear position signal voltage should be GP switch, wiring/coupler con- C31 tion signal higher than the following for 3 seconds nection, gearshift cam, etc. and more. Gear position sensor voltage > 0.6 V P0705 If lower than the above value, C31 (P0705) is indicated. Primary fuel CKP sensor (pickup coil) signal is pro- Primary fuel injector, wiring/cou- C32/C33 injector duced, but fuel injector signal is inter- pler connection, power supply to C34/C35 rupted 4 times or more continuously. In the injector E this case, the code C32 (P0201), C33 P0201/P0202 L (P0202), C34 (P0203) or C35 (P0204) P0203/P0204 is indicated. P Secondary Some failure exists in the fuel injector Secondary fuel injector, wir- C36/C37 fuel injector signal in a high load, high revolution ing/coupler connection, power C38/C39 M condition.In this case, the code C36 supply to the injector A P1764/P1765 (P1764), C37 (P1765), C38 (P1766) or C39 (P1767) is indicated. P1766/P1767 S Fuel pump No voltage is applied to the fuel pump, Fuel pump relay, lead wire/cou- relay although fuel pump relay is turned ON, pler connection, power source to C41 or voltage is applied to fuel pump fuel pump relay and fuel injec- although fuel pump relay is turned tors OFF. Voltage is applied to fuel pump Fuel pump relay switch circuit H although fuel pump relay is turned shorted to power source P0230 OFF. Fuel pump relay (switch side) No voltage is applied to the fuel pump, Fuel pump relay circuit open or L although fuel pump relay is turned ON. short Fuel pump relay (coil side). C42 Ignition Ignition switch signal is not input to the Ignition switch, lead wire/coupler, switch ECM. etc. P1650 * When the I.D. agreement is not verified. * Immobilizer/anti-theft system * ECM does not receive communication signal from the immobilizer antenna. * : Immobilizer system is equipped model only.
4-32 FI SYSTEM DIAGNOSIS DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM Exhaust con- EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- trol valve lowing voltage. pler actuator 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1675) is indicated. C46 When no actuator control signal is supplied from the ECM, communica- tion signal does not reach ECM or operation voltage does not reach EXCVA motor, C46 (P1658) is indi- cated. EXCVA can not operate. EXCVA position sensor voltage is EXCVA position sensor circuit H higher than specified value. shorted to VCC or ground circuit P1657 open EXCVA position sensor voltage is EXCVA position sensor circuit L lower than specified value. open or shorted to ground or VCC circuit open When no actuator control signal is EXCVA, EXCVA motor lead supplied from the ECM, communica- wire/coupler E P1658 tion signal does not reach ECM or L operation voltage does not reach EXCVA motor, C46 (P1658) is indi- P cated. EXCVA motor can not operate. C49 PAIR control PAIR control solenoid valve voltage is PAIR control solenoid valve, lead M P1656 solenoid not input to ECM. wire/coupler valve A C60 Cooling fan Cooling fan relay signal is not input to Cooling fan relay, lead wire/cou- S P0480 relay ECM. pler connection
FI SYSTEM DIAGNOSIS 4-33 “C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CMP sensor and rotor tip • CMP sensor circuit open or short • CMP sensor malfunction • ECM malfunction ECM CMP sensor G/Y CMP Br CMP INSPECTION 1 E Step 1 L 1) Turn the ignition switch OFF. P 2) Lift and support the fuel tank. (5-3) 3) Remove the air cleaner box. (5-13) M 4) Check the CMP sensor coupler for loose or poor contacts. If OK, then measure the CMP sensor resistance. SA 5) Disconnect the CMP sensor coupler and measure the resis- 1 tance. CMP sensor resistance: 0.9 – 1.7 kΩ (Terminal – Terminal) 6) If OK, then check the continuity between each terminal and ground. CMP sensor continuity: ∞ Ω (Infinity) (Terminal – Ground) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? YES Go to step 2. NO Replace the CMP sensor with a new one. 7) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-34 FI SYSTEM DIAGNOSIS Step 2 2 1) Crank the engine a few seconds with the starter motor, and measure the CMP sensor peak voltage at the coupler. 2) Repeat the above test procedure a few times and measure the highest peak voltage. V CMP sensor peak voltage: 0.5 V and more (+ B/Y – - Brown) 1 Peak volt adaptor 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () . Is the voltage OK? 2 • G/Y or Brown wire open or shorted to ground ECM coupler (Harness side) • Loose or poor contacts on the CKP sensor cou- (Black) (Gray) pler or ECM coupler (terminal C or T) • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for E open circuit and poor connection. • Replace the ECM with a known good one, and L inspect it again. P • Inspect that metal particles or foreign material stuck on the CMP sensor and rotor tip. M NO • If there are no metal particles and foreign mate- rial, then replace the CMP sensor with a new one. SA 3) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-35 “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip • CKP sensor circuit open or short • CKP sensor malfunction • ECM malfunction ECM CKP sensor B G/W CKP G G/BI CKP INSPECTION 1 E Step 1 L 1) Turn the ignition switch OFF. P 2) Lift and support the fuel tank. (5-3) 3) Check the CKP sensor coupler for loose or poor contacts. M If OK, then measure the CKP sensor resistance. SA 4) Disconnect the CKP sensor coupler and measure the resis- 1 tance. CKP sensor resistance: 142 – 194 Ω (Black – Green)
4-36 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and 1 ground. CKP sensor continuity:∞ Ω (Infinity) (Black – Ground) (Green – Ground) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? YES Go to step 2. NO Replace the CKP sensor with a new one. 6)After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 2 2 1) Crank the engine a few seconds with the starter motor, and V measure the CKP sensor peak voltage at the coupler. 2) Repeat the above test procedure a few times and measure E the highest peak voltage. L CKP sensor peak voltage: 0.5 V and more (+ Black – - Green) P 1 Peak volt adaptor 09900-25008: Multi-circuit tester set M Tester knob indication: Voltage () A . Is the voltage OK? S 2 • G/W or G/BI wire open or shorted to ground. ECM coupler (Harness side) • Loose or poor contacts on the CKP sensor cou- (Black) (Gray) pler or ECM coupler (terminal D or U). • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. • Inspect that metal particles or foreign material stuck on the CKP sensor and rotor tip. NO • If there are no metal particles and foreign mate- rial, then replace the CKP sensor with a new one. 3) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-37 “C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C13 IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage < 4.85 V • Air being drawn from vacuum passage between NOTE: throttle body and IAP sensor. Note that atmospheric pressure varies • IAP sensor circuit open or shorted to ground. depending on weather conditions as • IAP sensor malfunction. well as altitude. • ECM malfunction. Take that into consideration when inspecting voltage. P0105 H Sensor voltage is higher than specified • IAP sensor circuit shorted to VCC or ground cir- value. cuit open. L Sensor voltage is lower than specified • IAP sensor circuit open or shorted to ground or value. VCC circuit open. ECM IAP sensor E R L VCC G/B P IAP B/Br E2 SAM INSPECTION 1 Step 1 (When indicating C13:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then measure the IAP sensor input voltage.
4-38 FI SYSTEM DIAGNOSIS 4) Disconnect the IAP sensor coupler. 1 5) Turn the ignition switch ON. V 6) Insert the needle pointed probes to the lead wire coupler. 7) Measure the voltage at the Red wire and ground. 8) If OK, then measure the voltage at the Red wire and B/Br wire. IAP sensor input voltage: 4.5 – 5.5 V (+ Red – - Ground) (+ Red – - B/Br) 09900-25008: Multi-circuit tester set 1 09900-25009: Needle pointed probe set Tester knob indication: Voltage () V Is the voltage OK? YES Go to Step 2. • Loose or poor contacts on the ECM coupler NO (terminal A or S). • Open or short circuit in the Red wire or B/Br wire. E Step 1 (When indicating P0105-H:) 1 1) Turn the ignition switch OFF. L 2) Lift and support the fuel tank. (5-3) P 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then check the IAP sensor lead wire continuity. SAM 4) Disconnect the IAP sensor coupler. 1 5) Check the continuity between Red wire A and G/B wire B. If the sound is not heard from the tester, the circuit condition is OK.
FI SYSTEM DIAGNOSIS 4-39 6) Disconnect the ECM coupler. 1 ! 7) Check the continuity between G/B wire B and terminal 9. 8) If OK, then check the continuity between B/Br wire C and ter- minal S. IAPS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Continuity test () (Black) (Gray) ECM coupler (Harness side) Is the continuity OK? YES Go to Step 2. NO G/B wire shorted to VCC, or B/Br wire open. 9) After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 1 (When indicating P0105-L:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAP sensor coupler for loose or poor contacts. E If OK, then check the IAP sensor lead wire continuity. L P M 4) Disconnect the IAP sensor coupler. 1 A 5) Check the continuity between G/B wire B and ground. 6) Also, check the continuity between G/B wire B and B/Br wire S C. If the sound is not heard from the tester, the circuit condi- tion is OK.
4-40 FI SYSTEM DIAGNOSIS 7) Disconnect the ECM coupler. 1 ! 8) Check the continuity between Red wire A and terminal A. 9) Also, check the continuity between G/B wire B and terminal 9. IAPS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Continuity test () (Black) (Gray) ECM coupler (Harness side) Is the continuity OK? YES Go to Step 1 (4-37) and go to Step 2. NO Red wire or G/B wire open, or G/B wire shorted to ground 10)After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 2 2 1) Connect the IAP sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. E V 3) Start the engine at idle speed and measure the IAP sensor L output voltage at the wire side coupler (between G/B and B/Br wires). P IAP sensor output voltage: Approx. 2.6 V at idle speed (+ G/B – - B/Br) M 09900-25008: Multi-circuit tester set A 09900-25009: Needle pointed probe set S Tester knob indication: Voltage () Is the voltage OK? YES Go to Step 3. • Check the vacuum hose for crack or damage. NO • Open or short circuit in the G/B wire • If vacuum hose and wire are OK, replace the IAP sensor with a new one. 4)After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-41 Step 3 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total - v voltage is 4.5 – 5.0 V) and connect - terminal to the ground - terminal 2 and + terminal to the VCC terminal 3. 4) Check the voltage between Vout 4 and ground. Also, check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge. (4-42) 09917-47011: Vacuum pump gauge 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Is the voltage OK? 3 • G/B, Red or B/Br wire open or shorted to ECM coupler (Harness side) ground, or poor 9, A or S connection (Black) (Gray) • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. E • Recheck each terminal and wire harness for L open circuit and poor connection. • Replace the ECM with a known good one, and P inspect it again. If check result is not satisfactory, replace the IAP NO M sensor with a new one. A 5) After repairing the trouble, clear the DTC using SDS tool. (4-27) S
4-42 FI SYSTEM DIAGNOSIS Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (m) (mmHg) kPa (V) 0 0 760 100 3.1 – 3.6 2 000 610 707 94 2 001 611 707 94 2.8 – 3.4 5 000 1 524 634 85 5 001 1 525 634 85 2.6 – 3.1 8 000 2 438 567 76 8 001 2 439 567 76 2.4 – 2.9 10 000 3 048 526 70 E L P M A S
FI SYSTEM DIAGNOSIS 4-43 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is • ECM malfunction larger than specified value. 0.2 V Sensor voltage < 4.8 V P0120 H Sensor voltage is higher than specified • TP sensor circuit shorted to VCC or ground circuit value. open L Sensor voltage is lower than specified • TP sensor circuit open or shorted to ground or value. VCC circuit open ECM TP sensor R VCC P/B TP B/Br E E2 PL INSPECTION M 1 Step 1 (When indicating C14:) 1) Turn the ignition switch OFF. A 2) Lift and support the fuel tank. (5-3) S 3) Check the TP sensor coupler for loose or poor contacts. If OK, then measure the TP sensor input voltage. 4) Disconnect the TP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire B and ground. 7) If OK, then measure the voltage at the Red wire B and B/Br wire C. TP sensor input voltage: 4.5 – 5.5 V 1 (+ Red – - Ground) V (+ Red – - B/Br) 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Is the voltage OK? YES Go to Step 2. • Loose or poor contacts on the ECM coupler NO (terminal A or S). • Open or short circuit in the Red wire or B/Br wire.
4-44 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0120-H:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler. 1 5) Check the continuity between P/B wire A and Red wire B. If the sound is not heard from the tester, the circuit condition is OK. 6) Disconnect the ECM coupler. 1 7) Check the continuity between P/B wire A and terminal 8. E 8) Also, check the continuity between B/Br wire C and terminal L S. P TPS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A (Black) (Gray) Tester knob indication: Continuity test () ECM coupler (Harness side) Is the continuity OK? S YES Go to Step 2. NO P/B wire shorted to VCC, or B/Br wire open 9) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-45 Step 1 (When indicating P0120-L:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4)Disconnect the TP sensor coupler. 1 5)Check the continuity between P/B wire A and ground. 6)Also, check the continuity between P/B wire A and B/Br wire C. If the sound is not heard from the tester, the circuit condi- tion is OK. 7) Disconnect the ECM coupler. 1 8) Check the continuity between P/B wire A and terminal 8. E 9) Also, check the continuity between Red wire B and terminal L A. P TPS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A (Black) (Gray) Tester knob indication: Continuity test () ECM coupler (Harness side) Is the continuity OK? S YES Go to Step 1 (4-43) and go to Step 2. NO Red wire or P/B wire open, or P/B wire shorted to ground 10)After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-46 FI SYSTEM DIAGNOSIS Step 2 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler and ECM coupler. 3) Install the test harness to the TP sensor. 4) Check the continuity between terminal A and ground. TP sensor continuity: ∞ Ω (Infinity) (Terminal A – Ground) 5) If OK, then measure the TP sensor resistance at the test har- 2 ness terminals (between terminal A and terminal B). 6) Turn the throttle grip and measure the resistance. TP sensor resistance Throttle valve is closed: Approx. 1.1 kΩ Throttle valve is opened: Approx. 4.3 kΩ 2 E L P P/B M TPS R ECM SA B/Br 7) If OK, then measure the TP sensor resistance at the test har- 2 ness terminals (between terminal c and terminal D). TP sensor resistance: Approx. 4.68 kΩ (Terminal C – Terminal D) 09900-25008: Multi-circuit tester set 09900-28630: TPS test wire harness Tester knob indication: Resistance (Ω) Are the continuity and resistance OK? 2 YES Go to Step 3. NO • Reset the TP sensor position correctly. • Replace the TP sensor with a new one. P/B 8) After repairing the trouble, clear the DTC using SDS tool. TPS R ECM (4-27) B/Br
FI SYSTEM DIAGNOSIS 4-47 Step 3 1) Connect the TP sensor coupler 1 to the test harness. V 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the coupler (between + P/B and - B/Br) by turning the throttle grip. TP sensor output voltage 3 Throttle valve is closed: Approx. 1.1 V Throttle valve is opened: Approx. 4.3 V 09900-25008: Multi-circuit tester set P/B Tester knob indication: Voltage () TPS R ECM B/Br Is the voltage OK? 3 E • P/B, Red or B/Br wire open or shorted to ECM coupler (Harness side) ground, or poor 8, A or S connection L (Black) (Gray) • If wire and connection are OK, intermittent trou- P YES ble or faulty ECM. • Recheck each terminal and wire harness for M open circuit and poor connection. A • Replace the ECM with a known good one, and inspect it again. S NO If check result is not satisfactory, replace TP sen- sor with a new one. 4) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-48 FI SYSTEM DIAGNOSIS “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C15 Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction 0.15 V Sensor voltage < 4.85 V • ECM malfunction P0115 H Sensor voltage is higher than specified • ECT sensor circuit open or ground circuit open value. L Sensor voltage is lower than specified • ECT sensor circuit shorted to ground value. ECT sensor ECM B/BI ECT B/Br E2 E L INSPECTION 1 Step 1 (When indicating C15:) P 1) Turn the ignition switch OFF. M 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. A If OK, then measure the ECT sensor voltage at the wire side coupler. S 4) Disconnect the coupler and turn the ignition switch ON. 5) Measure the voltage between B/Bl wire terminal A and ground. 6) If OK, then measure the voltage between B/Bl wire terminal A and B/Br wire terminal B. ECT sensor voltage: 4.5 – 5.5 V 1 (+ B/Bl – - Ground) (+ B/Bl – - B/Br) 09900-25008: Multi-circuit tester set V Tester knob indication: Voltage () Is the voltage OK? YES Go to Step 2. • Loose or poor contacts on the ECM coupler NO (terminal 0 or S). • Open or short circuit in the B/Bl wire or B/Br wire
FI SYSTEM DIAGNOSIS 4-49 Step 1 (When indicating P0115-H:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler. 1 ! 5) Check the continuity between B/Bl wire A and terminal 0. 6) Also, check the continuity between B/Br wire B and terminal S. ECTS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Continuity test () (Black) (Gray) ECM coupler (Harness side) Is the continuity OK? E YES Go to Step 2. NO B/Bl or B/Br wire open L 7) After repairing the trouble, clear the DTC using SDS tool. (4-27) P SAM
4-50 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-L:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 4) Disconnect the ECT sensor coupler. 1 5) Check the continuity between B/Bl wire A and ground. If the sound is not heard from the tester, the circuit condition is OK. Tester knob indication: Continuity test () 6)Connect the ECT sensor coupler and turn the ignition switch 1 E ON. L V 7)Measure the voltage between B/Bl wire A and ground. ECT sensor output voltage: 0.15 – 4.85 V P (+ B/BI – - Ground) 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A Tester knob indication: Voltage () S Are the continuity and voltage OK? YES Go to Step 2. NO • B/BI wire shorted to ground • If wire is OK, go to Step 2. 8)After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-51 Step 2 2 1) Turn the ignition switch OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance. ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Refer to page 7-7 for details. Is the resistance OK? • B/Bl or B/Br wire open or shorted to ground, or 2 poor 0 or S connection. ECM coupler (Harness side) • If wire and connection are OK, intermittent trou- (Black) (Gray) YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and E inspect it again. NO Replace the ECT sensor with a new one. L 4) After repairing the trouble, clear the DTC using SDS tool. (4-27) P ECT sensor specification M Engine Oil Temp Resistance A 20 °C (68 °F) S Approx. 2.45 kΩ 50 °C (122 °F) Approx. 0.811 kΩ 80 °C (176 °F) Approx. 0.318 kΩ 110 °C (230 °F) Approx. 0.142 kΩ
4-52 FI SYSTEM DIAGNOSIS “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C21 Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction 0.15 V Sensor voltage < 4.85 V • ECM malfunction P0110 H Sensor voltage is higher than specified • IAT sensor circuit open or ground circuit open value. L Sensor voltage is lower than specified • IAT sensor circuit shorted to ground value. IAT sensor ECM Dg IAT B/Br E2 E INSPECTION L 1 Step 1 (When indicating C21:) P 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) M 3) Check the IAT sensor coupler for loose or poor contacts. A If OK, then measure the IAT sensor voltage at the wire side coupler. S 4) Disconnect the coupler and turn the ignition switch ON. 5) Measure the voltage between Dg wire terminal A and 1 ground. 6) If OK, then measure the voltage between Dg wire terminal A and B/Br wire terminal B. V IAT sensor input voltage: 4.5 – 5.5 V (+ Dg – - Ground) (+ Dg – - B/Br) 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Is the voltage OK? YES Go to Step 2. • Loose or poor contacts on the ECM coupler NO (terminal Q or S) • Open or short circuit in the Dg wire or B/Br wire
FI SYSTEM DIAGNOSIS 4-53 Step 1 (When indicating P0110-H:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler. 1 5) Check the continuity between Dg wire A and terminal Q. 6) Also, check the continuity between B/Br wire B and terminal S. IATS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set (Gray) Tester knob indication: Continuity test () (Black) ECM coupler (Harness side) Is the continuity OK? E YES Go to Step 2. L NO Dg wire or B/Br wire open P 7) After repairing the trouble, clear the DTC using SDS tool. (4-27) AM S
4-54 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-L:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler. 1 5) Check the continuity between Dg wire A and ground. If the sound is not heard from the tester, the circuit condition is OK. Tester knob indication: Continuity test () 6) Connect the IAT sensor coupler and turn the ignition switch 1 E ON. 7) Measure the voltage between Dg wire A and ground. L V IAT sensor output voltage: 0.15 – 4.85 V P (+ Dg – - Ground) 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A Tester knob indication: Voltage () S Are the continuity and voltage OK? YES Go to Step 2. NO • Dg wire shorted to ground • If wire is OK, go to Step 2. 8) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-55 Step 2 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Is the resistance OK? 2 • Dg or B/Br wire open or shorted to ground, or ECM coupler (Harness side) poor Q or S connection (Black) (Gray) • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Replace the IAT sensor with a new one. E IAT sensor specification L Intake Air Temp Resistance P 20 °C (68 °F) Approx. 2.45 kΩ 50 °C (122 °F) Approx. 0.808 kΩ M 80 °C (176 °F) Approx. 0.322 kΩ 110 °C (230 °F) Approx. 0.148 kΩ A NOTE: S IAT sensor resistance measurement method is the same way as that of the ECT sensor. Refer to page 7-7 for details.
4-56 FI SYSTEM DIAGNOSIS “C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C22 AP sensor voltage is not within the fol- • Clogged air passage with dust lowing range. • AP sensor circuit open or shorted to ground 0.5 V Sensor voltage < 4.85 V • AP sensor malfunction NOTE: • ECM malfunction Note that atmospheric pressure varies depending on weather conditions as well as altitude. Take that into consideration when inspecting voltage. P1450 H Sensor voltage is higher than specified • AP sensor circuit shorted to VCC or ground circuit value. open L Sensor voltage is lower than specified • AP sensor circuit open or shorted to ground or value. VCC circuit open AP sensor ECM R VCC E G/Y PL AP B/Br E2 AM INSPECTION S 1 Step 1 (When indicating C22:) 1) Turn the ignition switch OFF. 2) Remove the front seat. (8-7) 3) Check the AP sensor coupler for loose or poor contacts. If OK, then measure the AP sensor input voltage.
FI SYSTEM DIAGNOSIS 4-57 4) Disconnect the AP sensor coupler. 1 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire and ground. V 7) If OK, then measure the voltage at the Red wire A and B/Br wire B. AP sensor input voltage: 4.5 – 5.5 V (+ Red – - Ground) (+ Red – - B/Br) 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Is the voltage OK? YES Go to Step 2. • Loose or poor contacts on the ECM coupler NO (terminal A or S) • Open or short circuit in the Red wire or B/Br wire Step 1 (When indicating P1450-H:) 1 1) Turn the ignition switch OFF. E 2) Remove the front seat. (8-7) 3) Check the AP sensor coupler for loose or poor contacts. L If OK, then check the AP sensor lead wire continuity. P AM 4) Disconnect the AP sensor coupler. 1 S 5) Check the continuity between Red wire A and G/Y wire C. If the sound is not heard from the tester, the circuit condition is OK.
4-58 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. 1 7) Check the continuity between G/Y wire C and terminal P. ! 8) If OK, then check the continuity between B/Br wire B and ter- minal S. APS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Continuity test () (Black) (Gray) ECM coupler (Harness side) Is the continuity OK? YES Go to Step 2. NO G/Y wire shorted to VCC, or B/Br wire open 9) After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 1 (When indicating P1450-L:) 1 1) Turn the ignition switch OFF. 2) Remove the front seat. (8-7) 3) Check the AP sensor coupler for loose or poor contacts. If OK, then check the AP sensor lead wire continuity. E PL 4) Disconnect the AP sensor coupler. M 1 5) Check the continuity between G/Y wire C and ground. A V 6) Also, check the continuity between G/Y wire C and B/Br wire B. If the sound is not heard from the tester, the circuit condi- S tion is OK.
FI SYSTEM DIAGNOSIS 4-59 7) Disconnect the ECM coupler. 1 8) Check the continuity between Red wire A and terminal A. ! 9) If OK, then check the continuity between G/Y wire C and ter- minal P. APS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Continuity test () (Black) (Gray) ECM coupler (Harness side) Is the continuity OK? YES Go to Step 1 (4-56) and go to Step 2. NO Red or G/Y wire open, or G/Y wire shorted to ground 10)After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 2 2 1) Connect the AP sensor coupler and ECM coupler. V 2) Insert the needle pointed probes to the lead wire coupler. E Turn the ignition switch ON. 3) Measure the AP sensor output voltage at the wire side cou- pler (between G/Y and B/Br wires). PL AP sensor output voltage: Approx. 2.6 V at 760 mmHg (100 kPa) M (+ G/Y – - B/Br) 09900-25008: Multi-circuit tester set A 09900-25009: Needle pointed probe set S Tester knob indication: Voltage () YES Go to Step 3. • Check the air passage for clogging. NO • Open or short circuit in the G/Y wire • Replace the AP sensor with a new one. 4) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-60 FI SYSTEM DIAGNOSIS Step 3 3 1) Remove the AP sensor. 2) Connect the vacuum pump gauge to the vacuum port of the AP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 – 5.0 V) and connect - terminal to the ground V terminal 2 and + terminal to the VCC terminal 3. 3) Check the voltage between Vout 4 and ground. Also, check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge. (Below) 09917-47011: Vacuum pump gauge 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Is the voltage OK? 3 • Red, G/Y or B/Br wire open or shorted to ECM coupler (Harness side) ground, or poor A, P or S connection. (Black) (Gray) • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. E • Replace the ECM with a known good one, and L inspect it again. If check result is not satisfactory, replace AP sen- NO P sor with a new one. M 4) After repairing the trouble, clear the DTC using SDS tool. (4-27) A Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – S 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (m) (mmHg) kPa (V) 0 0 760 100 3.1 – 3.6 2 000 610 707 94 2 001 611 707 94 2.8 – 3.4 5 000 1 524 634 85 5 001 1 524 634 85 2.6 – 3.1 8 000 2 438 567 76 8 001 2 439 567 76 2.4 – 2.9 10 000 3 048 526 70
FI SYSTEM DIAGNOSIS 4-61 “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C23 The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON. • ECM malfunction 0.2 V Sensor voltage < 4.8 V P1651 H Sensor voltage is higher than specified • TO sensor circuit shorted to VCC or ground circuit value. open L Sensor voltage is lower than specified • TO sensor circuit open or shorted to ground or value. VCC circuit open TO sensor ECM R VCC B TOS B/Br E E2 PL INSPECTION 1 Step 1 (When indicating C23:) M 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) A 3) Check the TO sensor coupler for loose or poor contacts. S If OK, then measure the TO sensor resistance. 4) Disconnect the TO sensor coupler. 5) Measure the resistance between terminal A and terminal C. 1 TO sensor resistance: 16.5 – 22.3 kΩ (Terminal A – Terminal C) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Is the resistance OK? YES Go to Step 2. NO Replace the TO sensor with a new one.
4-62 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-H:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4)Disconnect the TO sensor coupler. 1 5)Check the continuity between Red wire A and Black wire B. If the sound is not heard from the tester, the circuit condition is ! OK. 6)Disconnect the ECM coupler. 1 E ! 7)Check the continuity between Black wire B and terminal L. L 8) Also, check the continuity between B/Br wire C and terminal S. TOS lead wire continuity: Continuity () P 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set M Tester knob indication: Continuity test () (Black) (Gray) A ECM coupler (Harness side) Is the continuity OK? S YES Go to Step 2. NO Black wire shorted to VCC, or B/Br wire open. 9)After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-63 Step 1 (When indicating P1651-L:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler. 1 5) Check the continuity between Black wire B and ground. ! 6) Also, check the continuity between Black wire B and B/Br wire C. If the sound is not heard from the tester, the circuit condition is OK. 7) Disconnect the ECM coupler. 1 E 8) Check the continuity between Red wire A and terminal A. L 9) Also, then check the continuity between Black wire B and terminal L. P TOS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A (Black) (Gray) Tester knob indication: Continuity test () ECM coupler (Harness side) S Is the continuity OK? YES Go to Step 2. NO Red or Black wire open, or Black wire shorted to ground. 10)After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-64 FI SYSTEM DIAGNOSIS Step 2 2 1) Connect the TO sensor coupler and ECM coupler. V 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Black and B/Br wires. TO sensor voltage (Normal): 0.4 – 1.4 V (+ Black – - B/Br) Also, measure the voltage when leaning the motorcycle. 2 5) Dismount the TO sensor from its bracket and measure the voltage when it is leaned 65° and more, left and right, from V the horizontal level. TO sensor voltage (Leaning): 3.7 – 4.4 V 65˚ (+ Black – - B/Br) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Voltage () E Is the voltage OK? 2 ECM coupler (Harness side) • Red, Black or B/Br wire open or shorted to L ground, or poor A, L or S connection P (Black) (Gray) • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. M • Recheck each terminal and wire harness for open circuit and poor connection. A • Replace the ECM with a known good one, and inspect it again. S • Loose or poor contacts on the ECM coupler NO • Open or short circuit • Replace the TO sensor with a new one. 6)After repairing the trouble, clear the DTC using SDS tool. (4-27) “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354) IGNITION SYSTEM MALFUNCTION * Refer to the IGNITION SYSTEM for details. (9-20)
FI SYSTEM DIAGNOSIS 4-65 “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. • STVA motor malfunction STVA ECM B B/Lg STVA. 1B P P/W STVA. 1A G G STVA. 2B W/BI W/B STVA. 2A INSPECTION 1 Step 1 E 1) Lift and support the fuel tank. (5-3) 2) Remove the air cleaner cover. (2-4) L 3)Check the STVA lead wire coupler for loose or poor contacts. P SAM 4) Turn the ignition switch ON to check the STV operation. 1 (STV operating order: Full open → 95% open) Is the operating OK? YES Go to Step 2. • Loose or poor contacts on the STVA coupler NO • Open or short circuit in the B/Lg, P/W, W/B or Green wires • If wire and connection are OK, go to Step 2. 5) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-66 FI SYSTEM DIAGNOSIS Step 2 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground. STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between Black 2 wire A and Pink wire B) and (between Green wire C and W/BI wire D). STVA resistance: Approx. 6.5 Ω (Black A – Pink B) (Green C – W/BI D) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Is the resistance OK? 2 E • W/B, P/W, Green and B/Lg wire open or shorted ECM coupler (Harness side) (Black) (Gray) to ground, or poor 1, 2, H and I connection L • If wire and connection are OK, intermittent trou- P YES ble or faulty ECM. • Recheck each terminal and wire harness for M open circuit and poor connection. A • Replace the ECM with a known good one, and inspect it again. S NO • Loose or poor contacts on the ECM coupler. • Replace the STVA with a new one. 5) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-67 ACTIVE CONTROL INSPECTION 1)Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2)Turn the ignition switch ON. 3)Click “Secondary throttle operating control” 1. 4)Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal. E L P M A S
4-68 FI SYSTEM DIAGNOSIS “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C29 Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is • ECM malfunction larger than specified value. 0.15 V Sensor voltage < 4.85 V P1654 H Sensor voltage is higher than specified • STP sensor circuit shorted to VCC or ground cir- value. cuit open L Sensor voltage is lower than specified • STP sensor circuit open or shorted to ground or value. VCC circuit open ECM BI R VCC Y Y/W STP B B/Br E2 E L STP sensor P INSPECTION M 1 Step 1 (When indicating C29:) A 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) S 3) Check the STP sensor coupler for loose or poor contacts. If OK, then measure the STP sensor input voltage. 4) Disconnect the STP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire A and ground. 7) Also, measure the voltage at the Red wire A and B/Br wire C. STP sensor input voltage: 4.5 – 5.5 V 1 (+ Red – - Ground) V (+ Red – - B/Br) 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Is the voltage OK? YES Go to Step 2. • Loose or poor contacts on the ECM coupler NO (terminal A or S) • Open or short circuit in the Red wire or B/Br wire
FI SYSTEM DIAGNOSIS 4-69 Step 1 (When indicating P1654-H:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler. 1 5) Check the continuity between Y/W wire B and Red wire A. ! If the sound is not heard from the tester, the circuit condition is OK. 6) Disconnect the ECM coupler. 1 E ! 7) Check the continuity between Y/W wire B and terminal J. L 8) Also, check the continuity between B/Br wire C and terminal S. P STPS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A (Black) (Gray) Tester knob indication: Continuity test () ECM coupler (Harness side) S Is the continuity OK? YES Go to Step 2. NO Y/W wire shorted to VCC, or B/Br wire open 9) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-70 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1654-L:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler. 1 5) Check the continuity between Y/W wire B and ground. 6) Also, check the continuity between Y/W wire B and B/Br wire C. If the sound is not heard from the tester, the circuit condi- tion is OK. 7) Disconnect the ECM coupler. 1 E ! 8) Check the continuity between Y/W wire B and terminal J. 9) Also, check the continuity between Red wire A and terminal L A. P STPS lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A (Black) (Gray) Tester knob indication: Continuity test () ECM coupler (Harness side) Is the continuity OK? S YES Go to Step 1 (4-68) and go to Step 2. NO Red or Y/W wire open, or Y/W wire shorted to ground 10)After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-71 Step 2 2 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Disconnect the STP sensor coupler. 4) Check the continuity between each terminal and ground. STP sensor continuity: ∞ Ω (Infinity) (Terminal – Ground) 5) If OK, then measure the STP sensor resistance at the wire 2 terminals (between Yellow wire A and Black wire B). 6) Close and open the secondary throttle valve by finger, and measure the valve closing and opening resistance. STP sensor resistance 2 E 2 Secondary throttle valve is closed: Approx. 0.5 kΩ Secondary throttle valve is opened: Approx. 3.9 kΩ L (Yellow A – Black B) P SAM 7) If OK, then measure the STP sensor resistance at the wire 2 terminals (between Blue wire c and Black wire B). STP sensor resistance: Approx. 4.69 kΩ (Blue c – Black B) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Are the continuity and resistance OK? YES Go to Step 3. NO • Reset the STP sensor position correctly. • Replace the STP sensor with a new one. 8) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-72 FI SYSTEM DIAGNOSIS Step 3 3 1)Turn the ignition switch OFF. V 2)Connect the STP sensor coupler. 3)Insert the needle pointed probes to the STP sensor coupler. 4)Disconnect the STVA lead wire coupler. 5)Turn the ignition switch ON. 6)Measure the STP sensor output voltage at the coupler (between + Yellow wire and - Black wire) by turning the secondary throttle valve (close and open) with a finger. STP sensor output voltage 3 3 Secondary throttle valve is closed : Approx. 0.5 V Secondary throttle valve is opened : Approx. 3.9 V 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Voltage () Is the voltage OK? 3 E • Red, Y/W or B/Br wire open or shorted to ECM coupler (Harness side) (Black) (Gray) ground, or poor A, J or S connection L • If wire and connection are OK, intermittent trou- P YES ble or faulty ECM. • Recheck each terminal and wire harness for M open circuit and poor connection. A • Replace the ECM with a known good one, and inspect it again. S NO If check result is not satisfactory, replace STP sensor with a new one. After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-73 “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short Switch voltage is not within the following range. • Gear Position switch malfunction Switch voltage > 0.6 V • ECM malfunction ECM Side-stand relay To engine stop switch Ignition GP switch switch BI GP P P N E1 B/W 6 1 Neutral indicator 5 light B/W 2 4 3 Side-stand switch INSPECTION 1 Step 1 E 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) L 3) Check the GP switch coupler for loose or poor contacts. If OK, then measure the GP switch voltage. P SAM 4) Support the motorcycle with a jack. 1 5) Fold the side-stand to up position. V 6) Make sure the engine stop switch is in the “RUN” position. 7) Insert the needle pointed probe to the lead wire coupler. 8) Turn the ignition switch ON. 9) Measure the voltage at the wire side coupler between Pink wire and B/W wire, when shifting the gearshift lever from 1st to Top. GP switch voltage:0.6 V and more (+ Pink – - B/W) 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Voltage ()
4-74 FI SYSTEM DIAGNOSIS Is the voltage OK? 1 • Pink wire open or shorted to ground ECM coupler (Harness side) • If wire and connection are OK, intermittent trou- (Black) (Gray) ble or faulty ECM. YES • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. • Pink or B/W wire open, or Pink wire shorted to ground NO • Loose or poor contacts on the ECM coupler (terminal M or X) • If wire and connection are OK, replace the GP switch with a new one. 10)After repairing the trouble, clear the DTC using SDS tool. (4-27) E PL SAM
FI SYSTEM DIAGNOSIS 4-75 “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short interrupted by 4 times or more continuously. • Injector malfunction • ECM malfunction ECM Fuel pump relay Y/R To engine #11 Gr/W stop switch #21 Gr/B #31 Gr/Y #41 Gr/R #4 #3 #2 #1 Primary fuel injector INSPECTION 1 E Step 1 L 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank (5-3) P 3) Check the injector coupler for loose or poor contacts. If OK, then measure the injector resistance. SAM 4) Disconnect the injector coupler and measure the resistance 1 between terminals. Injector resistance: 11 – 13 Ω at 20 °C (68 °F) (Terminal – Terminal)
4-76 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and 1 ground. STP sensor continuity: ∞ Ω (Infinity) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? YES Go to Step 2. NO Replace the injector with a new one. (5-23) 6) After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 2 2 1) Turn the ignition switch ON. V 2) Measure the injector voltage between Y/R wire and ground. Injector voltage: Battery voltage (+ Y/R – - Ground) NOTE: Injector voltage can be detected only 3 for seconds after ignition E switch is turned ON. L 09900-25008: Multi-circuit tester set P Tester knob indication: Voltage () Is the voltage OK? M 2 • Gr/W wire open or shorted to ground, or poor h ECM coupler (Harness side) A (Black) (Gray) connection (#1 cylinder side) S • Gr/B wire open or shorted to ground, or poor g connection (#2 cylinder side) • Gr/Y wire open or shorted to ground, or poor f connection (#3 cylinder side) YES • Gr/R wire open or shorted to ground, or poor e connection (#4 cylinder side) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Open circuit in the Y/R wire 3) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-77 “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767) SECOND- ARY FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Some failure exists in the fuel injector signal in a • Injector circuit open or short high load, high revolution condition. • Injector malfunction • ECM malfunction ECM Fuel pump relay Y/R To engine #12 Lg stop switch #22 Lg/W #32 Lg/G #42 Lg/BI #4 #3 #2 #1 Secondary fuel injector INSPECTION 1 E Step 1 L 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) P 3) Check the injector coupler for loose or poor contacts. If OK, then measure the injector resistance. SAM 4) Disconnect the injector coupler and measure the resistance 1 between terminals. Injector resistance: 11 – 13 Ω at 20 °C (68 °F) (Terminal – Terminal)
4-78 FI SYSTEM DIAGNOSIS 5) If OK, then check the continuity between each terminal and 1 ground. STP sensor continuity: ∞ Ω (Infinity) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? YES Go to Step 2. NO Replace the injector with a new one. (5-23) 6) After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 2 2 1) Turn the ignition switch ON. V 2) Measure the injector voltage between Y/R wire and ground. Injector voltage: Battery voltage (+ Y/R – - Ground) NOTE: Injector voltage can be detected only 3 seconds after ignition E switch is turned ON. L 09900-25008: Multi-circuit tester set P Tester knob indication: Voltage () Is the voltage OK? M 2 • Lg wire open or shorted to ground, or poor x ECM coupler (Harness side) A (Black) (Gray) connection (#1 cylinder side) S • Lg/W wire open or shorted to ground, or poor w connection (#2 cylinder side) • Lg/G wire open or shorted to ground, or poor v connection (#3 cylinder side) YES • Lg/BI wire open or shorted to ground, or poor u connection (#4 cylinder side) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Open circuit in the Y/R wire. 3) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-79 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C41 No voltage is applied to fuel pump • Fuel pump relay circuit open or short although fuel pump relay is turned ON, • Fuel pump relay malfunction or voltage is applied to fuel pump, • ECM malfunction although fuel pump relay is turned OFF. P0230 Voltage is applied to fuel pump although • Fuel pump relay switch circuit shorted to power H fuel pump relay is turned OFF. source • Faulty fuel pump relay (switch side) L No voltage is applied to fuel pump • Fuel pump relay coil circuit open or short although fuel pump relay is turned ON. • Faulty fuel pump relay (coil side) ECM M Fuel pump Engine stop switch To side-stand Ignition VM Y/R R/BI switch Side-stand switch FP Relay Y/B O/W E relay Fuel pump L relay P INSPECTION M 1 Step 1 (When indicating C41:) 1) Turn the ignition switch OFF. A 2) Remove the front seat. (8-7) S 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (5-6) Is the FP relay OK? 1 • Y/B or O/W wire open or short or poor ] con- ECM coupler (Harness side) nection (Black) (Gray) • Y/R or R/Bl wire open, shorted or poor W con- nection YES • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Replace the FP relay with a new one.
4-80 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0230-H:) 1 1) Turn the ignition switch OFF. 2) Remove the front seat. (8-7) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (5-6) Is the FP relay OK? 1 • Y/R wire shorted to power source ECM coupler (Harness side) • Y/B wire shorted to ground (Black) (Gray) • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Replace the FP relay with a new one. E 4) After repairing the trouble, clear the DTC using SDS tool. L (4-27) P Step 1 (When indicating P0230-L:) 1 1) Turn the ignition switch OFF. M 2) Remove the front seat. (8-7) 3) Check the FP relay coupler for loose or poor contacts. A If OK, then check the FP relay. (5-6) S Is the FP relay OK? 1 • Y/B wire open or poor ] connection ECM coupler (Harness side) • O/W wire open or shorted to ground (Black) (Gray) • R/BI or Y/R wire open or shorted to ground or poor W connection YES • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Replace the FP relay with a new one. 4) After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-81 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Ignition switch signal is not input to the ECM. • Ignition system circuit open or short • ECM malfunction When the ID agreement is not verified. • Immobilizer system malfunction ECM does not receive communication signal from the (For E-02, 19, 24) immobilizer antenna. (For E-02, 19, 24) INSPECTION * Refer to the IGNITION SWITCH INSPECTION for details. (9-39) E L P M A S
4-82 FI SYSTEM DIAGNOSIS “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C46 The operation signal does not reach the • EXCVA maladjusted EXCV actuator. • EXCVA circuit open or short EXCVA position sensor voltage low or • EXCVA motor malfunction high • EXCVA position sensor malfunction 0.1 V Sensor voltage < 4.9 V (without the above range) P1657 H Sensor voltage is higher than specified • EXCVA position sensor circuit shorted to VCC or value. ground circuit open L Sensor voltage is lower than specified • EXCVA position sensor circuit open or shorted to value. ground or VCC circuit open P1658 The operation signal does not reach the • EXCVA motor circuit open or short EXCVA motor. • EXCVA motor malfunction ECM does not receive communication signal from the STVA motor. ECM EXCVA E Gr B/R L MO P R/B MO B R P VCC Y Y MPS W B/Br E2 SAM INSPECTION 1 Step 1 (When indicating C46:) 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA lead wire coupler for loose or poor con- tacts. 4) Turn the ignition switch ON. 1 5) Check the operation of the EXCVA. (EXCVA operating order: Full close → Full open → 30% open) Is the operation OK? YES Go to Step 2. NO Go to Step 6.
FI SYSTEM DIAGNOSIS 4-83 Step 1 (When indicating P1657-H:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity. 4) Disconnect the EXCVA position sensor coupler. 1 5) Check the continuity between Red wire C and Yellow wire A. If the sound is not heard from the tester, the circuit condition is OK. 6) Disconnect the ECM coupler. 1 E 7) Check the continuity between Yellow wire A and terminal 5. ! L 8) Also, check the continuity between B/Br wire B and terminal S. P EXCVA lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A (Black) (Gray) Tester knob indication: Continuity test () ECM coupler (Harness side) S Is the continuity OK? YES Go to Step 4. NO Yellow wire shorted to VCC, or B/Br wire open 9) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-84 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-L:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity. 4) Disconnect the EXCVA position sensor coupler. 1 5) Check the continuity between Yellow wire A and ground. 6) Also, check the continuity between Yellow wire A and B/Br wire B. If the sound is not heard from the tester, the circuit condition is OK. 7) Disconnect the ECM coupler. 1 E 8) Check the continuity between Yellow wire A and terminal 5. 9) Also, check the continuity between Red wire C and terminal L A. P EXCVA lead wire continuity: Continuity () 09900-25008: Multi-circuit tester set M 09900-25009: Needle pointed probe set A (Black) (Gray) Tester knob indication: Continuity test () ECM coupler (Harness side) Is the continuity OK? S YES Go to Step 2 and Go to Step 4. NO Red or Yellow wire open, or Yellow wire shorted to ground 10)After repairing the trouble, clear the DTC using SDS tool. (4-27)
FI SYSTEM DIAGNOSIS 4-85 Step 1 (When indicating P1658:) 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank. (5-3) 3) Check the EXCVA motor coupler for loose or poor contacts. Is the contacting OK? YES Go to Step 6. NO Loose or poor contacts on the EXCV motor cou- pler 4) After repairing the trouble, clear the DTC using SDS tool. (4-27) Step 2 2 1) Turn the ignition switch OFF. 2) Check the installation of EXCV cables. (6-16) If it is necessary, adjust the EXCV cables. (6-8 to -9) E L 3) Disconnect the EXCVA position sensor lead wire coupler. 2 4) Turn the ignition switch ON. P 5) Measure the voltage between the Red wire terminal 1 and ground. M 6) If OK, then measure the voltage between the Red wire A terminal 1 and B/Br wire terminal 2. S Position sensor input voltage: 4.5 – 5.5 V (+ Red – - Ground) (+ Red – - B/Br) 09900-25008: Multi circuit tester set 2 Tester knob indication: Voltage () V Is the voltage OK? YES Go to Step 3. • Loose or poor contacts on the ECM coupler NO (terminal A or S) • Open or short circuit in the Red wire or B/Br wire 7) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-86 FI SYSTEM DIAGNOSIS Step 3 3 1) Turn the ignition switch OFF. 2) Check the continuity between Yellow wire and ground. Position sensor continuity: ∞ Ω (Infinity) 3) If OK, then measure the position sensor resistance. 4) Connect the position sensor coupler. 3 5) Set the EXCVA to adjustment position. (6-4) 6) Disconnect the position sensor coupler and measure the 3 E resistance. (between Yellow and White wires) L Position sensor resistance at adjustment position: Approx. 3.1 kΩ (+ Yellow – - White) P 09900-25008: Multi circuit tester set M Tester knob indication: Resistance (Ω) Is the resistance OK? SA YES Go to Step 4. NO Replace the EXCVA with a new one.
FI SYSTEM DIAGNOSIS 4-87 Step 4 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler. 3) Measure the position sensor output voltage at fully close posi- tion and fully open position. 4) Insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler. (+ Yellow – - B/Br) 5) Disconnect the EXCVA motor lead wire coupler 2. 6) To set the EXCV to fully close position, apply 12 volts to A 12 V and B terminals. Positive wire – A (Pink wire) terminal 4 Negative wire – B (Gray wire) terminal V 7) Turn the ignition switch ON. 8) Measure the position sensor output voltage at fully close posi- tion. 9) Then, to set the EXCV to fully open position, apply 12 volts to B and A terminals. Positive wire – B (Gray wire) terminal Negative wire – A (Pink wire) terminal 10)Measure the position sensor output voltage at fully open position. E Position sensor output voltage 4 EXCV is fully close: 0.5 – 1.3 V L EXCV is fully open: 3.7 – 4.5 V P (+ Yellow – - White) 09900-25008: Multi circuit tester set M 09900-25009: Needle pointed probe set A Tester knob indication: Voltage () Is the voltage OK? S 12 V YES Replace the ECM with a known good one, and inspect it again. NO Go to Step 5. 11)After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-88 FI SYSTEM DIAGNOSIS Step 5 5 1) If the position sensor output voltage is 0.5 V and less at fully close position, adjust the output voltage to specified by turn- ing out the No. 1 cable adjuster 1. 2) Repeat the above procedure (Step 4) until the out put voltage becomes specified value. (If C46/P1657 code is indicated after adjusting the voltage, increase the voltage to 0.4 V.) * Adjusting the cable with the EXCV fully opened or fully closed can damage the EXCVA. Be sure to adjust the cable with the EXCV set in adjustment position. (6-4) * Do not turn the EXCVA pulley using the wrench. 3) If the position sensor output voltage is 4.5 V and more at fully open position, adjust the output voltage to specified by turning out the No. 2 cable adjuster 2. Repeat the above procedure (Step 4) until the output voltage is within the specified value. Position sensor output voltage E EXCV is fully close: 0.5 Output Voltage 1.3 EXCV is fully open: 3.7 Output Voltage 4.5 L Is the voltage OK? P YES Replace the ECM with a known good one, and inspect it again. M NO Replace the EXCVA with a new one. A 3) After repairing the trouble, clear the DTC using SDS tool. (4-27) S
FI SYSTEM DIAGNOSIS 4-89 Step 6 6 1) Turn the ignition switch OFF. 2) Disconnect the motor lead wire coupler of the EXCVA. 3) Apply 12 volts to the terminal and check the operation of 6 EXCVA. 12 V 4) Then, swap the wires supplied 12 volts and check the opera- 6 E tion of EXCVA. (Check the operation of EXCVA both way.) L P M A 12 V Is the operation OK? S • Loose or poor contacts on the EXCVA or ECM coupler (terminal 3 or 4) • Open or short circuit in the B/R wire or R/B wire • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. • Replace the EXCVA with a new one. NO • Inspect that the EXCV and two cables move smoothly. (6-14) 5) After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-90 FI SYSTEM 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 “Exhaust valve operating control” 1. 4)Click each button 2. At this time, if an operation sound is heard from the EXCVA, the function is normal. E L P M A S
FI SYSTEM DIAGNOSIS 4-91 “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction • ECM malfunction ECM Engine stop Side-stand Ignition switch relay switch RAIR W/G O/W To side-stand switch PAIR control solenoid valve INSPECTION 1 Step 1 E 1)Turn the ignition switch OFF. 2)Remove the air cleaner box. (5-13) L 3)Check the PAIR control solenoid valve coupler for loose or poor contacts. P If OK, then measure the PAIR control solenoid valve resis- tance. AM 4)Remove the PAIR control solenoid valve. (11-6) 1 S 5)Measure the resistance between terminals. PAIR valve resistance: 18 – 22 Ω at 20 – 30 °C (68 – 86 °F) (Terminal – Terminal) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) Is the resistance OK? YES Go to Step 2. NO Replace the PAIR valve with a new one. 6)After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-92 FI SYSTEM DIAGNOSIS Step 2 2 1)Turn the ignition switch ON. V 2)Measure the voltage between O/W wire and ground. PAIR valve voltage: Battery voltage (+ O/W – - Ground) 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Is the voltage OK? 2 • W/G wire open or shorted to ground, or poor t ECM coupler (Harness side) connection failure. (Black) (Gray) • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Open or short circuit in the O/W wire. E 3)After repairing the trouble, clear the DTC using SDS tool. L (4-27) P ACTIVE CONTROL INSPECTION 1)Set up the SDS tool. (Refer to the SDS operation manual for further details.) M 2)Turn the ignition switch ON. A 3)Click “PAIR Sol operating control” 1. S 4)Click each button 2. At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.
FI SYSTEM DIAGNOSIS 4-93 “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short • ECM malfunction ECM Cooling fan Engine stop Side-stand Ignition relay switch relay switch FAR G/R O/W To Side-stand switch Cooling fan motor INSPECTION 1 Step 1 1) Turn the ignition switch OFF. E 2)Remove the front seat. (8-7) 3)Check the cooling fan relay coupler for loose or poor contacts. L If OK, then inspection the cooling fan relay. (7-7) P AM Is the cooling fan relay OK? 1 S ECM coupler (Harness side) • O/W and G/R wire open or shorted to ground, (Black) (Gray) or poor c connection • If wire and connection are OK, intermittent trou- YES ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. NO Replace the cooling fan relay with a new one. 4)After repairing the trouble, clear the DTC using SDS tool. (4-27)
4-94 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4)Click the operate button 2. At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal. NOTE: Cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 100 °C (212 °F) after starting the engine. E L P M A 5)Click the stop button 3 to check the operation properly. S
FI SYSTEM DIAGNOSIS 4-95 SENSORS CMP SENSOR INSPECTION The camshaft position sensor is installed on the cylinder head cover. (4-33) CMP SENSOR REMOVAL AND INSTALLATION • Remove the CMP sensor. (3-27) • Install the CMP sensor in the reverse order of removal. CKP SENSOR INSPECTION The crankshaft position sensor is installed on the right side of middle crankcase cover. (4-35) CKP SENSOR REMOVAL AND INSTALLATION • Remove the starter clutch cover. (3-21) • Install the starter clutch cover in the reverse order of removal. E IAP SENSOR INSPECTION L The intake air pressure sensor is installed at the rear side of the air cleaner box. (4-37) P IAP SENSOR REMOVAL AND INSTALLATION • Lift and support the fuel tank. (5-3) M A • Remove the IAP sensor from the air cleaner box. • Install the IAP sensor in the reverse order of removal. S TP SENSOR INSPECTION The throttle position sensor is installed at the right side of the No. 4 throttle body. (4-43) TP SENSOR REMOVAL AND INSTALLATION • Remove the TP sensor. (5-16) • Install the TP sensor in the reverse order of removal. TPS ADJUSTMENT • Adjust the TP sensor. (4-20)
4-96 FI SYSTEM DIAGNOSIS ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the cylin- der head. (4-48) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor. (7-7) • Install the ECT sensor in the reverse order of removal. ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) IAT SENSOR INSPECTION The intake air temperature sensor is installed on the right side of the air cleaner box. (4-52) IAT SENSOR REMOVAL AND INSTALLATION • Lift and support the fuel tank. (5-3) • Remove the IAT sensor from the air cleaner box. • Install the IAT sensor in the reverse order of removal. IAT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) E AP SENSOR INSPECTION L The AP sensor is located under the front seat. (4-56) P AP SENSOR REMOVAL AND INSTALLATION • Remove the AP sensor from the frame. M • Install the AP sensor in the reverse order of removal. A S TO SENSOR INSPECTION TO SENSOR REMOVAL AND INSTALLATION The tip-over sensor is located in front of the battery case. (4-61) • Lift and support the fuel tank. (5-3) • Remove the TO sensor from the battery case. • Install the TO sensor in the reverse order of removal. NOTE: When installing the TO sensor, the arrow mark A must be pointed upward.
FI SYSTEM DIAGNOSIS 4-97 STP SENSOR INSPECTION STP SENSOR REMOVAL AND INSTALLATION The secondary throttle position sensor is installed at the right side of the No. 4 throttle body. • Remove the STP sensor. (5-16) • Install the STP sensor in the reverse order of removal. STP SENSOR ADJUSTMENT • Adjust the STP sensor. (5-22) E L P M A S
FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM........................................................................... 5- 2 FUEL SYSTEM.............................................................................................. 5- 3 FUEL TANK LIFT-UP............................................................................. 5- 3 FUEL TANK REMOVAL......................................................................... 5- 3 FUEL TANK INSTALLATION................................................................ 5- 4 FUEL PRESSURE INSPECTION........................................................... 5- 4 FUEL PUMP INSPECTION.................................................................... 5- 5 FUEL DISCHARGE AMOUNT INSPECTION........................................5- 5 FUEL PUMP RELAY INSPECTION....................................................... 5- 6 FUEL PUMP AND FUEL FILTER REMOVAL........................................5- 7 FUEL MESH FILTER INSPECTION AND CLEANING..........................5- 9 5 FUEL PUMP AND FUEL MESH FILTER INSTALLATION....................5- 9 THROTTLE BODY........................................................................................ 5-12 CONSTRUCTION................................................................................... 5-12 AIR CLEANER BOX REMOVAL............................................................ 5-13 E THROTTLE BODY REMOVAL............................................................... 5-14 L THROTTLE BODY DISASSEMBLY....................................................... 5-15 P THROTTLE BODY CLEANING.............................................................. 5-17 INSPECTION.......................................................................................... 5-17 M THROTTLE BODY REASSEMBLY........................................................ 5-18 THROTTLE BODY INSTALLATION...................................................... 5-21 A AIR CLEANER BOX INSTALLATION................................................... 5-22 STP SENSOR ADJUSTMENT............................................................... 5-22 S FUEL INJECTOR REMOVAL................................................................. 5-23 FUEL INJECTOR INSPECTION............................................................. 5-23 FUEL INJECTOR INSTALLATION........................................................ 5-23 FAST IDLE.............................................................................................. 5-24 FAST IDLE ADJUSTMENT.................................................................... 5-24 THROTTLE VALVE SYNCHRONIZATION............................................ 5-26 THROTTLE POSITION SENSOR (TPS) SETTING................................5-29 Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.
5-2 FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe. Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector (the 2 fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of 3.0 kgf/cm (300 kPa, 43 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM. The fuel relieved by the fuel pressure regulator flows back to the fuel tank. E L P M A S 1 Fuel tank 7 Fuel feed hose 2 Fuel filter (For high pressure) 8 Fuel mesh filter (For low pressure) 3 Fuel pressure regulator 9 Fuel pump 4 Fuel delivery pipe A Before-pressurized fuel 5 Primary fuel injector B Pressurized fuel 6 Secondary fuel injector C Relieved fuel
FUEL SYSTEM AND THROTTLE BODY 5-3 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the right and left fuel tank lower side covers. (8-7) • Remove the fuel tank mounting bolts. . • Lift and support the fuel tank with the fuel tank prop stay 2. E FUEL TANK REMOVAL L • Lift and support the fuel tank. (Above) P • Disconnect the fuel pump lead wire coupler 1. • Disconnect the fuel tank breather hose 2 and fuel tank drain hose 3. M • Place a rag under the fuel feed hose and remove the fuel feed A hose 4. S When removing the fuel tank, do not leave the fuel feed hose 4 on the fuel tank side. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the fuel tank bracket mounting bolt. • Remove the fuel tank.
5-4 FUEL SYSTEM AND THROTTLE BODY FUEL TANK INSTALLATION • Installation is in the reverse order of removal. FUEL PRESSURE INSPECTION • Lift and support the fuel tank. (5-3) • Place a rag under the fuel feed hose and remove the fuel feed hose 1. • Install the special tools between the fuel tank and fuel delivery pipe. 09940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77331: Oil pressure gauge 09915-74521: Oil pressure gauge hose E Turn the ignition switch ON and check the fuel pressure. 2 L Fuel pressure: Approx. 300 kPa (3.0 kgf/cm , 43 psi) If the fuel pressure is lower than the specification, inspect the following items: P * Fuel hose leakage M * Clogged fuel filter * Pressure regulator A * Fuel pump S If the fuel pressure is higher than the specification, inspect the following items: * Fuel pump check valve * Pressure regulator * Before removing the special tools, turn the ignition switch to OFF position and release the fuel pressure slowly. * Gasoline is highly flammable and explosive. Keep heat, sparks and flame away. A To fuel tank B To fuel delivery pipe
FUEL SYSTEM AND THROTTLE BODY 5-5 FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor. If the fuel pump relay, tip-over sensor and fuel pump circuit con- nections are OK, the fuel pump may be faulty, replace the fuel pump with a new one. FUEL DISCHARGE AMOUNT INSPECTION Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Lift and support the fuel tank. (5-3) • Place a rag under the fuel feed hose and disconnect the fuel feed hose 1 from the fuel pump. • Connect a proper fuel hose 2 to the fuel pump. E L P M A S • Place the measuring cylinder and insert the fuel hose end into the measuring cylinder. • Disconnect the fuel pump lead wire coupler 3.
5-6 FUEL SYSTEM AND THROTTLE BODY • Connect a proper lead wire into the fuel pump lead wire cou- pler (fuel pump side) and apply 12 volts to the fuel pump (between Y/R wire and B/W wire) for 10 seconds and mea- sure the amount of fuel discharged. Battery + terminal (Yellow with red tracer) Battery - terminal (Black with white tracer) If the pump does not discharge the amount specified, it means that the fuel pump is defective or that the fuel filter is clogged. Fuel discharge amount: 168 ml (5.7/5.9 US/Imp oz) and more/10 sec. NOTE: The battery must be in fully charged condition. FUEL PUMP RELAY INSPECTION Fuel pump relay is located in back of the battery. • Remove the front seat. (8-7) • Remove the fuel pump relay 1. First, check the insulation between A and B terminals with E pocket tester. Then apply 12 volts to C and D terminals, + to C and - to D, and check the continuity between A and B. L If there is no continuity, replace it with a new one. P M A S
FUEL SYSTEM AND THROTTLE BODY 5-7 FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION E L P M A S 1 Fuel level gauge 5 Holder 2 Fuel pump case/Fuel filter cartridge 6 Fuel mesh filter ITEM N·m kgf-m lb-ft 3 Fuel pump 7 O-ring A 10 1.0 7.0 4 Rubber cushion A Fuel pump mounting bolt
5-8 FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the fuel tank. (5-3) • Remove the fuel pump assembly 1 by removing its mounting bolts diagonally. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the nuts. • Remove the lead wire 1, screws and fuel level gauge 2. E L P M A S • Remove the screw. • Remove the fuel pump 3 from the fuel pump plate 4. • Remove the fuel pump holder 5 and rubber cushion 6.
FUEL SYSTEM AND THROTTLE BODY 5-9 • Remove the fuel mesh filter 7. • Remove the fuel pump 8 from the fuel pump case/fuel filter cartridge 9. FUEL MESH FILTER INSPECTION AND E CLEANING L If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.P Blow the fuel mesh filter with compressed air. NOTE: M If the fuel mesh filter is clogged with many sediment or rust, A replace the fuel filter cartridge with a new one. S FUEL PUMP AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh filter in the reverse order of removal. Pay attention to the following points: • Install the new bushing 1 to the fuel pump. Use the new bushing to prevent fuel leakage. • Install the new O-ring to the fuel pipe. • Apply thin coat of the engine oil to new O-ring. Use the new O-ring to prevent fuel leakage.
5-10 FUEL SYSTEM AND THROTTLE BODY • Be sure to connect the wires to the proper terminals. A............... + terminal for fuel pump B............... + terminal for fuel level gauge E L P M A S • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) The O-ring must be replaced with a new one to prevent fuel leakage.
FUEL SYSTEM AND THROTTLE BODY 5-11 • When installing the fuel pump assembly, first tighten all the 3 fuel pump mounting bolts lightly and then to the specified 1 torque, in the ascending order of numbers. Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: 5 Apply a small quantity of the THREAD LOCK to the thread por- 4 tion of fuel pump mounting bolts. 99000-32050: THREAD LOCK “1342” 2 E PL SAM
5-12 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION E L P M A S Only for E-33 1 TP sensor 8 Cushion seal 2 STP sensor 9 Fast idle adjusting screw 3 STVA 0 Throttle stop screw 4 Fuel delivery pipe A Vacuum hose ITEM N·m kgf-m lb-ft 5 Fuel delivery pipe joint A Fuel delivery pipe mounting screw A 3.5 0.35 2.5 6 O-ring B STP sensor mounting screw B 3.5 0.35 2.5 7 Fuel injector C TP sensor mounting screw C 3.5 0.35 2.5
FUEL SYSTEM AND THROTTLE BODY 5-13 AIR CLEANER BOX REMOVAL • Lift and support the fuel tank. (5-3) • Disconnect the IAT sensor lead wire coupler 1, PAIR hose 2 and PCV hose 3. • Disconnect the IAP sensor lead wire coupler 4 and vacuum hose 5. • Loosen the throttle body clamp screws. E L P M A S • Remove the air cleaner box mounting bolt. • Remove the air cleaner box.
5-14 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY REMOVAL • Remove the air cleaner box. (5-13) • Disconnect the throttle cables from their drum. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body. • Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel pump. • Disconnect the STVA lead wire coupler 1, STP sensor lead E wire coupler 2 and TP sensor lead wire coupler 3. L P M A S • Remove the wire clamps 4 and disconnect the fuel injector lead wire couplers 5. • Loosen the throttle body clamp screws at the intake pipe side.
FUEL SYSTEM AND THROTTLE BODY 5-15 • Remove the throttle body assembly. THROTTLE BODY DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. • Disconnect the respective vacuum hoses 1 from each throt- tle body. • Disconnect the fuel feed hose 2. • Remove the fuel delivery pipe joint assembly 3 and plat 4. E L P M A S • Remove the secondary fuel delivery pipe assembly 5. • Remove the primary fuel delivery pipe assembly 6.
5-16 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel injectors 7, secondary fuel delivery pipes 8 and primary fuel delivery pipes 9. • Remove the fuel delivery pipe 0 and fuel delivery pipe joints A. • Remove the TP sensor and STP sensor with the special tool. E 09930-11950: Torx wrench L NOTE: Prior to disassembly, mark the each sensor’s original position P with a paint or scribe for accurate reinstallation. M SA Never remove the STVA B from the throttle body. Never remove the secondary throttle valve C and throttle valve D.
FUEL SYSTEM AND THROTTLE BODY 5-17 The fast idle screw E is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary. THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. E L Do not use wire to clean passageways. Wire can dam- P age passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to M use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer’s A instructions for proper use and cleaning of the throttle S body components. Do not apply carburetor cleaning chemicals to the rubber and plastic materials. INSPECTION Check following items for any damage or clogging. *O-ring * Throttle valve * Secondary throttle valve * Vacuum hose
5-18 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • With the STV fully open, install the STP sensor 1 and tighten the STP sensor mounting screw to the specified torque. NOTE: * Apply thin coat of the engine oil to the O-ring. * Align the secondary throttle shaft end A with the groove B of STP sensor. * Apply SUZUKI SUPER GREASE “A” to the secondary throttle shaft end A if necessary. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) 09930-11950: Torx wrench STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft) NOTE: * Make sure the STP valve open or close smoothly. * If the STP sensor adjustment is necessary, refer to page 5-22 for STP sensor setting procedure. E • With the throttle valve fully closed, install the TP sensor 2 L and tighten the TP sensor mounting screw to the specified torque. P NOTE: M * Apply thin coat of the engine oil to the O-ring. * Align the throttle shaft end C with the groove D of TP sensor. A * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary. S 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) 09930-11950: Torx wrench TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft) NOTE: * Make sure the throttle valve open or close smoothly. * TP sensor setting procedure. (4-20)
FUEL SYSTEM AND THROTTLE BODY 5-19 • Apply thin coat of the engine oil to the new O-ring 3 and cusion seal 4. Replace the cushion seal and O-ring with the new ones. • Apply thin coat of the engine oil to the new O-rings 5. Replace the O-ring with the new ones. • Install the joints. • Install the fuel injector 6 by pushing it straight to the delivery E pipe 7. L NOTE: Align the boss E of the injector with the groove F of the delivery pipe. P M Never turn the injector while pushing it. A S • Apply thin coat of the engine oil to the new O-rings. #2#2#2 #2#2#3 • Assemble the fuel delivery pipes as shown. Fuel delivery pipe mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft) NOTE: The screw section G of joint is turned to a #2 side and the longer one H body is turned to the injector side. * Replace the O-rings with the new ones. * Never turn the fuel delivery pipes while pushing it. #2#2#2 #2#3#2
5-20 FUEL SYSTEM AND THROTTLE BODY • Assemble the fuel delivery pipes as shown. Never turn the fuel delivery pipes while pushing it. • Install the primary fuel delivery pipe assembly 8 and second- ary fuel delivery pipe assembly 9 to the throttle body assem- bly. Never turn the fuel injectors while installing them. • Tighten the fuel delivery pipe mounting screws to the speci- fied torque. Fuel delivery pipe mounting screw: E 3.5 N·m (0.35 kgf-m, 2.5 lb-ft) L P M A • Install the plat 0. S NOTE: The boss G of the outside. • Apply thin coat of the engine oil to the new O-rings. Replace the O-rings with the new ones. • Install the fuel delivery pipe joint assembly. • Tighten the fuel delivery pipe mounting screws to the speci- fied torque. Fuel delivery pipe mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
FUEL SYSTEM AND THROTTLE BODY 5-21 THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector. 1 Primary injector 2 Secondary injector #1 Y/R and Gr/W Y/R and Lg #2 Y/R and Gr/B Y/R and Lg/W #3 Y/R and Gr/Y Y/R and Lg/G #4 Y/R and Gr/R Y/R and Lg/Bl • Connect the throttle pulling cable 3 and throttle returning cable 4 to the throttle cable drum. E L • Loosen each throttle cable lock-nut. P • Turn in each throttle cable adjuster fully and locate each outer 0 mm (0 in) cable so that the clearance is 0 mm (0 in). • Tighten each lock-nut. M • Adjust the throttle cable play. A Refer to page 2-15 for details. S 0 mm (0 in)
5-22 FUEL SYSTEM AND THROTTLE BODY AIR CLEANER BOX INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Install the air cleaner box and tighten the throttle body clamp screws as shown in the illustration. LEFT #1 #2 #3 #4 RIGHT SIDE SIDE 10˚ ± 10˚ 10˚ ± 10˚ 30˚ ± 10˚ 10˚ ± 10˚ VIEW OF TOP E STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor L output voltage and adjust the STP sensor position as follows: • Disconnect the STVA lead wire coupler. P • Remove the air cleaner box cover. (2-4) • Insert the needle pointed probes to the STP sensor coupler. M • Turn the ignition switch ON. A • Close the secondary throttle valve by finger, and measure the STP sensor output voltage. S STP sensor output voltage ST valve is fully closed: 0.48 – 0.52 V (+ Yellow – - Black) 09900-25008: Multi-circuit tester set V 09900-25009: Needle pointed probe set Tester knob indication: Voltage () • Loosen the STP sensor mounting screw. • Adjust the STP sensor 1 until resistance comes to specifica- tion and tighten the STP sensor mounting screw. 09930-11950: Torx wrench STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
FUEL SYSTEM AND THROTTLE BODY 5-23 FUEL INJECTOR REMOVAL • Remove the air cleaner box. (5-13) • With battery negative cable disconnected, disconnect the injector couplers. • Remove the fuel delivery pipe assembly. (5-15) • Remove the primary and secondary fuel injectors #1, #2, #3 and #4. (5-16) FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank. The fuel injector can be checked without removing it from the throttle body. Refer to page 4-75 to -78 for details. FUEL INJECTOR INSTALLATION E • Apply thin coat of the engine oil to new injector cushion seal and O-rings. L • Install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. (5-20) P M A S
5-24 FUEL SYSTEM AND THROTTLE BODY FAST IDLE The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed. Ambient Temp. Fast idle rpm Fast idle cancel- ling time –5 °C (23 °F) 1 400 – 2 000 r/min Approx. 60 sec. 15 °C (59 °F) 1 400 – 2 000 r/min Approx. 20 sec. 25 °C (77 °F) 1 400 – 2 000 r/min Approx. 10 sec. FAST IDLE ADJUSTMENT • Lift and support the fuel tank. (5-3) • Start up the engine and run it in idling condition for warming up at the water temperature of 80 – 90 °C (176 – 194 °F). • Set the idle rpm to 1 150 r/min by the throttle stop screw 1. E • Check and adjust the TP sensor. (4-20) PL • Turn the ignition switch OFF. M • Disconnect the TP sensor coupler 2 and install the test har- ness. SA V • Start up the engine. • Measure the TP sensor output voltage at the wire terminals (between + terminal Red and - terminal Black). TP sensor output voltage at idle position: Approx. 1.125 V 09900-28630: TPS test wire harness 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () • Turn the ignition switch OFF. • Remove the air cleaner box cover (2-4) and disconnect the STVA coupler. (5-14) • Turn the ignition switch ON. • Open the secondary throttle valve fully by turning it with your finger. • With the secondary throttle valve held at this position, mea- sure the output voltage of the TP sensor as shown.
FUEL SYSTEM AND THROTTLE BODY 5-25 • Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened. Example:TP sensor output voltage with the STV fully open Minus TP sensor output voltage at idle is 0.027 V STV fully open 1.152 V Idle - 1.125 V 0.027 V TP sensor output voltage variation: 0.021 – 0.032 V • If the voltage variation is out of specification, turn in or out the fast idle adjust screw 3 to adjust the voltage to specification. The fast idle screw is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary. • Cool down the engine to ambient air temperature and start the engine to check the fast idle rpm comes with in the specified rpm. E Standard L Fast idle rpm: 1 400 – 2 000 r/min (Cold engine) P Idle rpm : 1 150 ± 100 r/min (Warmed engine) • If it is not at the specified rpm, the cause may possibly be M short-circuit in water temperature sensor or wiring harness or STVA. A S
5-26 FUEL SYSTEM AND THROTTLE BODY THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. USE OF DIGITAL VACUUM TESTER Step 1 • Lift and support the fuel tank. (5-3) • Start up the engine and run it in idling condition for warming up. • Stop the warmed-up engine. • Disconnect the IAP sensor coupler 1 and remove the IAP sensor from the air cleaner box. • Disconnect the vacuum hose 2 from each throttle body. • Connect the vacuum tester hose 3 to each vacuum nipple on E the throttle body. L P M A S Step 2 • Remove the air cleaner box. (5-13) • Connect a tachometer and start up the engine. • Bring the engine rpm to 1 150 r/min by the throttle stop screw. • Check the vacuum of the four cylinders and balance the four throttle valves with the balance screw 4. Avoid dirt drawn into the throttle body while running the engine without air cleaner box cover. Dirt drawn into the engine will damage the internal engine parts. NOTE: * During balancing the throttle valves, always set the engine rpm at 1 150 r/min, using throttle stop screw. * After balancing the four valves, set the idle rpm to 1 150 r/min by the throttle stop screw. * If the above procedures cannot still synchronize the valves, proceed to the next step.
FUEL SYSTEM AND THROTTLE BODY 5-27 Step 3 • Turn in all the idle air screws to the complete close position. • Check for difference of vacuum between #1 and #2. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower. Similarly perform the same procedures between #3 and #4. • Check for the synchronization adjustment. If the adjustment is not yet correct, remove each idle air screw and clean them with a spray-type carburetor cleaner and blow dry with a com- pressed air. • Also, clean the idle air screw passageways. NOTE: * Slowly turn the idle air screw in clockwise and count the num- ber of turns until the screw is lightly seated. * Make a note of how many turns were made so the screw can be reset correctly after cleaning. Step 4 Repeat the procedures of Step 2 and Step 3. E USE OF VACUUM BALANCER GAUGE L Calibrating each vacuum gauge P • Lift and support the fuel tank. (5-3) • Start up the engine and run it in idling condition for warming up. M • Stop the warmed-up engine. A • Disconnect the IAP sensor coupler and remove the IAP sen- sor. (5-14) S • Disconnect the vacuum hose 1 from the #1 throttle body. • Connect one of the vacuum balancer gauge hose 2 to the vacuum nipple on the #1 throttle body.
5-28 FUEL SYSTEM AND THROTTLE BODY • Connect a tachometer. • Start up the engine and keep it running at 1 150 r/min by turn- ing throttle stop screw 3. Avoid dirt drown into the throttle body while running the engine without air cleaner box. Dirt drawn into the engine will damage the internal engine parts. • Turn the air screw 4 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 5 in the tube to the center line 6. NOTE: The vacuum gauge is positioned approx. 30° from the horizontal level. • After making sure that the steel ball stays steady at the center E line, disconnect the hose from the #1 throttle body vacuum nipple and connect the next hose to this vacuum nipple. L • Turn air screw to bring the other steel ball 7 to the center line. P • Repeat the above process on the third and fourth hoses. M The balancer gauge is now ready for use in balancing the throt- tle valves. SA Throttle valve synchronization Using the vacuum balancer gauge, inspect the throttle valve synchronization in the same manner as the digital vacuum tester. Pay attention to the following points: The vacuum gauge is positioned approx. 30° from the horizontal level, and in this position the four balls should be within one ball 30˚ dia. If the difference is larger than one ball, turn the balance adjusting screw on the throttle body and bring the ball to the same level. A correctly adjusted throttle valve synchronization has the balls in the #1 through #4 at the same level. 09913-13121: Vacuum balancer gauge NOTE: * During balancing the throttle valves, always set the engine rpm at 1 150 r/min, using throttle stop screw. * After balancing the four valves, set the idle rpm to 1 150 r/min by the throttle stop screw.
FUEL SYSTEM AND THROTTLE BODY 5-29 THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS setting condition. (Refer to page 4-20 for TPS setting procedure.) E L P M A S
EXHAUST SYSTEM 6-1 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM...................................................................................... 6- 2 EXHAUST CONTROL SYSTEM............................................................ 6- 2 OPERATION........................................................................................... 6- 3 EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)......................................................... 6- 4 EXCVA REMOVAL................................................................................. 6- 4 EXCVA INSTALLATION........................................................................ 6- 6 EXCVA INSPECTION............................................................................. 6- 8 4 EXCV CABLE REPLACEMENT............................................................. 6- 8 EXCVA ADJUSTMENT.......................................................................... 6-10 EXCV/MUFFLER REMOVAL................................................................. 6-13 EXCV INSPECTION............................................................................... 6-14 EXCV/MUFFLER INSTALLATION......................................................... 6-14 EXHAUST PIPE REMOVAL................................................................... 6-15 6 EXHAUST PIPE INSTALLATION.......................................................... 6-15 PLE SAM
6-2 EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exhaust control system (EXCS) consists of the exhaust control valve (EXCV), exhaust control valve actuator (EXCVA) and exhaust control valve cables (EXCV cables). EXCV is installed between the exhaust pipes and muffler. EXCVA is mounted on the right side of the seat rail. The EXCV is operated by the EXCVA via the cables. This system is designed to improve the engine torque at low engine rpm. E L P M A S 1 Exhaust control valve actuator (EXCVA) 2 Exhaust control valve (EXCV)
EXHAUST SYSTEM 6-3 OPERATION The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then the ECM determines the EXCV opening angle based on the engine rpm and gear positions. Every time the ignition switch is turned ON, the EXCVA automatically drives the EXCV and detects full close/open position voltages and sets the EXCV to middle position. FULL OPEN E PL FULL CLOSE AM S
6-4 EXHAUST SYSTEM EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA REMOVAL • Turn the ignition switch OFF. • Remove the front seat. • Lift and support the fuel tank. (5-3) • Connect the special tool (Mode select switch) to the dealer mode coupler. (4-18) • After turning the special tool’s switch ON, turn the ignition switch ON. 09930-82720: Mode select switch • Check the cable slots A of the EXCVA pulley face upward (adjustment position) as shown. • Turn the ignition switch OFF. Before removing the EXCVA, be sure to set the EXCVA pulley to the adjustment position. E • Disconnect the EXCVA lead wire couplers 1. L P M A S • Remove the EXCVA mounting bolts.
EXHAUST SYSTEM 6-5 • Remove the brake fluid reservoir tank mounting bolt 2 and front footrest bracket mounting bolts 3. • Move the front footrest assembly. • Hold the EXCVA pulley with an adjustable wrench, and loosen the pulley mounting bolt. * When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged. * Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA. E • Disconnect the No. 2 cable 4 and then No. 1 cable 5 from the pulley. L • Remove the EXCVA. P M A S
6-6 EXHAUST SYSTEM EXCVA INSTALLATION • Make the No. 1 cable straight and turn the No. 1 cable adjuster 1 in or out until the inner cable length A becomes 40 – 41 mm (1.57 – 1.61 in). • After adjusting the inner cable length A, tighten the lock-nut 2. No. 1 cable: 41G0CL • Make the No.2 cable straight and turn in the cable adjuster 3 fully. No. 2 cable: 41G0OL • Connect the No. 1 cable 4 (41G0CL) and No. 2 cable 5 E (41G0OP) to the EXCVA pulley. L P M A S • Check the EXCVA to adjustment position. (6-4) Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA. • Install the pulley 6 to the shaft 7. NOTE: Make sure that the shaft’s line B and cable slots C facing upward as shown.
EXHAUST SYSTEM 6-7 • Hold the pulley with an adjustable wrench, and then tighten the pulley mounting bolt to the specified torque. EXCVA pulley mounting bolt: 5 N·m (0.5 kgf-m, 3.5 lb-ft) When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged. • After connecting the No. 2 cable 8, loosen the lock-nut 9 and turn the adjuster 0 in or out until 16.0 mm (0.63 in) and more of the thread length D on the cable adjuster can be pro- vided and tighten the lock-nut 9. No. 2 cable: 41G0OP • Tighten the EXCVA mounting bolt to the specified torque. E EXCVA mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) L P M A S The cable slots of EXCVA pulley must be located upward (adjustment position). (6-4) • Install the front footrest assembly. Front footrest bracket mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
6-8 EXHAUST SYSTEM EXCVA INSPECTION 4-82 EXCV CABLE REPLACEMENT • Disconnect the EXCV cables from the EXCVA pulley. (6-4 to -5) • Remove the cable guide. • Disconnect the EXCV cables from the EXCV pulley. (6-14) NOTE: The EXCV cables are identified by the plated chrome color and 41G0OP shape. No. 1 cable 1: 41G0CL No. 2 cable 2: 41G0OP 41G0CL • Connect the EXCV cables (No. 1 and No. 2) temporarily to the E EXCVA pulley. L • Check or adjust the clearance A becomes the adjuster end and EXCVA pulley to provide 3.0 mm (0.12 in) and more. P • Install the muffler body. (6-14) AM S • Make the No. 1 cable straight and turn the No. 1 cable adjuster 3 in or out until the inner cable length B becomes 40 – 41 mm (1.57 – 1.61 in). • After adjusting the inner cable length B, tighten the lock-nut 4. No. 1 cable: 41G0CL
EXHAUST SYSTEM 6-9 • Make the No. 2 cable straight and turn in the cable adjuster 5 fully. • Loosen the lock-nuts 6 and turn the No.2 cable adjuster 7 in or out until the inner cable length C becomes 62 – 63 mm (2.44 – 2.48 in). • After adjusting the inner cable length C, tighten the lock-nuts 6. • Connect the No. 1 cable and No. 2 cable to the EXCVA pul- E ley. (6-6) L • Check the EXCVA to adjustment position. (6-4) P Do not use the adjustable wrench to turn EXCVA pul- M ley so as not to cause damage to the internal gear of EXCVA. A • Install the pulley 8 to the shaft 9. S NOTE: Make sure that the shaft’s line D and cable slots E facing upward as shown. • Hold the EXCVA pulley with an adjustable wrench, and then tighten the pulley mounting bolt to the specified torque. EXCVA pulley mounting bolt: 5 N·m (0.5 kgf-m, 3.5 lb-ft) When loosening or tightening the pulley bolt, be sure to fix the pulley with an adjustable wrench, or EXCVA may get damaged.
6-10 EXHAUST SYSTEM • After connecting the No. 2 cable 0, loosen the lock-nut A and turn the adjuster B in or out until 16 – 17 mm (0.63 – 0.67 in) of the thread length F on the cable adjuster cam be pro- vided and tighten the lock-nut A. • Install the EXCVA. (6-6 to -7) The cable slots of the EXCVA pulley must be located upward (adjustment position). (6-4) EXCVA ADJUSTMENT E 1st step: L • Set the EXCVA to adjustment position. (6-4) P M A S • Make sure that the No. 2 cable and No. 1 cable are fixed into the clamp.
EXHAUST SYSTEM 6-11 2nd step: • Turn the mode select switch OFF. • Turn the ignition switch ON to check the EXCVA operation. • Turn the mode select switch ON. • If C46 is not indicated on the LCD (DISPLAY), the adjustment is correctly completed. In this case, it is unnecessary to pro- ON OFF ceed to 3rd step. • If C46 is indicated, repeat the adjustment procedure from 3rd and 4th step. 3rd step: E • This procedure is only required when C46 is indicated. • Turn the ignition switch OFF. L • Insert the two copper wires into the back side of the position sensor lead wire coupler 1. P • Disconnect the EXCVA motor lead wire coupler 2. SAM • To set the EXCV to fully close position, apply 12 volts to A and B terminals. Positive wire –– A (Pink wire) terminal Negative wire –– B (Gray wire) terminal To prevent the motor damage, stop applying 12 V as 12 V soon as the EXCV reaches fully close position.
6-12 EXHAUST SYSTEM • Turn the ignition switch ON. • Measure the position sensor output voltage at fully close posi- V tion. Position sensor output voltage EXCV is fully close: 0.5 output voltage 1.3 V (+ Yellow – - B/Br) 09900-25008: Multi circuit tester set 09900-25009: Needle pointed probe set Tester knob indication: Voltage () If the measured voltage is less than specification, adjust the No.1 cable adjuster as follows: • Set the EXCVA to adjustment position. (6-4) Adjusting the No. 1 cable with the EXCV fully closed can damage the EXCVA. Be sure to adjust the No.1 cable with the EXCV set in adjustment position. • Turn out the No. 1 cable adjuster 3. • Repeat the above procedure until the output voltage becomes E specified value. L Position sensor output voltage EXCV is fully close: 0.5 output voltage 1.3 V P • To next step. M NOTE: If C46 code is indicated after adjusting the voltage, increase the voltage to 0.9 V. SA 4th step: To set the EXCV to fully open position, apply 12 volts to A and B terminals. Positive wire –– B (Gray wire) terminal Negative wire –– A (Pink wire) terminal 12 V To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully open position. Measure the position sensor output voltage at fully open posi- tion. V Position sensor output voltage EXCV is fully open: 3.7 output voltage 4.5 V (+ Yellow – - B/Br)
EXHAUST SYSTEM 6-13 If the measured voltage is more than specification, adjust the No.2 cable adjuster as follows: • Set the EXCVA to adjustment position. (6-4) Adjusting the No. 2 cable with the EXCV fully opened can damage the EXCVA. Be sure to adjust the No. 2 cable with the EXCV set in adjustment position. • Turn out the No. 2 cable adjuster 1. • Repeat the above procedure until the output voltage comes within the specified value. Position sensor output voltage EXCV is fully open: 3.7 output voltage 4.5 V • After adjusting the EXCV cables, perform 2nd step to confirm C46 is not indicated. EXCV/MUFFLER REMOVAL • Disconnect the two cables from the EXCVA pulley. (Refer to E the EXCVA REMOVAL procedures.) (6-4 to -5) • Remove the right under cowling. (8-5) L • Move the front footrest assembly. (8-5) P • Remove the cable guide. M A • Loosen the connector bolt 1. S • Remove the muffler mounting bolts 2. • Remove the muffler body 3.
6-14 EXHAUST SYSTEM • Remove the EXCV cover 3 and disconnect the two cables from the EXCV pulley. EXCV INSPECTION • Turn the EXCV by hand and check that it moves smoothly. • If it does not move smoothly, replace the EXCV together with the muffler body. • Decarbonize the EXCV if necessary. * Do not attempt to disassemble the EXCV. * The EXCV is available only as the muffler body assembly. E EXCV/MUFFLER INSTALLATION L • Connect the EXCV cables temporarily to the EXCV pulley.P • Adjust the clearance A between the adjuster end and EXCV pulley to provide 3 mm (0.12 in) and more. M • Adjust the inner cable length of the No.2 cable. (6-9) • Install the EXCV cover. A S • Install the muffler body 1. Exhaust pipe connector bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
EXHAUST SYSTEM 6-15 • Install the cable guide. • Install the front footrest assembly. (6-7) • Install the EXCVA. (Refer to the EXCVA INSTALLATION pro- cedures.) (6-6 to -7) EXHAUST PIPE REMOVAL 3-5 EXHAUST PIPE INSTALLATION 3-14 E L P M A S
6-16 EXHAUST SYSTEM * When adjusting the No. 1 and No. 2 cables, the cable slots of EXCVA pulley must be located to adjustment position. * Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA. 5 N·m (0.5 kgf-m, 3.5 lb-ft) No. 1 23 N·m (2.3 kgf-m, 16.5 lb-ft) No. 2 16 – 17 mm (0.63 – 0.67 in) E 23 N·m (2.3 kgf-m, 16.5 lb-ft) PL Replace the gaskets with M the new ones. SA 40 – 41 mm 62 – 63 mm (1.57 – 1.61 in) (2.44 – 2.48 in) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m No. 1 No. 2 (2.3 kgf-m,16.5 lb-ft) 3 mm (0.12 in) Replace the exhaust pipe connector with 3 mm (0.12 in) a new one.
COOLING AND LUBRICATION SYSTEM 7-1 COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT...................................................................................... 7- 2 COOLING CIRCUIT...................................................................................... 7- 3 COOLING CIRCUIT INSPECTION......................................................... 7- 3 RADIATOR AND WATER HOSES............................................................... 7- 4 RADIATOR REMOVAL.......................................................................... 7- 4 RADIATOR CAP INSPECTION.............................................................. 7- 4 RADIATOR INSPECTION AND CLEANING.......................................... 7- 4 RADIATOR INSTALLATION.................................................................. 7- 5 WATER HOSE INSPECTION................................................................. 7- 5 COOLING FAN.............................................................................................. 7- 6 REMOVAL.............................................................................................. 7- 6 INSPECTION.......................................................................................... 7- 6 INSTALLATION...................................................................................... 7- 6 COOLING FAN RELAY INSPECTION................................................... 7- 7 ECT SENSOR............................................................................................... 7- 7 E REMOVAL.............................................................................................. 7- 7 L INSPECTION.......................................................................................... 7- 7 7 P INSTALLATION...................................................................................... 7- 8 THERMOSTAT.............................................................................................. 7- 9 M REMOVAL.............................................................................................. 7- 9 INSPECTION.......................................................................................... 7- 9 A INSTALLATION...................................................................................... 7-10 WATER PUMP.............................................................................................. 7-11 S REMOVAL AND DISASSEMBLY.......................................................... 7-11 INSPECTION.......................................................................................... 7-13 REASSEMBLY AND INSTALLATION................................................... 7-14 LUBRICATION SYSTEM.............................................................................. 7-17 OIL PRESSURE..................................................................................... 7-17 OIL FILTER............................................................................................. 7-17 OIL PRESSURE REGULATOR.............................................................. 7-17 OIL STRAINER....................................................................................... 7-17 OIL JET................................................................................................... 7-17 OIL PUMP............................................................................................... 7-17 OIL PRESSURE SWITCH...................................................................... 7-17 OIL COOLER.......................................................................................... 7-17 ENGINE LUBRICATION SYSTEM CHART........................................... 7-19 ENGINE LUBRICATION SYSTEM......................................................... 7-20
7-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F). If the motorcycle is to be exposed to temperatures below –31 °C (–24 °F), this mixing ratio should be increased up to 55% or 60% according to the figure. Anti-freeze density Freezing point 50% –30 °C (–24 °F) 55% –40 °C (–44 °F) 60% –55 °C (–67 °F) * Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. * Do not put in 60% and more anti-freeze or 50% and less. (Refer to below figure.) * Do not use a radiator anti-leak additive. 50% Engine coolant including reserve tank capacity Anti-freeze 1 200 ml (3.1/2.6 US/lmp.pt) E Water 1 200 ml (3.1/2.6 US/lmp.pt) L (˚F) (˚C) P 32 0 14 –10 (˚F) (˚C) (kgf/cm²) M150 –4 –20 302 –30 A 284140 1.5 –22 –40 –40 S 266 130 0.9 reezing point 248 120 0.5 F –58 –50 Boiling point –76 –60 230 110 0 Gauge pressure –94 –70 212 100 20 40 60 80 100 0 10 20 30 40 50 60 Density (%) Density (%) Fig. 1 Engine coolant density-freezing Fig. 2 Engine coolant density-boiling point curve point curve * You can be injured by scalding 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. * The engine must be cool before servicing the cooling system. * Coolant is harmful; • If it comes in contact with skin or eyes, flush with water. • If swallowed accidentally, induce vomiting and call physician immediately. • Keep it away from children.
COOLING AND LUBRICATION SYSTEM 7-3 COOLING CIRCUIT RESERVOIR THERMOSTAT ENGINE COOLANT TANK CYLINDER HEAD TEMPERATURE SENSOR CYLINDER RADIATOR WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, E inspect the cooling circuit for tightness. • Remove the under cowlings. (8-5) L • Remove the radiator cap 1 and connect the tester 2 to the filler. P M Do not remove the radiator cap when the engine is hot. A S • Give a pressure of about 120 kPa (1.2 kgf/cm², 17 psi) and see if the system holds this pressure for 10 seconds. • If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the entire system and replace the leaking com- ponent or part. When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. Do not allow the pressure to exceed the radiator cap release pressure, or the radiator can be damaged.
7-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowlings. (8-5) • Drain the engine coolant. (2-17) • Remove the radiator assembly. (3-5) • Remove the reservoir tank 1, cooling fan 2 and bracket 3 from the radiator. E RADIATOR CAP INSPECTION L • Fit the cap 1 to the radiator cap tester 2. P • Build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 93 – 123 kPa (0.93 – 1.23 M 2 kgf/cm , 13.2 – 17.5 psi) and that, with the tester held stand- still, the cap is capable of holding that pressure for at least 10 A seconds. S • Replace the cap if it is found not to satisfy either of these two requirements. Radiator cap valve opening pressure Standard: 93 – 123 kPa 2 (0.93 – 1.23 kgf/cm , 13.2 – 17.5 psi) RADIATOR INSPECTION AND CLEANING • Road dirt or trash stuck on the fins must be removed. • Use of compressed air is recommended for this cleaning.
COOLING AND LUBRICATION SYSTEM 7-5 • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. RADIATOR INSTALLATION • Install the radiator. • Route the radiator hoses. (10-24) • Pour engine coolant. (2-17) • Bleed air from the cooling circuit. (2-18) • Install the under cowlings. (8-6) WATER HOSE INSPECTION • Remove the under cowlings. (8-5) E • Lift and support the fuel tank. (5-3) L • Any water hose found in a cracked condition or flattened must be replaced. P • Any leakage from the connecting section should be corrected by proper tightening. M A S
7-6 COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the under cowlings. (8-5) • Drain the engine coolant. (2-17) • Remove the radiator assembly. (3-5) • Remove the cooling fan 1. INSPECTION • Remove the under cowlings. (8-5) • Disconnect the cooling fan coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. E • The voltmeter is for making sure that the battery 2 applies 12 L volts to the cooling fan motor 3. With the cooling fan motor P with electric motor fan running at full speed, the ammeter 4 should be indicating not 5 amperes and more. M • If the fan motor does not turn, replace the motor assembly with a new one. A NOTE: S When making above test, it is not necessary to remove the cool- ing fan. INSTALLATION • Install the cooling fan 1. • Tighten the cooling fan mounting bolts to the specified torque. Cooling fan mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) • Install the radiator assembly. • Route the radiator hoses. (10-24) • Pour engine coolant. (2-17) • Bleed the air from the cooling circuit. (2-18) • Install the under cowlings. (8-6)
COOLING AND LUBRICATION SYSTEM 7-7 COOLING FAN RELAY INSPECTION Cooling fan relay is located in rear of the battery. • Remove the front seat. (8-7) • Remove the cooling fan relay 1. First check the insulation between A and B terminals with tester. Then apply 12 volts to C and D terminals, + to C and - to D, and check the continuity between A and B. If there is no continuity, replace it with a new one. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test () E ECT SENSOR L REMOVAL P • Keep the motorcycle upright. M • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) A • Disconnect the ECT sensor coupler 1. • Place a rag under the ECT sensor and remove the ECT sen- sor. S INSPECTION • Check the ECT sensor by testing it at the bench as shown in the figure. Connect the ECT sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove. • Heat the oil to raise its temperature slowly and read the col- umn thermometer 3 and the ohmmeter.
7-8 COOLING AND LUBRICATION SYSTEM • If the ECT sensor ohmic value does not change in the propor- tion indicated, replace it with a new one. Temperature sensor specification Temperature Standard resistance 20 °C (68 °F) Approx. 2.45 kΩ 50 °C (122 °F) Approx. 0.811 kΩ 80 °C (176 °F) Approx. 0.318 kΩ 110 °C (230 °F) Approx. 0.142 kΩ Cooling fan operating temperature: Standard (OFF→ON): Approx. 105 °C (221 °F) (ON→OFF): Approx. 100 °C (212 °F) NOTE: As coolant temperature rises, the cooling fan operates for 5 sec- onds when the temperature arrives each at 50 °C (122 °F), 70 °C (158 °F) and 90 °C (194 °F)/above 4 000 r/min. If the resistance is noted to show infinity or too much different resistance value, replace the ECT sensor with a new one. E * Take special care when handling the ECT sensor. It may cause damage if it gets a sharp impact. L * Do not contact the ECT sensor and the column ther-P mometer with a pan. M INSTALLATION A • Tighten the ECT sensor to the specified torque. S ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) Take special care when handling the ECT sensor. It may cause damage if it gets a sharp impact. • Install the fuel tank. (5-4) • Install the front seat. • Pour engine coolant. (2-17)
COOLING AND LUBRICATION SYSTEM 7-9 THERMOSTAT REMOVAL • Remove the front seat. (8-7) • Lift and support the fuel tank. (5-3) • Place a rag under the thermostat cover. • Remove the thermostat cover 1. • Remove the thermostat 2. E INSPECTION L Inspect the thermostat pellet for signs of cracking. P Test the thermostat at the bench for control action, in the follow- ing manner. M • Pass a string 1 between flange 2 of thermostat, as shown. • Immerse the thermostat in the water contained in a beaker, as A shown in the illustration. Note that the immersed thermostat is S in suspension. Heat the water 3 by placing the beaker on a stove 4 and observe the rising temperature on a thermome- ter 5. • Read the thermometer just when opening the thermostat. This reading, which is the temperature level at which the thermo- stat valve begins to open, should satisfy the standard value. Thermostat valve opening temperature Standard: Approx. 82 °C (180 °F)
7-10 COOLING AND LUBRICATION SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in). Thermostat valve lift A Standard: 8.0 mm and over at 95 °C (0.31 in and over at 203 °F) • A thermostat failing to satisfy either of the two requirements (start-to-open temperature and valve lift) must be replaced. INSTALLATION • Install the thermostat. NOTE: The jiggle valve A of the thermostat faces upside. • Install the thermostat cover 1. E • Tighten the thermostat cover bolts to the specified torque. L Thermostat cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) P M A S • Install the fuel tank. (5-4) • Install the front seat. • Pour engine coolant. (2-17)
COOLING AND LUBRICATION SYSTEM 7-11 WATER PUMP REMOVAL AND DISASSEMBLY NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer. (7-13) • Remove the under cowlings. (8-5) • Drain the engine coolant. (2-17) • Drain the engine oil. (2-12) • Remove the gearshift lever 1. • Remove the engine sprocket cover 2. E • Disconnect the water hoses. PL SAM • Release the gear position switch lead wire from the clamp 3. • Remove the water pump 4.
7-12 COOLING AND LUBRICATION SYSTEM • Remove the water pump cover 5 and clamp 6. • Remove the impeller securing bolt by holding the impeller with a water pump pliers. • Remove the mechanical seal ring 7 and rubber seal 8 from E the impeller. L P M A S • Remove the impeller shaft 9 and washer 0. • Remove the mechanical seal with the special tool. 09921-20240: Bearing remover set (12 mm) NOTE: If there is no abnormal condition, the mechanical seal removal is not necessary. The removed mechanical seal must be replaced with a new one.
COOLING AND LUBRICATION SYSTEM 7-13 • Remove the oil seal using a suitable bar. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. The removed oil seal must be replaced with a new one. INSPECTION MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. • Replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. OIL SEAL E • Visually inspect the oil seal for damage, with particular atten- tion given to the lip. L • Replace the oil seal that shows indications of leakage. P M A S IMPELLER SHAFT JOURNAL • Visually inspect the journal for damage or scratch. • Replace the water pump body if necessary. SEAL WASHER • Visually inspect the seal washer for damage, with particular attention given to the sealing face. • Replace the seal washer that shows indications of leakage.
7-14 COOLING AND LUBRICATION SYSTEM REASSEMBLY AND INSTALLATION • Install the oil seal with the special tool. 09913-70210: Bearing installer set (22) NOTE: The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the new mechanical seal using a suitable size socket E wrench. L P M A NOTE: S On the new mechanical seal, the sealer A has been applied. • Apply SUZUKI SUPER GREASE “A” to the impeller shaft. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the impeller shaft to the water pump body.
COOLING AND LUBRICATION SYSTEM 7-15 • Install the rubber seal 1 into the impeller. • After wiping off the oily or greasy matter from the mechanical seal ring, install it into the impeller. NOTE: The paint marked side B of mechanical seal ring faces the rub- ber seal. • Install the washer 2 and seal washer 3 onto the impeller securing bolt 4. NOTE: The metal side C of seal washer and the curved side D of washer face the impeller securing bolt head. • Install the impeller 5 and its securing bolt onto the shaft. E • Tighten the impeller securing bolt to the specified torque. L Impeller securing bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft) NOTE: P Before installing the impeller securing bolt, apply a small quan- tity of the THREAD LOCK to it. M 99000-32050: THREAD LOCK “1342” A S • Install the new O-rings 6 and 7. Use the new O-rings to prevent engine coolant leak- age. NOTE: * Apply engine coolant to the O-ring 6. * Apply SUZUKI SUPER GREASE “A” to the O-ring 7. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Tighten the water pump cover screws to the specified torque. Water pump cover screw: 5 N·m (0.5 kgf-m, 3.5 lb-ft) NOTE: Fit the clamp E to the water pump cover screw.
7-16 COOLING AND LUBRICATION SYSTEM • Install the water pump. NOTE: Set the water pump shaft end F to the oil pump shaft G as shown. 8 N·m (0.8 kgf-m, 6.0 lb-ft) E PL SAM • Tighten the water pump mounting bolts to the specified torque. Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) NOTE: Pass the gear position switch lead wire 8 under the water pump lib. • Connect the water hoses. (10-24) • Install the engine sprocket cover. • Install the gearshift lever. • Pour engine coolant. (2-17) • Pour engine oil. (2-12) • Install the under cowlings. (8-6)
COOLING AND LUBRICATION SYSTEM 7-17 LUBRICATION SYSTEM OIL PRESSURE 2-33 OIL FILTER 2-13 OIL PRESSURE REGULATOR 3-49 OIL STRAINER 3-49 OIL JET 3-60 OIL PUMP 3-46 OIL PRESSURE SWITCH E 9-34 L OIL COOLER P REMOVAL • Remove the under cowlings. (8-5) M • Drain the engine oil. (2-12) A • Remove the oil cooler. (3-4) S
7-18 COOLING AND LUBRICATION SYSTEM INSPECTION AND CLEANING • Road dirt or trash stuck to the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. INSTALLATION E • Install a new O-ring 1. L Use the new O-rings to prevent engine oil leakage. P NOTE: M Apply engine oil to the O-ring 1. A S • Tighten the oil cooler hose bolts to the specified torque. Oil cooler hose bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
COOLING AND LUBRICATION SYSTEM 7-19 ENGINE LUBRICATION SYSTEM CHART INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER OIL JET CAM CHAIN CAMSHAFT JOURNALS, TENSION ADJUSTER CAMFACES AND TAPPETS EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER CAMSHAFT JOURNALS, CAM DRIVE CHAIN CAMFACES AND TAPPETS BALANCER SHAFT STARTER CLUTCH BEARING SUB-GALLERY #1 PISTON COOLING #2 PISTON COOLING #3 PISTON COOLING #4 PISTON COOLING OIL JET OIL JET OIL JET OIL JET E #1 PISTON AND #2 PISTON AND #3 PISTON AND #4 PISTON AND L CYLINDER WALL CYLINDER WALL CYLINDER WALL CYLINDER WALL P #1 CRANK PIN #2 CRANK PIN #3 CRANK PIN #4 CRANK PIN BEARING BEARING BEARING BEARING AM ORIFICE #1 CRANKSHAFT #2 CRANKSHAFT #3 CRANKSHAFT #4 CRANKSHAFT #5 CRANKSHAFT JOURNAL BEARING JOURNAL BEARING JOURNAL BEARING JOURNAL BEARING JOURNAL BEARING S GENERATOR MAIN-GALLERY OIL PRESSURE OIL JET SWITCH (#14) OIL COOLER COUNTERSHAFT DRIVESHAFT ORIFICE LEFT-SIDE RIGHT-SIDE OIL FILTER BEARING BEARING CLUTCH PUSH PRIMARY DRIVEN PIECE GEAR BEARING COUNTERSHAFT DRIVESHAFT OIL PRESSUER OIL PUMP GEARS AND GEARS AND REGULATOR BUSHINGS BUSHINGS CLUTCH PLATES OIL STRAINER OIL PAN
7-20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM TTo sub-o sub-o sub- gallergallergalleryy E L MAIN GALLERY P M A S
COOLING AND LUBRICATION SYSTEM 7-21 E A PL SUB-GALLERY SAM VIEW OF A MAIN GALLERY To transmission
CHASSIS 8-1 CHASSIS CONTENTS EXTERIOR PARTS....................................................................................... 8- 3 FASTENER REMOVAL AND INSTALLATION......................................8- 3 SCREEN................................................................................................. 8- 5 BODY COWLING COVER AND LOWER BRACKET COVER..............8- 5 UNDER COWLING................................................................................. 8- 5 BODY COWLING................................................................................... 8- 6 AIR INTAKE PIPE.................................................................................. 8- 7 COWLING BRACE................................................................................. 8- 7 FRONT SEAT......................................................................................... 8- 7 FUEL TANK LOWER SIDE COVER...................................................... 8- 7 REAR SEAT AND SEAT TAIL COVER................................................. 8- 8 FRAME COVER...................................................................................... 8- 8 FRONT WHEEL............................................................................................ 8- 9 CONSTRUCTION................................................................................... 8- 9 REMOVAL.............................................................................................. 8-10 INSPECTION AND DISASSEMBLY...................................................... 8-11 REASSEMBLY AND INSTALLATION................................................... 8-13 E FRONT FORK............................................................................................... 8-17 CONSTRUCTION................................................................................... 8-17 L REMOVAL AND DISASSEMBLY.......................................................... 8-18 INSPECTION.......................................................................................... 8-21 P REASSEMBLY....................................................................................... 8-22 INSTALLATION...................................................................................... 8-26 M SUSPENSION SETTING........................................................................ 8-26 STEERING DAMPER.................................................................................... 8-28 8 A CONSTRUCTION................................................................................... 8-28 REMOVAL.............................................................................................. 8-29 S INSPECTION.......................................................................................... 8-29 INSTALLATION...................................................................................... 8-29 STEERING.................................................................................................... 8-30 CONSTRUCTION................................................................................... 8-30 REMOVAL.............................................................................................. 8-31 INSPECTION AND DISASSEMBLY...................................................... 8-32 REASSEMBLY....................................................................................... 8-33 INSTALLATION...................................................................................... 8-33 STEERING TENSION ADJUSTMENT................................................... 8-35 HANDLEBARS.............................................................................................. 8-36 CONSTRUCTION................................................................................... 8-36 REMOVAL.............................................................................................. 8-36 INSTALLATION...................................................................................... 8-37 REAR WHEEL............................................................................................... 8-40 CONSTRUCTION................................................................................... 8-40 REMOVAL.............................................................................................. 8-41 INSPECTION AND DISASSEMBLY...................................................... 8-42 REASSEMBLY AND INSTALLATION................................................... 8-44 REAR SHOCK ABSORBER......................................................................... 8-48 CONSTRUCTION................................................................................... 8-48 REMOVAL.............................................................................................. 8-49
8-2 CHASSIS CHASSIS CONTENTS INSPECTION.......................................................................................... 8-49 REAR SHOCK ABSORBER DISPOSAL............................................... 8-50 INSTALLATION...................................................................................... 8-51 SUSPENSION SETTING........................................................................ 8-51 REAR SUSPENSION.................................................................................... 8-52 CONSTRUCTION................................................................................... 8-52 REMOVAL.............................................................................................. 8-53 INSPECTION AND DISASSEMBLY...................................................... 8-55 REASSEMBLY....................................................................................... 8-58 INSTALLATION...................................................................................... 8-60 FINAL INSPECTION AND ADJUSTMENT............................................ 8-61 FRONT BRAKE............................................................................................. 8-62 CONSTRUCTION................................................................................... 8-62 BRAKE PAD REPLACEMENT.............................................................. 8-63 BRAKE FLUID REPLACEMENT........................................................... 8-64 CALIPER REMOVAL............................................................................. 8-65 CALIPER DISASSEMBLY..................................................................... 8-65 E CALIPER INSPECTION......................................................................... 8-66 CALIPER REASSEMBLY...................................................................... 8-66 L CALIPER INSTALLATION..................................................................... 8-67 BRAKE DISC INSPECTION................................................................... 8-68 P MASTER CYLINDER REMOVAL AND DISASSEMBLY.......................8-69 MASTER CYLINDER INSPECTION....................................................... 8-70 M MASTER CYLINDER REASSEMBLY.................................................... 8-71 MASTER CYLINDER INSTALLATION.................................................. 8-72 A REAR BRAKE............................................................................................... 8-73 CONSTRUCTION................................................................................... 8-73 S BRAKE PAD REPLACEMENT.............................................................. 8-74 BRAKE FLUID REPLACEMENT........................................................... 8-75 CALIPER REMOVAL............................................................................. 8-75 CALIPER DISASSEMBLY..................................................................... 8-76 CALIPER INSPECTION......................................................................... 8-76 CALIPER REASSEMBLY...................................................................... 8-77 CALIPER INSTALLATION..................................................................... 8-78 MASTER CYLINDER REMOVAL........................................................... 8-79 MASTER CYLINDER DISASSEMBLY................................................... 8-79 MASTER CYLINDER INSPECTION....................................................... 8-80 MASTER CYLINDER REASSEMBLY.................................................... 8-80 MASTER CYLINDER INSTALLATION.................................................. 8-81 TIRE AND WHEEL........................................................................................ 8-82 TIRE REMOVAL..................................................................................... 8-82 INSPECTION.......................................................................................... 8-82 VALVE INSPECTION............................................................................. 8-83 TIRE INSTALLATION............................................................................. 8-84 BALANCER WEIGHT INSTALLATION................................................. 8-85 DRIVE CHAIN............................................................................................... 8-86 DRIVE CHAIN CUTTING........................................................................ 8-86 DRIVE CHAIN CONNECTING................................................................ 8-87
CHASSIS 8-3 EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece 1. • Pull out the fastener a. Installation • Let the center piece stick out toward the head so that the pawls 2 close. • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. E • Push in the head of center piece until it becomes flush with the fastener outside face. PL SAM FASTENER (Type B) Removal • Pry up the head of fastener center piece 1 with a screw driver. • Pull out the fastener a.
8-4 CHASSIS Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. • Push in the head of center piece. E L P M A S
CHASSIS 8-5 SCREEN REMOVAL • Remove the screws. • Remove the combination meter 1. (9-29) • Disconnect the turnsignal lead wire couplers. • Remove the rear view mirrors/turn signals 2. • Remove the screen 3. INSTALLATION • Install the screen in the reverse order of removal. • Refer to the rear view mirrors/turn signals cable routing. (10-38) BODY COWLING COVER AND LOWER E BRACKET COVER L REMOVAL • Remove the body cowling cover 1 by removing the fasteners. P • Remove the lower bracket cover 2 by removing the bolts. INSTALLATION M • Install the body cowling cover and lower bracket cover in the reverse order of removal. A UNDER COWLINGS REMOVAL • Remove the body cowling cover. (Above) • Remove the fasteners. • Remove the fasteners 1 and screw 2.
8-6 CHASSIS • Remove the right under cowling. NOTE: “” indicates hook location. • Remove the left under cowling. NOTE: “” indicates hook location. INSTALLATION • Install the right and left under cowlings in the reverse order of removal. BODY COWLING E REMOVAL • Remove the screen. (8-5) L • Remove the right and left under cowlings. (8-5 to -6) P • Remove the screws. M A S • Disconnect the lead wire coupler 1 and remove wire clamp 2. • Remove the body cowling. INSTALLATION • Install the body cowling in the reverse order of removal.
CHASSIS 8-7 AIR INTAKE PIPE REMOVAL • Remove the body cowling. (8-6) • Remove the fasteners. • Remove the air intake pipes 1. INSTALLATION • Install the right and left air intake pipes in the reverse order of removal. COWLING BRACE REMOVAL • Remove the body cowling. (8-6) • Remove the cowling brace 1. INSTALLATION • Install the cowling brace in the reverse order of removal. • Tighten the cowling brace bolts. Cowling brace bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) FRONT SEAT E REMOVAL • Remove the front seat by removing the bolts. L INSTALLATION P • Install the front seat in the reverse order of removal. M A S FUEL TANK LOWER SIDE COVER REMOVAL • Remove the front seat. (Above) • Remove the right and left fuel tank lower side covers 1. INSTALLATION • Install the right and left fuel tank lower side covers in the reverse order of removal.
8-8 CHASSIS REAR SEAT AND SEAT TAIL COVER REMOVAL • Remove the rear seat (seat tail cover) with the ignition key. INSTALLATION • Hook the seat hook to the frame and push down the seat (seat tail cover) firmly until the seat (seat tail cover) snaps into the locked position. FRAME COVER REMOVAL • Remove the front and rear seats. (8-7 and -8) • Remove the bolts. • Disconnect the seat lock cable 1. • Disconnect the rear combination light lead wire coupler 2. • Remove the fasteners. E • Remove the frame cover. L NOTE: P “” indicates hook location. M INSTALLATION • Install the frame cover in the reverse order of removal. A S
CHASSIS 8-9 FRONT WHEEL CONSTRUCTION E L P M A S 1 Brake disc 6 Front axle 2 Collar 7 Front wheel ITEM N·m kgf-m lb-ft 3 Dust seal A Front axle bolt A 100 10.0 72.5 4 Bearing B Brake disc bolt B 23 23.0 16.5 5 Spacer
8-10 CHASSIS REMOVAL • Remove the brake calipers. Do not operate the brake lever while removing the cal- ipers. • Loosen two axle pinch bolts 1 on the right front fork leg. • Remove the front axle bolt 2. • Raise the front wheel off the ground and support the motorcy- E cle with a jack or a wooden block. L P Do not carry out the work with the motorcycle resting on the side-stand. Do not support the motorcycle with M the exhaust pipe. Make sure that the motorcycle is supported securely. A • Loosen two axle pinch bolts 3 on the left front fork leg. S • Draw out the front axle and remove the front wheel. NOTE: After removing the front wheel, fit the calipers temporarily to the original positions. • Remove the collar 4.
CHASSIS 8-11 INSPECTION AND DISASSEMBLY TIRE INSPECTION (8-82) • Remove the brake disc. BRAKE DISC INSPECTION (8-68) • Remove the dust seals on both sides with the special tool. 09913-50121: Oil seal remover The removed dust seals must be replaced with new ones. AXLE SHAFT E • Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit. L 09900-20607: Dial gauge (1/100) P 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) M Axle shaft runout: Service Limit: 0.25 mm (0.010 in) A WHEEL S • Make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel. Wheel runout: Service Limit (Axial and Radial): 2.0 mm (0.08 in) WHEEL BEARINGS • Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. • Replace the bearing in the following procedure if there is any- thing unusual.
8-12 CHASSIS • Remove the wheel bearings with the special tool. 09921-20240: Bearing remover set The removed bearings should be replaced with new ones. E L P M A S
CHASSIS 8-13 REASSEMBLY AND INSTALLATION Reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 100 N·m E (10.0 kgf-m, 72.5 lb-ft) PL SAM WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
8-14 CHASSIS • Install the wheel bearings with the special tools as follows. 09941-34513: Bearing/Steering race installer set 09924-84510: Bearing installer set First install the right wheel bearing, then install the spacer and left wheel bearing. The sealed cover of the bearing must face outside. Left Right Left Right E L P Clearance AM Spacer S • Install the dust seal with the special tool. 09913-70210: Bearing installer set (52 mm) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) BRAKE DISC • Make sure that the brake disc is clean and free of any greasy matter. • Apply THREAD LOCK to the disc mounting bolts and tighten them to the specified torque. Brake disc bolt (Front): 23 N·m (2.3 kgf-m, 16.5 lb-ft) 99000-32130: THREAD LOCK SUPER “1360”
CHASSIS 8-15 • Install the collar 1 in the right side. WHEEL • Install the front wheel with the front axle and hand-tighten the front axle bolt temporarily. The directional arrow on the tire should point to the wheel rotation, when remounting the wheel. BRAKE CALIPER E • Tighten the brake caliper mounting bolts to the specified torque. L Front brake caliper mounting bolt: P 39 N·m (3.9 kgf-m, 28.0 lb-ft) M A FRONT AXLE S • Hold the front axle with the special tool and tighten the front axle bolt 1 to the specified torque. 09900-18740: Heaxagon socket (24 mm) Front axle bolt: 100 N·m (10.0 kgf-m, 72.5 lb-ft) • Tighten two axle pinch bolts 2 on the right fork leg to the specified torque. Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Move the front fork up and down 4 or 5 times.
8-16 CHASSIS • Tighten two axle pinch bolts on the left front fork leg to the specified torque. Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) E L P M A S
CHASSIS 8-17 FRONT FORK CONSTRUCTION E L P M A S (USA) (Others) 1 O-ring 0 Oil seal 2 Spring retainer A Oil seal stopper ring 3 Spacer B Dust seal 4 Washer C Inner tube 5 Spring A Front fork cap bolt ITEM N·m kgf-m lb-ft 6 Adjuster rod B Lock-nut A 23 2.3 16.5 7 Inner rod/Damper rod (cartridge) C Front axle pinch bolt B 29 2.9 21.0 8 Outer tube D Damper rod bolt C 23 2.3 16.5 9 Oil seal retainer D 23 2.3 16.5
8-18 CHASSIS REMOVAL AND DISASSEMBLY • Remove the front wheel. (8-10) • Disconnect the brake hose from the brake hose guides on the front fender. • Remove the front fender. • Loosen the front fork upper clamp bolts 1, left and right. E • Loosen the handlebar clamp bolts 2, left and right. L NOTE: * Slightly loosen the front fork cap bolts 3 before loosening the lower clamp bolts to facilitate later disassembly. P * Be sure to adjust the rebound damping force adjuster 4 to the softest position before removing the front fork. M SA • Loosen the front fork lower clamp bolts, left and right. • Remove the front forks, left and right. NOTE: Hold the front fork by the hand to prevent sliding out of the steer- ing stem. • Separate the front fork cap bolt from the front fork. • Compress the front fork spring with the special tool A and insert the special tool B between the lock-nut and the spring retainer. 09940-94930: Front fork spacer holder A 09940-94922: Stopper plate B
CHASSIS 8-19 • Remove the front fork cap bolt from the inner rod by loosening the lock nut. • Compress the fork spring with the special tool and remove the special tool. • Remove the front fork cap bolt 5, adjuster rod 6, spring retainer 7, spacer 8, washer 9 and spring 0. * Do not disassemble the front fork cap bolt 5. * After removing the front fork cap bolt 5, avoid hold- ing the outer tube vertically by hand to prevent the inner tube from falling and damaged. • Invert the front fork and stroke the inner rod several times to E let out fork oil. L • Under the inverted condition of front fork, drain oil completely by holding the fork for a while. P M A S • Remove the front axle pinch bolt A. • Remove the damper rod bolt with the special tool. 09940-30221: Front fork assembling tool
8-20 CHASSIS • Remove the inner rod/damper rod (cartridge) B. Do not disassemble the inner rod/damper rod (car- tridge). • Slide the outer tube to remove it from the inner tube. NOTE: Be careful not to damage the “ANTI-FRICTION” metals. • Remove the dust seal C and oil seal stopper ring D. E L P M A S • Remove the oil seal with the special tool. 09913-50121: Oil seal remover The removed oil seal must be replaced with a new one. • Remove the oil seal retainer E.
CHASSIS 8-21 INSPECTION INNER AND OUTER TUBES • Inspect the inner tube outer surface and outer tube inner sur- face for scratches. • Inspect the “ANTI-FRICTION” metal surfaces for scratches. • If any defects are found, replace them with the new ones. Do not remove the “ANTI-FRICTION” metals, A and B. FORK SPRING • Measure the fork spring free length. Upper side • If it is shorter than the service limit, replace it with a new one. Front fork spring free length: Service Limit: 225 mm (8.86 in) E Lower side DAMPER ROD • Move the inner rod by hand to examine it for smoothness. L • If any defects are found, replace inner rod/damper rod (car- tridge) with a new one. P SAM
8-22 CHASSIS REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. 1Dust seal 2Oil seal stopper ring 3Oil seal 4Oil seal retainer * When installing the oil seal to outer tube, be careful not to damage the oil seal lip. * Avoid using solvents for washing to prevent oil seal damage. * Apply fork oil to the Anti-friction metals and lip of the oil seal. * Make sure that the oil seal stopper ring has been fit- ted securely. E • Insert the inner tube into the outer tube and fit the oil seal and L dust seal with the special tool. 09940-52861: Front fork oil seal installer P NOTE: M Stamped mark on the oil seal should face outside. A S DAMPER ROD BOLT • Insert the inner rod/damper rod (cartridge) into the inner tube. • Apply THREAD LOCK to the damper rod bolt and tighten it to the specified torque with the special tool. 99000-32050: THREAD LOCK “1342” (USA) 99000-32110: THREAD LOCK SUPER “1322” (Others) Use a new damper rod bolt gasket 1 to prevent oil leakage.
CHASSIS 8-23 09940-30221: Front fork assembling tool Damper rod bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) FORK OIL • Place the front fork vertically without spring. • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube. Capacity (each leg): 510 ml (17.2/17.9 US/lmp oz) 99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent fork oil • Move the inner rod slowly with the special tool ten times and E more until no more bubbles come out from the oil. L 09940-50120: Inner rod holder NOTE: P Refill front fork oil up to the top of the outer tube so that bubbles are visible while bleeding air. M A S • Refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until no more bubbles come out from the oil. • Keep the front fork vertically and wait 5 – 6 minutes. NOTE: * Always keep oil level over the cartridge top end, or air may enter the cartridge during this procedure. * Take extreme care so as to pump out air completely. • Hold the front fork vertically and adjust fork oil level with the special tool. NOTE: When adjusting the fork oil level, compress the outer tube fully without the fork spring. Fork oil level: 101 mm (3.98 in) 09943-74111: Front fork oil level gauge
8-24 CHASSIS FRONT FORK INNER ROD LOCK NUT • Adjust the height H of the inner rod threads by turning the lock-nut 1 as shown in illustration. H: 11 mm (0.43 in) FORK SPRING • Install the fork spring as shown in the illustration. Upper side Lower side • Install the spring 1, washer 2, spacer 3 and spring retainer E 4. PL SAM FRONT FORK CAP BOLT • Pull up the inner rod with the special tool A. • Compress the spring with the special tool B and then insert the special tool C between the lock-nut and the spacer. 09940-50120: Inner rod holder A 09940-94930: Front fork spacer holder B 09940-94922: Stopper plate C
CHASSIS 8-25 • Make sure that the height H of the inner rod threads is as fol- lows. H: 11 mm (0.43 in) • Slowly turn the cap bolt completely by hand until the end of the cap bolt seats on the lock nut. • Apply fork oil to the O-ring. Make sure that the rebound damping force adjuster 1 to the softest position before installing the cap bolt. • Hold the cap bolt 2 and tighten the lock-nut 3 to the speci- fied torque. Inner rod lock-nut: 29 N·m (2.9 kgf-m, 21.0 lb-ft) • Remove the special tools. • Install the front fork cap bolt to the outer tube temporarily. E L P M A S
8-26 CHASSIS INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Set the upper surface of the outer tube height A at 4.0 mm (0.157 in) from the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts 1 to the specified torque. Front fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Tighten the front fork cap bolt 2 to the specified torque and recheck the front fork outer tube upper surface height A from the upper surface of the steering stem upper bracket. Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Position the handle bears on the upper bracket. (8-38) • Tighten the front fork upper clamp bolts 3 and handlebar E clamp bolts 4. L Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) P • Remount the front wheel. (8-15) M • Cable routing (10-21) • Front brake hose routing (10-25) A S SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT 1 0 There are five grooved lines on the side of the spring adjuster. 2 3 Position 0 provides the maximum spring pre-load and position 5 4.5 4 5 provides the minimum spring pre-load. STD position: 4 DAMPING FORCE ADJUSTMENT Compression damping force Fully turn the damping force adjuster 1 clockwise. It is at stiffest position and turn it out to standard setting position. (For E-02, 19): 6 clicks out from stiffest position (For E-03, 24, 28, 33): 14 clicks out from stiffest position
CHASSIS 8-27 Rebound damping force Fully turn the damping force adjuster 1 clockwise. It is at stiffest position and turn it out to standard setting position. (For E-02, 19): 11 clicks out from stiffest position (For E-03, 24, 28, 33): 9 clicks out from stiffest position NOTE: Make sure to check the 1st click position by the last click sound when turning in the adjuster. STANDARD FRONT SUSPENSION SETTING (For E-02, 19) FRONT Spring pre-load Damping force adjuster adjuster Compression Rebound Solo and 4 16 clicks out from 11 clicks out from dual riding stiffest position stiffest position (For E-03, 24, 28, 33) FRONT Spring pre-load Damping force adjuster E adjuster Compression Rebound L Solo and 4 14 clicks out from 9 clicks out from dual riding stiffest position stiffest position P M Be sure to adjust the spring pre-load and damping force on both front fork legs equally. A S
8-28 CHASSIS STEERING DAMPER CONSTRUCTION E L P M A S 1 Steering damper 4 Convex curve side of the washer 2 Dust seal faces down side. ITEM N·m kgf-m lb-ft 3 Steering stem head nut A Damper rod bolt AB 23 2.3 16.5 B Damper rod nut 3 90 9.0 65.0
CHASSIS 8-29 REMOVAL • Remove the lower bracket cover. (8-5) • Remove the nut 1 by holding the nut 2. • Remove the bolt 3 and remove the steering damper. INSPECTION • Inspect the steering damper body, bearing and oil seal for damage and oil leaking. • Move the steering damper rod by hand to inspect for a smooth movement. • If any defects are found, replace the steering damper with a new one. Do not remove the bolt A. E PL INSTALLATION Install the steering damper in the reverse order of removal. Pay attention to the following points: M • Apply SUZUKI SUPER GREASE “A” to the bearings and dust seals. SA 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the steering damper and tighten the bolt 1 and nut 2. Steering damper bolt and nut: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
8-30 CHASSIS STEERING CONSTRUCTION E L P M A S 1 Steering stem upper bracket 8 Steering stem lower bracket 2 Handlebars A Steering stem head nut ITEM N·m kgf-m lb-ft 3 Handlebar balancer B Steering stem lock-nut A 90 9.0 65.0 4 Steering stem nut C Front fork upper clamp bolt B 90 9.0 65.0 5 Dust seal cover D Handlebar clamp bolt C 23 2.3 16.5 6 Dust sea E Front fork lower clamp bolt D 23 2.3 16.5 7 Bearing E 23 2.3 16.5
CHASSIS 8-31 REMOVAL • Remove the under cowling. (8-5 to -6) • Support the motorcycle with a jack or a wooden block. Do not work by using side stand. Do not support the motorcycle with exhaust pipe. Make sure that the motorcycle is supported securely. • Remove the front wheel. (8-10) • Remove the front forks. (8-18) • Remove the steering damper. (8-29) • Remove the steering stem head nut and washer. • Remove the steering stem upper bracket. NOTE: It is not necessary to remove the ignition switch, when replacing only the steering stem lower bracket and bearings. (Ignition switch removal: 9-38) • Remove the brake hose clamp bolt. E L P M A • Remove the steering stem lock-nut, washer and steering stem S nut with the special tools. 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench socket • Draw out the steering stem lower bracket. NOTE: Hold the steering stem lower bracket by hand to prevent it from falling.
8-32 CHASSIS • Remove the dust seal cover 1, dust seal 2, steering stem upper bearing inner race 3 and bearing 4. INSPECTION AND DISASSEMBLY E Inspect the removed parts for the following abnormalities. L * Handlebars distortion * Race wear and brinelling P * Bearing wear or damage * Abnormal noise of bearing M If any abnormal points are found, replace defective parts with the new ones. A S • Remove the steering stem lower bearing inner race with a chisel. The removed bearing inner race must be replaced with a new one. • Drive out the steering stem bearing outer races (upper and lower) using the steel rod. The removed bearing outer race must be replaced with a new one.
CHASSIS 8-33 REASSEMBLY Reassemble the steering stem in the reverse order of disassem- bly. Pay attention to the following points: OUTER RACE • Press in the upper and lower bearing outer races with the special tools. 09941-34513: Steering outer race installer set 09913-70210: Bearing installer set (55) INNER RACE • Press in the lower bearing inner race with the special tool. 09925-18011: Steering bearing installer INSTALLATION E Install the steering stem in the reverse order of removal. Pay attention to the following points: L BEARING P • Apply SUZUKI SUPER GREASE “A” to the bearings and bearing races. M A 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) S • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race. STEM NUT • Install the dust seal and dust seal cover. • Tighten the steering stem nut to the specified torque with the special tools. 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench socket Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
8-34 CHASSIS • Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will be 1/4 – 1/2 turn seated properly. • Loosen the stem nut by 1/4 – 1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle. NOTE: When installing the washer, align the stopper lug to the groove of steering stem. • Install the steering stem lock-nut and tighten it to the specified E torque with the special tools. L 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench socket P Steering stem lock-nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft) SAM FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem upper bracket in the fol- lowing steps: 1) Install the upper bracket, washer 1 and steering stem head nut 2 temporarily. NOTE: Pay attention to the direction of the washer. 2) Position the handlebars on the front forks and tighten the steering stem head nut 2. Steering stem head nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft) 3) Tighten the front fork upper and lower clamp bolts. (8-26) • Install the steering damper. (8-29) • Install the front wheel. (8-15) • Cable routing (10-21)
CHASSIS 8-35 STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 – 30 mm (0.8 – 1.2 in). • Remove the steering damper. (8-29) • Check to make sure that the cables and wire harnesses are properly routed. • With the front wheel in the straight ahead state, hitch the spring scale (special tool) on one handlebar grip end as shown in the figure and read the graduation when the handle- bar starts moving. Do the same on the other grip end. Initial force: 200 – 500 grams 09940-92720: Spring scale • If the initial force read on the scale when the handlebar starts turning is either too heavy or too light, adjust it till it satisfies the specification. 1) First, loosen the front fork upper clamp bolts, handlebar clamp bolts, steering stem head nut and steering stem lock-nut, and then adjust the steering stem nut by loosening or tightening it. E 2) Tighten the steering stem lock-nut, stem head nut, handlebar L clamp bolts and front fork upper clamp bolts to the specified torque and re-check the initial force with the spring scale P according to the previously described procedure. 3) If the initial force is found within the specified range, adjust- M ment has been completed. A NOTE: Hold the front fork legs, move them back and forth and make S sure that the steering is not loose.
8-36 CHASSIS HANDLEBARS CONSTRUCTION E L P WD M FFWD A S 1 Left handle grip 5 Handlebar (RH) 2 Right handle throttle grip 6 Handlebar (LH) 3 Right handle switch 7 Handle balancer ITEM N·m kgf-m lb-ft 4 Left handle switch A Handlebar clamp bolt A 23 2.3 16.5 REMOVAL • Remove the brake master cylinder 1. • Remove the right handle switch 2. • Remove the handle balancer 3. • Remove the right handle throttle grip 4.
CHASSIS 8-37 • Remove the left handle switch 5 and disconnect the clutch lever switch lead wire. • Remove the handle balancer 6. • Remove the left handle grip 7. • Disconnect the clutch cable 8. • Remove the clutch lever holder 9. • Loosen the handlebar clamp bolts and front fork upper clamp bolts. • Remove the steering stem upper bracket 0 by removing the E steering stem head nut. L NOTE: Place a rag under the steering stem upper bracket to prevent scratching the body cowling and the air intake pipes. P M A S • Remove the handlebars A by sliding them upward. INSTALLATION Install the handlebars in the reverse order of removal. Pay atten- tion to the following points: • Install the handlebars temporarily. • Install the steering stem upper bracket and washer. (8-34)
8-38 CHASSIS • Insert the protrusion A of the handlebars into the hole B of the steering stem upper bracket. • Tighten the front fork upper clamp bolts 1 and handlebar clamp bolts 2 to the specified torque. Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Apply a handle grip bond onto the left handlebar before E installing the handlebar grip. Handle grip bond 39442-09D00: HANDLE GRIP BOND PL SAM • Install the clutch lever holder, align the holder’s mating sur- face C with punched mark D on the handlebar. • Install the front brake master cylinder. (8-72) Up side
CHASSIS 8-39 • Apply the SUZUKI SUPER GREASE “A” to the throttle cables and cable drum. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • When remounting the right and left handle switches, engage the stopper with the handlebar hole. After installing the steering, the following adjustments are required before driving. • Cable routing (10-21) • Throttle cable play (2-15) • Clutch lever play (2-16) E L P M A S
8-40 CHASSIS REAR WHEEL CONSTRUCTION E L P M A S *1 1 Rear axle 0 Spacer *1 Except for E-03, 28, 33 2 Caliper bracket A Sprocket mounting drum 3 Brake disc B Sprocket 4 Collar C Bearing 5 Dust seal D Dust seal 6 Rear wheel E Collar ITEM N·m kgf-m lb-ft 7 Spacer A Brake disc bolt A 35 3.5 25.5 8 Bearing B Rear sprocket nut B 93 9.3 67.5 9 Cushion C Rear axle nut C 100 10.0 72.5
CHASSIS 8-41 REMOVAL • Remove the cotter pin. (For E-03, 28, 33) • Loosen the axle nut 1. • Remove the under cowling. (8-5 to -6) • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. • Remove the rear wheel by disengaging the drive chain. Do not operate the brake pedal with the rear wheel removed. • Remove the collar 2. E • Remove the brake disc 3. L P M A • Remove the collar 4. S • Loosen the rear sprocket mounting bolt and separate the rear sprocket 5 from its mounting drum 6. • Draw out the rear sprocket mounting drum 6 from the wheel hub. • Remove the rear sprocket mounting drum retainer 7.
8-42 CHASSIS • Remove the dust seal with the special tool. 09913-50121: Oil seal remover The removed dust seal must be replaced with a new one. • Remove the dust seal with the special tool. 09913-50121: Oil seal remover The removed dust seal must be replaced with a new one. INSPECTION AND DISASSEMBLY E TIRE INSPECTION (2-27 and 8-82) L WHEEL INSPECTION (8-82) P REAR AXLE M • Using a dial gauge, check the rear axle for runout. • If the runout exceeds the limit, replace the rear axle. A Axle shaft runout: Service Limit: 0.25 mm (0.010 in) S 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) WHEEL DAMPER • Inspect the damper for wear and damage. • Replace the damper if there is anything unusual.
CHASSIS 8-43 SPROCKET • Inspect the sprocket teeth for wear. • If they are worn as shown, replace the two sprockets and drive chain as a set. A Normal wear B Excessive wear BEARINGS • Inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • Replace the bearing if there is anything unusual. • Remove the sprocket mounting drum bearing 1 and wheel E bearing 2 with the special tool. L 09921-20240: Bearing remover set (1 30 mm) (2 28 mm) P M The removed bearings must be replaced with the new ones. A S
8-44 CHASSIS REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left Right 100 N·m (10.0 kgf-m, 72.5 lb-ft) 93 N·m 35 N·m (9.3 kgf-m, 67.5 lb-ft) (3.5 kgf-m, 25.5 lb-ft) E PL AM E-02, 19, 24 S 25 N·m (2.5 kgf-m, 18.0 lb-ft) E-03, 28, 33 100 N·m (10.0 kgf-m, 72.5 lb-ft)
CHASSIS 8-45 BEARINGS • Apply SUZUKI SUPER GREASE “A” to the bearings before installing. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the new bearing to the sprocket mounting drum with the special tool. 09924-84510: Bearing installer set • First install the right wheel bearing, then install the left wheel E bearing with the special tools. L 09941-34513: Steering race installer 09924-84510: Bearing installer set P M The sealed cover of the bearing must face outside. SA Left Right Left Right Spacer Clearance
8-46 CHASSIS WHEEL DAMPER • To install the wheel dampers, apply a special tire lubricant or neutral soapy liquid to the damper surface. * Three protrusions A on the damper must face out- side. * Never use oil, grease or gasoline on the damper in place of the tire lubricant. DUST SEALS E • Install the new dust seal with the special tool. 09913-70210: Bearing installer set (1 68) L (2 52) P M A S • Apply SUZUKI SUPER GREASE “A” to the dust seal lip before assembling rear wheel. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) REAR SPROCKET AND SPROCKET MOUNTING DRUM • Install the rear sprocket mounting drum spacer 1. • Install the rear sprocket mounting drum to the rear wheel.
CHASSIS 8-47 • Tighten the sprocket mounting nuts to the specified torque. Rear sprocket nut: 93 N·m (9.3 kgf-m, 67.5 lb-ft) NOTE: Stamped mark A on the sprocket should face outside. • Install the collar 2. BRAKE DISC • Apply THREAD LOCK to the disc bolts and tighten them to the specified torque. NOTE: Make sure that the brake disc is clean and free of any greasy matter. 99000-32130: THREAD LOCK SUPER “1360” Brake disc bolt: 35 N·m (3.5 kgf-m, 25.5 lb-ft) • Install the collar 1. E REAR AXLE • Remount the rear wheel and rear axle shaft, and install the washer 1 (Except for E-03, 28, 33) and rear axle nut 2. L P • Adjust the chain slack after rear wheel installation. (2-21) M A S
8-48 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION E Left Right L P M A S 1 Rear shock absorber A Rear shock absorber mount- ing bolt/nut ITEM N·m kgf-m lb-ft 2 Rear shock absorber bracket B Rear shock absorber bracket A 50 5.0 36.0 nut B 115 11.5 83.0
CHASSIS 8-49 REMOVAL • Lift and support the fuel tank with the fuel tank prop stay. (5-3) • Remove the regulator/rectifier 1. (10-40) • Remove the under cowling. (8-5 to -6) • Support the motorcycle with a jack relieve no load on the rear shock absorber. • Remove the rear shock absorber upper and lower mounting bolts and nuts. • Take out the rear shock absorber. E L P M A INSPECTION S Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one. Do not attempt to disassemble the rear shock absorber unit. It is unserviceable.
8-50 CHASSIS REAR SHOCK ABSORBER DISPOSAL * The rear shock absorber unit contains high-pressure nitrogen gas. * Mishandling can cause explosion. * Keep away from fire and heat. High gas pressure caused by heat can cause an explosion. * Release gas pressure before disposing. GAS PRESSURE RELEASE The rear cushion damper unit contains high-pressure nitrogen gas. Make sure to observe the following precautions. * Never apply heat or disassemble the damper unit 9 mm since it can explode or oil can splash hazardously. (0.35 in) * When discarding the rear cushion unit, be sure to release gas pressure from the unit following the pro- cedures below. E Mark the drill center at the location A using a center punch. L Wrap the rear cushion unit with a vinyl bag and fix it on a vise as shown. P Drill a 2 – 3 mm (0.08 – 0.12 in) hole at the marked drill center using a drilling machine and let out gas while taking care not to get the vinyl bag entangled with the drill bit. M A * Be sure to wear protective glasses since drilling S chips and oil may fly off with blowing gas when the drill bit has penetrated through the body. * Make sure to drill at the specified position. Other- wise, pressurized oil may spout out forcefully.
CHASSIS 8-51 INSTALLATION Remount the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber upper/lower mounting bolts and nuts. Rear shock absorber mounting nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft) SUSPENSION SETTING After installing the rear suspension, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT The set length 172.6 mm (6.80 in) provides the maximum spring pre-load. E The set length 182.6 mm (7.19 in) provides the minimum spring pre-load. L STD length: 177.6 mm (6.99 in) P DAMPING FORCE ADJUSTMENT M Rebound side A Fully turn the damping force adjuster 1 clockwise. It is at stiffest position and turn it out to standard setting position. S STD position: 12 clicks out from stiffest position [Fine-tune the adjuster by turning it slightly until two punch marks align.] Compression side Fully turn the damping force adjuster 2 clockwise. It is at stiffest position and turn it out to standard setting position. STD position: 14 clicks out from stiffest position [Fine-tune the adjuster by turning it slightly until two punch marks align.] Standard suspension setting REAR Spring set length Damping force adjuster Rebound Compression Solo and 177.6 mm (6.99 in) 12 clicks out from stiffest position 14 clicks out from stiffest position dual riding
8-52 CHASSIS REAR SUSPENSION CONSTRUCTION E L P M A S 1 Rear shock absorber A Swingarm pivot boss (LH) 2 Rear cushion rod A Rear shock absorber mounting 3 Rear cushion lever bolt/nut ITEM N·m kgf-m lb-ft 4 Spacer B Rear cushion lever bolt/nut A 50 5.0 36.0 5 Bearing C Rear cushion rod bolt/nut B 78 7.8 56.5 6 Chain cover D Swingarm pivot shaft C 78 7.8 56.5 7 Chain buffer E Swingarm pivot lock nut D 15 1.5 11.0 8 Chain adjuster F Swingarm pivot nut E 90 9.0 65.0 9 Chain adjuster lock-nut G Swingarm pivot boss nut (RH) F 100 10.0 72.5 0 Swingarm pivot boss (RH) H Swingarm pivot boss nut (LH) GH 65 6.5 47.0
CHASSIS 8-53 REMOVAL • Cut the drive chain. (8-86) NOTE: It is not necessary to cut the drive chain, unless replacing drive chain or swingarm. • Remove the rear wheel. (8-41) • Remove the side-stand 1. NOTE: It is not necessary to remove the side-stand, unless when replacing the cushion lever. • Remove the brake hose guide 2. E • Remove the brake caliper from the swingarm. L P M A S • Remove the rear shock absorber. (8-49) • Remove the cushion lever mounting bolt/nut 3. • Remove the cushion lever 4. NOTE: Slightly loosen the cushion rod mounting bolt/nut A to facilitate later disassembly. • Remove the swingarm pivot shaft lock-nut with the special tool. 09940-14940: Swingarm pivot thrust adjuster socket wrench
8-54 CHASSIS • Hold the swingarm pivot shaft 5 and remove the swingarm pivot nut 6. 09944-28320: Hexagon socket (19 mm) • Draw out the swingarm pivot shaft. • Remove the rear suspension assembly. • Remove the cushion rods 7. • Remove the rear fender (lower) 8. E • Remove the chain cases 9 and chain buffer 0. L P M A S SWINGARM PIVOT BOSS REMOVAL AND INSTALLATION • Remove the swingarm. (8-53 to -54) • Remove the swingarm pivot boss nut. NOTE: Remove the swingarm pivot boss when only replacing it. • Remove the swingarm pivot boss by removing its set screws.
CHASSIS 8-55 • Set the swingarm pivot boss by its set screws. • Tighten the swingarm boss nut to the specified torque. Swingarm pivot boss nut: 65 N·m (6.5 kgf-m, 47.0 lb-ft) INSPECTION AND DISASSEMBLY E SPACER L • Remove the spacers from swingarm. • Remove the spacers from the cushion lever. P • Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones. M A S SWINGARM BEARING • Insert the spacer into bearing and check the play when mov- ing the spacer up and down. • If excessive play is noted, replace the bearing with a new one.
8-56 CHASSIS • Draw out the swingarm pivot bearings 1 and the swingarm cushion rod upper bearings 2 with the special tool. 09921-20240: Bearing remover set (1 28 mm) (2 17 mm) The removed bearings must be replaced with new ones. CUSHION LEVER BEARING E • Insert the spacer into bearing and check the play when mov- ing the spacer up and down. L • If excessive play is noted, replace the bearing with a new one. P M A S • Draw out the cushion lever bearings with the special tool. 09921-20240: Bearing remover set (1 20 mm) (2 17 mm) The removed bearings must be replaced with new ones. CUSHION LEVER AND CUSHION LEVER RODS • Inspect the cushion lever and cushion lever rods for damage.
CHASSIS 8-57 SWINGARM PIVOT SHAFT • Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. Swingarm pivot shaft runout: Service limit: 0.3 mm (0.01 in) 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) CHAIN BUFFER • Inspect the chain buffer for wear and damage. • If any defects are found, replace the chain buffer with a new one. PLATE E • Inspect the plate for damage and excessive bend. L P M A S
8-58 CHASSIS REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: Left Right 115 N·m 11.5 kgf-m ( ( 83.0 lb-ft 50 N·m 5.0 kgf-m ( ( 36.0 lb-ft Apply SUZUKI SUPER GREASE “A” to the bearings, washers and dust seals. E 1 mm (0.04 in) 1 mm (0.04 in) PL M 78 N·m 7.8 kgf-m A ( ( S 56.5 lb-ft 78 N·m 7.8 kgf-m Washer ( ( 56.5 lb-ft NOTE: When installing the bearing, stamped mark on the bearing must face outside. 1 mm (0.04 in) 1 mm (0.04 in) 15 N·m 1.5 kgf-m ( ( 11.0 lb-ft 100 N·m 65 N·m 65 N·m 90 N·m 10.0 kgf-m 6.5 kgf-m 6.5 kgf-m 9.0 kgf-m ( ( ( ( ( ( 72.5 lb-ft 47.0 lb-ft ( ( 65.0 lb-ft 47.0 lb-ft
CHASSIS 8-59 SWINGARM BEARING • Install the center spacer. • Press the bearings into the swingarm pivot with the special tool. 09941-34513: Steering race installer NOTE: When installing the bearing, stamped mark on the bearing must face outside. • Press the swingarm cushion rod upper side bearings with the special tool. 09924-84521: Bearing installer set NOTE: When installing the bearing, stamped mark on the bearing must face outside. CUSHION LEVER BEARING E • Press the bearings into the cushion lever with the special tool. 09924-84521: Bearing installer set L NOTE: P When installing the bearing, stamped mark on the bearing must face outside. M A S • Apply SUZUKI SUPER GREASE “A” to the bearings, spacers. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
8-60 CHASSIS • Assemble the cushion rod onto the swingarm temporarily. NOTE: The stamped marks A on the cushion rod should be face out- side. • Remount the chain cases 1 chain buffer 2 and rear fender 3. INSTALLATION E Install the swingarm in the reverse order of disassembly and L removal, and pay attention to the following points. P SWINGARM PIVOT THRUST CLEARANCE ADJUSTMENT Adjust swingarm pivot thrust clearance in the following procedure. • Insert the swingarm pivot shaft and tighten to the specified M torque. A 09944-28320: Hexagon socket (19 mm) S Swingarm pivot shaft: 15 N·m (1.5 kgf-m, 11.0 lb-ft) • Hold the swingarm pivot shaft and tighten the swingarm pivot nut 1 to the specified torque. Swingarm pivot nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) • Tighten the swingarm pivot lock-nut to the specified torque with the special tool. 09940-14940: Swingarm pivot thrust adjuster socket wrench Swingarm pivot lock-nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft)
CHASSIS 8-61 SHOCK ABSORBER AND CUSHION LEVER MOUNTING NUT • Install the washers A and cushion lever. (8-58) • Tighten the cushion lever mounting nut 1 to the specified torque. Cushion lever mounting nut: 78 N·m (7.8 kgf-m, 56.5 lb-ft) • Assemble the cushion lever, cushion rod. (8-58) Cushion rod nut 2: 78 N·m (7.8 kgf-m, 56.5 lb-ft) • Install the rear shock absorber. (8-51) • Route the brake hose and install the brake hose guides. E (10-26) • Install the rear wheel. (8-47) L • Install the side-stand. (10-36) P • Connect the drive chain. (8-87) M FINAL INSPECTION AND ADJUSTMENT A After installing the rear suspension and wheel, the following adjustments are required before driving. * Drive chain (2-21) S * Tire pressure (2-27)
8-62 CHASSIS FRONT BRAKE CONSTRUCTION E L P M A S 1 Brake lever 9 Brake hose 2 Dust boot A Master cylinder mounting bolt ITEM N·m kgf-m lb-ft 3 Piston set B Brake hose union bolt A 10 1.0 7.0 4 Piston seal C Caliper mounting bolt B 23 2.3 16.5 5 Dust seal D Caliper air bleeder valve C 39 3.9 28.0 6 Brake caliper piston E Caliper housing bolt D 7.5 0.75 5.5 7 Brake pad F Brake pad mounting pin E 22 2.2 16.0 8 Brake pad spring G Master cylinder air bleeder valve F 15 1.5 11.0 G 6.0 0.6 4.5
CHASSIS 8-63 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods. * When storing the brake fluid, seal the container completely and keep away from children. * When replenishing brake fluid, take care not to get dust into fluid. * When washing brake components, use fresh brake fluid. Never use cleaning solvent. * A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent. Handle brake fluid with care: The fluid reacts chemically with paint, plastics, rubber materials etc. and will damage then severely. BRAKE PAD REPLACEMENT • Loosen the pad mounting pins 1. • Remove the brake caliper by removing the caliper mounting E bolts 2. • Remove the pad mounting pins 1, brake pads and spring. L P * Do not operate the brake lever with the pads removed. M * Replace the brake pads as a set, otherwise braking A performance will be adversely affected. NOTE: S * When the brake caliper is removed, care must be used so as not to cause stress to the brake hose. (Hang the brake caliper on the frame with a string, etc.) * When removing the pad spring, push the piston all the way into the brake caliper. • Inspect the pad mounting pins for bent or damage. If any defects are found, replace the pad mounting pins with the new ones.
8-64 CHASSIS • Install the spring to the caliper, bring its wider side of pawl A facing top. • Install the new brake pads. • Install the brake caliper. • Tighten each bolt to the specified torque. Pad mounting pin 1: 15 N·m (1.5 kgf-m, 11.0 lb-ft) Front brake caliper mounting bolt 2: 39 N·m (3.9 kgf-m, 28.0 lb-ft) NOTE: * After replacing the brake pads, pump the brake lever a few times to check for proper brake operation and then check the brake fluid level. E BRAKE FLUID REPLACEMENT L P • Place the motorcycle on a level surface and keep the handle- bars straight. M • Remove the brake fluid reservoir cap 1 and diaphragm. • Drain the old brake fluid as much as possible. • Fill the reservoir with new brake fluid. A S • Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • Loosen the air bleeder valve and pump the brake lever until old brake fluid flows out of the bleeder system. • Close the caliper air bleeder valve and disconnect a clear hose. Fill the reservoir with new fluid to the upper mark of the reservoir. Specification and classification: DOT 4 Bleed air from the brake system. (2-26)
CHASSIS 8-65 CALIPER REMOVAL • Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta- cle. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. • Remove the brake pads and spring. (8-63) Never reuse the brake fluid left over from previous servicing and stored for long periods of time. Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage. CALIPER DISASSEMBLY E • Remove the caliper air bleeder valve 1. L • Separate the caliper halves by removing the caliper housing bolts 2 with the special tools. P 09930-11920: Torx bit JT40H 09930-11940: Bit holder M A S • Remove the O-ring 3. Replace the O-ring with a new one. • Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air. Avoid using high pressure air to prevent piston dam- age.
8-66 CHASSIS • Remove the dust seals 4 and piston seals 5. Avoid reusing the dust seals and piston seals to pre- vent fluid leakage. CALIPER INSPECTION BRAKE CALIPER • Inspect the brake caliper cylinder wall for nicks, scratches or other damage. BRAKE CALIPER PISTON • Inspect the brake caliper piston surface for any scratches or other damage. E CALIPER REASSEMBLY L Reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: P • Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves. Specification and classification: DOT 4 M A S * Clean the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them. * Do not wipe the brake fluid off after cleaning the components. * When cleaning the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or oth- ers. * Replace the piston seals and dust seals with the new ones when reassembly. Apply the brake fluid to both seals when installing them.
CHASSIS 8-67 PISTON SEAL • Install the piston seals as shown in the illustration. Dust seal Caliper body Piston seal O-RING • Install the new O-ring 1 and reassemble caliper halves. Replace the O-ring with a new one. • Temporarily tighten the air bleeder valve 2. E • Tighten each bolt to the specified torque. L Front brake caliper housing bolt 3: 22 N·m (2.2 kgf-m, 16.0 lb-ft) 09930-11920: Torx bit JT40H P 09930-11940: Bit holder M A S CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Install the spring and brake pads. (8-64) • Install the brake caliper. (8-64) • Tighten each bolt to the specified torque. Front brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) * The seal washers should be replaced with the new ones to prevent fluid leakage. * Bleed air from the system after reassembling the cal- iper. (2-26)
8-68 CHASSIS BRAKE DISC INSPECTION • Visually check the brake disc for damage or cracks. • Measure the thickness with a micrometer. • Replace the disc if the thickness is less than the service limit or if damage is found. Front disc thickness: Service Limit: 5.0 mm (0.20 in) 09900-20205: Micrometer (0 – 25 mm) • Remove the brake calipers. (8-63) • Measure the runout with a dial gauge. • Replace the disc if the runout exceeds the service limit. Front disc runout: Service Limit: 0.30 mm (0.012 in) 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand * Brake disc removal (8-11) * Brake disc installation (8-14) E L P M A S
CHASSIS 8-69 MASTER CYLINDER REMOVAL AND DISAS- SEMBLY • Drain the brake fluid. (8-64) • Disconnect the front brake light switch lead wires 1. • Place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose. Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The fluid reacts chemically with paint, plastics and rubber materials, etc. and will damage them severely. • Remove the master cylinder by removing the master cylinder bolts. E L P • Remove the reservoir cap 3, insulator 4, diaphragm 5 and reservoir tank 6. M A S • Remove the brake switch 7 and brake lever 8.
8-70 CHASSIS • Remove the dust boot 9 push rod 0 and snap ring A. • Remove the following parts. B Secondary cup C Piston D Primary cup E Return spring F Return spring guide G Air bleeder valve • Remove the dust rubber H and snap ring I. E L P M A S • Remove the air bleeder valve J, connector K and O-ring L. MASTER CYLINDER INSPECTION • Inspect the master cylinder bore for any scratches or other damage.
CHASSIS 8-71 • Inspect the piston surface for any scratches or other damage. • Inspect the primary cup, secondary cup and dust seal for wear or damage. MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disas- sembly. Pay attention to the following points: * Clean the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them. * Do not wipe the components with a rag. * Apply brake fluid to the cylinder bore and all the E component to be inserted into the bore. L Specification and classification: DOT 4 P • Install the O-ring to the brake hose connector. M Use a new O-ring to prevent the fluid leakage. A S • Apply SUZUKI SUPER GREASE “A” to the push rod. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99500-25010: SUZUKI SUPER GREASE “A” (others)
8-72 CHASSIS • Apply SUZUKI SILICONE GREASE to the brake lever mount- ing bolt. 99000-25100: SUZUKI SILICONE GREASE • Align the convex part A of brake light switch with the hole B of master cylinder when installing the brake light switch. MASTER CYLINDER INSTALLATION E Install the master cylinder in the reverse order of removal. Pay L attention to the following points: • When installing the brake master cylinder 1 onto the handle- P bars 2, align the master cylinder holder’s mating surface with punched mark A on the handlebars and tighten the upper clamp bolt 3 first as shown. M Front brake master cylinder mounting bolt: A 10 N·m (1.0 kgf-m, 7.0 lb-ft) S “UP” mark Clearance • Tighten the union bolt. (Brake hose routing: 10-25) Brake hose union bolt: 23 N·m (2.3 kgf.m, 16.5 lb-ft) * The seal washers should be replaced with the new ones to prevent fluid leakage. * Bleed air from the system after reassembling the master cylinder. (2-26)
CHASSIS 8-73 REAR BRAKE CONSTRUCTION E L P M A S 1 Brake pedal A Caliper air bleeder valve 2 Piston/Cup set B Brake hose union bolt ITEM N·m kgf-m lb-ft 3 Reservoir hose C Brake caliper mounting bolt A 6.0 0.6 4.5 4 Brake hose D Brake master cylinder mounting bolt B 23 2.3 16.5 5 Brake pad E Brake master cylinder rod lock-nut C 25 2.5 18.0 6 Shim F Brake caliper housing bolt D 10 1.0 7.0 7 Piston G Brake pad mounting pin E 18 1.8 13.0 8 Brake pad spring F 37 3.7 27.0 G 17 1.7 12.5
8-74 CHASSIS * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods. * When storing the brake fluid, seal the container completely and keep away from children. * When replenishing brake fluid, take care not to get dust into fluid. * When washing brake components, use fresh brake fluid. Never use cleaning solvent. * A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent. Handle brake fluid with care: The fluid reacts chemically with paint, plastics, rubber materials etc. and will damage then severely. BRAKE PAD REPLACEMENT • Remove the pad mounting pin 1 and spring 2. E L P • Remove the brake pads. M A * Do not operate the brake pedal with the pads removed. S * Replace the brake pads as a set, otherwise braking performance will be adversely affected. • Install the new brake pads and shims. Pad mounting pin: 17 N·m (1.7 kgf-m, 12.5 lb-ft) NOTE: After replacing the brake pads, pump the brake pedal a few times to set the brake parts correctly and then check the brake fluid level.
CHASSIS 8-75 BRAKE FLUID REPLACEMENT • Remove the brake fluid reservoir cap 1. • Replace the brake fluid in the same manner as the front brake. (8-64) Specification and classification: DOT 4 Bleed air from the brake system. (2-26) CALIPER REMOVAL E • Remove the cotter pin. (For E-03, 28, 33) L • Loosen the rear axle nut 1. P • Loosen the chain adjuster lock-nuts 2. • Loosen the chain adjusters 3. M • Push the rear wheel forward. A S • Remove the brake pads. (8-74) • Remove the union bolt 4 and catch the brake fluid in a suit- able receptacle. • Remove the brake caliper by removing the brake caliper mounting bolts 5. NOTE: Slightly loosen the caliper housing bolts 6 to facilitate later dis- assembly before removing the caliper mounting bolts. Never reuse the brake fluid left over from previous servicing and stored for long periods. Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage.
8-76 CHASSIS CALIPER DISASSEMBLY • Remove the caliper air bleeder valve 1. • Remove the caliper housing bolts 2. • Separate the caliper halves. • Remove the O-ring 3. Replace the O-ring with a new one. • Place a rag over the piston to prevent it from popping out and E then force out the pistons using compressed air. L P Avoid using high pressure air to prevent piston dam- age. M A S • Remove the dust seals and piston seals. Avoid reusing the dust seals and piston seals to pre- vent fluid leakage. CALIPER INSPECTION CALIPER INSPECTION (8-66) BRAKE DISC INSPECTION (8-68) Service Limit Rear disc thickness: 4.5 mm (0.18 in) Rear disc runout: 0.30 mm (0.012 in)
CHASSIS 8-77 CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves. Specification and classification: DOT 4 * Clean the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them. * Do not wipe the brake fluid off after cleaning the components. * When cleaning the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine the oth- ers. * Replace the piston seals and dust seals with new ones when reassembly. Apply the brake fluid to both seals when installing them. E PISTON SEAL L • Install the piston seals as shown in the illustration. P M Dust seal A Caliper body S Piston seal O-RING • Install the new O-ring 1 and reassemble caliper halves. Replace the O-ring with a new one.
8-78 CHASSIS • Completely clean the thread of caliper housing and bolts. • Apply THREAD LOCK to the caliper housing bolts. 99000-32130: THREAD LOCK SUPER “1360” CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Tighten each bolt to the specified torque. Brake hose union bolt 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Brake caliper housing bolt 2: 37 N·m (3.7 kgf-m, 27.0 lb-ft) Brake caliper mounting bolt 3: 25 N·m (2.5 kgf-m, 18.0 lb-ft) E • Adjust the chain slack. (2-21) L Bleed air from the system after reassembling the cali-P per. (2-26) M A S
CHASSIS 8-79 MASTER CYLINDER REMOVAL • Drain the brake fluid. (8-64) • Remove the brake fluid reservoir mounting bolt 1. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 2 and disconnect the brake hose. • Loosen the lock-nut 3. • Remove the mounting bolts 4. Immediately and completely wipe off any brake fluid contacting any parts of the motorcycle. The fluid reacts chemically with paint, plastic and rubber mate- rials, etc. and will damage them severely. E • Disconnect the reservoir hose. L • Remove the master cylinder by turning the master cylinder rod 5. P M A S MASTER CYLINDER DISASSEMBLY • Remove the reservoir cap 1 and diaphragm 2. • Remove the connector 3 by removing the screw. • Remove the O-ring 4. Replace the O-ring with a new one.
8-80 CHASSIS • Pull out the dust boot 5, then remove the snap ring 6. 09900-06108: Snap ring pliers • Remove the push rod 7, piston/primary cup 8 and spring 9. MASTER CYLINDER INSPECTION E CYLINDER, PISTON AND CUP SET L • Inspect the cylinder bore wall for any scratches or other dam- age. P • Inspect the cup set and each rubber part for damage. M A S MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disas- sembly. Pay attention to the following points: * Clean the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them. * Do not wipe the components with a rag. * Apply brake fluid to the cylinder bore and all the component to be inserted into the bore. Specification and classification: DOT 4
CHASSIS 8-81 • Apply SUZUKI SILICONE GREASE to the push rod end. 99000-25100: SUZUKI SILICONE GREASE MASTER CYLINDER INSTALLATION Install the master cylinder in the reverse order of removal. Pay attention to the following points: • Apply THREAD LOCK to the master cylinder mounting bolts. 99000-32050: THREAD LOCK “1342” (USA) 99000-32110: THREAD LOCK SUPER “1322” (Others) • Tighten each bolt to the specified torque. (Brake hose routing: 10-26) Brake hose union bolt 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft) E Master cylinder mounting bolt 2: L 10 N·m (1.0 kgf-m, 7.0 lb-ft) Master cylinder rod lock-nut 3: P 18 N·m (1.8 kgf-m, 13.0 lb-ft) M * The seal washers should be replaced with the new A ones to prevent fluid leakage. S * Bleed air from the system after reassembling the master cylinder. (2-26) • Adjust the brake pedal height. (2-25)
8-82 CHASSIS TIRE AND WHEEL TIRE REMOVAL The most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. For operating procedures, refer to the instructions supplied by the tire changer manufacturer. NOTE: When removing the tire in the case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the valve position. Even though the tire is refitted to the original position after repairing puncture, the tire may have to be balanced again since such a repair can cause imbalance. INSPECTION E WHEEL Wipe the wheel clean and check for the following: L • Distortion and crack • Any flaws and scratches at the bead seating area. P • Wheel rim runout (8-11) M A TIRE S Tire must be checked for the following points: • Nick and rupture on side wall • Tire tread depth (2-27) • Tread separation • Abnormal, uneven wear on tread • Surface damage on bead • Localized tread wear due to skidding (Flat spot) • Abnormal condition of inner liner
CHASSIS 8-83 VALVE INSPECTION • Inspect the valve after the tire is removed from the rim. • Replace the valve with a new one if the seal A rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the seal has abnormal deformation, replace the valve with a new one. • Any dust or rust around the valve hole B must be cleaned off. E • Then install the valve C in the rim. L NOTE: To properly install the valve into the valve hole, apply a special P tire lubricant or neutral soapy liquid to the valve. M Be careful not to damage the lip C of valve. A S
8-84 CHASSIS TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points. * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant. • When installing the tire, the arrow A on the side wall should point to the direction of wheel rotation. • Align the chalk mark put on the tire at the time of removal with the valve position. • For installation procedure of tire onto the wheel, follow the E instructions given by the tire changer manufacturer. L • Bounce the tire several times while rotating. This makes the tire bead expand outward to contact the wheel, thereby facili- P tating air inflation. • Inflate the tire. M A * Do not inflate the tire to more than 400 kPa (4.0 S kgf/cm², 57 psi). If inflated beyond this limit, the tire can burst and possibly cause injury. Do not stand directly over the tire while inflating. * In the case of preset pressure air inflator, pay special care for the set pressure adjustment.
CHASSIS 8-85 • In this condition, check the “rim line” B cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides. Coat the bead with lubricant and fit the tire again. • When the bead has been fitted properly, adjust the pressure to specification. • As necessary, adjust the tire balance. Do not run with a repaired tire at a high speed. Cold inflation tire pressure Front Rear Solo riding 250 kPa 290 kPa (2.50 kgf/cm², 36 psi) (2.90 kgf/cm², 42 psi) Dual riding 250 kPa 290 kPa (2.50 kgf/cm², 36 psi) (2.90 kgf/cm², 42 psi) E BALANCER WEIGHT INSTALLATION L P • When installing the balancer weights to the wheel, set the two balancer weights A on both sides of wheel rim. M Weight difference between the two balancer weights A must be less than 10 g (0.02 lb). S
8-86 CHASSIS DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain. E 09922-22711: Drive chain cutting and joining tool set L NOTE: When using the special tool, apply a small quantity of grease to P the threaded parts of the special tool. AM S DRIVE CHAIN CUTTING • Set up the special tool as shown in the illustration. 1Tool body 2Grip handle 3Pressure bolt “A” 4Pressure bolt “B” 5Bar 6Adjuster bolt (with through hole) 7Pin remover 8Chain holder (engraved mark 500) with reamer bolt M5 × 10 5 mm (0.2 in) NOTE: The tip of pin remover 7 should be positioned inside approxi- mately 5 mm (0.2 in) from the end face of pressure bolt “A” 3 as shown in the illustration.
CHASSIS 8-87 • Place the drive chain link being disjointed on the holder part 8 of the tool. • Turn in both the adjuster bolt 6 and pressure bolt “A” 3 so that each of their end hole fits over the chain joint pin properly. • Tighten the pressure bolt “A” 3 with the bar. • Turn in the pressure bolt “B” 4 with the bar 5 and force out the drive chain joint pin 9. Continue turning in the pressure bolt “B” 4 until the joint pin has been completely pushed out of the chain. NOTE: After the joint pin 9 is removed, loosen the pressure bolt “B” 4 and then pressure bolt “A” 3. • Remove the joint pin 9 of the other side of joint plate. E L Never reuse joint pins, O-rings and plates. After joint pins, O-rings and plates have been removed from the P drive chain, the removed joint pins, O-rings and plates should be discarded and new joint plate, O-rings and M plate must be installed. A S DRIVE CHAIN CONNECTING JOINT PLATE INSTALLATION (F50) • Set up the special tool as shown in the illustration. 1Tool body 5Adjuster bolt 2Grip handle (without hole) 3Joint plate holder 6Pressure bolt “A” (engraved mark “F50”) 7Bar 4Wedge holder & wedge pin • Connect both ends of the drive chain with the joint pin 8 inserted from the wheel side A as installed on the motorcycle. 9O-ring … 4 pcs. 0Joint plate Joint set part number DID: 27620-40F00 Do not use joint clip type of drive chain. The joint clip may have a chance to drop which may cause severe damage to motorcycle and severe injury.
8-88 CHASSIS • Apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0. NOTE: When positioning the joint plate 0 on the tool, its stamp mark must face the joint plate holder 3 side. • Set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 to secure the wedge holder & wedge pin 4. • Turn in the pressure bolt “A” 6 and align two joint pins A properly with the respective holes of the joint plate 0 • Turn in the pressure bolt “A” 6 further using the bar 7 to press the joint plate over the joint pins. • Continue pressing the joint plate until the distance between E the two joint plates come to the specification. L Joint plate distance specification W P DID 21.10 – 21.30 mm (0.831 – 0.839 in) M Should pressing of the joint plate be made excessively A beyond the specified dimension, the work should be redone using the new joint parts. S JOINT PIN STAKING • Set up the special tool as shown in the illustration. 1Tool body 2Grip handle 3Pressure bolt “A” 4Adjuster bolt (without hole) 5Staking pin (stowed inside grip handle behind rubber cap) 6Bar NOTE: Before staking the joint pin, apply a small quantity of grease to the staking pin 5.
CHASSIS 8-89 • Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “A” 3 with the bar until the pin end diameter becomes the specified dimension. Pin end diameter specification D DID 5.50 – 5.80 mm (0.217 – 0.228 in) * After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found. * Should any abnormal condition be found, reassem- ble the chain link using the new joint parts. • Adjust the drive chain, after connecting it. (2-21) E L P M A S
ELECTRICAL SYSTEM 9-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING .......................................................................... 9- 3 CONNECTOR......................................................................................... 9- 3 COUPLER............................................................................................... 9- 3 CLAMP................................................................................................... 9- 3 FUSE....................................................................................................... 9- 3 SEMI-CONDUCTOR EQUIPPED PART................................................ 9- 4 BATTERY............................................................................................... 9- 4 CONNECTING THE BATTERY.............................................................. 9- 4 WIRING PROCEDURE........................................................................... 9- 4 USING THE MULTI-CIRCUIT TESTER.................................................. 9- 5 LOCATION OF ELECTRICAL COMPONENTS ..........................................9- 6 CHARGING SYSTEM .................................................................................. 9- 8 TROUBLESHOOTING............................................................................ 9- 8 INSPECTION.......................................................................................... 9- 9 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK E SYSTEM ....................................................................................................... 9-12 L TROUBLESHOOTING............................................................................ 9-12 P STARTER MOTOR REMOVAL.............................................................. 9-13 STARTER MOTOR DISASSEMBLY...................................................... 9-14 M STARTER MOTOR INSPECTION.......................................................... 9-14 STARTER MOTOR REASSEMBLY....................................................... 9-15 A STARTER RELAY INSPECTION........................................................... 9-16 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS S 9 INSPECTION.......................................................................................... 9-17 IGNITION SYSTEM ...................................................................................... 9-20 IMMOBILIZER (Except for E-03, 28, 33)............................................... 9-21 TROUBLESHOOTING............................................................................ 9-23 INSPECTION.......................................................................................... 9-25 COMBINATION METER .............................................................................. 9-29 DESCRIPTION........................................................................................ 9-29 REMOVAL AND DISASSEMBLY.......................................................... 9-30 INSPECTION.......................................................................................... 9-31 LAMPS ......................................................................................................... 9-35 HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT....................................................... 9-35
9-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS RELAYS ....................................................................................................... 9-37 TURN SIGNAL/SIDE-STAND RELAY................................................... 9-37 STARTER RELAY.................................................................................. 9-37 FUEL PUMP RELAY.............................................................................. 9-37 COOLING FAN RELAY.......................................................................... 9-37 IGNITION SWITCH REMOVAL.............................................................. 9-38 IGNITION SWITCH INSTALLATION...................................................... 9-38 SWITCHES INSPECTION...................................................................... 9-39 BATTERY ..................................................................................................... 9-40 SPECIFICATIONS.................................................................................. 9-40 INITIAL CHARGING............................................................................... 9-40 SERVICING............................................................................................ 9-42 RECHARGING OPERATION................................................................. 9-42 PLE SAM
ELECTRICAL SYSTEM 9-3 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting. • When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires. • Inspect each terminal on the coupler for being loose or bent. • Inspect each terminal for corrosion and contamination. E L CLAMP P • Clamp the wire harness at such positions as indicated in CORRECT INCORRECT “WIRE HARNESS ROUTING”. (10-18 to -20) M • Bend the clamp properly so that the wire harness is clamped securely. A • In clamping the wire harness, use care not to allow it to hang down. S • Do not use wire or any other substitute for the band type clamp. FUSE • When a fuse blows, always investigate the cause to correct it and then replace the fuse. • Do not use a fuse of a different capacity. • Do not use wire or any other substitute for the fuse.
9-4 ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water replenishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery. • Be sure to recharge the battery in a well-ventilated and open area. • Note that the charging system for the MF battery is different E from that of a conventional battery. Do not replace the MF L battery with a conventional battery. P CONNECTING THE BATTERY M • When disconnecting terminals from the battery for disassem- A bly or servicing, be sure to disconnect the - battery lead wire, first. S • When connecting the battery lead wires, be sure to connect the + battery lead wire, first. • If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush. • After connecting the battery, apply a light coat of grease to the battery terminals. • Install the cover over the + battery terminal. WIRING PROCEDURE • Properly route the wire harness according to the “WIRING HARENESS ROUTING” section. (10-18 to -20)
ELECTRICAL SYSTEM 9-5 USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. • When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged. • After using the tester, be sure to turn the switch to the OFF position. 09900-25008: Multi-circuit tester set Before using the multi-circuit tester, read its instruc- tion manual. NOTE: * When connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them. * Use the needle pointed probe to prevent the rubber of the E water proof coupler from damage. L 09900-25009: Needle pointed probe set P M A S
9-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS E L P M A S 1 Battery 0 Ignition coil (No.1, 2, 3, 4) 2 Cooling fan relay (7-7) A STV actuator (4-65) 3 Fuel pump relay (5-6) B STP sensor (4-68) 4 AP sensor (4-56) C TP sensor (4-43) 5 ECM (Engine Control Module) D IAT sensor (4-52) 6 Mode selection switch coupler (4-25) E Starter motor 7 Starter relay/Main fuse F Oil pressure switch 8 PAIR control solenoid valve (11-6) G CKP sensor (4-35) 9 CMP sensor (4-33) H Cooling fan (7-6)
ELECTRICAL SYSTEM 9-7 E L P M A S 1 IAP sensor (4-37) 9 Regulator/Rectifier 2 Secondary fuel injector (4-77) 0 Horn 3 Primary fuel injector (4-75) A Generator 4 ECT sensor (4-48) B Fuse box 5 Fuel level gauge (5-8) C Turn signal/Side-stand relay 6 Fuel pump (5-8) D Speed sensor 7 TO sensor (4-61) E GP switch 8 EXCVA (6-4) F Side-stand switch
9-8 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier IG. switch Generator IC y Load SCR Batter TROUBLESHOOTING E Battery runs down quickly Step 1 L 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? P YES Remove accessories. M NO Go to Step 2. A Step 2 1) Check the battery for current leaks. (9-9) S Is the battery for current leaks OK? YES Go to Step 3. NO • Short circuit of wire harness • Faulty electrical equipment Step 3 1) Measure the regulated voltage between the battery terminals. (9-10) Is the regulated voltage OK? YES • Faulty battery • Abnormal driving condition NO Go to Step 4. Step 4 1) Measure the resistance of the generator coil. (9-10) Is the resistance of generator coil OK? YES Go to Step 5. NO • Faulty generator coil • Disconnected lead wires
ELECTRICAL SYSTEM 9-9 Step 5 1) Measure the generator no-load performance. (9-11) Is the generator no-load performance OK? YES Go to Step 6. NO Faulty generator Step 6 1) Inspect the regulator/rectifier. (9-11) Is the regulator/rectifier OK? YES Go to Step 7. NO Faulty regulator/rectifier Step 7 1) Inspect wirings. Is the wirings OK? YES Faulty battery NO • Short circuit of wire harness • Poor contact of couplers Battery overcharges E • Faulty regulator/rectifier • Faulty battery L • Poor contact of generator lead wire coupler P INSPECTION M BATTERY CURRENT LEAKAGE • Remove the front seat. (8-7)A • Turn the ignition switch to the OFF position. S • Disconnect the battery - lead wire. • Measure the current between - battery terminal and the - battery lead wire using the multi-circuit tester. If the reading exceeds the specified value, leakage is evident. 09900-25008: Multi-circuit tester set Battery current (leak): Under 3 mA Tester knob indication: Current (, 20 mA) A * In case of a large current leak, turn the tester to high range first to avoid tester damage. * Do not turn the ignition switch to the “ON” position when measuring current.
9-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. (8-7) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the + and - battery termi- nals using the multi-circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/recti- fier. (9-10 and -11) NOTE: When making this test, be sure that the battery is in fully-charged condition. Battery 09900-25008: Multi-circuit tester set Tester knob indication: Voltage () Regulated voltage (Charging output): DCV 14.0 – 15.5 V at 5 000 r/min GENERATOR COIL RESISTANCE E • Lift and support the fuel tank. (5-3) L • Disconnect the generator coupler. • Measure the resistance between the three lead wires. P If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insu- lated properly. M 09900-25008: Multi-circuit tester set A Tester knob indication: Resistance (Ω) S Generator coil resistance: 0.2 – 0.9 Ω (White – White) ∞ Ω (White – Ground) W NOTE: W When making above test, it is not necessary to remove the gen- erator. W
ELECTRICAL SYSTEM 9-11 GENERATOR NO-LOAD PERFORMANCE • Lift and support the fuel tank. (5-3) • Disconnect the generator coupler. W • Start the engine and keep it running at 5 000 r/min. • Using the multi-circuit tester, measure the voltage between W three lead wires. If the tester reads under the specified value, replace the gen- W erator with a new one. 09900-25008: Multi-circuit tester set Tester knob indication: Voltage (~) Generator no-load performance: 65 V and more at 5 000 r/min (When engine is cold) REGULATOR/RECTIFIER • Lift and support the fuel tank. (5-3) • Disconnect the regulator/rectifier couplers. • Measure the voltage between the lead wires using the multi circuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. (10-40) E PL 09900-25008: Multi-circuit tester set Tester knob indication: Diode test () B/R1 B/W1 M B/R2 B/W2 A Unit: V + Probe of tester to: B/R1 B/R2 B1 B2 B3 B/W1 B/W2 B2 S B/R1 0 0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2 0.5 – 1.2 B1 B/R2 0 0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2 0.5 – 1.2 0.4 – 0.7 0.4 – 0.7 B3 B1 0.4 – 0.7 0.4 – 0.7 B2 B3 0.4 – 0.70.4 – 0.7 Probe of tester to:B/W1 0 - B/W2 0 1.4 V and more (tester’s battery voltage) NOTE: If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.
9-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch To Ignition Fuse (30 A) coil O/W R Starter Y/G motor O/B Fuse GP switch (10 A) (Neutral) Battery Starter relay Bl B/Y Starter button Turn signal/ G Clutch switch side-stand relay side-stand B/W switch TROUBLESHOOTING E Make sure that the fuses are not blown and the battery is fully-charged before diagnosing. L Starter motor will not run P Step 1 1) Shift the transmission to neutral. M 2) Pull the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN” position and lis- ten for a click from the starter relay when the starter button is pushed. Is a click sound heard? SA YES Go to Step 2. NO Go to Step 3. Step 2 1) Check if the starter motor runs when its terminal is connected to the battery + terminal. (Do not use thin “wire” because a large amount of current flows.) Does the starter motor run? • Faulty starter relay YES • Loose or disconnected starter motor lead wire • Loose or disconnected between starter relay and battery + terminal NO Faulty starter motor
ELECTRICAL SYSTEM 9-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and B/Y -) when the starter button is pushed. Is a voltage OK? YES Go to Step 4. • Faulty engine stop switch • Faulty clutch switch • Faulty GP switch • Faulty turn signal/side-stand relay NO • Faulty starter button • Faulty ignition switch • Faulty side-stand switch • Poor contact of connector • Open circuit in wire harness Step 4 1) Check the starter relay. (9-16) Is the starter relay OK? YES Poor contact of the starter relay NO Faulty starter relay E Starter motor runs but does not crank the engine L Step 1 P 1) The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up. 2) Check the side-stand switch. (9-17) M Is the side-stand switch OK? A YES Go to Step 2. S NO Faulty side-stand switch Step 2 1) Check the starter clutch. Is the starter clutch OK? YES Faulty starter clutch NO • Open circuit in wire harness • Poor contact of connector STARTER MOTOR REMOVAL • Disconnect the battery - lead wire. • Lift and support the fuel tank. • Disconnect the starter motor lead wire 1. • Remove the starter motor 2.
9-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. E L 1 O-ring 4 Armature P 2 Housing end (inside) 5 Housing end (outside) ITEM N·m kgf-m lb-ft 3 Starter motor case A Lead wire mounting bolt A 30.32.0 M A STARTER MOTOR INSPECTION CARBON BRUSH S Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut A. If abnormal wear is found, replace the armature with a new one. If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth. If there is no undercut, scrape out the insulator with a saw blade. 1 Insulator 2 Segment
ELECTRICAL SYSTEM 9-15 ARMATURE COIL INSPECTION Check for continuity between each segment and between each segment and the armature shaft using the multi-circuit tester. If there is no continuity between the segments or there is conti- nuity between the segments and shaft, replace the armature with a new one. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test () OIL SEAL INSPECTION Check the oil seal lip for damage or leakage. If any damage is found, replace the housing end. STARTER MOTOR REASSEMBLY E Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: L • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. P 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) M A S • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. 99000-25140: SUZUKI MOLY PASTE • Fit the projection of the starter motor case to the depression of the housing end. • Apply SUZUKI SUPER GREASE to the O-ring. 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
9-16 ELECTRICAL SYSTEM • Tighten the starter motor lead wire mounting bolt to the speci- fied torque. Lead wire mounting bolt: 3 N·m (0.3 kgf-m, 2.0 lb-ft) STARTER RELAY INSPECTION • Remove the front seat. (8-7) • Disconnect the battery - lead wire from the battery. • Remove the frame cover. (8-8) • Remove the starter relay cover. • Disconnect the starter motor lead wire 1, battery lead wire 2 and starter relay coupler 3. • Remove the starter relay 4. • Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the E multi-circuit tester. If the starter relay clicks and continuity is L found, the relay is ok. 09900-25008: Multi-circuit tester set P Tester knob indication: Continuity test () M A Do not apply battery voltage to the starter relay for more than five seconds, since the relay coil may over- heat and get damaged. S Measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. 09900-25008: Multi-circuit tester set Starter relay resistance: 3 – 6 Ω
ELECTRICAL SYSTEM 9-17 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH The side-stand switch coupler is located above the crankcase. • Lift and support the fuel tank. (5-3) • Disconnect the side-stand switch coupler and measure the voltage between Green and Black/White lead wires. 09900-25008: Multi-circuit tester set Tester knob indication: Diode test () Green Black/White (+ Probe) (- Probe) ON 0.4 – 0.6 V (Side-stand up) OFF 1.4 V and more (Side-stand down) (Tester’s battery voltage) E NOTE: L If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery. P M A S
9-18 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Lift and support the fuel tank. (5-3) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmis- sion in “NEUTRAL”. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test () Blue Black/White ON (Neutral) OFF (Except neutral) When disconnecting and connecting the gear position switch coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Connect the gear position switch coupler to the wiring har- ness. E • Turn the ignition switch to “ON” position and side-stand to V upright position. L • Measure the voltage between Pink and Black/White lead P wires using the multi-circuit tester when shifting the gearshift lever from low to top. M 09900-25008: Multi-circuit tester set A 09900-25009: Needle pointed probe set Tester knob indication: Voltage () S Gear position switch voltage: 0.6 V and more * Low to top gear position (Pink + – B/W -) * Except neutral position (Pink + – B/W -) Use the special tool, to prevent the rubber of the water proof coupler from damage.
ELECTRICAL SYSTEM 9-19 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester. Then apply 12 V to terminals D and C (+ to D and - to C) and check the continuity between D and E. If there is no continuity, replace the turn signal/side-stand relay with a new one. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test () SIDE-STAND RELAY DIODE TURN E SIGNAL L RELAY P M A S DIODE INSPECTION Measure the voltage between the terminals using the multi-cir- cuit tester. Refer to the following table. + Probe of tester to: C, BA C, B 1.4 V and more Probe of (Tester’s battery voltage) - tester to:A 0.4 – 0.6 V 09900-25008: Multi-circuit tester set Tester knob indication: Diode test () NOTE: If the multi circuit tester reads 1.4 V and below when the tester probes are not connected, replace its battery.
9-20 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch ECM Side- #1 stand Power source relay circuit CKP #2 sensor Fuse Waveform arrangement Ignition circuit #3 switch CPU #4 Fuse Waveform arrangement circuit CMP Battery sensor TP ECT GP sensor sensor switch E NOTE: L The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine P speed reaches 13 300 r/min, this circuit cuts off fuel at the fuel injector. But under no load, the clutch lever is pulled or the gear position is neutral, this circuit cuts off fuel when engine speed reaches 12 900 r/min. M E-03, 33, 24: The circuit cuts off the ignition primary current for all spark plugs. A Under no load, the engine can run over 12 900 r/min though the ignition cut-off circuit is effec- S tive, which may possibly cause engine damage. Do not run the engine without load over 12 900 r/min at anytime.
ELECTRICAL SYSTEM 9-21 IMMOBILIZER (Except for E-03, 28, 33) DESCRIPTION The immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start. Immobi-antenna Indicator light Indicator light Immobilizer E Transponder antenna PL M ID ECM SA
9-22 ELECTRICAL SYSTEM Operation When the ignition switch is turned ON with the engine stop switch in ON, the immobi-antenna and ECM are powered ON. The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID. With the signal received, the transponder transmits the key ID signal to ECM so that ECM can make com- parison with its own ID, and if it matches, the engine is made ready to start. Transponder Immobi-antenna Ignition switch ECM E Also, when the ignition switch is turned ON, the indicator light L flashes as many as the number of IDs registered in ECM. There- Flashing Lighting P after, if the IDs are in agreement, the indicator light turns on for 2 registered Normal two seconds to notify of completion in successful communica- 3 registered Normal tion. M 4 registered Normal If the indicator light (LED) flashes fast, it notifies of communica- A Abnormal tion error or disagreement of ID. S Fast flashing Approx. 1.6 sec. Approx. 2.0 sec. NOTE: If the indicator light flashes fast, turn the ignition switch OFF then ON to make judgment again as there is possible misjudg- ment due to environmental radio interference. When the battery performance is lowered in winter (low temperature), the system may at times makes a Indicator light re-judgment at the time of beginning the starter motor operation. In this case, the indicator light operation starts immediately after the starter operation. NOTE: In the case that the LED flashes fast, remains lit or unlit, the probable cause of such a failure may be due to abnormal condition in the key, key cylinder, wiring harness or ECM. (If such a failure exists, contact your dis- tributor or dealer.)
ELECTRICAL SYSTEM 9-23 TROUBLESHOOTING No spark or poor spark NOTE: Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections. Is there connection in the ignition system couplers? YES Go to Step 2. NO Poor connection of couplers Step 2 1) Measure the battery voltage between input lead wires at the ECM with the ignition switch in the “ON” position. (E-02, 19, 24: O/G and B/W, E-03, 28, 33: O/W and B/W) Is the voltage OK? YES Go to Step 3. • Faulty ignition switch NO • Faulty turn signal/side-stand relay • Faulty engine stop switch • Broken wire harness or poor connection of related circuit couplers E Step 3 L 1) Measure the ignition coil primary peak voltage. (9-25) NOTE: P This inspection method is applicable only with the multi circuit tester and the peak volt adaptor. M Is the peak voltage OK? A YES Go to Step 4. S NO Go to Step 5. Step 4 1) Inspect the spark plugs. (2-5 to -6) Is the spark plug OK? YES Go to Step 5. NO Faulty spark plug(-s).
9-24 ELECTRICAL SYSTEM Step 5 1) Inspect the ignition coil/plug caps. (9-26) Is the ignition coil/plug cap OK? YES Go to Step 6. NO • Poor connection of the ignition coil/plug cap(-s). • Faulty ignition coil/plug cap(-s). Step 6 1) Measure the crankshaft position sensor peak voltage and its resistance. (9-27 to -28) NOTE: The crankshaft position sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor. Is the peak voltage and resistance OK? • Faulty ECM YES • Open or short circuit in wire harness • Poor connection of ignition couplers NO • Faulty CKP sensor • Metal particles or foreign material being stuck on the CKP sensor and rotor tip E L P M A S
ELECTRICAL SYSTEM 9-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. (5-13) • Disconnect all the ignition coil/plug cap lead wire couplers before removing the ignition coil/plug caps. • Remove all of the ignition coil/plug caps. * Do not remove the ignition coil/plug cap before dis- connecting the lead wire coupler, or the lead wire will be damaged. * Do not pry up the ignition coil/plug cap with a screw- driver or a bar to avoid damage. * Be careful not to drop the ignition coil/plug cap as it may open or short in a circuit. • Connect the new four spark plugs to each ignition coil/plug cap. • Connect all the ignition coil/plug cap lead wire couplers to the ignition coil/plug caps respectively, and ground them on the cylinder head (each spark plug hole). E Avoid grounding the spark plugs and suppling the L New spark electrical shock to the cylinder head cover (magne- plug Contact to sium parts) to prevent the magnesium material from the cylinder head P damage. M NOTE: Be sure that all couplers and spark plugs are connected properly A and the battery used is in fully-charged condition. S Inspect each ignition coil primary peak voltage at the ignition coil/plug cap coupler. • Connect the multi-circuit tester with peak voltage adaptor as follows. No. 1 ignition coil/plug cap: W/Bl wire terminal (+ Probe) – Ground (- Probe) terminal No. 2 ignition coil/plug cap: Black wire terminal (+ Probe) – Ground (- Probe) terminal No. 3 ignition coil/plug cap: Yellow wire terminal (+ Probe) – Ground (- Probe) terminal No. 4 ignition coil/plug cap: Peak volt Green wire terminal (+ Probe) – Ground (- Probe) terminal adaptor 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set To engine ECM stop switch Before using the multi-circuit tester and peak volt IG coil adaptor, be sure to refer to the appropriate instruction manual.
9-26 ELECTRICAL SYSTEM NOTE: Use the special tool, to prevent the rubber of the water proof coupler from damage. • Shift the transmission into neutral and turn ignition switch “ON”. • Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage. • Repeat the above inspection a few times and measure the highest peak voltage. Tester knob indication: voltage () Ignition coil primary peak voltage: 80 V and more Do not touch the tester probes and spark plugs to pre- vent an electric shock while testing. If the peak voltage is lower than the standard range, check the ignition coil/plug cap as follow. E IGNITION COIL/PLUG CAP RESISTANCE • Check the ignition coil/plug cap for resistance in both primary L and secondary coils. If the resistance is not within the stan- dard range, replace the ignition coil/plug cap with a new one. P 09900-25008: Multi-circuit tester set M Tester knob indication: Resistance (Ω) Ignition coil/plug cap resistance A Primary : 1.1 – 1.9 Ω (+ tap – - tap) S Secondary: 10.8 – 16.2 kΩ (Plug cap – - tap)
ELECTRICAL SYSTEM 9-27 CKP SENSOR PEAK VOLTAGE • Remove the front seat. (8-7) NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Disconnect the both couplers 1. • Connect the multi-circuit tester with peak volt adaptor as fol- lows. • Measure the CKP sensor peak voltage between Green/Blue and Green/White lead wires at the ECM coupler (Black) A. G/W wire (+ Probe) – G/Bl wire (- Probe) 09900-25008: Multi-circuit tester set G/W 09900-25009: Needle pointed probe set A Black coupler G/Bl Before using the multi-circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual. E • Shift the transmission into the neutral and turn ignition switch “ON”. L ECM • Crank the engine a few seconds with the starter motor by CKP sensor coupler P coupler G/W depressing starter button and check the CKP sensor peak G/Bl W voltage. M G/W • Repeat the above test procedure a few times and measure CKP sensor Peak the highest peak voltage. A volt Tester knob indication: Voltage () adaptor S CKP sensor peak voltage: 0.5 V and more (Green/Blue – Green/White)
9-28 ELECTRICAL SYSTEM If the peak voltage is lower than the standard range, check the peak voltage at the CKP sensor lead wire coupler. • Lift and support the fuel tank. (5-3) Green • Disconnect the CKP sensor lead wire coupler and connect the multi-circuit tester with the peak volt adaptor. Black wire (+ Probe) – Green wire (- Probe) • Measure the CKP sensor peak voltage at the CKP sensor Black lead wire coupler. Tester knob indication: Voltage () CKP sensor peak voltage: 0.5 V and more (Green – Black) CKP sensor If the peak voltage is lower than the standard range, check each coupler coupler connection or replace the CKP sensor and inspect it GG again. BB CKP sensor Peak volt adaptor CKP SENSOR RESISTANCE E • Measure the resistance between the lead wires and ground. If L the resistance is not as specified, the CKP sensor must be CKP sensor replaced. P coupler 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) M CKP sensor CKP sensor resistance: 142 – 194 Ω (Green – Black) A ∞ Ω (Green – Ground) S
ELECTRICAL SYSTEM 9-29 COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition. The rpm pointer is driven by the stepping motor. The LCDs indicate Speed, Odo/Trip1/Trip2/Clock/Fuel reserve’s trip and Engine coolant temp./FI (DTC) respectively. LED (Light Emitting Diode) LED is used for the illumination light and each indicator light. LED is maintenance free. LED is less electric-power consuming and stronger to vibration resistance com- pared to the bulb. Engine revolution indicator lamp This speedometer is equipped the engine revolution indicator lamp. The engine revolution indicator lamp is adjustable from 5 000 – 13 750 r/min. (from 5 000 r/min to 10 000 r/min, every 500 r/min and 10 000 r/min to 13750 r/min, every 250 r/min initial setting: 11 000 r/min) E L P M : *1 A *4 *3 S *2 *3 1 Adjust switch (Trip/Clock/Engine revolution) 8 Engine coolant temperature/FI (DTC) 2 Tachometer 9 Gear position indicator 3 Speedometer *1 LED (Combination meter light) 4 Engine revolution indicator *2 LCD 5 Select switch *3 LED 6 Odo/Trip 1/Trip 2/Clock/Fuel reserve’s trip *4 Stepping motor 7 Engine revolution indicator light
9-30 ELECTRICAL SYSTEM REMOVAL AND DISASSEMBLY • Remove the screws 1. • With the hooked parts 2 of the combination meter pulled from the headlight housing, disconnect the combination meter lead wire coupler. • Remove the combination meter. When disconnecting and reconnecting the combina- tion meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Disassemble the combination meter as follows. Do not attempt to disassemble the combination meter unit 2. E L P M A S 1 Combination meter cover 3 Combination meter case 2 Combination meter unit
ELECTRICAL SYSTEM 9-31 INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights [FI light, Fuel level indicator light, Engine revolution indicator lamp and immobilizer indicator light (For E-02, 19, 24)] immediately after turning the ignition switch on. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depend- ing on each switch position. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire har- ness/coupler. STEPPING MOTOR Check that the pointer calibrates itself immediately after turning the ignition switch on and stops at zero point. If abnormal condition is found, replace the combination meter unit with a new one after checking its wire har- ness/coupler. PLE NOTE: M The pointer may not return to the proper position even turning the ignition switch on under low temperature A condition. In that case, you can reset the pointer to the proper position by following the instruction below: S 1) With the function switch A pressed, turn the ignition switch on. 2) Release the function switch A, 3 to 5 seconds after turning the ignition switch on. 3) Press the function switch A twice (within 1 second). →Reset * Complete the operation within 10 seconds after the ignition switch has been turned on. Time Ignition switch Adjuster switch OFF PUSH 0 ON • • 3 sec. • 5 sec. Release • Push • • Push→Reset • 10 sec. Pointer will return to the starting point right after the completion of the operation. In the case of the pointer not returning to the proper position after doing above, replace the combination meter unit.
9-32 ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection (7-7 to -8) • Lift and support the fuel tank. (5-3) • Disconnect the ECT sensor coupler 1. When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Connect the variable resistor A between the terminals. • Disconnect the oil pressure switch lead wire from the oil pres- sure switch. NOTE: Leave the oil pressure switch lead wire open. • Turn the ignition switch ON. • Check the LCD and LED operations when the resistance is adjusted to the specified values. E Resistance A LED B LCD C LCD D Water temperature 2.45 kΩ and over OFF “---” ------- 19 °C and below L Approx. 0.811 kΩ OFF “50” ------- Approx. 50 °C P Approx. 0.1 kΩ ON ON “120” – “139” Flicker 120 – 139 °C 0 Ω (Jumper wire) ON “HI” Flicker 140 °C and over M If either one or all indications are abnormal, replace the combi- nation meter with a new one. A NOTE: S If the engine stop switch is turned OFF or side-stand/ignition inter-lock system is not working while the ignition switch is ON, the LCD displays “CHEC”. But it is not a malfunction. This condition implies that combination meter receives no signal from the ECM. In that case, they are restored to normal indication by turning the engine stop switch to RUN position.
ELECTRICAL SYSTEM 9-33 FUEL LEVEL GAUGE INSPECTION • Remove and disassemble the fuel pump assembly. (5-8) • Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. Float position Resistance 196.4 mm 48.4 mm (1.91 in) 179 – 185 Ω (6.67 in) 196.4 mm (6.67 in) 3 – 5 Ω 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) 48.4 mm (1.91 in) FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly, check E the fuel level gauge and its lead wire/coupler. L If the fuel level gauge and its lead wire/coupler are functioning properly, replace the combination meter with a new one. P SAM
9-34 ELECTRICAL SYSTEM SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. SPEED SENSOR • Lift and support the fuel tank. (5-3) • Disconnect speed sensor coupler 1. • Remove the speed sensor 2 by removing its mounting bolt. • Connect 12 V battery, 10 kΩ resistor and the multi-circuit tester as shown in the right illustration. B/R : Black with Red tracer B/W : Black with White tracer 10 kΩ 12 V B: Black B/W 09900-25008: Multi-circuit tester set B B/R Tester knob indication: Voltage () Speed sensor • Under above condition, if a suitable screwdriver touching the E pick-up surface of the speed sensor is moved, the tester read- L ing voltage changes (0 V→12 V or 12 V→0 V). If the tester reading voltage does not change, replace the speedometer sensor with a new one. P NOTE: M The highest voltage reading in this test will be the same as that of battery (12 V). A S (Battery voltage) OIL PRESSURE INDICATOR NOTE: Before inspecting the oil pressure switch, check if the engine oil level is correct. (2-12) • Remove the right under cowling. (8-5) • Disconnect the oil pressure switch lead wire from the oil pres- sure switch. • Turn the ignition switch ON. • Check if the oil pressure indicator A will light and LCD B will flicker, when grounding the lead wire. If any indications are abnormal, replace the combination meter with a new one after checking connection of couplers.
ELECTRICAL SYSTEM 9-35 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 55 W H7 1 12 V 60 W HB3 2 POSITION LIGHT 3 12 V 5 W × 2 BRAKE LIGHT/TAILLIGHT: LED LICENCE PLATE LIGHT 4 12 V 5 W E L P M A S TURN SIGNAL LIGHT 5 12 V 21 W × 4 If you have touched and the bulb with your bare hands, clean it with a cloth moistened with alcohol or soapy water to maintain lens clarity.
9-36 ELECTRICAL SYSTEM HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. NOTE: * Use a screw driver + for adjuster A, B and C. * To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. A: Horizontal adjuster (Low beam) B: Vertical adjuster (Low beam) C: Horizontal adjuster (Hi beam) D: Vertical adjuster (Low beam) E L P M A S
ELECTRICAL SYSTEM 9-37 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection. If the bulb, turn signal switch and circuit connection are OK, the turn signal relay may be faulty. In this case, replace the turn sig- nal/side-stand relay with a new one. NOTE: E * Make sure that the battery is fully charged. SIDE-STAND RELAY * Refer to the page 9-17 for the side-stand relay and diode DIODE TURN inspection. L SIGNAL P RELAY SAM STARTER RELAY 9-16 FUEL PUMP RELAY 5-6 COOLING FAN RELAY 7-7
9-38 ELECTRICAL SYSTEM IGNITION SWITCH REMOVAL • Remove the air cleaner box. (5-13) • Disconnect the ignition switch lead wire coupler (Green) 1. • Disconnect the immobilizer lead wire coupler (Black) 2. (For E-02, 19, 24) • Remove the cable guide 3. • Remove the ignition switch mounting bolts with the special tools. 09930-11920: Torx bit JT40H 09930-11940: Bit holder IGNITION SWITCH INSTALLATION E Install the ignition switch in the reverse order of removal. L Pay attention to the following points: P • Apply thread lock to the ignition switch bolts. M When reusing the ignition switch bolt, clean thread and apply the THREAD LOCK. A S 99000-32050: THREAD LOCK “1342” (USA) 99000-32110: THREAD LOCK SUPER “1322” (Others)
ELECTRICAL SYSTEM 9-39 SWITCHES INSPECTION Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color O/W Y/G O/R Y/W assemblies with new ones. Position HAZARD SWITCH PUSH Color HORN BUTTON Position BLblLgColor (OFF) Position B/Bl B/W (ON) IGNITION SWITCH (For E-02, 19, 24) PUSH Color FRONT BRAKE SWITCH R O Gr Br Position Color B/R B/Bl ON Position OFF OFF LOCK ON P REAR BRAKE SWITCH IGNITION SWITCH (For E-03, 28, 33) Color OW/B Color Position R O O/Y Gr Br OFF Position ON ON E OFF CLUTCH SWITCH LOCK L Color B/W B/Y P Position P DIMMER SWITCH OFF Color MON Position WYO OIL PRESSURE SWITCH HI () A Color ( ) Position G/Y Ground LO S TURN SIGNAL SWITCH ON (engine is at stop) Color Lg Lbl B OFF (engine Position is running) L NOTE: PUSH Before inspecting the oil pressure switch, check if the R engine oil level is correct. (2-12) PASSING LIGHT SWITCH Color WIRE COLOR OY Position B : Black Lbl : Light blue R : Red Br : Brown Lg : Light green W : White Gr : Gray O : Orange Y : Yellow PUSH B/BI : Black with Blue tracer ENGINE STOP SWITCH B/R : Black with Red tracer B/W : Black with White tracer Color O/B O/W B/Y : Black with Yellow tracer Position G/Y : Green with Yellow tracer ( ) O/B : Orange with Black tracer OFF O/R : Orange with Red tracer ( ) O/W : Orange with White tracer RUN O/Y : Orange with Yellow tracer W/B : White with Black tracer Y/G : Yellow with Green tracer Y/W : Yellow with White tracer
9-40 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation FT12A-BS Capacity 12 V, 36 kC (10 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes A. NOTE: When filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground. • Remove the caps 2. E NOTE: L * After filling the electrolyte completely, use the removed cap 2 as sealing caps of battery-filler holes. P * Do not remove or pierce the sealed areas 3 of the electrolyte container. M A S • Insert the nozzles of the electrolyte container 4 into the bat- tery’s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill. • Make sure air bubbles 5 are coming up each electrolyte con- tainer, and leave in this position for about more than 20 min- utes.
ELECTRICAL SYSTEM 9-41 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery. Wait for about 20 minutes. • Insert the caps 6 into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover. * Never use anything except the specified battery. * Once the caps have been installed to the battery, do not remove the caps. * Do not tap the caps with a tool such as hammer when installing them. E L P M A S CORRECT INCORRECT For initial charging, use the charger specially designed for MF battery. * For charging the battery, make sure to use the charger specially designed for MF battery. Other- wise, the battery may be overcharged resulting in shortened service life. * Do not remove the cap during charging. * Position the battery with the cap facing upward during charging.
9-42 ELECTRICAL SYSTEM SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper. RECHARGING OPERATION • Using the multi circuit tester, check the battery voltage. If the voltage reading is the 12.0 V (DC) and less, recharge the bat- tery with a battery charger. A Charging period B Stop charging * When recharging the battery, remove the battery from the motorcycle. * Do not remove the caps on the battery top while recharging. E Recharging time: 5 A for 1 hour or 1.2 A for 5 to 10 hours (V) (at 0 – 40 ˚C) 14 L P13 Be careful not to permit the charging current to exceed 5 A at any time. M 12 11 • After recharging, wait for 30 minutes and more and check the 10 A battery voltage with a multi circuit tester. • If the battery voltage is the 12.5 V and less, recharge the bat- 100 75 50 25 0 (%) tery again. S Battety charged condition • If battery voltage is still 12.5 V and less, after recharging, replace the battery with a new one. • When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.
SERVICING INFORMATION 10-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING................................................................................ 10- 3 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION.......................................................................................... 10- 3 ENGINE................................................................................................ 10- 7 RADIATOR (COOLING SYSTEM)....................................................... 10-13 CHASSIS.............................................................................................. 10-14 BRAKES............................................................................................... 10-15 ELECTRICAL....................................................................................... 10-16 BATTERY............................................................................................. 10-17 WIRING HARNESS, CABLE AND HOSE ROUTING.................................10-18 WIRING HARNESS ROUTING............................................................. 10-18 CABLE ROUTING................................................................................ 10-21 THROTTLE BODY HOSE ROUTING................................................... 10-22 FUEL TANK DRAIN HOSE ROUTING................................................. 10-23 COOLING SYSTEM HOSE ROUTING................................................. 10-24 E FRONT BRAKE HOSE ROUTING....................................................... 10-25 L REAR BRAKE HOSE ROUTING......................................................... 10-26 P PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING................................10-27 FUEL TANK INSTALLATION.............................................................. 10-28 M FUEL TANK LOWER SIDE COVER CUSHION RUBBER/ FASTENER INSTALLATION............................................................... 10-29 A AIR INTAKE PIPE CUSHION RUBBER INSTALLATION...................10-29 COWLING INSTALLATION................................................................. 10-30 S FRAME COVER INSTALLATION........................................................ 10-31 SEAT LOCK CABLE ROUTING.......................................................... 10-31 REAR FENDER INSTALLATION......................................................... 10-32 UNDER COWLING HEAT SHIELD INSTALLATION...........................10-33 10 BODY COWLING COVER CUSHION INSTALLATION.......................10-34 WINDSCREEN TAPE CUSHION INSTALLATION..............................10-34 HEADLIGHT TAPE CUSHION INSTALLATION..................................10-35 AIR INTAKE COVER TAPE CUSHION INSTALLATION....................10-35 SIDE-STAND INSTALLATION............................................................. 10-36 GEARSHIFT PEDAL INSTALLATION................................................. 10-36 HANDLEBAR BALANCER.................................................................. 10-37 FRONT FOOTREST INSTALLATION.................................................. 10-37 REAR VIEW MIRROR INSTALLATION............................................... 10-38 REAR COMBINATION LIGHT INSTALLATION..................................10-39 REGULATOR/RECTIFIER INSTALLATION........................................10-40 SPECIAL TOOLS................................................................................. 10-41
10-2 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TIGHTENING TORQUE.............................................................................. 10-45 ENGINE................................................................................................ 10-45 FI SYSTEM AND INTAKE AIR SYSTEM............................................. 10-46 COOLING SYSTEM.............................................................................. 10-46 CHASSIS.............................................................................................. 10-47 TIGHTENING TORQUE CHART.......................................................... 10-48 SERVICE DATA.......................................................................................... 10-49 PLE SAM
SERVICING INFORMATION 10-3 TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM C00 NO FAULT ––––––––––– ––––––––––– C11 CMP sensor The signal does not reach ECM for 3 CMP sensor wiring and mechan- sec. or more, after receiving the starter ical parts P0340 signal. CMP sensor, intake cam pin, wiring/coupler connection C12 CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts P0335 signal. CKP sensor, lead wire/coupler connection IAP sensor The sensor should produce following IAP sensor, lead wire/coupler voltage. connection C13 0.5 V sensor voltage < 4.85 V In other than the above range, C13 (P0105) is indicated. H Sensor voltage is higher than specified IAP sensor circuit shorted to value. VCC or ground circuit open E P0105 Sensor voltage is lower than specified IAP sensor circuit open or L value. Lshorted to ground or VCC circuit P open TP sensor The sensor should produce following TP sensor, lead wire/coupler voltage. M connection C14 0.2 V sensor voltage < 4.80 V In other than the above range, C14 A (P0120) is indicated. S H Sensor voltage is higher than specified TP sensor circuit shorted to value. VCC or ground circuit open P0120 Sensor voltage is lower than specified TP sensor circuit open or L value. shorted to ground or VCC circuit open ECT sensor The sensor voltage should be the fol- ECT sensor, lead wire/coupler lowing. connection C15 0.15 V sensor voltage < 4.85 V In other than the above range, C15 (P0115) is indicated. H Sensor voltage is higher than specified ECT sensor circuit open or P0115 value. ground circuit open L Sensor voltage is lower than specified ECT sensor circuit shorted to value. ground
10-4 SERVICING INFORMATION DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection C21 0.15 V sensor voltage < 4.85 V In other than the above range, C21 (P0110) is indicated. H Sensor voltage is higher than specified IAT sensor circuit open or P0110 value. ground circuit open L Sensor voltage is lower than specified IAT sensor circuit shorted to value. ground AP sensor The sensor voltage should be the fol- AP sensor, wiring/coupler con- lowing. nection C22 0.5 V sensor voltage < 4.85 V In other than the above range, C22 (P1450) is indicated. H Sensor voltage is higher than specified AP sensor circuit shorted to value. VCC or ground circuit open P1450 Sensor voltage is lower than specified AP sensor circuit open or L value. shorted to ground or VCC circuit E open TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler L lowing for 2 sec. and more, after igni- connection C23 tion switch is turned ON. P 0.2 V sensor voltage < 4.8 V M In other than the above value, C23 (P1651) is indicated. A H Sensor voltage is higher than specified TO sensor circuit shorted to value. VCC or ground circuit open S P1651 Sensor voltage is lower than specified TO sensor circuit open or L value. shorted to ground or VCC circuit open Ignition sig- CKP sensor (pick-up coil) signal is pro- Ignition coil, wiring/coupler con- C24/C25 nal duced, but signal from ignition coil is nection, power supply from the C26/C27 interrupted 8 times or more continu- battery ously. In this case, the code C24 P0351/P0352 (P0351), C25 (P0352), C26 (P0353) or P0353/P0354 C27 (P0354) is indicated. Secondary When no actuator control signal is STVA motor, STVA lead C28 throttle valve supplied from the ECM, communica- wire/coupler actuator tion signal does not reach ECM or operation voltage does not reach P1655 STVA motor, C28 (P1655) is indicated. STVA can not operate.
SERVICING INFORMATION 10-5 DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM STP sensor The sensor should produce following STP sensor, lead wire/coupler voltage. connection C29 0.15 V sensor voltage < 4.85 V In other than the above range, C29 (P1654) is indicated. H Sensor voltage is higher than specified STP sensor circuit shorted to value. VCC or ground circuit open P1654 Sensor voltage is lower than specified STP sensor circuit open or L value. shorted to ground or VCC circuit open Gear posi- Gear position signal voltage should be GP switch, wiring/coupler con- C31 tion signal higher than the following for 3 seconds nection, gearshift cam, etc. and more. Gear position sensor voltage > 0.6 V P0705 If lower than the above value, C31 (P0705) is indicated. Primary fuel CKP sensor (pickup coil) signal is pro- Primary fuel injector, wiring/cou- C32/C33 injector duced, but fuel injector signal is inter- pler connection, power supply to C34/C35 rupted 4 times or more continuously. In the injector E this case, the code C32 (P0201), C33 P0201/P0202 L (P0202), C34 (P0203) or C35 (P0204) P0203/P0204 is indicated. P Secondary Some failure exists in the fuel injector Secondary fuel injector, wir- C36/C37 fuel injector signal in a high load, high revolution ing/coupler connection, power C38/C39 M condition.In this case, the code C36 supply to the injector A P1764/P1765 (P1764), C37 (P1765), C38 (P1766) or C39 (P1767) is indicated. P1766/P1767 S Fuel pump No voltage is applied to the fuel pump, Fuel pump relay, lead wire/cou- relay although fuel pump relay is turned ON, pler connection, power source to C41 or voltage is applied to fuel pump fuel pump relay and fuel injec- although fuel pump relay is turned tors OFF. Voltage is applied to fuel pump Fuel pump relay switch circuit H although fuel pump relay is turned shorted to power source. P0230 OFF. Fuel pump relay (switch side) No voltage is applied to the fuel pump, Fuel pump relay circuit open or L although fuel pump relay is turned ON. short Fuel pump relay (coil side) C42 Ignition Ignition switch signal is not input to the Ignition switch, lead wire/coupler, switch ECM. etc. P1650 * When the ID agreement is not verified. * Immobilizer/anti-theft system * ECM does not receive communication signal from the immobilizer antenna. * : Immobilizer system is equipped model only.
10-6 SERVICING INFORMATION DTC No. DETECTED DETECTED FAILURE CONDITION CHECK FOR ITEM Exhaust con- EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- trol valve lowing voltage. pler actuator 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1675) is indicated. C46 When no actuator control signal is supplied from the ECM, communica- tion signal does not reach ECM or operation voltage does not reach EXCVA motor, C46 (P1658) is indi- cated. EXCVA can not operate. EXCVA position sensor voltage is EXCVA position sensor circuit H higher than specified value. shorted to VCC or ground circuit P1657 open EXCVA position sensor voltage is EXCVA position sensor circuit L lower than specified value. open or shorted to ground or VCC circuit open When no actuator control signal is EXCVA, EXCVA motor lead supplied from the ECM, communica- wire/coupler E P1658 tion signal does not reach ECM or L operation voltage does not reach EXCVA motor, C46 (P1658) is indi- P cated. EXCVA can not operate. C49 PAIR control PAIR control solenoid valve voltage is PAIR control solenoid valve, lead M P1656 solenoid not input to ECM. wire/coupler valve A C60 Cooling fan Cooling fan relay signal is not input to Cooling fan relay, lead wire/cou- S P0480 relay ECM. pler connection
SERVICING INFORMATION 10-7 ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of adjustment Adjust. 2. Worn valve guides or poor seating of valves Repair or replace. 3. Mistiming valves Adjust. 4. Excessively worn piston rings Replace. 5. Worn-down cylinder bores Replace. 6. Too slowly starter motor cranks See electrical section. 7. Poor seating of spark plugs Retighten. Plug not sparking 1. Fouled spark plugs Clean. 2. Wet spark plugs Clean and dry. 3. Defective ignition coil Replace. 4. Defective CKP sensor Replace. 5. Defective ECM Replace. 6. Open-circuited wiring connections Repair or replace. No fuel reaching the intake manifold 1. Clogged fuel filter or fuel hose Clean or replace. 2. Defective fuel pump Replace. E 3. Defective fuel pressure regulator L Replace. 4. Defective fuel injector Replace. 5. Defective fuel pump relay P Replace. 6. Defective ECM Replace. 7. Open-circuited wiring connections Check and repair. M Incorrect fuel/air mixture A Adjust. 1. TP sensor out of adjustment 2. Defective fuel pump Replace. S Replace. 3. Defective fuel pressure regulator 4. Defective TP sensor Replace. 5. Defective CKP sensor Replace. 6. Defective IAP sensor Replace. 7. Defective ECM Replace. 8. Defective ECT sensor Replace. 9. Defective IAT sensor Replace. 10. Defective AP sensor Replace.
10-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace. 6. Defective ignition coil/plug caps Replace. 7. Defective CKP sensor Replace. 8. Defective ECM Replace. 9. Defective TP sensor Replace. 10. Defective fuel pump Replace. 11. Imbalanced throttle valve Adjust. 12. Damaged or cracked vacuum hose Replace. Engine stalls often. Incorrect fuel/air mixture 1. Defective IAP sensor or circuit Repair or replace. 2. Clogged fuel filter Clean or replace. 3. Defective fuel pump Replace. 4. Defective fuel pressure regulator Replace. 5. Defective ECT sensor Replace. 6. Defective thermostat Replace. E 7. Defective IAT sensor Replace. 8. Damaged or cracked vacuum hose LReplace. Fuel injector improperly operatingP 1. Defective fuel injectors Replace. 2. No injection signal from ECM Repair or replace. M Repair or replace. 3. Open or short circuited wiring connection 4. Defective battery or low battery voltage Replace or recharge. A Control circuit or sensor improperly operating S Replace. 1. Defective ECM 2. Defective fuel pressure regulator Replace. 3. Defective TP sensor Replace. 4. Defective IAT sensor Replace. 5. Defective CMP sensor Replace. 6. Defective CKP sensor Replace. 7. Defective ECT sensor Replace. 8. Defective fuel pump relay Replace. Engine internal parts improperly operating 1. Fouled spark plugs Clean. 2. Defective CKP sensor or ECM Replace. 3. Clogged fuel hose Clean. 4. Out of adjustment tappet clearance Adjust.
SERVICING INFORMATION 10-9 Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace. Noise seems to come from piston 1. Worn down pistons or cylinders Replace. 2. Carbon combustion chambers fouled with carbon Clean. 3. Worn piston pins or piston pin bore Replace. 4. Worn piston rings or ring grooves Replace. Noise seems to come from timing chain 1. Stretched chain Replace. 2. Worn sprockets Replace. 3. Tension adjuster not working Repair or replace. Noise seems to come from clutch 1. Worn splines of countershaft or hub Replace. 2. Worn teeth of clutch plates Replace. 3. Distorted clutch plates, driven and drive Replace. 4. Worn clutch release bearing Replace. E 5. Weakened clutch dampers L Replace the primary P driven gear. Noise seems to come from crankshaft 1. Rattling bearings due to wear Replace. M Replace. 2. Worn and burnt big-end bearings 3. Worn and burnt journal bearings Replace. A Replace thrust bearing. 4. Too large thrust clearance Noise seems to come from balancer S 1. Worn and burnt journal bearings Replace. Noise seems to come from transmission 1. Worn or rubbing gears Replace. 2. Worn splines Replace. 3. Worn or rubbing primary gears Replace. 4. Worn bearings Replace. Noise seems to come from water pump 1. Too much play on pump shaft bearing Replace. 2. Worn or damaged impeller shaft Replace. 3. Worn or damaged mechanical seal Replace. 4. Contact between pump case and impeller Replace.
10-10 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust. 5. Ignition not advanced sufficiently due to poorly Replace ECM. working timing advance circuit 6. Defective ignition coils Replace. 7. Defective CKP sensor Replace. 8. Defective ECM Replace. 9. Clogged air cleaner element Clean. 10. Clogged fuel hose, resulting in inadequate fuel Clean and prime. supply to injector 11. Defective fuel pump Replace. 12. Defective TP sensor Replace. 13. Defective STP sensor or STVA Replace. Defective air flow system 1. Clogged air cleaner element Replace. 2. Defective throttle valve Adjust or replace. E 3. Defective secondary throttle valve Adjust or replace. 4. Sucking air from throttle body joint LRepair or replace. 5. Defective ECM P Replace. 6. Imbalancing throttle valve synchronization Adjust. Defective control circuit or sensor 1. Low fuel pressure M Repair or replace. 2. Defective TP sensor Replace. A Replace. 3. Defective IAT sensor S Replace. 4. Defective CMP sensor 5. Defective CKP sensor Replace. 6. Defective GP sensor Replace. 7. Defective IAP sensor Replace. 8. Defective ECM Replace. 9. TP sensor out of adjustment Replace. 10. Defective STP sensor and/or STVA Replace.
SERVICING INFORMATION 10-11 Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinders Replace. 5. Poor seating of valves Repair. 6. Fouled spark plugs Clean or replace. 7. Incorrect spark plugs Adjust or replace. 8. Clogged fuel injectors Replace. 9. Defective secondary fuel injectors Replace. 10. TP sensor out of adjustment Adjust. 11. Clogged air cleaner element Replace. 12. Imbalancing throttle valve synchronization Adjust. 13. Sucking air from throttle valve or vacuum hose Retighten or replace. 14. Too much engine oil Drain out excess oil. 15. Defective fuel pump or ECM Replace. 16. Defective CKP sensor and ignition coils Replace. Defective control circuit or sensor 1. Low fuel pressure Repair or replace. E 2. Defective TP sensor Replace. 3. Defective IAT sensor L Replace. 4. Defective CMP sensor P Replace. 5. Defective CKP sensor Replace. 6. Defective GP sensor Replace. M Replace. 7. Defective IAP sensor 8. Defective ECM Replace. A Replace. 9. Defective AP sensor 10. TP sensor out of adjustment Adjust. S Adjust. 11. Imbalanced throttle valve synchronization 12. Defective STP sensor and/or STVA Replace. 13. Defective EXCVA Replace.
10-12 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts 1. Heavy carbon deposit on piston crowns Clean. 2. Not enough oil in the engine Add oil. 3. Defective oil pump or clogged oil circuit Replace or clean. 4. Sucking air from intake pipes Retighten or replace. 5. Use incorrect engine oil Change. 6. Defective cooling system See radiator section. Lean fuel/air mixture 1. Short-circuited IAP sensor/lead wire Repair or replace. 2. Short-circuited IAT sensor/lead wire Repair or replace. 3. Sucking air from intake pipe joint Repair or replace. 4. Defective fuel injectors Replace. 5. Defective ECT sensor Replace. Other factors 1. Ignition timing is too advanced due to defective Replace. timing advance system (ECT sensor, GP sensor, CKP sensor and ECM). 2. Drive chain is too tight. Adjust. Dirty or heavy 1. Too much engine oil in the engine Check with inspection E exhaust smoke Lwindow, drain out excess oil. 2. Worn piston rings or cylinders P Replace. 3. Worn valve guides Replace. 4. Scored or scuffed cylinder walls Replace. 5. Worn valves stems M Replace. 6. Defective stem seal Replace. A 7. Worn oil ring side rails Replace. S Slipping clutch 1. Weakened clutch springs Replace. 2. Worn or distorted pressure plates Replace. 3. Distorted clutch plates or pressure plates Replace. Dragging clutch 1. Some clutch spring weakened while others Replace. are not. 2. Distorted pressure plates or clutch plates Replace. Transmission will 1. Broken gearshift cam Replace. not shift. 2. Distorted gearshift forks Replace. 3. Worn gearshift pawl Replace. Transmission will 1. Broken return spring on shift shaft Replace. not shift back. 2. Rubbing or stickily shift shaft Repair or replace. 3. Distorted or worn gearshift forks Replace. Transmission jumps 1. Worn shifting gears on driveshaft or Replace. out of gear. countershaft 2. Distorted or worn gearshift forks Replace. 3. Weakened stopper spring on gearshift stopper Replace. 4. Worn gearshift cam plate Replace.
SERVICING INFORMATION 10-13 RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats 1. Not enough engine coolant Add coolant. 2. Radiator core clogged with dirt or scale Clean. 3. Faulty cooling fan Repair or replace. 4. Defective cooling fan relay, or open- or short- Repair or replace. circuited 5. Defective ECM Replace. 6. Defective ECT sensor Replace. 7. Clogged water passage Clean. 8. Air trapped in the cooling circuit Bleed air. 9. Defective water pump Replace. 10. Use incorrect coolant Replace. 11. Defective thermostat Replace. Engine overcools 1. Defective ECT sensor Replace. 2. Extremely cold weather Put on the radiator cover. 3. Defective thermostat Replace. 4. Defective cooling fan relay, or open- or short- Repair or replace. circuited 5. Defective ECM Replace. E L P M A S
10-14 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering 1. Overtightened steering stem nut Adjust. 2. Broken bearing in steering stem Replace. 3. Distorted steering stem Replace. 4. Not enough pressure in tires Adjust. Wobbly handlebars 1. Loss of balance between right and left front forks Adjust. 2. Distorted front fork Repair or replace. 3. Distorted front axle or crooked tire Replace. 4. Loose steering stem nut Adjust. 5. Worn or incorrect tire or wrong tire pressure Adjust or replace. 6. Worn bearing/race in steering stem Replace. Wobbly front wheel 1. Distorted wheel rim Replace. 2. Worn front wheel bearings Replace. 3. Defective or incorrect tire Replace. 4. Loose axle or axle pinch bolt Retighten. 5. Incorrect front fork oil level Adjust. 6. Incorrect front wheel weight balance Adjust. Front suspension 1. Weakened springs Replace. too soft 2. Not enough fork oil Replenish. E 3. Wrong weight fork oil Replace. 4. Improperly set front fork spring adjuster LAdjust. 5. Improperly set front fork damping force adjuster Adjust. Front suspension 1. Too viscous fork oil P Replace. too stiff 2. Too much fork oil M Drain excess oil. 3. Improperly set front fork spring adjuster Adjust. 4. Improperly set front fork damping force adjuster Adjust. A 5. Bent front axle Replace. Noisy front suspen- 1. Not enough fork oil Replenish. S sion 2. Loose bolts on suspension Retighten. Wobbly rear wheel 1. Distorted wheel rim Replace. 2. Worn rear wheel bearing or swingarm bearings Replace. 3. Defective or incorrect tire Replace. 4. Worn swingarm and rear suspension bearings Replace. 5. Loose nuts or bolts on rear suspensions Retighten. Rear suspension 1. Weakened spring of shock absorber Replace. too soft 2. Leakage of oil or gas shock absorber Replace. 3. Improperly set rear spring pre-load adjuster Adjust. 4. Improperly set damping force adjuster Adjust. Rear suspension 1. Bent shock absorber shaft Replace. too stiff 2. Bent swingarm pivot shaft Replace. 3. Worn swingarm and rear suspension bearings Replace. 4. Improperly set rear spring pre-load adjuster Adjust. 5. Improperly set damping force adjuster Adjust. Noisy rear suspen- 1. Loose nuts or bolts on rear suspension Retighten. sion 2. Worn swingarm and suspension bearings Replace.
SERVICING INFORMATION 10-15 BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system Repair or replace. power 2. Worn pads Replace. 3. Oil adhesion of engaging surface of pads/shoe Clean disc and pads. 4. Worn disc Replace. 5. Air in hydraulic system Bleed air. 6. Not enough brake fluid in the reservoir Replenish. Brake squeaking 1. Carbon adhesion on pad surface Repair surface with sandpaper. 2. Tilted pad Correct pad fitting or replace. 3. Damaged wheel bearing Replace. 4. Loosen front wheel axle or rear wheel axle Tighten to specified torque. 5. Worn pads Replace. 6. Foreign material in brake fluid Replace brake fluid. 7. Clogged return port of master cylinder Disassemble and clean master cylinder. Excessive brake 1. Air in hydraulic system Bleed air. E lever stroke 2. Insufficient brake fluid Replenish fluid to specified L level; bleed air. 3. Improper quality of brake fluid Replace with correct fluid. P Leakage of brake 1. Insufficient tightening of connection joints Tighten to specified torque. fluid 2. Cracked hose M Replace. 3. Worn piston and/or cup Replace piston and/or cup. Brake drags 1. Rusty part Clean and lubricate. A 2. Insufficient brake lever or brake pedal Lubricate. pivot lubrication S
10-16 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective spark plugs Replace. 3. Defective CKP sensor Replace. 4. Defective ECM Replace. 5. Defective TO sensor Replace. 6. Open-circuited wiring connections Check and repair. Spark plug soon 1. Mixture too rich Inspect FI system. become fouled with 2. Idling speed set too high Adjust fast idle or throttle carbon. stop screw. 3. Incorrect gasoline Change. 4. Dirty air cleaner element Replace. 5. Too cold spark plugs Replace with hot type plug. Spark plug become 1. Worn piston rings Replace. fouled too soon. 2. Worn piston or cylinders Replace. 3. Excessive clearance of valve stems in valve Replace. guides 4. Worn stem oil seal Replace. Spark plug elec- 1. Too hot spark plugs Replace with cold type E trodes overheat or plugs. burn 2. Overheated the engine LTune up. 3. Loose spark plugs P Retighten. 4. Too lean mixture Inspect FI system. Generator does not 1. Open- or short-circuited lead wires, or loose lead Repair or replace or charge. connections M retighten. 2. Short-circuited, grounded or open generator coil Replace. A 3. Short-circuited or punctured regulator/rectifier Replace. Generator does 1. Lead wires tend to get shorted or open-circuited Repair or retighten. S charge, but charg- or loosely connected at terminals. ing rate is below the 2. Grounded or open-circuited generator coil Replace. specification. 3. Defective regulator/rectifier Replace. 4. Defective cell plates in the battery Replace the battery. Generator over- 1. Internal short-circuit in the battery Replace the battery. charges 2. Damaged or defective regulator/rectifier Replace. 3. Poorly grounded regulator/rectifier Clean and tighten ground connection. Unstable charging 1. Lead wire insulation frayed due to vibration, Repair or replace. resulting in intermittent short-circuiting. 2. Internally shorted generator Replace. 3. Defective regulator/rectifier Replace. Starter button is not 1. Run down battery Repair or replace. effective. 2. Defective switch contacts Replace. 3. Brushes not seating properly on starter motor Repair or replace. commutator 4. Defective starter relay/starter interlock switch Replace. 5. Defective main fuse Replace.
SERVICING INFORMATION 10-17 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates Battery runs down 1. Trouble in the charging system Check the generator, regu- quickly. lator/rectifier and circuit connections and make nec- essary adjustments to obtain specified charging operation. 2. Cell plates have lost much of their active Replace the battery and material as a result of overcharging. correct the charging sys- tem. 3. Internal short-circuit in the battery Replace the battery. 4. Too low battery voltage Recharge the battery fully. 5. Too old battery Replace the battery. Battery “sulfation” 1. Incorrect charging rate Replace the battery. E (When not in use batteries should be checked at least once a month to avoid sulfation.) L 2. The battery was left unused in a cold climate for Replace the battery if badly too long. P sulfated. M A S
10-18 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Engine ground lead wire TO sensor Engine ground lead wire Fuel shut-off valve TO sensor Regulator/Rectifier Clamp Fixed clamp To brake light Clutch cable switch Clamp To brake light E-33 only Regulator/Rectifier switch Clamp PAIR control ECM solenoid valve Clamp E Fixed clamp Clamp Fixed clamp Clamp Fixed L CMP sensor clamp Fixed clamp Secondary PTo regulator/rectifier fuel injector To generator M ATo speed Clamp S sensor IAP sensor Primary fuel injector Fixed clamp Clamp Wiring harness must be passed under the license lead wire. Fixed clamp ECM rubber cushion Fixed clamp FUSE Clamp Side-stand switch Speed sensor Pass the generator lead wire between the water hoses.
SERVICING INFORMATION 10-19 Clamp (After binding the lead wires, cut the clamp end.) Clamp Locate the junction of the wire harness to the center of the headlight. Clamp (After binding the lead wires, cut the clamp end.) Backside of the headlight 10 mm (0.4 in) E PL Immobilizer label M Backside of the fuel tank (E-02, 19, 24) A Wire harness protector tape IAT sensor S STP sensor STV actuator TP sensor Guide Cooling fan lead wire Brake light switch CKP sensor Oil pressure switch Clamp
10-20 SERVICING INFORMATION Clamp Clamp Grommet CKP sensor GP switch lead wire GP switch lead wire is made to slacken. Oil pressure switch GP switch 14 N·m 1.4 kgf-m ( ) 10.0 lb-ft 5 N·m (0.5 kgf-m, 3.5 lb-ft)E 1.5 N·m PL (0.15 kgf-m, 1.0 lb-ft) AM 10 N·m S (1.0 kgf-m, 7.0 lb-ft) Engine ground lead wire 6 N·m (0.6 kgf-m, 4.5 lb-ft) Clamp 45˚ Generator Clamp Grommet 11 N·m 4.5 N·m 1.1 kgf-m 0.45 kgf-m ( ) ( ) 3.0 lb-ft 8.0 lb-ft Speed sensor
SERVICING INFORMATION 10-21 CABLE ROUTING Clutch cable, Part No. Clutch cable, Lot No. Clutch cable guide Wiring harness Clutch cable *1 Throttle cable guide Water bypass hose Clutch cable *3 guide E LClutch cable Throttle cable *2 P M A Throttle cable guide S Throttle cable No. 1 0 mm (0 in) Clutch cable Throttle cable No. 2 0 mm (0 in) 0 mm (0 in) Pass the throttle cable No. 1 through over the Be careful not to bind the water bypass hose *1 throttle cable No. 2. *3 between the clutch cable and cylinder head cover. *2 Pass the clutch cable through outside of the water bypass hose.
10-22 SERVICING INFORMATION THROTTLE BODY HOSE ROUTING E L P M A S 1 Fuel feed hose 4 Purge hose (E-33 only) 2 PCV (breather) hose 5 Surge hose (E-33 only) 3 IAP sensor vacuum hose 6 EVAP canister (E-33 only)
SERVICING INFORMATION 10-23 FUEL TANK DRAIN HOSE ROUTING *1 E L P *2 M A 45˚ 45˚ S *3 *3 1 Fuel feed hose 5 Hose clamp 2 Breather hose *1 Pass the breather hose 2 and drain hose 3 through under the wiring harness. 3 Drain hose *2 Pass the breather hose 2 and drain hose 3 through ahead of the fuse box. 4 Wiring harness *3 White painted marking
10-24 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING : The ends of the clamp should face..... : The clamp screw head should face..... Hose clamp bolt tightening torque: 2 N·m (0.2 kgf-m, 1.5 lb-ft) Backward. Marking (White) Backward. Backward. Backward. Air bleeder 6 N·m 0.6 kgf-m ( ) 4.5 lb-ft Backward. Right side. Right down side. Left side. Left side. E Marking (Green) L Union bolt 12 N·m (1.2 kgf-m, 8.5 lb-ft) P Jiggle valve M Left side. Marking A (Green) S Thermostat Marking (White) Marking (Red) Marking Left side. (Green) Left down side. Marking (White) Left side. Left down side. Marking 45˚ Marking (White) Align the marking with the rib of pipe. Do not touch the end of clamp to the hose.
SERVICING INFORMATION 10-25 FRONT BRAKE HOSE ROUTING *1 1 – 2 mm (0.04 – 0.08 in) 49˚ *2 42˚ *3 *5 *4 E *4 L P 14˚ M 42˚ 42˚ A *3 S *3 *7 *6 *1 Clamp ends should face downward. *5 After positioning the clamp with stopper, tighten the clamp bolt. *2 Clamp ends should face backward. *6 Insert the clamp to the hole of the front fender fully. *3 After the brake hose union has contacted the *7 The green paint is right side and face upside. stopper, tighten the union bolt. *4 Clamp the brake hose firmly. A Brake hose guide
10-26 SERVICING INFORMATION REAR BRAKE HOSE ROUTING *2 28˚ *1 *3 E *1 L P M A *1 S 5˚ *2 *1 Clamp ends should face backward. *3 White paint faces topside. *2 After the brake hose union has contacted the stopper, tighten the union bolt.
SERVICING INFORMATION 10-27 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING E L P M AApprox. Approx. Approx. S 0˚ 0˚ 45˚ *1 1 PAIR control solenoid valve 3 Air cleaner box 2 PAIR reed valve *1 To air cleaner box
10-28 SERVICING INFORMATION FUEL TANK INSTALLATION 2 mm (0.08 in) 5 mm (0.20 in) 4 mm (0.16 in) E L P M A S A Apply an adhesive agent. 3 Fuel tank cover 1 Velcro fastening 4 Fuel tank side cushion 2 Frame cover cushion
SERVICING INFORMATION 10-29 FUEL TANK LOWER SIDE COVER CUSHION RUBBER/ FASTENER INSTALLATION 33 – 39 mm (1.30 – 1.54 in) 41 – 47 mm (1.61 – 1.85 in) PLE 1 Cushion tape 2 Velcro fastening 3 Cushion rubber AM AIR INTAKE PIPE CUSHION RUBBER INSTALLATION S Align the cushion rubber to the aligned mark. NOTE: Clean an adhesive surface before adhering the cushion rubber.
10-30 SERVICING INFORMATION COWLING INSTALLATION Windscreen Cowling brace Right under cowling cover Body cowling Frame Cushion Left under rubber cowling cover Clamp connector E EB L Right under cowling P “A” Oil pan Left air intake pipe Left air intake M cover To “J” Right air intake Right air intake cover pipe A “D” Left under Right-side S cowling cowling “C” To “H” J Left-side cowling To “F” Steering stem lower Left under inner cowling bracket cover To “G” Front under cowling To “I” To frame Body cowling “F” cover “I” “H” To “E” To “D” To “B” “G” To “C” Right under inner cowling To “A” Center under cowling
SERVICING INFORMATION 10-31 FRAME COVER INSTALLATION PLE SEAT LOCK CABLE ROUTING M SA
10-32 SERVICING INFORMATION REAR FENDER INSTALLATION *1 35 mm (1.38 in) E L P M A S 1 Seat rail 5 Rear fender (lower) 2 Rear fender (front) 6 Chain cover No.1 3 Rear fender cover (front) 7 Swingarm 4 Rear fender (rear) *1 Cushion rubber
SERVICING INFORMATION 10-33 UNDER COWLING HEAT SHIELD INSTALLATION Forward Up side 1 mm (0.04 in) 1 mm (0.04 in) 1 mm E (0.04 in) PL 15 mm M(0.59 in) A 15 mm S (0.59 in) 2 mm (0.08 in) 10 mm (0.4 in) 2 mm (0.08 in) 1 Left under cowling 3 Heat shield (L) 5 Fuel tank hose clamp 2 Right under cowling 4 Heat shield (R) NOTE: Clean an adhesive surface before adhering the heat shield.
10-34 SERVICING INFORMATION BODY COWLING COVER CUSHION INSTALLATION 15 mm 15 mm (0.59 in) (0.59 in) 25 mm (0.98 in) E PL WINDSCREEN TAPE CUSHION INSTALLATION SAM 4 mm (0.16 in) 10 mm (0.40 in) 10 mm (0.40 in) 5 mm (0.20 in) 4 mm (0.16 in) 7 mm (0.28 in)
SERVICING INFORMATION 10-35 HEADLIGHT TAPE CUSHION INSTALLATION 3 – 7 mm (0.12 – 0.28 in) E PL AIR INTAKE COVER TAPE CUSHION INSTALLATION SAM NOTE: Align the tape cushion to the aligned mark. Clean an adhesive surface before adhering the tape cushion.
10-36 SERVICING INFORMATION SIDE-STAND INSTALLATION (USA) (Others) 50 N·m (5.0 kgf-m, 36.0 lb-ft) 40 N·m (4.0 kgf-m, 29.0 lb-ft) 50 N·m (5.0 kgf-m, 36.0 lb-ft) E PL GEARSHIFT PEDAL INSTALLATION AM S Footrest 50 – 60 mm (1.97 – 2.36 in)
SERVICING INFORMATION 10-37 HANDLEBAR BALANCER 1 Handlebar 4 Handle balancer expander E 2 Throttle grip 5 Handlebar balancer ITEM N·m kgf-m lb-ft 3 Nut 6 Screw PL A 5.5 0.5 4.0 FRONT FOOTREST INSTALLATION SAM *1 . 18 N m (1.8 kgf-m, 13.0 lb-ft) 1 Footrest 5 Spring 2 Bank sensor 6 E-ring 3 Holder *1 Align the cutaway. 4 Pin
10-38 SERVICING INFORMATION REAR VIEW MIRROR INSTALLATION E*A MPL SA 1 Body cowling 5 Turn signal lead wire coupler 2 Cowling brace 6 Mirror cover 3 Cushion 7 Mirror body 4 Turn signal lead wire *A Locate the turn signal lead wire coupler 5 between the mirror cover 6 and mirror body 7.
SERVICING INFORMATION 10-39 REAR COMBINATION LIGHT INSTALLATION * A (2 pcs.) (2 pcs.) (2 pcs.) E PL SAM (2 pcs.) (2 pcs.) . 2.0 N m (0.2 kgf-m, 1.5 lb-ft) 1 Frame cover 5 License plate light 2 Brake light/Taillight cushion 6 Rear fender 3 Brake light/Taillight *A Align the brake light/Taillight cushion to the parting line. 4 Brake light/Taillight bracket
10-40 SERVICING INFORMATION REGULATOR/RECTIFIER INSTALLATION FWD 20 mm (0.8 in) E PL SAM 1 Regulator/Rectifier 2 Battery holder rubber cushion NOTE: To remove or install the regulator/rectifier easily, hold its bolt head with an open-end wrench.
SERVICING INFORMATION 10-41 SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-20203 09900-06108 Hexagon socket 09900-20102 Micrometer Micrometer Snap ring pliers (24 mm) Vernier calipers (25 – 50 mm) (50 – 75 mm) 09900-20205 09900-20602 09900-20605 09900-20607 Micrometer 09900-20508 Dial gauge Dial calipers Dial gauge (0 – 25 mm) Cylinder gauge set (1/1000 mm, 1 mm) (1/100 mm, 10 – 34 mm) (1/100 mm, 10 mm) E L P 09900-20803 M 09900-22301 09900-20701 09900-20806 09900-20805 09900-21304 09900-22302 A Magnetic stand Thickness gauge Tire depth gauge V-block set (100 mm) Plastigauge S 09900-22401 (10 – 18 mm) 09900-25009 09900-28630 09900-22403 (18 – 35 mm) 09900-25008 Needle pointed TPS test wire har- 09910-20115 Small bore gauge Multi circuit tester set probe set ness Conrod stopper
10-42 SERVICING INFORMATION 09913-13121 09913-10750 Vacuum balancer 09913-50121 09913-70210 09915-40610 Adapter gauge Oil seal remover Bearing installer set Oil filter wrench 09915-64512 09915-74521 09915-74540 09915-77331 Compression gauge Oil pressure gauge Oil pressure gauge Meter 09916-10911 set hose attachment (for high pressure) Valve lapper set E L P 09916-14530 09916-21111 09916-20630 09916-20640 M 09916-14510 Valve lifter attach- Valve seat cutter Valve seat cutter Solid pilot Valve lifter ment set (N-126) (N-100-4.5) A S 09916-33210 09916-33320 09916-43211 09916-53310 Valve guide reamer Valve guide reamer 09916-34542 Valve guide Valve guide (4.5 mm) (9.8 mm) Reamer handle remover/installer remover/installer
SERVICING INFORMATION 10-43 09917-47011 09920-34830 09920-53740 09916-53330 09916-84511 Vacuum pump Starter clutch Clutch sleeve hub Attachment Tweezers gauge holder holder 09922-22711 09921-20210 09921-20240 Drive chain cutting 09923-74511 09924-84510 Bearing remover Bearing remover set and joining tool Bearing remover Bearing installer set E L P 09925-18011 M 09924-84521 Steering bearing 09930-11920 09930-11940 09930-11950 Bearing installer set installer Torx bit JT40H Bit holder Torx wrench A S 09930-82720 09940-14911 09930-30104 09930-34980 09930-44520 Mode selection Steering stem nut Sliding shaft Rotor remover Rotor holder switch wrench
10-44 SERVICING INFORMATION 09940-14940 09940-14990 09940-14960 Swingarm pivot Engine mounting 09940-30221 09940-40211 Steering nut thrust adjuster thrust adjuster Front fork assem- Fuel pressure wrench socket socket wrench socket wrench bling tool gauge adaptor 09940-40220 09940-50120 09940-52861 09940-94922 Fuel pressure gauge Front fork inner Front fork oil seal 09940-92720 Front fork spring hose attachment rod holder installer Spring scale stopper plate E L P 09940-94930 09941-34513 M09944-28320 Front fork spacer Steering race 09943-74111 Hexagon socket 09904-41010 holder installer A SFork oil level gauge (19 mm) SDS Set 99565-01010-006 CD-ROM Ver. 6 NOTE: When order the special tool, please confirm whether it is available or not.
SERVICING INFORMATION 10-45 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Exhaust pipe bolt 23 2.3 16.5 Muffler connecting bolt 23 2.3 16.5 Muffler mounting bolt 23 2.3 16.5 Speed sensor rotor bolt 25 2.5 18.0 Speed sensor bolt 4.5 0.45 3.0 Engine sprocket nut 115 11.5 83.0 Engine mounting bolt and nut (M: 12) 75 7.5 54.0 (M: 10) 55 5.5 39.8 Engine mounting thrust adjuster 23 2.3 16.5 Engine mounting thrust adjuster lock-nut 45 4.5 32.5 Engine mounting pinch bolt 23 2.3 16.5 Cylinder head cover bolt Initial 10 1.0 7.0 Final 14 1.4 10.0 Spark plug 11 1.1 8.0 Cam chain guide bolt 10 1.0 7.0 Camshaft journal holder bolt 10E 1.0 7.0 Cam chain tension adjuster cap bolt 23 2.3 16.5 Cam chain tension adjuster mounting bolt 10 1.0 7.0 L Cam chain tensioner bolt P 10 1.0 7.0 Cylinder head bolt (M: 10) Step 1/step 3 31 3.1 22.5 Final step 60° M 10 1.0 7.0 (M: 6) PAIR reed valve cover bolt A 10 1.0 7.0 Water jacket plug 9.5 0.95 6.9 Water inlet cover bolt S 10 1.0 7.0 Clutch cover bolt 10 1.0 7.0 Clutch sleeve hub nut 95 9.5 68.5 Clutch spring set bolt 10 1.0 7.0 Clutch release adjuster cap 11 1.1 8.0 Clutch lifter adjuster lock-nut 23 2.3 16.5 Starter clutch cover bolt 10 1.0 7.0 Starter idle gear cover bolt 10 1.0 7.0 Valve timing inspection plug 11 1.1 8.0 Starter clutch bolt 55 5.5 40.0 Generator cover bolt 10 1.0 7.0 Generator rotor bolt 120 12.0 87.0 Generator stator set bolt 10 1.0 7.0 Gearshift cam stopper bolt 10 1.0 7.0 Gearshift cam stopper plate bolt 13 1.3 9.5 Oil pressure switch 14 1.4 10.0 Oil filter 20 2.0 14.5
10-46 SERVICING INFORMATION ITEM N·m kgf-m lb-ft Crankcase bolt (M: 6) (Initial) 6 0.6 4.5 (Final) 11 1.1 8.0 (M: 8) (Initial) 15 1.5 11.0 (Final) 26 2.6 19.0 Crankshaft journal bolt (M: 9) (Initial) 18 1.8 13.0 (Final) 50° Oil gallery plug (M: 6) 10 1.0 7.0 (M: 8) 18 1.8 13.0 (M: 10) 18 1.8 13.0 (M: 16) 35 3.5 25.5 Oil drain plug 23 2.3 16.5 Piston cooling oil jet bolt 10 1.0 7.0 Oil pump mounting bolt 10 1.0 7.0 Conrod bearing cap bolt (Initial) 37 3.7 27.0 (Final) 60° (1/6 turn) Bearing retainer screw 10 1.0 7.0 Breather cover bolt 10 1.0 7.0 Oil strainer bolt 10 1.0 7.0 Oil pan bolt 10 1.0 7.0 E Oil cooler mounting bolt 10 1.0 7.0 L Oil cooler union bolt 10 1.0 7.0 Water bypass union 12 1.2 8.5 P Gearshift fork shaft retainer bolt 10 1.0 7.0 Starter motor mounting bolt M 10 1.0 7.0 A FI SYSTEM AND INTAKE AIR SYSTEM S N·m kgf-m lb-ft ITEM CKP sensor mounting bolt 8 0.8 6.0 IAT sensor 18 1.8 13.0 Fuel delivery pipe mounting screw 3.5 0.35 2.5 Fuel pump mounting bolt 10 1.0 7.0 TPS and STPS mounting screw 3.5 0.35 2.5 EXCVA mounting bolt 10 1.0 7.0 EXCVA pulley mounting bolt 5 0.5 3.5 COOLING SYSTEM ITEM N·m kgf-m lb-ft Impeller securing bolt 8 0.8 6.0 Water pump cover screw 5 0.5 3.5 Water pump mounting bolt 10 1.0 7.0 Cooling fan mounting bolt 8 0.8 6.0 ECT sensor 18 1.8 13.0 Thermostat cover bolt 10 1.0 7.0 Thermostat air bleeder bolt 6 0.6 4.5
SERVICING INFORMATION 10-47 CHASSIS ITEM N·m kgf-m lb-ft Steering stem head nut 90 9.0 65.0 Steering stem lock-nut 90 9.0 65.0 Steering damper bolt and nut 23 2.3 16.5 Front fork upper clamp bolt 23 2.3 16.5 Front fork lower clamp bolt 23 2.3 16.5 Front fork cap bolt 23 2.3 16.5 Front fork inner rod lock-nut 29 2.9 21.0 Front fork damper rod bolt 23 2.3 16.5 Front axle bolt 100 10.0 72.5 Front axle pinch bolt 23 2.3 16.5 Handlebar clamp bolt 23 2.3 16.5 Front brake master cylinder mounting bolt 10 1.0 7.0 Front brake caliper mounting bolt 39 3.9 28.0 Front brake caliper housing bolt 22 2.2 16.0 Front brake pad mounting pin 15 1.5 11.0 Brake hose union bolt 23 2.3 16.5 Clutch lever holder mounting bolt 10E 1.0 7.0 Air bleeder valve (Front brake caliper) 7.5 0.75 5.5 Air breeder valve (Master cylinder and Rear brake caliper) 6.0 0.6 4.3 L Brake disc bolt (Front) P 23 2.3 16.5 Brake disc bolt (Rear) 35 3.5 25.5 Rear brake caliper mounting bolt M 25 2.5 18.0 Rear brake caliper housing bolt 37 3.7 27.0 Rear brake pad mounting pin A 17 1.7 12.5 Rear brake master cylinder mounting bolt 10 1.0 7.0 S Rear brake master cylinder rod lock-nut 18 1.8 13.0 Front footrest bracket mounting bolt 23 2.3 16.5 Swingarm pivot shaft 15 1.5 11.0 Swingarm pivot nut 100 10.0 72.5 Swingarm pivot lock-nut 90 9.0 65.0 Swingarm pivot boss nut 65 6.5 47.0 Cushion lever mounting nut 78 7.8 56.5 Cushion rod mounting nut 78 7.8 56.5 Rear shock absorber mounting bolt and nut 50 5.0 36.0 (Upper and Lower) Rear axle nut 100 10.0 72.5 Rear sprocket nut 93 9.3 67.5 Side-stand mounting bracket bolt 50 5.0 36.0 Cowling brace bolt and nut 23 2.3 16.5 Rear shock absorber bracket nut 115 11.5 83.0 Seat rail bolt 50 5.0 36.0 Rear view mirror nut 10 1.0 7.0
10-48 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 1.0 7.0 8 13 1.3 9.5 23 2.3 16.5 10 29 2.9 21.0 50 5.0 36.0 12 45 4.5 32.5 85 8.5 61.5 14 65 6.5 47.0 135 13.5 97.5 16 105 10.5 76.0 210 21.0 152.0 18 160 16.0 115.5 240 24.0 173.5 Conventional bolt “4” marked bolt “7” marked bolt E PL SAM
SERVICING INFORMATION 10-49 SERVICE DATA VALVE + VALVE GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN. 30 — (1.18) EX. 24 — (0.94) Valve clearance (when cold) IN. 0.10 – 0.20 — (0.004 – 0.008) EX. 0.20 – 0.30 — (0.008 – 0.012) Valve guide to valve stem IN. 0.010 – 0.037 — clearance (0.0004 – 0.0015) EX. 0.030 – 0.057 — (0.0012 – 0.0022) Valve guide I.D. IN. & EX. 4.500 – 4.512 — (0.1772 – 0.1776) Valve stem O.D. IN. 4.475 – 4.490 — (0.1762 – 0.1768) EX. 4.455 – 4.470 — (0.1754 – 0.1760) Valve stem deflection IN. & EX. — 0.25 E (0.010) Valve stem runout IN. & EX. — 0.05 L (0.002) Valve head thickness IN. & EX. P — 0.5 (0.02) Valve seat width IN. & EX. 0.9 – 1.1 — M (0.035 – 0.043) Valve head radial runout IN. & EX. — 0.03 A (0.001) Valve spring free length SIN. & EX. — 37.5 (1.48) Valve spring tension IN. & EX. Approx. 147 N (15.0 kgf, 33.1 lbs) — at length 33.55 mm (1.32 in) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height IN. 37.58 – 37.63 37.28 (1.480 – 1.481) (1.468) EX. 36.28 – 36.33 35.98 (1.428 – 1.430) (1.417) Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 — (0.9454 – 0.9459) Camshaft journal O.D. IN. & EX. 23.959 – 23.980 — (0.9433 – 0.9441) Camshaft runout — 0.10 (0.004) Cam chain pin (at arrow “3”) 14th pin — Cylinder head distortion — 0.20 (0.008)
10-50 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 300 – 1 700 kPa 1 000 kPa 2 (13 – 17 kgf/cm², 185 – 242 psi) (10 kgf/cm , 142 psi) Compression pressure difference — 200 kPa 2 (2 kgf/cm , 28 psi) Piston to cylinder clearance 0.035 – 0.045 0.120 (0.0014 – 0.0018) (0.0047) Cylinder bore 73.400 – 73.415 Nicks or (2.8900 – 2.8903) Scratches Piston diam. 73.360 – 73.375 73.280 (2.8882 – 2.8888) (2.8850) Measure at 15 mm (0.6 in) from the skirt end. Cylinder distortion — 0.02 (0.008) Piston ring free end gap 1st Approx. 6.5 (0.26) 5.2 (0.20) 2nd T Approx. 8.0 (0.31) 6.4 (0.25) Piston ring end gap 1st 0.06 – 0.18 0.50 (0.002 – 0.007) (0.020) 2nd T 0.06 – 0.18 0.50 (0.002 – 0.007) E (0.020) Piston ring to groove clearance 1st — 0.180 L (0.0071) 2nd — 0.150 P (0.0059) Piston ring groove width 1st 1.30 – 1.32 — (0.0512 – 0.0520) M0.81 – 0.83 2nd (0.0319 – 0.0327) — A 1.51 – 1.53 SOil (0.0594 – 0.0602) — Piston ring thickness 1st 1.08 – 1.10 — (0.0425 – 0.0433) 2nd 0.77 – 0.79 — (0.0303 – 0.0311) Piston pin bore I.D. 15.002 – 15.008 15.030 (0.5906 – 0.5909) (0.5917) Piston pin O.D. 14.995 – 15.000 14.980 (0.5903 – 0.5906) (0.5898)
SERVICING INFORMATION 10-51 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 15.010 – 15.018 15.040 (0.5909 – 0.5913) (0.5921) Conrod big end side clearance 0.10 – 0.20 0.30 (0.004 – 0.008) (0.012) Conrod big end width 19.95 – 20.00 — (0.7854 – 0.7874) Crank pin width 20.10 – 20.15 — (0.7913 – 0.7933) Conrod big end oil clearance 0.032 – 0.056 0.080 (0.0013 – 0.0022) (0.0031) Crank pin O.D. 34.976 – 35.000 — (1.3770 – 1.3780) Crankshaft journal oil clearance 0.010 – 0.028 0.080 (0.0004 – 0.0011) (0.0031) Crankshaft journal O.D. 34.982 – 35.000 — (1.3772 – 1.3780) Crankshaft thrust bearing thickness Right side 2.420 – 2.440 — (0.0953 – 0.0961) Left side 2.360 – 2.500 — (0.0929 – 0.0984) Crankshaft thrust clearance 0.060 – 0.110 E — (0.0024 – 0.0043) Crankshaft runout L 0.05 — (0.002) P BALANCER M Unit: mm (in) ITEM STANDARD LIMIT Balancer shaft journal oil clearance 0.028 – 0.052 0.080 A (0.0011 – 0.0020) (0.0031) Balancer shaft journal O.D. 22.976 – 22.992 S (0.9046 – 0.9052) — OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60 °C, 140 °F) 100 – 400 kPa (1.0 – 4.0 kgf/cm², 14 – 57 psi) — at 3 000 r/min
10-52 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/2 turn back — Drive plate thickness No. 1, 2 and 3 2.72 – 2.88 2.42 (0.107 – 0.113) (0.095) Drive plate claw width No. 1, 2 and 3 13.85 – 13.96 13.05 (0.5453 – 0.5496) (0.5138) Driven plate distortion — 0.10 (0.004) Clutch spring free height 57.01 54.2 (2.244) (2.134) Clutch lifter adjusting pin screw 0.2 – 0.4 — height (0.008 – 0.016) Wave spring washer height — 4.30 (0.169) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 1.553 (73/47) — Final reduction ratio 2.470 (42/17) E — Gear ratios Low 2.562 (41/16) — L 2nd 2.052 (39/19) — 3rd 1.714 (36/21) — P 4th 1.500 (36/24) — 5th 1.360 (34/25) — M Top A 1.269 (33/26) — Shift fork to groove clearance 0.10 – 0.30 0.50 S (0.004 – 0.012) (0.020) Shift fork groove width 5.0 – 5.1 — (0.197 – 0.201) Shift fork thickness 4.8 – 4.9 — (0.189 – 0.193) Drive chain Type DID530 V9 — Links 110 links — 20-pitch length — 319.4 (12.57) Drive chain slack (on side-stand) 20 – 30 — (0.79 – 1.18) Gearshift lever height 50 – 60 — (1.97 – 2.36)
SERVICING INFORMATION 10-53 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 82 °C (180 °F) — ature Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) — ECT sensor resistance 20 °C Approx. 2.45 kΩ — (68 °F) 50 °C Approx. 0.811 kΩ — (122 °F) 80 °C Approx. 0.318 kΩ — (176 °F) 110 °C Approx. 0.142 kΩ — (230 °F) Radiator cap valve opening pres- 93 – 123 kPa — sure (0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi) Cooling fan operating temperature OFF→ON Approx. 105 °C (221 °F) — ON→OFF Approx. 100 °C (212 °F) — Engine coolant type Use an antifreeze/coolant compatible with alumi- num radiator, mixed with distilled water only, at the — ratio of 50:50. Engine coolant Reserve Approx. 250 ml — tank side (0.3/0.2 US/lmp qt) E Engine Approx. 2 150 ml — side (2.3 – 1.9 US/lmp qt) L P INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE Injector resistance M (primary and secondary) A 11 – 13 Ω at 20 °C (68 °F) Fuel pump discharge amount 168 ml (5.7/5.9 US/lmp oz) and more/10 sec. S Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm², 43 psi) set pressure
10-54 SERVICING INFORMATION FI SENSORS ITEM SPECIFICATION NOTE CMP sensor resistance 0.9 – 1.7 kΩ CMP sensor peak voltage 0.5 V and more When cranking CKP sensor resistance 142 – 194 Ω 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. 2.6 V at idle speed TP sensor input voltage 4.5 – 5.5 V TP sensor resistance Approx. 4.68 kΩ Closed Approx. 1.1 kΩ Opened Approx. 4.3 kΩ TP sensor output voltage Closed Approx. 1.1 V Opened Approx. 4.3 V ECT sensor input voltage 4.5 – 5.5 V ECT sensor output voltage 0.15 – 4.85 V ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F) IAT sensor input voltage 4.5 – 5.5 V IAT sensor output voltage 0.15 – 4.85 V IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F) E AP sensor input voltage 4.5 – 5.5 V L AP sensor output voltage Approx. 2.6 V at 760 mmHg (100 kPa) P TO sensor resistance 16.5 – 22.3 kΩ TO sensor voltage Normal M0.4 – 1.4 V Leaning 3.7 – 4.4 V When A leaning 65° GP switch voltage 0.6 V and more From 1st to Top Injector voltage S Battery voltage Ignition coil primary peak voltage 80 V and more When cranking STP sensor input voltage 4.5 – 5.5 V STP sensor resistance Approx. 4.69 kΩ Closed Approx. 0.5 kΩ Opened Approx. 3.9 kΩ STP sensor output voltage Closed Approx. 0.5 V Opened Approx. 3.9 V STV actuator resistance Approx. 6.5 Ω EXCVA position sensor input volt- 4.5 – 5.5 V age EXCVA position sensor resistance Approx. 3.1 kΩ At adjustment position EXCVA position sensor output volt- Closed 0.5 – 1.3 V age Opened 3.7 – 4.5 V PAIR control solenoid valve resis- 18 – 22 Ω at 20 – 30 °C (68 – 86 °F) tance
SERVICING INFORMATION 10-55 THROTTLE BODY ITEM SPECIFICATION Bore size 44 mm I.D. No. 41G1 (For E-33), 41G0 (For the others) Idle r/min 1 150 ± 100 r/min Fast idle r/min 1 400 – 2 000 r/min (When cold engine) Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1.2.4.3 Spark plug Type NGK: CR9E DENSO: U27ESR-N Gap 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. CKP sensor resistance 142 – 194 Ω CKP sensor peak voltage 0.5 V and more Ignition coil resistance Primary 1.1 – 1.9 Ω Terminal – E Terminal Secondary 10.8 – 16.2 kΩ Plug cap – L Terminal Ignition coil primary peak voltage 80 V and more P Generator coil resistance 0.2 – 0.9 Ω Generator no-load voltage 65 V (AC) and more at 5 000 r/min (When engine is cold) M Regulated voltage A14.0 – 15.5 V at 5 000 r/min Starter relay resistance S 3 – 6 Ω GP switch voltage 0.6 V and more (From 1st to Top) Battery Type FT12A-BS designation Capacity 12 V 36 kC (10 Ah)/10 HR Fuse size Headlight HI 10 A LO 15 A Signal 10 A Ignition 10 A Fuel 10 A Fan 15 A Main 30 A
10-56 SERVICING INFORMATION WATTAGE Unit: W ITEM STANDARD/SPECIFICATION E-03, 28, 33 Others Headlight HI 60 ← LO 55 ← Position/Parking light 5 × 2 ← Brake light/Taillight LED ← Turn signal light 21 × 4 ← License plate light 5 ← Combination meter light LED ← Turn signal indicator light LED ← High beam indicator light LED ← Neutral indicator light LED ← FI indicator light/Oil pressure indi- cator light/Engine coolant temp. LED ← indicator light Fuel level indicator light LED ← Engine RPM indicator light LED ← Immobilizer indicator light ELED BRAKE + WHEEL Unit: mm (in) ITEM STANDARDL LIMIT Rear brake pedal height 55 – 65 — P (2.2 – 2.6) Brake disc thickness Front 5.3 – 5.7 5.0 M(0.209 – 0.224) (0.20) Rear 4.8 – 5.2 4.5 A (0.189 – 0.205) (0.18) Brake disc runout S — 0.30 (0.012) Master cylinder bore Front 19.050 – 19.093 — (0.7500 – 0.7517) Rear 14.000 – 14.043 — (0.5512 – 0.5529) Master cylinder piston diam Front 19.018 – 19.034 — (0.7487 – 0.7494) Rear 13.957 – 13.984 — (0.5495 – 0.5506) Brake caliper cylinder bore Leading 30.280 – 30.356 — Front (1.1921 – 1.1951) Trailing 34.010 – 34.086 — (1.3390 – 1.3420) Rear 38.180 – 38.230 — (1.5031 – 1.5051) Brake caliper piston diam Leading 30.150 – 30.200 — Front (1.1870 – 1.1890) Trailing 33.884 – 33.934 — (1.3340 – 1.3360) Rear 38.080 – 38.130 — (1.4992 – 1.5012) Brake fluid type DOT 4 —
SERVICING INFORMATION 10-57 ITEM STANDARD LIMIT Wheel rim runout Axial — 2.0 (0.08) Radial — 2.0 (0.08) Wheel rim size Front 17 M/C × MT 3.50 — Rear 17 M/C × MT 6.00 — Wheel axle runout Front — 0.25 (0.010) Rear — 0.25 (0.010) TIRE ITEM STANDARD LIMIT Cold inflation tire pressure Front 250 kPa — (Solo riding) (2.50 kgf/cm², 36 psi) Rear 290 kPa — (2.90 kgf/cm², 42 psi) Cold inflation tire pressure Front 250 kPa — (Dual riding) (2.50 kgf/cm², 36 psi) Rear 290 kPa — (2.90 kgf/cm², 42 psi) E Tire size Front 120/70 ZR17 M/C (58 W) — L Rear 190/50 ZR17 M/C (73 W) — Tire type E-02, 19 BRIDGESTONE: — P BT014F SJ Front BRIDGESTONE: Others — M BT014F J A E-02, 19 BRIDGESTONE: — Rear BT014R J S Others BRIDGESTONE: — BT014R E Tire tread depth Front — 1.6 (Recommended depth) (0.06) Rear — 2.0 (0.08)
10-58 SERVICING INFORMATION SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT Front fork stroke 120 — (4.92) Front fork spring free length 230.0 225 (9.06) (8.86) Front fork oil level (without spring, 101 — outer tube fully compressed) (3.98) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (each leg) 510 ml — (17.2/17.9 US/Imp oz) Front fork spring adjuster 4 th groove from top — Front fork damping force adjuster Rebound 11 clicks out from stiffest position — (For E-02, 19) Compression 16 clicks out from stiffest position — Front fork damping force adjuster Rebound 9 clicks out from stiffest position — (For E-03, 24, 28, 33) Compression 14 clicks out from stiffest position — Rear shock absorber spring pre-set 177.6 — length (6.99) Rear shock absorber damping Rebound 12 clicks out from stiffest position — force adjuster Compression 14 clicks out from stiffest position — Rear wheel travel 130 — (5.1) E Swingarm pivot shaft runout — L 0.3 P (0.01) FUEL + OIL ITEM SPECIFICATION NOTE M Fuel type Use only unleaded gasoline of at least 90 pump A octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl S E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible. Gasoline used should be graded 95 octane or Others higher. An unleaded gasoline is recommended. Fuel tank capacity 17.5 L E-33 Including (4.6/3.8 US/lmp gal) reserve 18 L Others (4.8/4.0 US/lmp gal) Fuel level Approx. 4.5 L indicator light (1.2/1.0 US/lmp gal) lighting Engine oil type SAE 10 W-40, API SF/SG or SH/SJ with JASO MA Engine oil capacity Change 3.0 L (3.2/2.6 US/lmp qt) Filter change 3.3 L (3.5/2.9 US/lmp qt) Overhaul 3.6 L (3.8/3.2 US/lmp qt)
EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS...............................................................11- 2 FUEL INJECTION SYSTEM..................................................................11- 2 CRANKCASE EMISSION CONTROL SYSTEM...................................11- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM).............11- 4 NOISE EMISSION CONTROL SYSTEM...............................................11- 5 PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION...............................................................................................11- 6 PAIR HOSES.........................................................................................11- 6 PAIR REED VALVE..............................................................................11- 6 PCV HOSE............................................................................................11- 6 PAIR CONTROL SOLENOID VALVE...................................................11- 6 PAIR (AIR SUPPLY) SYSTEM DIAGRAM..................................................11- 8 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING.......................................11- 9 PLE SAM 11
11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM 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. E L P M A S 1 Fuel tank 7 Fuel feed hose 2 Fuel filter (For high pressure) 8 Fuel mesh filter (For low pressure) 3 Fuel pressure regulator 9 Fuel pump 4 Fuel delivery pipe A Before-pressurized fuel 5 Primary fuel injector B Pressurized fuel 6 Secondary fuel injector C Relieved fuel
EMISSION CONTROL INFORMATION 11-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body. E L P M A S 1 PAIR control solenoid valve B FUEL/AIR MIXTURE 2 PCV hose C BLOW-BY GAS A FRESH AIR D EXHAUST GAS
11-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system, exhaust control system and three-way catalyst system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, IAPS and CKPS. The exhaust gas flow is performed by the exhaust control valve actuator which is controlled by the ECM by changing the exhaust control valve angle. E L P M A S 1 PAIR control solenoid valve 7 Exhaust control valve actuator 2 PAIR reed valve 8 Exhaust control valve 3 Air cleaner box 9 Three-way catalyst (Except for E-03, 24, 28, 33) 4 Primary fuel injector A FRESH AIR 5 Secondary fuel injector B EXHAUST GAS 6 ECM
EMISSION CONTROL INFORMATION 11-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. 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. • Replacing the exhaust system or muffler with a system or muffler not marked with the same model spe- cific code as the code listed on the Motorcycle Noise Emission Control Information label. E L P M A S
11-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses for secure connection. PAIR REED VALVE • Lift and support the fuel tank. (5-3) • Remove the PAIR reed valve cover. (3-27) • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the PAIR reed valve with a new one. PCV HOSE • Remove the PCV hose from the crankcase breather cover. E • Inspect the PCV hose for wear and damage. • If it is worn or damaged, replace the PCV hose with a new L one. P M A PAIR CONTROL SOLENOID VALVE REMOVAL S • Remove the air cleaner box. (5-13) • Disconnect the PAIR control solenoid valve lead wire coupler 1 and PAIR hoses. • Remove the PAIR control solenoid valve 2. INSPECTION • Check that air flows through the air inlet port to the air outlet port. • If air does not flow out, replace the PAIR control solenoid valve with a new one. A Air flow
EMISSION CONTROL INFORMATION 11-7 • Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow. • If air does not flow out, the solenoid valve is in normal condi- tion. 12V • Check the resistance between the terminals of the PAIR con- trol solenoid valve. Resistance: 18 – 22 Ω at 20 – 30 °C (68 – 86 °F) 09900-25008: Multi-circuit tester set Tester knob indication: Resistance (Ω) INSTALLATION E If the resistance is not within the standard range, replace the PAIR control solenoid valve with a new one. L Installation is in the reverse order of removal. P • Connect the PAIR control solenoid valve lead wire coupler and PAIR hoses securely. AM S
11-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM DIAGRAM *1 *1 *2 *3 E L *1 P M A S 1 PAIR control solenoid valve *1 From air cleaner 2 PAIR reed valve *2 To #1 and #2 cylinders A FRESH AIR *3 To #3 and #4 cylinders B EXHAUST GAS
EMISSION CONTROL INFORMATION 11-9 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING E L P M AApprox. Approx. Approx. S 0˚ 0˚ 45˚ *1 1 PAIR control solenoid valve 3 Air cleaner box 2 PAIR reed valve *1 To air cleaner box
WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. IGNITION IGNITION IGNITION IGNITION PAIR COIL #1 COIL #2 COIL #3 COIL #4 SOLENOID ECM T : TURN SIGNAL INDICATOR LIGHT HANDLEBAR SWITCH (R) B : HI BEAM INDICATOR LIGHT ENGINE STOP STARTER FRONT BRAKE N : NEUTRAL INDICATOR LIGHT SWITCH BUTTON SWITCH SIDE STAND F : FUEL INDICATOR LIGHT OFF OFF SWITCH OIL: OIL INDICATOR LIGHT RUN PUSH ON FREE I : IMMOBILIZER INDICATOR LIGHT PUSH GrW/Bl GrB GrY GrG O/WW/G G B/WB/WB/WLg W/GB/YBlB/BrW/RO/BlBl/BBl/GBYGr/BGr/YGr/RBr/YG/RB/BrY/GY/BR/YY/BlBl/RBl/YB/WY/RGrG/BlBrB/BrDgG/YDgrPBY/WGO/GR/BlG/WB/YRB/BlG/BP/BWB/GYB/RR/BP/WW/BB/BrBl/BBl/GBl/RBl/YRO/GWW/RDgrGrB/W Lg/WLg/GLg/Bl Bl/W W/Bl Gr/W B/Lg Bl/W T IGNITION SWITCH BRAKE LIGHT T OIL IMMOBI G B/WSWITCH SPEED ON B O/BO/WB/RB/BlY/GO/RY/WSENSOROFF ON SPEEDOMETER I LOCK OFF N P F B R O Gr Br Y B G R O W/B B/RB/W O/BO/WO/GW/BY/GOW/YB/RB/WP R O W Br R/YB/WO/BlO/YG B/W O/GW/B Bl/BB/YLgBR/Bl B/RP Y/BlB/GB/WB/LgBr/YG/YO/G POSITION LIGHT (R) Br Br B/W B/W B/R B/R FRONT TURN SIGNAL LIGHT (R) P P B Lg Y/Bl Y/Bl B B/W B/G B/G LICENSE LIGHT G/Y G/Y REAR TURN SIGNAL LIGHT (R) HEADLIGHT (LO) B/Br B/Lg B/Lg Br B B/W Bl/B Bl/B E B/W B Lg B Lg Lg B/W B/W B/Y Y REAR COMBINATION LIGHT HEADLIGHT (HI) B/Y B B B/W Br Br L Br Br Br B/W B/W B/W B/W B/W B B Br/Y Br/Y W/B W/B W/B B B/W R/Bl R/Bl B B O/G O/G P Lg Lg FRONT TURN SIGNAL LIGHT (L) B/Br W B B Br Br B/W B/W B/W B/W REAR TURN SIGNAL LIGHT (L) POSITION LIGHT (L) AM S B/BlO/G G/Y Y/BO/WY/RR/Bl R B B/Br BlP B/W B/YBr G/BlG/W B/BlB/Br B/RR/BRYB/Br Y/RB/WB/Lg ON Lg B Y R W O R Bl G Br R R B/WB/W R B B B B B B B OFF B/BlLbl Y/W B/WB/Y W/YY/W R/BlO/Y O/G O/RBl/B O/Y O/B Lbl B/BrG/Y B/W G/RO/WO/R HORN OIL Y/RB/WB/Lg Gr P B Y W PRESSURE 456 BBl B B B B/RB/RB/WB/W BlP B/W SWITCH M W W W G B B Bl B/YY/GRR B/W FUEL PUMP CMP AP FAN RELAY FUEL 123 RELAY TO SENSOR ECT SENSOR B/BlLgLblB O W Y B/WB/Y PUMP REGULATOR/ SENSOR GP EXCVA COOLING RECTIFIER SWITCH SENSOR FAN GENERATOR CKP MOTOR B/W SENSOR FUSE BOX 1 1. HEAD HI 10 A 2. HEAD LO 15 A OFF L HI FREE 3. FUEL 10 A 1: MAIN FUSE (30 A) BATTERY PUSH ON PUSH PUSH LO 4. IGNITION 10 A STARTER STARTER HORN HAZARD R PASSING DIMMER CLUTCH 5. SIGNAL 10 A MOTOR RELAY BUTTON SWITCH TURN SIGNAL LIGHT SWITCH SWITCH 6. FAN 15 A LIGHT SWITCH SWITCH HANDLEBAR SWITCH (L) B/BrG/BR B/LgP/WGW/BRY/WB/Br DgB/Br R P/BB/BrGr/WY/RGr/BY/RGr/YY/RGr/RY/RLgY/RLg/WY/RLg/GY/R Y/R Lg/Bl 12 B P G W/BIBlYB IAP TP SENSOR IAT SENSOR PRIMARY PRIMARY SECONDARY SECONDARY SENSOR INJECTOR INJECTOR INJECTOR INJECTOR STVA STP #1 #3 #1 #3 SENSOR PRIMARY PRIMARY SECONDARY SECONDARY INJECTOR INJECTOR INJECTOR INJECTOR #2 #4 #2 #4
E-03, 28, 33 IGNITION IGNITION IGNITION IGNITION PAIR COIL #1 COIL #2 COIL #3 COIL #4 SOLENOID ECM T : TURN SIGNAL INDICATOR LIGHT HANDLEBAR SWITCH (R) B : HI BEAM INDICATOR LIGHT ENGINESTOP STARTER FRONT BRAKE SIDE STAND N : NEUTRAL INDICATOR LIGHT SWITCH BUTTON SWITCH SWITCH F : FUEL INDICATOR LIGHT OFF OFF OIL: OIL INDICATOR LIGHT RUN PUSH ON FREE PUSH GrW/Bl GrB GrY GrG O/WW/G G B/WB/WB/WLgLg/G W/GB/YBlB/BrW/RBl/WBl/BBl/GW/BlBYGr/WGr/BGr/YGr/RG/RB/BrY/GY/BY/BlBl/RBl/YB/WY/RGrG/BlBrB/BrDgG/YDgrPBO/YY/WB/LgGO/WR/BlG/WB/YRB/BlG/BP/BWB/GYB/RR/BP/WW/BB/BrBl/WBl/BBl/GBl/RBl/YRO/WWW/RDgrGrB/W Lg/WLg/Bl T T IGNITION SWITCH G BRAKE LIGHT SPEED ON B/WSWITCH B OIL O/BO/WB/RB/BlY/GO/RY/WSENSOROFF ON SPEEDOMETER LOCK OFF N P F B R O GrBr O W/B B/RB/W O/Y O/BO/WO/GW/BY/GOW/YB/RB/WP R O O/YWBr G B/W O/GW/B Bl/BB/YLgBR/Bl B/RP Y/BlB/GB/WB/LgBr/YG/YO/G POSITION LIGHT (R) Br Br B/W B/W B/R B/R FRONT TURN SIGNAL LIGHT (R) P P B Lg Y/Bl Y/Bl B B/W B/G B/G LICENSE LIGHT G/Y G/Y REAR TURN SIGNAL LIGHT (R) HEADLIGHT (LO) B/Br B/Lg B/Lg Br B B/W Bl/B Bl/B B/W B Lg B Lg Lg B/W B/W B/Y Y REAR COMBINATION LIGHT HEADLIGHT (HI) B/Y B B B/W Br Br Br Br Br B/W B/W B/W B/W B/W B B Br/Y E W/B W/B W/B B B/W R/Bl R/Bl B B O/G O/G Lg Lg FRONT TURN SIGNAL LIGHT (L) B/Br W B B Br Br L B/W B/W B/W B/W REAR TURN SIGNAL LIGHT (L) POSITION LIGHT (L) P M B/BlO/G G/Y A Y/RB/WB/Lg S Y/BO/WY/RR/Bl R B B/Br BlP B/W B/YBr G/BlG/W B/BlB/Br B/RR/BRY B/Br ON Lg B Y R W O R Bl G Br R R B/WB/W R B B OFF B/Bl Lbl Y/W B/WB/Y W/YY/W R/Bl O/Y O/G O/RBl/B O/Y O/B Lbl B/BrG/Y B/W G/RO/WO/R HORN OIL Y/RB/WB/Lg GrP B Y W PRESSURE 456 BBl B B B B/RB/RB/WB/W BlP B/W SWITCH M R R W W W G B B Bl B/YY/G B/W FUEL PUMP CMP AP FAN RELAY LgLblB O W Y FUEL 123 RELAY TO SENSOR ECT SENSOR B/Bl B/WB/YPUMP REGULATOR/ SENSOR EXCVA RECTIFIER GP SENSOR COOLING GENERATOR SWITCH CKP FAN B/W SENSOR MOTOR FUSE BOX 1 1. HEAD HI 10 A 2. HEAD LO 15 A OFF L HI FREE 3. FUEL 10 A 1: MAIN FUSE (30 A) BATTERY PUSH ON PUSH PUSH LO 4. IGNITION 10 A STARTER STARTER HORN HAZARD R PASSING DIMMER CLUTCH 5. SIGNAL 10 A MOTOR RELAY BUTTON SWITCH TURN SIGNAL LIGHT SWITCH SWITCH 6. FAN 15 A LIGHT SWITCH SWITCH HANDLEBAR SWITCH (L) B/BrG/BR B/LgP/WGW/BRY/WB/Br DgB/Br R P/BB/BrGr/WY/RGr/BY/RGr/YY/RGr/RY/RLgY/R Lg/WY/RLg/GY/R Y/R Lg/Bl B P G W/BIBlYB IAP TP SENSOR IAT SENSOR PRIMARY PRIMARY SECONDARY SECONDARY SENSOR INJECTOR INJECTOR INJECTOR INJECTOR STVA STP #1 #3 #1 #3 SENSOR PRIMARY PRIMARY SECONDARY SECONDARY INJECTOR INJECTOR INJECTOR INJECTOR #2 #4 #2 #4
Prepared by E PL January, 2005 Part No. 99500-39270-01E M Printed in Japan A S 524
TOP GSX-R1000 GSX-R1000 Printed in Japan K5 99500-39270-01E K5 No.7892 GSX-R1000_01E 99500-39270-01E 2005.1.19 Cover_14 for PS printing (20mm) 1/1 BOTTOM TDP7